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Drivers Manual - TransChicago Truck Group

1. Trailer ABS Indicator Low Oil Pressure Warning oo N 12 3 4 gt e 7 j f j j j t opt opt OPT OPT OPT OPT opt oPr OPT exe B99988 8 5 9 i MI D l Ee E IB8 VOLTS HELL eR CES joe 8 9 10 D t 12 18 08 31 2006 14 15 16 17 18 19 1610836 1 Optional Indicator 9 High Coolant Temperature 14 Left Turn Signal Indicator 2 Check Engine Indicator Warning 15 Low Battery Voltage Warning 3 Stop Engine Indicator 10 Fasten Seat Belt Warning 16 Driver Display Screen 4 Malfunction Indicator Light MIL 11 Parking Brake On Warning 17 High Beam Indicator 5 Tractor ABS Indicator 12 Diesel Particulate Filter DPF 18 Low Air Pressure Warning 6 Transmission Temperature Status Indicator 19 Right Turn Signal Indicator Indicator 13 High Exhaust System Temperature HEST Warning Fig 2 40 ICU3 07 Dash Message Center EPA07 Compliant a set of 18 warning and indi to those found on a conventional lightbar 2 27 cator lights similar panel a 10 key keypad on the auxiliary instrument Instruments and Controls Identification HEADLIGHTS ON A 888888 8 MI ODOMETER SCREEN IF NO FAULTS POWER ON IGNITION ON ICU INITIALIZES ELECTRONIC GAUGE NEEDLES SWEEP WARNING INDICATOR LIGHTS COME ON BUZZER SOUNDS IF FAULT DETECTED
2. WERE DETECTED Y ABS 136 123456 7 MI FAULT CODE 12 3 VOLTS SCREEN PARK BRAKE l RELEASED MOVING 123456 7 RELEASE PARK BRAKE MI 02 14 2003 123 VOLTS f040420a Fig 2 41 ICU3 ICU3 07 Ignition Sequence a message display screen The message display screen is a 2 line by 20 character vacuum fluorescent display that provides a wide range of information to the driver Some of the information that can be provided by the message center includes odometer readings outside air temperature messages from remote locations such as com pany docks and offices shipper s terminals etc if equipped with a communications sys tem such as Truckweb or Qualcomm trip information such as trip miles and hours idle hours average mph and leg miles and hours fuel information such as fuel used and miles per gallon fuel used idling and PTO fuel used engine information such as miles hours gal lons of fuel used and PTO fuel used diagnostic information such as listings of ac tive faults and troubleshooting information vehicle information such as datalink operation and use data dash part number and software number Some of the advanced features supported by the ICU2M are Truckweb with instant messages AMT display Fuel Use Efficiency Level FUEL system display target miles per gallon MPG and bright ness control Truckweb With Truckweb and the necessary hardwar
3. 2 43 Failure Display Mode Fault CODES on nadie px teg pen aa SS qu MS 2 47 In Case of Accident 00 4 2 46 Maintenance and Diagnostics orn Rx xS 2 46 Side Sensor Display 0 0005 2 45 Special Road Situations 2 46 Collision Warning System CWS Eaton VORAD EVT 300 with ICU Integrated display u iz 2 aj te ee OW rue e esp Uv ees 2 47 Dash Switches llle 2 48 Headway Alerts 0 000 bee eee 2 48 Maintenance and Diagnostics s dem 2 52 Side Sensor Display sss 2 51 Special Road Situations 2 52 Controls 222 4440 h604 49 4 o O08 545680545 2 5 Air Suspension Dump Valve 2 9 Allison Automatic Transmission Controls llus 2 11 Automatic Engine Idler Timer 2 10 Baggage Compartment Light Switches SleeperCabs ONIY wie ctor bth oe ehhh be 2 13 Battery Isolator System 000 2 6 Bunk Reading Light Switches SleeperCabs on Mt P a yc ae Mcr 2 12 CB Radio Connections llus 2 10 Cigarette Lighter llle 2 10 Clear Reading Light Switches SleeperCabs Only s duse x So eic be ave at TR nus E pe I es 2 12 Controlled Traction Differential Control Valve SWIG a Zuani eq e ERR ds NES Euer qs 2 9 Courtesy Light Switch 2 12 Dome Light Switches sse 2 11 Exhaust Aftertreatment Regen Switch
4. 2 39 Instrumentation Control Unit ICUM a x te tec status qoe op i bcn ae UR TR 2 26 Alert S6reens ossa eg do waa 2 34 AMT Display uy ER ORE ER RAS 2 30 Brightness Control ss licam m LEER 2 30 Direct Access Screens 0 4 2 36 Fuel Use Efficiency Level FUEL eer chew oe heath ek dais 2 30 ICU2M Ignition Sequence 2 32 ICU2M Odometer 20000 0s 2 34 IGU2M Roll Call 25 3 hac hee ees ee Bary 2 33 Instant Messages 00000000e 2 29 Keypad sora saii s uenerit ged 2 31 Stationary Access Screens Used With Parking Brake PODIGO xcti ecu YR nunc PREM EA ed 2 36 Target MPG v2 8 tx actus ee sche wie tete ECRIRE 2 30 The Message Display SCIBON es usos tvi YU ey ee VEL E ade 2 33 TEUCKWOD a tite eck ee da rede a don Ge ung 2 28 Warning and Indicator Lights 2 31 Instrumentation Control Unit MGB os ences Setter ach edi Sh ob Sod Dba da dere ine dee Gok 2 24 ICU Ignition Sequence 2 25 Warning and Indicator Lights 2 24 Instrumentation Control Unit IGUAM ecco zanahoria amp dote tna tene Eius amp 2 14 Alert Screens i oci SG ew serado rets 2 17 Automated Manual Transmissions ee eee eee 2 18 Buzzer and Chime less 2 16 Direct Access Screens 00005 2 18 Gauges za cuneus e rds Re REX ER RA 2 14 General Information ls 2 14 Ignition Sequence ls
5. ika a eaa ie ni ra 2 6 Fifth Wheel Air Slide Control Valve Switch c cs e eeue eee eee 2 8 Index Subject Page Hazard Warning Light Switch Tab 3 eaueR3 9x93 PAR REGE Y RU 2 10 Headlight Dimmer 2 10 Headlight Switch and Daytime Running Lights 2 7 Heater Air Conditioner CONOIS oo deret ee ae Tuis 2 8 Idle Shutdown Timer les 2 5 Ignition Switch and Key rss 2 5 Interaxle Differential Lockout Control Valve Switch leen 2 8 Interrupt Switch 2 7 Lane Guidance System Rocker Switch 4 5 2 4 caso ER pr wis 2 10 Left and Right Windshield Fan SWIIGHeS xg oce ee ecg ca Peek x ERU 2 8 Low Voltage Disconnect 2 6 Mid Roof Fluorescent Light Switches SleeperCabs aud PEL Mn 2 12 Mirror Heat Switeli uus ss 2 5 Panel Lamp Control Switch 2 7 Parking Brake Control Valve 2 9 Power Mirrors ce ce cacce retrageri toimiii 2 6 Rear Wall Fluorescent Light SWIIGBS csi 63 30 Ra a EN eee e 2 12 Red Map Light Switches 2 11 Read Eight Switel s zszi zkeauegem ach Remi 2 7 Suspension Seat Adjustment CONOIS us esae ios Reve Rene La ess s 2 11 Tilt Steering Wheel lsslsn 2 13 Trailer Air Supply Valve 00005 2 9 Trailer Brake Hand Control Valve Lever llle 2 10 Transmission Controls liess 2 11 Tum Signal Lever
6. Press the LEG key for the Leg miles and Leg Hours screen and Roll and Hard Brake Screen Data for each of the above screens can be reset cleared To reset display the screen and push the Set Reset key twice within six seconds a confirma tion screen will display after you press the key once NOTE Resetting Trip Miles and Hours also resets Leg Miles and Hours and Roll Counts Press the TEMP key to display the outside air tem perature Stationary Access Screens The stationary access screens provide a wealth of information Using the general keys arrow keys to scroll up down and to the left or right you control the following functions e trip information including trip miles and hours idle hours and average speed and leg miles and hours e fuel information including fuel used fuel economy and idle and PTO fuel usage engine information including engine miles and hours engine and PTO gallons and oil level on some Mercedes engines if equipped and enabled diagnostic information including J1587 fault codes service information including mileage or time to next service setup information of various kinds vehicle information including datalink status ICU serial number and software version Many features of the ICU4M ICU4M 2 are user programmable The set function of the set reset key can be used to program the display In addition the reset function of the set reset key can be
7. See Fig 11 14 If repairs are needed see Group 46 of the Century Class Trucks Workshop Manual for instructions or take the vehicle to an authorized Freightliner dealer 05 06 98 1 Steering Gear Mounting Bolt 2 Pitman Arm Pinch Bolt Nut 3 Drag Link Nut f461664 Fig 11 14 Steering Gear Fasteners 3 1 Check the mounting bolts and pitman arm nut for tightness 3 2 Check the drag link nuts for missing cotter pins 3 3 Inspect the steering drive shaft and steer ing linkage for excessive looseness or other damage 3 4 Tighten loose nuts and have damaged parts replaced as needed 4 Check the condition of the serpentine drive belt Look for signs of glazing wear frayed edges damage breaks or cracks or oil contamination If a belt is glazed worn damaged or oil soaked have the belt replaced following the instructions in Group 01 of the Century Class Trucks Work shop Manual Check the drive belt for proper tension Use your index finger to apply force at the center of the belt free span See Fig 11 15 There is no adjustment for belt tension on engines with auto matic belt tensioners If there is not proper ten sion have the belt tensioner replaced See Group 01 of the Century Class Trucks Workshop Manual for instructions or take the vehicle to an authorized Freightliner dealer 10 31 94 A Deflection 1200036a B Belt Free Span Fig 11 15 Checking Belt Tensio
8. lllllleeeeeeeee I 9 1 Meritor Tandem Drive Axles with Interaxle Differential 0 ccc eee 9 2 Meritor Interaxle Differential Lockout Operation lesse 9 2 Eaton Single Reduction Axles with Controlled Traction Differential lessen 9 2 Eaton 2 Speed Tandem Axles csse pua eons RE ERE KR or POSS EP ES CEOs EERE OL RREEXS 9 3 Eaton Interaxle Differential Lockout Operation 0 0 00 cece eee 9 3 Rear Axles Meritor Single Drive Axles with Traction Equalizer Some Meritor single drive axles are equipped with a traction equalizer which is a load sensing self actuating feature A traction equalizer provides nor mal differential action where traction is good When one wheel begins to spin faster than the other clutch plates in the differential housing automatically en gage delivering power to both wheels There is no operator control with this feature A traction equalizer occasionally tends to slip in a jerking motion producing irregular intervals of sharp noises This generally occurs when the vehicle is op erating at low speeds on fairly sharp turns This con dition called slip stick is corrected by adding a fric tion modifier to the axle lubricant This additive tends to reduce the static coefficient of friction to a value equal to or lower than the sliding coefficient Refer to the vehicle maintenance manual for addi tional information on friction modifiers and when t
9. 3 To upshift into 1st gear only partial depression of the clutch pedal is needed Do not push the clutch pedal all the way to the floor and engage the clutch brake instead partially depress the clutch pedal and move the shift lever into neu tral 8 16 Transmissions 4 Release the clutch pedal and allow the engine to decelerate until the road speed and the engine rpm match 5 Partially depress the clutch pedal and move the shift lever into 1st gear 6 Double clutch to continue upshifting until in fourth gear See Table 8 3 7 To upshift into high range with the transmission still in 4th gear push the range selection lever up to put the transmission into high range then partially depress the clutch pedal and move the shift lever into neutral As the shift lever passes through neutral the transmission will automati cally shift from low range to high range 8 Release the clutch pedal and let the engine slow until the road speed and engine rpm match 9 Partially disengage the clutch and move the shift lever into 5th gear 10 To upshift from 5th gear into 5th overdrive flip the splitter control button up to the overdrive po sition then immediately release the accelerator and press and release the clutch pedal It is not necessary to move the shift lever when shifting from direct to overdrive the transmission will shift when synchronization with the engine s speed is reached Accelerate the engin
10. 4 Check the Komfort Latch for function and cracks or other damage 5 Check the upper seat belt mount on the door pillar for damage 7 1910004a 6 Check web retractor for function and damage Fig 5 7 Fastening the Three Point Belt 7 Check the mounting bolts for tightness and tighten any that are loose 3 Position the shoulder strap diagonally across your chest with the adjustable D loop bracket if Seat Belt Operation equipped The shoulder strap must be centered on your shoulder and chest away from your face Three Point Seat Belt With Komfort Latch and neck See Fig 5 8 If desired engage the NOTE For vehicles not equipped with the Kom POON Este as TONNS fort Latch see the seat belt operation under the Pull on the shoulder strap to lessen the pressure heading Three Point Seat Belt 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 A WARNING can significantly reduce the seat belt s effective ness in an accident or a sudden stop While Wear three point seat belts only as described holding the belt slack press the Komfort Latch below Three point seat belts are designed to be lever up clamping the seat belt webbing worn by one person at a time In case of an acci dent or sudden stop personal injury or death Figs aro Fig S10 could result from misuse Fasten the seat belts before driving Fastenin
11. 8 4 Transmissions Downshifting With the transmission in forward F request a down shift by pushing downward on the control If the re quested gear is available the transmission will down shift NOTE If a requested gear is not available an audible warning will sound and a message will appear on the message display screen advising that the gear is not available An unavailable requested downshift is not stored in memory The downshift must be requested again All shift requests with the clutch disengaged while the vehicle is in motion will be ignored Skip shifting is not available with the Meritor version of SmartShift While in the forward position in the lowest available gear a downshift request will not cause a shift into neutral Reverse 1 To select reverse R slide the mode selector Switch upward to the next position above the Neutral position NOTE Reverse low RL is the default reverse gear 2 Select reverse high RH by pulling upward on the control before disengaging the clutch NOTE It is not possible to shift between low range reverse and high range reverse with the vehicle in motion If reverse is selected above the minimum detectable speed in forward an audible warning will sound and a warning mes sage will appear on the message display screen Using the Clutch Use the clutch to start and stop the vehicle Fuller Straight Shift Models General Information Fuller T 14607A B a
12. Bottom Cushion Front Height To adjust the height of the front of the bottom cush ion lift the bottom cushion front height adjustment handle and pull forward or push back to the desired setting Seat Belts and Tether Belts General Information Seat belt assemblies are designed to secure persons in the vehicle to help reduce the chance of injury or the amount of injury resulting from accidents or sud den stops For this reason Daimler Trucks North America LLC urges that the driver and all passen 5 5 gers regardless of age or physical condition use seat belts when riding in the vehicle A WARNING Always use the vehicle s seat belt system when operating the vehicle Failure to do so can result in severe personal injury or death Seat belt assemblies in Daimler Trucks North America DTNA vehicles meet Federal Motor Ve hicle Safety Standard 209 Type 1 and Type 2 re quirements When transporting a child always use a child re straint system or the vehicle seat belts as appropri ate To determine whether a child restraint system is required review and comply with applicable state and local laws Any child restraint used must comply with Federal Motor Vehicle Safety Standard 213 Child Restraint Systems When providing a child restraint system always carefully read and follow all instructions pertaining to installation and usage for the child Make certain the child remains in the re straint system at all tim
13. 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 personal injury or death The fifth wheel plate must be kept well lubricated with chassis grease to prevent friction and binding between the tractor fifth wheel plate and the trailer For lubrication instructions see Group 31 of the Century Class Trucks Maintenance Manual Fontaine Fifth Wheels General Information The Fontaine sliding fifth wheel mount is designed to provide optimum axle loading for maximum tractor use with different lengths and types of trailers The sliding fifth wheel mount is used with the Fontaine H5092 series and 6000 7000 No Slack II series fifth wheels and is equipped with either an air operated release slide AWB or HAWB models or a manual release slide MWS or HMWS models On Fontaine fifth wheels kingpin release is accom plished by activating a manual lock control handle located on either the right side or left side of the fifth wheel Kingpin lockup occurs when the kingpin is forced into the jaws and the lock control handle moves to the locked position The fifth wheel top plate is mounted on a slide as sembly which is attached to slide rails that are mounted on the vehicle frame The slide rails permit forward and rearward movement of the slide assem bly allowing for optimum weight distribution ov
14. Released Applied Truck or Tractor Only 2 14 3 21 Truck or Tractor w Single Trailer 3 21 4 28 Truck or Tractor w Two Trailers 5 35 6 42 Table 11 4 Maximum Allowable Service Brake Air Leakage 26 Test the service brakes When starting to move the vehicle and before picking up speed test the brakes with the foot pedal and parking brake control valve yellow knob to be sure they will bring the vehicle to a safe stop Weekly Post Trip Inspection and Maintenance Procedures 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 han dling battery parts and related accessories 1 Inspect the batteries and battery cables Check the battery cables for chafing and proper rout ing Replace the battery cable if damaged Check that the battery hold down is secure If it is loose tighten the hold down bolts if it is bro ken replace it 2 Check the level of the wheel bearing lubricant in the hub cap at each end of the front axle If needed fill the hubs to the level indicated on the hub cap See Group 35 of the Century Class Trucks Maintenance Manual for recommended lubricants IMPORTANT Before removing the fill plug al ways Clean the hub cap and plug 3 Examine the steering components Pretrip Inspection and Daily Maintenance
15. Turbocharged engines must be checked at full load and governed en gine speed Table 2 6 Intake Air Restriction 01 18 95 1600148a Fig 2 67 Intake Air Restriction Indicator NOTE Rain or snow can wet the filter and cause a temporarily higher than normal reading Ammeter An ammeter measures current flowing to and from the battery When the batteries are charging the meter needle moves to the plus side of the gauge when the batteries are being discharged the needle moves to the minus side A consistent negative read ing when the engine is running indicates a possible problem with the charging system Borg Indak Analog Clock The analog clock features electronic setting Do not pull the set knob The time can be set either forward turn knob to the right or backward turn the knob to the left A slight turn of the knob either right or left will change the setting of the clock one minute at a time Holding the knob to either the right or the left will allow accelerated sweeping of the hands for set ting the hour Pana Pacific Digital Clock A Pana Pacific clock has black characters on a con stantly backlighted green display with a brightness that automatically adjusts for day or night The clock has a 24 hour alarm with a three minute snooze fea ture 1 To set the time of day 1 1 Push the Run Set lower switch to the right TIME SET position NOTE When the hour setting is for a time b
16. l p 1 pw M i vh 1 67 8 c9 DR DR DR Lo Lo Lo Lo Lo Lo 1260341 1260342 f260343 1260344 v R On DR n R vow ie Lo R ie Lo R y 9 A AT A 4 4 PEE 15 Speed RT and RTX Ky NAS ME ae P Dy BN EV M Cv ovS fov 6 6 lt 8 40 DR DR DR Lo Lo Lo Lo Lo 260345 1260346 1260347 i 1260348 Table 8 2 Fuller Shift Progressions Move the deep reduction button to the forward position to engage the deep reduction gears Depress the clutch pedal to the floor shift into low low gear 10 speed transmissions or 1st gear of deep reduction 15 speed transmissions then engage the clutch with the engine at or near idle speed to start the vehicle moving Ac celerate to 80 percent of engine governed speed For 10 speed transmissions When ready for the next upshift move the deep reduction button rearward then break torque by momentarily releasing the accelerator or de pressing the clutch pedal Do not move the shift lever For 15 speed transmissions Shift upward from 1st gear of deep reduction to 5th gear of deep reduction double clutching be tween shifts and accelerating to 80 percent of engine governed speed See Table 8 2 When ready for the next upshift move the deep reduction button from the forward position to the rearward position then double clutch through neutral and move the shift lever to the 4th gear position in the low range 6 Shift upward from low gear 10 speed transmis sions or 4th
17. peratures below 4 F 20 C will require a grid heater block heater and oil pan heater NOTICE NEVER use ether as a starting aid on a DD HD engine Doing so will result in injector damage A winterfront may be used to improve cab heating At least 25 percent of the grill opening should remain open in sectioned stripes that run perpendicular to the charge air cooler tube flow direction This as sures even cooling across each tube and reduces header to tube stress and possible failure Winter fronts should only be used when the ambient tem perature remains below 10 F 12 C Driving on Flat Dry Pavement Use the following guidelines when driving on flat dry pavement e f driving on open stretches with a light load place the progressive braking switch in the LOW position 7 6 Engines and Clutches f you find you are still using the service brakes move the switch to a higher position until you do not need to use the service brakes to slow the vehicle If you are carrying a heavier load and road traction is good move the progressive braking switch to the HIGH position Check your progressive braking switch often for proper position since road conditions can change quickly Never skip a step when oper ating the progressive braking switch Always go from OFF to LOW and then to a higher posi tion Descending a Long Steep Grade Control speed is the constant speed at which the forces pushi
18. 0 00 00 cease 2 10 Utility Light Switch 2 7 Windshield Wiper Washer Controls 22 2 3s Ax eeu RE o 2 7 Dashboard Care llle 12 1 Defogging and Defrosting Using Fresh AIF Lunes xen x peer des ache e De hut e lega 4 2 Detroit Diesel Heavy Duty Engine DDT3 AIB use some Owe Rn 7 4 DDEC VI Driving TIPS see 6 ed ERR 7 6 DDEC WI ss nes Biot ba diu mh b E E ates qs 7 4 Door VIDIBOWS uua Raters deb od eu ae a EAs 3 12 E Eaton 2 Speed Tandem Axles 9 3 Subject Dual Range 2 Speed Tandem Axle Operation with Multispeed Transmissions Eaton Interaxle Differential Lockout Operation Eaton Single Reduction Axles with Controlled Traction Differential Emergency Kit Optional Emergency Starting with Jumper Cables Engine Operation CAT Cummins DDE S60 M B Cold Weather Operation CAT Cummins DDE S60 MEB iios Be RR High Altitude Operation Normal Operation Caterpillar Normal Operation Cummins Normal Operation Detroit Diesel S60 DDEC Ill Normal Operation Mercedes Benz Engine Shutdown CAT Cummins DDE S60 M B Caterpillar Cummins DDE S60 Mercedes Benz Engine Starting CAT Cummins DDE S60 M B Cold Weather Starting Normal Starting Starting After Extended Shutdown or Oil Change EPA Emission Control Labels EPA Vehicle Noise Emission Control
19. 1 Chock the front and rear of the trailer tires to prevent the trailer from moving A WARNING Keep the fifth wheel plate lubricated to prevent binding between the tractor and trailer A binding fifth wheel could cause erratic steering and loss of vehicle control possibly resulting in serious personal injury or death The kingpin lock mechanism must be fully open and the fifth wheel plate must be completely lu bricated with chassis grease For lubrication in structions see Group 31 of the Century Class Trucks Maintenance Manual 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 mechanism to prevent a false lockup See Fig 10 5 Adjust the trailer landing gear to give enough alignment 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 en ters the throat of the locking mechanism When the trailer is picked up by the fifth wheel stop the tractor then continue slow backward motion until positive lockup occurs 5 Apply the tractor parking brakes 10 2 Fifth Wheels and Trailer Couplings 11 07 94 D c 1310106a A Locks open B Locks closed C Kingpin correctly entering the lock Not
20. 13 In an Emergency Hazard Vraming MONS 2 tionivenrttugin RR itera RENESA ETAR ENAERE PERENE EEEE Ri 13 1 Fre Exting isher respe korenti Daum Hog debis paa READ ber Koea i E ETa 38 Remene 13 1 Emergency Kit Optional esecscrcresrscr ateraia EEr EAEE REA OEE ERG YR E E 13 1 TOWING 2 Mek oe bouche be penae ne EE AGREE EE a e a A 13 1 Emergency Starting with Jumper Cables lleesleeeeeeeeeee eee 13 3 Freine Cab occas sie ane oF oe oe Bee eee ok eee Be et ee hh Be tee gn EAEAN 13 4 In an Emergency Hazard Warning Lights The hazard warning light switch tab is located on the turn signal control lever See Fig 13 1 To operate the hazard lights pull the tab out All of the turn sig nal lights and both of the indicator lights on the con trol panel will flash s 2 J N 9 26 95 1541098 Fig 13 1 Hazard Warning Light Switch Tab To cancel the hazard warning lights push the turn signal control lever either up or down then return the lever to its neutral position Fire Extinguisher A fire extinguisher is located in the cab by the driv er s door Emergency Kit Optional An optional emergency kit package is located be tween the seats at the front of the center console if the vehicle does not have a sleeper compartment If there is a sleeper compartment the emergency kit is located elsewhere depending on vehicle configura tion The package includes one or more of each of the following
21. Do not cut drill braze solder weld strike or probe any part of the air bag system Seats and Seat Belts Do not expose the air bag module to elec tricity Never probe a circuit Do not attempt to adapt reuse or install an air bag system in any vehicle other than the specific vehicle for which it is designed Do not cut wires or tamper with the connec tor between the vehicle wiring harness and the air bag module Cutting or removing the connector from the system will disable the safety shunt and could cause unintentional deployment Allow deployed air bag systems to cool after deployment Wear rubber gloves and safety glasses when handling a deployed air bag Wash your hands and exposed skin surface areas immediately after handling a de ployed system Store transport dispose of and recycle deployed air bag system components in accordance with all applicable federal state and local regulations The air bag module may contain perchlor ate material special handling may apply see www dtsc ca gov hazardouswaste perchlorate Keep all heavy objects in the cab secured SPACE System Optional The Seat Pretensioner Activation for Crash survival Enhancement SPACE system when used with seat belts provides additional protection to the driver in severe frontal collisions The SPACE system provides a significant increase in seat stability during a severe frontal collision When the SPACE module se
22. Engine Oil Temperature Gauge 11 Turbocharger Boost Pressure Gauge 12 Coolant Temperature Gauge WONDAP wh f610264 NOTE Instruments and controls and their locations may vary from those shown Voltmeter Pyrometer Dash Message Center or Driver Message Center Tachometer Speedometer Primary Air Pressure Gauge Fuel Gauge Forward Axle Oil Temperature Gauge Secondary Air Pressure Gauge Transmission Oil Temperature Gauge Rear Axle Oil Temperature Gauge Fig 2 3 Instrument and Control Panel Layout upper RH DR dash shown The engine protection shutdown sequence is as fol lows 1 The red stop engine light or engine protection light comes on to indicate that the engine pro tection system has been activated 2 The engine ECU begins to reduce the maximum 3 engine torque and speed If the condition does not improve the engine will shut down within 30 seconds 2 4 Instruments and Controls Identification 03 01 99 3 f610263 NOTE Instruments and controls and their locations may vary from those shown 1 Ignition Switch 2 Heater Air Conditioner Controls 3 AM FM Stereo Radio Cassette Player Clock Fig 2 4 Instrument and Control Panel Layout lower RH DR dash shown The driver must safely bring the vehicle to a stop on the side of the road and shut down the engine as soon as the red light is seen If the engine shuts down while the vehicle is
23. Seat Position Indicators Seats installed in vehicles built before November 28 2005 are equipped with seat position indicators A back cushion tilt position indicator and a fore aft seat position indicator allow the driver to see where the seat is adjusted within the adjustment ranges Armrest Angle optional armrests To adjust the vertical angle of the armrest turn the adjustment knob on the underside of the armrest Freightliner Bostrom Seat See Fig 5 4 for seat adjustment controls Back Cushion Tilt To tilt the back cushion lean forward slightly to re move pressure from the cushion and hold the back cushion tilt lever rearward Lean backward slowly to the desired position and release the lever to lock the cushion in place Weight and Height Adjustment To raise the seat press the upper portion of the weight and height adjustment switch To lower the seat press the lower portion of the switch Isolator To engage the isolator put the isolator lever in the center position Lock out the isolator by moving the lever to the right Fore and Aft Seat Adjustment Hold the fore and aft adjustment lever to the left and slide the seat forward or backward to the desired po sition 5 2 Seats and Seat Belts P d s y NYS y 2 3 4 5 A 6 1 7 03 12 2001 f910456 Isolator and Fore Aft Seat Adjustment Lever Bottom Cushion Angle Guide Armrest Adjustment Knob Back Cushion Tilt Position Ind
24. The voltmeter Fig 2 65 indicates the vehicle charg ing 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 potential charging system problems and have them fixed before the batteries discharge enough to create starting difficulties The voltmeter will normally show approximately 13 7 to 14 1 volts when the engine is running The voltage of a fully charged battery is 12 7 to 12 8 volts when the engine is stopped A completely discharged bat tery will produce only about 12 0 volts The voltmeter will indicate 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 over charged 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 en gine is stopped the voltmeter shows only the gel cell battery voltage and does not indicate the voltage of the engine starting batteries NOTICE 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 exter nal charger is needed dis
25. first aid kit a reflective vest and a tri angular reflector and flare kit If there is an emergency while driving cautiously pull off the road paying attention to other traffic Turn on the hazard warning lights Place the flares and reflec tor along the side of the road to alert other drivers that an emergency situation exists 13 1 Use extreme care when placing flares in emer gency situations that involve exposure to flam mable substances such as fuel An explosion or fire could occur causing serious personal injury Towing When it is necessary to tow the vehicle make sure the instructions below are closely followed to prevent damage to the vehicle 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 tow ing vehicle Otherwise brake capacity will be in adequate which could result in personal injury or death Front Towing Hookup 1 Disconnect the battery ground cables 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 2 Remove both drive axle shafts On dual drive axles if the vehicle is to be lifted and towed re move only the rearmost drive axle shafts On vehicles equipped with an air fairing remove both the forward and rearmost drive axle shafts if there is insufficient towing clearance B
26. high coolant temperature e CI ing th t Aw Metro uie cce E Hess e the parking brake is applied and the vehicle is moving at a speed of at least 2 mph 3 km h Record significant data using the event key if a data logging unit is installed VORAD failures e g WARNING HEADWAY FAILURE i Is roll ied E re d e Some roll stability RSA messages A friendly chime sounds when the parking brake is off and the door is open or when the headlights are on and the door is open 2 16 Instruments and Controls Identification Ignition Sequence When the ignition key is turned on the ICU4M ICU4M 2 begins a self test During the first half of this process the following events occur Observing these events is a good way to make sure the ICUAM ICUAM 2 is functioning properly All gauges controlled by the cluster sweep to full scale and return All display segments of the message center turn on and then turn off e The buzzer sounds for three seconds e The battery voltage low air pressure and parking brake warning lights come on and then go off The fasten seat belt warning light illuminates for 15 seconds In the second half of the self test the software revi sion level of the ICU4M ICU4M 2 displays on the message center followed by the active faults if any When the self test is complete the fasten seat belt screen displays if the engine is not running If the engine is running the idle hours scr
27. least five minutes each month even during cool weather This helps prevent drying and cracking of tubing seals reducing refrigerant leaks in the system Operate the air conditioner only after the engine compartment is warm and the inte rior of the cab is 70 F 21 C or higher During cold weather the heater can be operated at the same time to prevent discomfort 1 If the cab is hot inside temporarily open the win dows to let the hot air out 4 3 2 Move the air selection switch to the nonair con ditioning face only position and turn the fan switch off before starting the engine See Fig 4 6 1 2 3 4 o T SN o 2 VER 3 x 4 6 p 6 5 9 07 95 1830720 Fan Switch Air Conditioning Settings Face Only Setting non air conditioning Temperature Control Switch Maximum Air Conditioning Fresh Air Recirculation Switch 07 01 Go t Fig 4 6 Air Conditioning Settings Start the engine Move the air selection switch to either one of the air conditioning settings With the control at ei ther one of the air conditioning settings fresh air is drawn into the cab With the control at maxi mum air conditioning the air inside the cab is recirculated IMPORTANT If the outside air is dusty or smoky set the air selection switch at maximum air conditioning and keep the windows and vent closed to prevent drawing in dust or smoke On vehicles with the fresh air recirculation switch recirculated a
28. miles per gallon back to zero 2 36 Instruments and Controls Identification IDLE HOURS 1234 56 12 3 GAL 1234567 MI FASTEN SEATBELTS gt 1234567 MILES IGNITION ON ONLY Y Y IDLING TRIP TRIP MILES 123456 7 IDLE HOURS 1234 56 LEG MILES 123456 7 INFORMATION TRIP HOURS 1234 56 AVERAGE MPH 12 3 LEG HOURS 1234 56 R R R a4 FUEL FUEL USED 12345 6 IDLE GALLONS 12345 6 INFORMATION AVERAGE MPG 12 34 PTO GALLONS 12345 6 R R ENGINE ENG MILES 1234567 8 ENG GALLONS 123456 7 INFORMATION ENG HOURS 123456 78 PTO GALLONS 123456 7 Y Y R RESET PUSH RESET SET KEY TWICE S SET PUSH RESET SET KEY ONCE 01 28 98 See applicable figure f040324a Fig 2 50 Trip Information Fuel Information and Engine Information NOTE Resetting Trip Miles and Hours does not also reset Fuel Used and Average MPG or Idle Gallons and PTO Gallons Fuel Informa tion must be reset separately Idle Gallons and PTO Gallons displays the gallons of fuel used idling and to operate the Power Takeoff unit if installed At the start of a trip or whenever desired press RESET to set idle gallons and PTO gallons back to zero Engine Information Engine information provides two data screens En gine Miles and Hours and Engine Gallons and PTO Gallons See Fig 2 50 or Fig 2 51 Engine Miles and Hours displays the total miles and hours logged by the
29. such as a cigarette Always comply with the washer fluid manufacturer s rec ommended safety precautions 3 Check the coolant level If the coolant is low fill the surge tank to the MAX line with a 50 50 mixture of water and the type of antifreeze currently installed in your ve hicle See Fig 11 2 05 18 98 1500312 1 Coolant Fill Cap Fig 11 2 Coolant Level Checking CAUTION Coolant must be filled to the full line of the surge tank Low coolant could result in engine over heating which could cause engine damage 4 Inspect the radiator and charge air cooler 4 1 Inspect the radiator and charge air cooler for clogged fins Use compressed air or water directed from the fan side of the core to backflush any material restricting airflow 4 2 Inspect the radiator and charge air cooler for damage and accumulated debris Straighten bent or damaged fins to permit airflow across all areas of the cores NOTE When traveling through areas of high insect concentration it may be necessary to clean the exterior of the radiator or the charge air cooler core as often as every 200 miles 320 km 4 3 On vehicles equipped with air condition ing also inspect and clean the condenser If clogged the condenser can restrict air flow through the radiator Pretrip Inspection and Daily Maintenance 4 4 Check the radiator for leaks If leaks are found have the radiator repaired or re placed See Group
30. the word Warning flashes on the message display screen above the message Low Fuel Level Turn Signal On Screen This warning message the alarm tone is optional comes on whenever the turn signal remains on be yond a preset time or distance traveled The word Warning flashes on the display screen above the message Turn Signal On To dismiss this message either turn off the turn sig nal or press any key on the keypad Service Warnings Service warning screens display during the ignition sequence and indicate that a service interval has been reached or exceeded and maintenance is re quired The messages may indicate the number of miles or hours until the next service or once Instruments and Controls Identification passed the number of miles or hours ago that main tenance should have been performed The messages read X Miles To Next Service X Hours To Next Service Service Was Due X Mi Ago and Service Was Due X Hr Ago The letter X represents the number of miles or hours programmed The ICU2M can be programmed using ServiceLink to generate service warnings in either miles or hours but not both No Datalink Activity Screen The No Datalink Activity screen comes on when ever the datalink is not receiving data If the condition persists take the vehicle in for ser vice as soon as possible to discover the cause of the problem Direct Access Screens The driver can also override the regu
31. 2 23 and Fig 2 24 The ICUAM ICUAM 2 instrument cluster is an individual gauge cluster with an intelligent lightbar and integrated warning and indicator lights See Fig 2 25 Some main features of the ICU4M ICU4M 2 are e gauges sweep 270 degrees and have pointers lit by an LED light emitting diode service intervals are programmable from the keypad a warning chime and alert message display warns the driver if the door is opened without first setting the parking brake if low oil pressure or high coolant temperature is detected a red warning light at the bottom of the gauge illuminates a warning buzzer sounds and a flashing alert message appears on the display along with a text message giv ing additional information The dash message center is the heart of the ICUAM ICUAM 2 It has three parts a set of 24 warning and indicator lights a 10 key keypad on the auxiliary instrument panel a message display screen in the center The message display screen is a two line by twenty character liquid crystal display LCD Gauges There can be up to 14 removable gauges on the driver s instrument panel The ICUAM ICUAM 2 can also drive gauges located on the auxiliary instrument panel Gauges cannot be removed from the front of the panel The standard gauges are speedometer engine coolant temperature engine oil pressure battery voltmeter e fuel level Other available gauges include tachometer
32. 6 under the heading Brake System for instructions regarding use of the parking brake valve Trailer Air Supply Valve The red octagonal shaped knob Fig 2 10 operates the trailer air supply valve After the vehicle and its air hoses are connected to a trailer and the pressure in the air system is at least 65 psi 447 kPa the trailer air supply valve knob must be pushed in and should stay in to charge the trailer air supply system and release the trailer spring parking brakes Before disconnecting a trailer or when operating a vehicle without a trailer the trailer air supply valve knob must be pulled out See Chapter 6 under the heading Brake System for instructions regarding use of the trailer air supply valve 2 9 Controlled Traction Differential Control Valve Switch A controlled traction differential feature is included on some rear axles A control valve switch Fig 2 11 engages and disengages the controlled traction fea ture A guard is positioned around the switch to mini mize accidental activation See Chapter 9 for complete operating instructions TRACTION CONTROL DIFFERENTIAL LOCK UNLOCK DO NOT ENGAGE DURING SPIN OUT 09 26 95 f350142 Fig 2 11 Controlled Traction Differential Switch Air Suspension Dump Valve The air suspension dump valve allows the air in the vehicle air suspension to be quickly exhausted low ering the rear of the vehicle This makes it easier to connect
33. 7 3 Engine Lamps avoid automatic engine protection sequences See Fig 7 4 A slow 10 second flashing of the high exhaust sys tem temperature HEST lamp indicates that a parked regen is in progress The engine high idle speed is controlled by the engine software not the vehicle operator A steadily illuminated HEST lamp alerts the operator of high exhaust temperature during the regen pro cess if the vehicle speed is below 5 mph 8 km h or during a parked regen NOTE The HEST lamp does not signify the need for any kind of vehicle or engine service it alerts the vehicle operator of high exhaust tem peratures A WARNING Active regeneration can occur automatically any time the vehicle is moving The exhaust gas tem perature could reach 1500 F 800 C which is hot enough to ignite or melt common materials and to burn people The exhaust can remain hot after the vehicle has stopped moving A steadily illuminated yellow diesel particulate filter DPF lamp indicates that a filter regen is recom mended because the filter is reaching capacity Bring the vehicle to highway speeds to allow for an auto matic regen or perform a parked regen A flashing yellow DPF lamp indicates that a DPF regen is necessary because the filter is reaching maximum capacity To avoid engine derate bring the vehicle to highway speeds to allow for an automatic regen or perform a parked regen as soon as pos sible A flashing yellow DPF
34. Aftertreatment System ATS IMPORTANT EPAO07 emissions regulations apply to vehicles domiciled in Canada and the USA at the time of printing this manual Vehicles that are domiciled outside of the USA and Canada may not have EPA07 compliant engines with an emission aftertreatment system de pending upon local statutory emissions guide lines All on road diesel engines for vehicles domiciled in the USA or Canada and built after December 31 2006 but before January 1 2010 must meet EPAO7 guidelines for reduced exhaust emissions of particu late matter and nitrogen oxides NOx NOx is limited to just over 1 gram per brake horsepower hour g bhp hr and particulate matter cannot exceed 0 01 g bhp hr NOTICE It is extremely important that the following guide lines be followed for vehicles with EPAO7 compliant engines or damage may occur to the aftertreatment device and the warranty may be compromised Use ultralow sulfur diesel with 15 ppm sulfur content or less Do not use fuel blended with used engine lube oil or kerosene Engine lube oil must have a sulfated ash level less than 1 0 wt 96 currently referred to as CJ 4 oil IMPORTANT Using non specification fuels or oils can lead to shortened Diesel Particulate Fil ter DPF cleaning or exchange intervals For example using Cl 4 oil with 1 396 sulfated ash 8096 more ash content may result in the need for DPF cleaning or exchange 20 to 30 sooner than
35. Alert Switch on vehicles without Smart Cruise 4 Headway Adjustment Switch 5 Headway Volume Switch 1610414 Fig 2 60 Dash Switches for Collision Warning System and SmartCruise Headway Alerts The ICU displays indicator lights Fig 2 61 and messages that advise of multiple warning levels sys tem power or system failure See Table 2 3 for a complete description of the warning messages this system displays with the inte grated ICU 1 2 FASTEN SEATBELTS 0000432 MILES 07 3 2000 3 1 SmartCruise Lamp HDWY CRUISE 2 Headway Alert Lamp HDWY DETECT 3 System Failure Lamp HDWY FAIL f610412 Fig 2 61 ICU Indicator Lights 2 48 Instruments and Controls Identification ICU Message Speed Set 55 mph 88 5 km h Headway Set 3 0s ICU Display Messages Description The Speed Set and Headway readings will display when the vehicle speed drops 5 mph 8 km h below the set speed The vehicle will automatically accelerate to the set speed when the headway is clear up to the Headway Set distance WARNING CWS has failed HDWY FAIL lamp will also illuminate HEADWAY FAILURE WARNING Vehicle speed is below 30 mph 48 km h minimum cruise speed An audible CRUISE OFF tone will also be heard The cruise is off HEADWAY RANGE Displays current headway setting maximum setting displayed 7 601895 HEADWAY ALERT VOLUME Displays current audible tone volume maximum volume shown E
36. EDU 5 1 Seat Belts and Tether BENG ues acacrere Eee RS Russ EEA oS REMeRARIS REA E SE 5 5 Sleeper Compartment Restraints 0 00 0 eee eee 5 8 supplemental Restraint System Optional 6 2 22 ceveeeed es bebe te bees beer w need eens 5 9 Air Bag Optional vcucsk pas Suda ene EORERSORENA RAE ER ee SO RU SERS SELES EES AEn RENERE 5 9 SPAGE System Optional oues rore ER p heroes Lanes OE eE QUEE BA THER AA 5 10 Seats and Seat Belts Seats General Information Unless otherwise noted all seat adjustments should be made while seated and before the engine is started Due to the maximum adjustability of mid and high back air suspension seats it is possible to combine the seat back recline adjustment and the seat slide adjustment so that the seat back contacts the back wall It is the responsibility of the driver to adjust the seat to prevent damage to the seat and the cab inte rior Keep hands tools and other objects away from the scissor points under the seats Failure to do So could cause personal injury Seat Adjustment The following is a description of adjustments that can be made to various Freightliner installed seats Not all seats have all of the adjustments listed below See Fig 5 1 1 Back Cushion Tilt This adjustment enables the back cushion to pivot forward or backward 2 Lumbar Support Lumbar support changes the shape of the seat back to give more or less sup port to the occupant s lumba
37. Forward for IN 7 Rearward for OUT Fig 8 10 Fuller 15 Speed RT RTO and RTX Model Transmissions Shift Patterns 1 For all driving conditions use the highest gear that is still low enough to start the vehicle moving with the engine idling and without slipping the clutch excessively 2 Use the clutch brake to stop gear rotation when shifting into low low low 1st whichever is used as a starting ratio or reverse when the vehicle is stationary The clutch brake is actuated by de pressing the clutch pedal all the way to the floor For normal upshifts and downshifts only a partial disengagement of the clutch is necessary to break engine torque 3 Use double clutching between all upshifts and downshifts 4 Never move the shift lever into low gear while in high range 5 Do not preselect with the deep reduction button When making the shift from a deep reduction ratio to a low range ratio move the deep reduc tion button from a forward position to a rearward position then complete the shift immediately 6 Never move the deep reduction button from a rearward position to a forward position when the transmission is in high range 7 Do not shift from high range to low range at high vehicle speeds 8 Do not make range shifts with the vehicle moving in reverse gear 9 Never attempt to move the range preselection lever with the gear shift lever in neutral while the vehicle is moving Preselection with the range pr
38. Gauge Fuel Gauge Transmission Oil Temperature Gauge Forward Axle Oil Temperature Gauge Rear Axle Oil Temperature Gauge f601127 OO GON Fig 2 66 Instrument Panel Gauges right side Fuel Gauge The fuel gauge Fig 2 66 indicates the level of fuel in the fuel tank s If equipped with a second fuel gauge each fuel tank level is indicated on a sepa rate gauge Transmission Oil Temperature Gauge During normal operation the transmission oil tem perature gauge Fig 2 66 reading should not ex ceed 250 F 121 C for Fuller transmissions NOTICE A sudden increase in oil temperature that is not caused by a load increase may indicate mechani cal failure Bring the vehicle to a safe stop and investigate the cause to prevent further damage Do not operate the engine until the cause has been determined and corrected Forward and Rear Axle Oil Temperature Gauges During normal operation forward and rear axle oil temperature gauges Fig 2 66 should read between 160 and 220 F 71 and 104 C for Meritor drive axles 180 and 200 F 82 and 93 C for Eaton drive axles Under heavy loads such as when climbing steep grades temperatures up to a maximum of 250 F 121 C are not unusual NOTICE A sudden increase in oil temperature that is not caused by a load increase may indicate mechani cal failure Bring the vehicle to a safe stop and inves
39. Inspect the exterior surfaces of the cham ber for damage Make sure that breather holes in the non pressure section s are open and free of debris See Group 42 of the Century Class Trucks Workshop Manual to replace any damaged parts 22 5 On all parking brake installations make sure the end cover cap or dust plug is se curely snapped into place NOTE On most MGM parking brake cham bers equipped with an integral release bolt an end cover cap is installed over the re lease bolt 22 6 Check for rusted connections missing snap rings and damaged camshaft grease seals Have damaged or missing parts repaired or replaced Inspect the air brake lines 23 1 Check the clearance between the hoses and the exhaust manifold or other hot spots Excessive heat will cause material in the hoses to deteriorate rapidly or be come brittle Provide at least 6 inches 11 11 150 mm of clearance More clearance is recommended if the hose is located above the heat source 23 2 Check for kinks dents or swelling of the hoses If damaged have the hose re placed with the same size and type NOTE Do not route the hose on top of any thing likely to be stepped on 23 3 Check for damage to hoses located near moving parts such as drivelines kingpins suspensions and axles If moving parts are catching or pinching the lines correct as needed 23 4 Check for hose damage caused by abra sion If abraded have the hose replaced Che
40. LOCK 3 2 X For manually operated models raise the safety latch and pull the slide operating rod Fig 10 9 outward until the shoulder is outside of the operating rod support then lower the operating rod as far as it will go 4 Lower the trailer landing gear just enough to re move the weight from the tractor 5 Pull the trailer air supply valve to cut off the air supply to the trailer CAUTION After moving the fifth wheel to the desired posi tion be sure the trailer landing gear will not at any time come in contact with the tractor frame or other components Make sure that the front of the trailer will not come in contact with the rear of the cab or with other components if they ex tend beyond the rear of the cab 6 Slowly move the tractor forward or backward until the fifth wheel is in the desired location 7 Apply the tractor parking brakes Check to be sure that the lockpins are seated in the holes and that the operating rod is in the locked position with the safety latch securing the operating rod Failure to achieve complete lockup may cause the trailer to detach from the tractor possibly resulting in serious personal injury or death NOTE The fifth wheel may have to be moved slightly to enable the locking pins to enter the fully locked position 8 Lock the sliding member into position using one of the following methods For air operated models Set the cab operated control switch to LOCK Vis
41. Label EPAO07 Exhaust Emissions Regulations EPAO07 Exhaust Aftertreatment System ATS Diesel Particulate Filter Maintenance EPAO7 ATS Operation Parked Regen Exterior Switches Battery Disconnect Switch F Federal Motor Vehicle Safety Standard FMVSS Labels Fire Extinguisher Index Subject Page Fire in tie Cab case 2 cen EE REOS mu ku id tied 13 4 In Case of a Cab Fire sls 13 4 Fontaine Fifth Wheels nnana anaana aaa 10 11 Fifth Wheel Locking Operalioti usse e E RE ta aai e 10 12 Fifth Wheel Lubrication 10 15 Fifth Wheel Slide Operation 10 14 General Information 10 11 Freightliner SmartShift Transmission Shift Control 8 1 General Information ln 8 1 Operation Eaton AutoShift TransmiSsslOH xax a a dala em de gene ber RR 8 1 Operation Meritor SureShift Transmission eee eee 8 4 Eres nas s d Bethe he bo de eat d de oedema psc et 4 4 Fuller Deep Reduction and Range Shift Models 0206 8 11 General Information 8 11 Opetatigh vac scm Rates na RS me ada E 8 11 Fuller Range Shift Models linn 8 6 General Information ll 8 6 Operation seg see dge e xe RSoUy bed 8 6 Fuller Splitter and Range Shift Modals 1 5 1 hee Ru RERO ducto une ORE E a ae 8 8 General Information
42. NU NRA eas 01 27 97 1601259 1 Red Alert Light vehicle or object detected 2 Ambient Light Sensor 3 Yellow Indicator Light no vehicle or object detected Fig 2 59 Side Sensor Display Instruments and Controls Identification 2 The ambient light sensor senses lighting condi tions and automatically adjusts the intensity of indicator and alert lights 3 The red alert light illuminates when objects are detected by the side sensor s If the right turn signal is activated and the side sensor detects an object the red alert light will illuminate and the DDU speaker will sound a high frequency double tone This tone is sounded only once per activation of the turn signal The red light will also illuminate and stay on if a failure of the side sensor is detected If objects are temporarily un able to be detected during heavy rain both the red and yellow lights will illuminate Special Road Situations Certain special road situations may affect the sys tem s ability to detect objects These situations in clude the effects of curves dips and hills which can provide an unexpected result NOTE A warning may sound when an object is detected in front of the vehicle even though the driver intends to turn away or stop before reach ing the object When an object is detected in a very sharp right or left hand turn the audible alarm will not sound When approaching a curve before turning into it alarms may s
43. Passenger s Side Using the Cab Access Stairs for Right Hand Drive Vehicles Fig 3 12 A WARNING If the optional cab access stairs do not move into position or if there is not enough room for them to deploy use the fixed steps on the outside sur face of the moving stairs Fig 3 5 and follow the access instructions for the standard fixed step system Freightliner recommends you practice using the fixed steps until you are familiar with their use Enter the cab only as specified in the following steps Keep your body close to the cab and maintain three point contact with the cab at all times This means one hand and two feet or two hands and one foot Do not lean out away from the cab Do not engage in horseplay Do not enter the cab with dirty or greasy hands or feet Disregarding this careful step by step procedure can result in your falling from the cab and pos sible personal injury or death IMPORTANT Do not attempt to exit the cab while carrying any items in your hands 1 Grasp the upper inside cab grab handle Fig 3 12 and stand in the threshold of the door facing into the cab 2 With your right hand grasp the forward grab handle 3 9 3 Move your right foot very carefully to the top step 4 Move your left hand to the lower inside cab grab handle and grip it tightly 5 Move your left foot to the next step 6 Maintaining three point contact with the cab at all times very carefully move your left hand
44. Release the parking brake Shifting Into a Starting Gear CAUTION Always use the proper starting gear Do not shift into neutral and coast as this will result in dam age to the transmission 1 Press the system switch down into the ON posi tion to activate the ESS system 2 Press the top portion of the shift intent switch IMPORTANT Use the clutch brake only when initially engaging a gear with the vehicle stand ing still 3 Push the clutch pedal to the bottom of its travel so that the clutch brake stops the transmission input shaft from rotating 4 Move the shift lever and engage a starting gear 5 Slowly release the clutch pedal NOTE If you do not shift the transmission out of neutral into a gear within two seconds the ESS system will time out and deactivate The trans mission returns to manual operation To reacti vate the ESS system press the shift intent switch again See the following procedures for upshifting and downshifting for instructions on how to use the shift intent switch Upshifting 1 To upshift into the next higher gear 1 1 Press the top portion of the shift intent switch 1 2 Apply pressure with the shift lever toward the neutral position 8 20 Transmissions 1 3 Press the top portion of the shift intent 3 To skip a gear press the shift intent switch into switch again far enough so that the the shift handle while in neutral one time for switch goes into a second posi
45. Side Shown ing the button will disable the stairs for one cycle of opening and closing the door The next time you open the door the stairs will deploy unless you ve pressed the disable button again The cab stairs will not operate in any of the following conditions The stairs will not deploy if the parking brake is not set The stairs will not deploy if the vehicle is in motion The stairs will automatically stow if the vehicle begins to move The stairs will not stow if there is any weight on them The stairs will not deploy if the cab is tilted The stairs will stop moving out if they hit any thing The stairs will stop moving out if you press the outside or inside buttons described above A WARNING If the optional cab access stairs do not move into position or if there is not enough room for them to deploy use the fixed steps on the outside sur face of the moving stairs Fig 3 5 and follow the access instructions for the standard fixed step system Freightliner recommends you practice using the fixed steps until you are familiar with their use Enter the cab only as specified in the following steps Keep your body close to the cab and maintain three point contact with the cab at all times This means one hand and two feet or two 3 2 Vehicle Access hands and one foot Do not lean out away from the cab Do not engage in horseplay Do not enter the cab with dirty or greasy hands or feet
46. UNINTENTIONAL VEHICLE MOVEMENT DO NOT MOVE SHIFT TO USE IDLE ENGINE CLOSE HOOD ENGAGE PARKING BRAKES PUT TRANSMISSION IN NEUTRAL AND HI RANGE IF EQUIPPED THEN OFE TOON SWITCH LEVER OR RANGE IF DESIRED TURN SELECTOR WHEN U THERMOSTAT ON ica EQUIPPED OPTIMIZED IDLE IS ON 11 13 96 1080062 Fig 7 14 Optimized Idle Dash Label 2 6 MODE 7 U WI ILI 8 1 11 08 96 10 9 1601250 1 Down Button 6 Mode Button 2 Up Button 7 Cooling Icon 3 Upper Lower 8 Cool Heat Selection Temperature Icon Button 4 Temperature Display 9 Heating Icon 5 Degrees Fahrenheit 10 Degrees Celsius Indicator Indicator Fig 7 15 Optimized Idle Thermostat The thermostat consists of an LCD readout and four buttons The display normally shows the temperature of the sleeper but changes accordingly as the buttons are pressed Up increases the set point and comfort zone Down decreases the set point and comfort zone Cool heat detects either cooling or heating operation Mode scrolls through the various functions It can also be used to set desired temperature values 1 Activate Optimized Idle engine mode as fol lows 1 1 Setthe parking brake 1 2 If it is tilted close and secure the hood 13 Start the engine and let it idle 1 4 Put the transmission in neutral 1 5 Turn on the cruise control IMPORTANT The cruise control must be turn
47. a 601896 HEADWAY EVENT DATA Accident reconstruction segment was saved WAS SAVED HDWY EVENT DATA NOT SAVED MEMORY FULL Second accident reconstruction segment was not saved Only one accident reconstruction segment may be saved OBJECT AHEAD Displayed if an object is detected and has a headway 0 5 to 1 second Also Y displayed if a very slow or stationary target is detected in the vehicle 1601891 headway OBJECT AREAD Displayed if an object is detected and has a headway of more than 1 second and up to 2 seconds 601892 Cee AHEAD Displayed if an object is detected and has a headway of more than 2 seconds and up to 3 seconds 601893 APPROACHING OBJECT 1601894 Displayed if an object is within 15 ft 4 5 m and the vehicle is traveling less than 5 mph 8 km h Table 2 3 ICU Display Messages The speaker provides audible alert tones to warn of closing on an object ahead and when equipped with a side sensor of objects alongside when the turn signal is activated in preparation for a lane change Additional tones indicate speaker volume system failure and data extraction pass or fail The object ahead alerts given by the system are based on headway to the vehicle ahead that is the time required by the host vehicle to travel ahead and reach the vehicle ahead A simple way to figure the headway is to look when the vehicle ahead drives by a certain object like a traffic sign and then start counti
48. available Driver Message Center Gear information is presented to the driver via the level IIl ICU Driver Message Center The current for ward numerical gear is displayed until a new gear is requested During the shifting process the letters SH appear until the shift is completed Then the newly engaged numerical gear is displayed When neutral N is engaged N will appear on the mes sage display screen When reverse R is engaged RL will appear on the message display screen IMPORTANT The information shown on the message display screen indicates the state of the transmission only not the state of the SmartShift control Neutral Position Neutral N is in the center of the three positions of the selector switch at the end of the control Select neutral by sliding the mode selector switch to the center position NOTE Neutral is always available during opera tion When in neutral upshift and downshift re quests are ignored If the mode selector switch is moved from neutral to forward F while the vehicle is moving the transmission will shift into a gear causing the engine to go to a high torque level under the engine s rated torque Selecting a Starting Gear 1 Select forward F by sliding the selector switch downward to the next position below the neutral position NOTE When forward is selected the transmis sion controller is signaled to engage the default starting gear 2 Select a different star
49. brake is activated 7 22 Engines and Clutches If the engine is equipped with both cruise control and an engine brake the engine brake can operate auto matically while in cruise control mode If the cruise control engine brake function is turned on the engine brake will come on low when the set road speed increases a few miles per hour kilometers per hour above the cruise set speed The maximum amount of braking low medium high is selected with the dash Switches When the vehicle returns to the set cruise speed the engine brake will turn off The engine brake will only operate when the accel erator pedal is fully released Disengaging the clutch will prevent the engine brake from operating Vehicles equipped with antilock braking systems ABS have the ability to turn the engine brake off if a wheel slip condition is detected The engine brake will automatically turn itself back on once the wheel slip is no longer detected The system will deactivate the engine brake when the engine speed falls below 1000 rpm or when the vehicle slows down to a pre set speed depending on programming to prevent stalling the engine For a specific explanation of the engine brake sys tem for your vehicle see the engine operation manual supplied with the engine Jacobs Engine Brake Operation Do not use the engine brake if road surfaces are slippery Using the engine brake on wet icy or snow covered roads could result in loss of
50. brakes and then drive the vehicle There would be no means of stopping the vehicle which could result in se rious personal injury or vehicle damage Before releasing the spring parking brakes make the connection to a towing vehicle or chock the tires After correcting the brake system problem uncage the spring parking brakes before resuming normal vehicle operation Brake System 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 passengers are wearing seat belts During normal brake stops depress the foot brake control pedal until braking action slows down the ve hicle Increase or decrease the pressure on the pedal so that the vehicle comes to a smooth safe stop Apply the spring parking brakes if the vehicle is to be parked IMPORTANT An air brake proportioning system is used in tractor air brake systems when the vehicle is not equipped with ABS When operat ing in bobtail mode the rear brake chambers whose axle load has been greatly reduced re ceive reduced or proportional air pressure while the front axle brake chambers receive full nor mal air pressure This results in a different brake pedal feel as the pedal seems to re quire more travel and or effort to slow or stop the vehicle However the air brake proportioning system actually improves vehicle control when the tractor is in the bobtail mode of operati
51. compart ment for manually working the tilt pump Hydraulic Lockup Hydraulic lockup can occur for the following reasons very cold temperatures use of the wrong hydraulic fluid air in the system e sudden cab movement a ruptured hydraulic line Vehicle Access continued pumping after the cab goes over center e tilt strut in locked position while lowering the cab Any of the above situations will cause the velocity fuses to function as check valves and lock up the tilt cylinders To unlock the cylinders the cab must be moved in the opposite direction of travel For example if the cab is moving toward the full tilt position when the lockup occurs move the control lever to Lower and work the pump a few strokes This will unlock the cylinders Move the control lever to Raise and allow the cab to descend to a full tilt position If the cab is moving toward the lowered operating position when the lockup occurs move the control lever to Raise and work the pump a few strokes This will unlock the cylinders Move the control lever to Lower and allow the cab to descend to the oper ating position Tilting the Cab Before tilting the cab make sure there is ad equate clearance in front of the vehicle and that the area is free of people and objects Do not tilt the cab with the engine running Tilt ing the cab could engage the transmission If the engine is running the vehicle could move caus ing a
52. continue engage the axle lock CAUTION Axle lock should only be engaged when the ve hicle is moving slowly at low throttle Engage ment at high speed or power can damage the axle s Do not engage the axle lock while the WHEEL SPIN light is on To do so could damage the rear axle See Chapter 9 for axle lock instructions Vehicles with electronic engines and ABS may have automatic traction control ATC On these vehicles the ATC system automatically limits wheel spin dur ing reduced traction situations If the vehicle has ATC there will be a momentary contact rocker switch on the dash labeled NORM SPIN and ATC When the ATC system is in the NORMAL mode it will apply gentle braking to the spinning wheel to feed power to the wheel s with better traction If both wheels are spinning the system will signal the electronic engine to reduce power 6 4 Steering and Brake Systems Pressing NORM SPIN will temporarily allow more drive wheel spin to help burn through a thin layer of ice or to help throw off accumulated mud or snow SPIN mode is indicated by a flashing WHEEL SPIN light Pressing NORM SPIN again will cycle the sys tem back to normal operation The Meritor WABCO ABS system combines one front axle control channel with one rear axle to form one control circuit For example the sensor and sole noid control valve on the left front axle form a control circuit with the sensor and solenoid control valve o
53. dash panel next to the climate control switches Windshield Washer Reservoir The windshield washer reservoir is located on the left hand side of the frontwall behind the access panel See Fig 3 31 Cab Front Access Panel CAUTION Step back from the front access panel when opening it The access panel can open quickly and could hit a person possibly resulting in per sonal injury Vehicle Access 03 26 98 1820313 1 Washer Reservoir Fig 3 31 Windshield Washer Reservoir The front access panel Fig 3 32 allows the driver access to the engine oil dipstick the coolant fill cap and the windshield washer reservoir To open the panel reach under the lower edge of the panel and release the two latches located near the lower cor ners See Fig 3 33 You must hold the left side latch open while lifting the access panel in order to hold the secondary latch open With the latches released grip the panel firmly with both hands and lift The panel will stay open until you grab the strap and pull it shut Make sure the panel is shut securely and both latches latch GED N i ES 04 03 98 1720304 NOTE The cab is shown partially tilted Fig 3 32 Opening the Front Access Panel 05 19 98 l 5 1500311 A Use this strap to close the access panel 1 Access Panel Left Hand Latch Fig 3 33 Access Panel Inside View Heater and Air Conditioner HVAC General InermasllOl i425 d ox dr R
54. downshifting too soon or missing the full use of a gear by downshifting too late The shift points of any vehicle can be deter mined by a simple road test method Run the vehicle and determine the maximum road speed possible in 7 15 every gear at the engine governed full load speed setting The top road speed possible in a gear would be the shift point for that gear The results should be re corded in the proper order of shifting and displayed inside the cab NOTICE Engine overspeed engine speed exceeds high idle no load rpm can damage the engine To slow the vehicle on downgrades and curves using the engine shift to a lower gear and allow the vehicle to decelerate in that gear The engine pro vides maximum braking effect when running at the top end of the operating range but it must not be allowed to exceed its full load rated rpm Continue to downshift as further reduction in vehicle speed is re quired If the vehicle is above the allowable maxi mum speed of a lower gear use the service brakes to slow the vehicle to an acceptable speed where the transmission may be downshifted safely Again the importance of knowing the shift points is demon strated IMPORTANT The engine governor has no con trol over engine rpm when the engine is being pushed by a loaded vehicle down a grade Use service brakes and gears in combination on long grades to keep the vehicle speed under control and the engine rpm below full load ra
55. engine oil temperature transmission fluid temperature rear axle temperature on vehicles with tandem axles forward rear and rear rear ammeter system air pressure primary secondary appli cation and suspension pyrometer turbo boost air pressure Some gauges have a red warning light integrated into the gauge These are listed below with an indi cation of how the warning light is activated engine coolant temperature high engine oil pressure low fuel level low e transmission fluid temperature high Keypad The ICUAM ICUAM 2 is controlled by a keypad lo cated on the auxiliary dash panel See Fig 2 26 This keypad which has 10 keys can be used to do the following tasks Call up information onto direct access screens while the vehicle is moving using the dedi cated keys TEMP FUEL TRIP and LEG 2 14 Instruments and Controls Identification 4 5 6 7 8 9 10 11 12 13 l o i E Y EE m j a 34 r OPT et OPT i N vse oer SEN OPT freck ene finrae water FASTEN SEATBELTS RACT TRLR eck oer 1 44 2 r ENGINE PROTECT HEATER iN rue 0000432 MILES ABS ABS j TRANS IDLE BRAKE t TEE E35 A EDIEN b 1 15 21 20 19 18
56. equipped with one or more devices that record specific vehicle data The type and amount of data recorded varies depending on how the vehicle is equipped such as the brand of engine if an air bag is installed or if the vehicle features a collision avoidance system etc Customer Assistance Center Having trouble finding service Call the Customer Assistance Center at 1 800 385 4357 or 1 800 FTL HELP Call night or day weekdays or weekends for dealer referral vehicle information breakdown coor dination or Fleetpack assistance Our people are knowledgeable professional and committed to fol lowing through to help you keep your truck moving Reporting Safety Defects If you believe that your vehicle has a defect which could cause a crash or could cause injury or death you should immediately inform the National Highway Traffic Safety Administration NHTSA in addition to notifying Daimler Trucks North America LLC If 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 Daimler Trucks North America LLC To contact NHTSA you may call the Vehicle Safety Hotline toll free at 1 888 327 4236 TTY 1 800 424 9153 go to www safercar gov or write to Administrator NHTSA 1200 New Jersey Avenue SE Washington
57. fixed steps until you are familiar with their use Enter the cab only as specified in the following steps Keep your body close to the cab and maintain three point contact with the cab at all times This means one hand and two feet or two hands and one foot Do not lean out away from the cab Do not engage in horseplay Do not enter the cab with dirty or greasy hands or feet Disregarding this careful step by step procedure can result in your falling from the cab and pos sible personal injury or death 1 Open the driver s door and place anything that you are carrying in the cab 2 Grasp the aft grab handle Fig 3 11 with your left hand and grab the forward grab handle with your right hand Reach up as far as you re com fortable 3 Very carefully place your left foot on the bottom step and pull yourself up 4 Place your right foot on the next step and care fully pull yourself up 5 Place your left foot on the top step and carefully move your left hand to the forward grab handle and your right hand to the steering wheel Hold on very tightly and maintain three point contact with the cab at all times 6 Then slowly move your right foot to the deck at the top of the stairs 7 Holding tightly to the steering wheel with your right hand move your left hand to the steering wheel 8 With both of your hands gripping the steering wheel tightly step into the cab with your left foot 3 7 1720309a 5 Aft Grab H
58. gear 15 speed transmissions to the top gear in low range see Table 8 2 double clutching between shifts and accelerating to 80 percent of engine governed speed While in the top gear of the low range shift pat tern and ready for the next upshift flip the range preselection lever up into high range Double clutch through neutral and shift into the bottom gear in high range see Table 8 2 As the shift lever passes through neutral the transmission will automatically shift from low range to high range With the transmission in high range shift pro gressively upward through each of the high range gears see Table 8 2 double clutching between shifts Alternate Upshifting Procedures 15 Speed Transmissions Only The shift from deep reduction to low range can also be made from 2nd 3rd or 4th gear of deep reduc tion but must be made to the next gear lower in the low range The shift from 2nd gear of deep reduction Transmissions to 1st gear in low range or 3rd gear of deep reduc tion to 2nd gear in low range and 4th gear of deep reduction to 3rd gear in low range is an upshift and the same procedure should be followed as that shown for shifting from 5th gear of deep reduction to 4th gear in low range See step 5 under Upshifting Downshifting 1 With the transmission in high range shift pro gressively downward to the bottom gear in high range double clutching between shifts 2 When in the bott
59. go from OFF to LOW and then to a higher position Engines and Clutches Engine Starting CAT Cummins DDE S60 M B Normal Starting Whenever you start an engine watch for any signs of engine problems If the engine vibrates misfires or makes unusual noises turn the engine off as soon as possible and determine the cause of the problem Frequently engine damage may be avoided by a quick response to early indications of problems NOTICE When starting a vehicle equipped with a manual transmission and clutch lockout switch the clutch pedal must be fully depressed during the entire start sequence Failure to do so can cause the pinion 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 rotating 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 the starter to bump the engine for maintenance pro cedures is strictly prohibited Use of these meth ods 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 IMPORTANT The starter cannot be used for priming the fuel system Priming is done by op erating the manual hand priming pump located on the fuel filter
60. have locked the tilt cylinders To unlock them see Hydraulic Lockup Returning the Cab from a Tilted Position Stay completely clear of the cab s travel path at all times Once the safety stop has been re leased don t lean over the frame rails the en gine or the transmission for any reason To do So could result in serious injury or death 1 Secure all loose articles in the cab and bunk and make sure the doors are securely latched 2 Make sure the parking brakes are applied Move the pump lever to the return position If the vehicle is equipped with an electric hydraulic tilt system make sure the tilt system power switch on the dash is activated 5 Check the cab travel path for obstructions 6 From full tilt operate the cab tilt pump until the cab reaches the balance point From that point the cab will continue to lower NOTE To slow the cab descent reverse the tilt pump lever after the cab passes the balance point 7 Allow the cab to lower to the safety stop 8 Move the safety stop away from the right tilt cyl inder rod you may need to raise the cab slightly See Fig 3 24 9 Lower the cab to the operating position and make sure the cab latches engage IMPORTANT If the cab stops after it has gone beyond 45 degrees don t force it down with the tilt pump The safety stop is in the locked posi tion or the velocity fuses have locked the tilt cylinders Release the safety stop or to unlock
61. 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 Freightliner Service Parts Catalog or contact your Freight liner Dealer 3 Check the steering wheel for excessive play 3 1 With the front tires straight ahead turn the Steering wheel until motion is observed at the front wheels 3 2 Align a reference mark on a ruler then slowly turn the steering wheel in the oppo site direction until motion is again detected at the wheels 3 3 Measure the lash free play at the rim of the steering wheel Excessive lash exists if steering wheel movement exceeds 2 1 4 inches 57 mm with an 18 inch 450 mm steering wheel If there is excessive lash check the steer ing system for wear or incorrect adjust ment of the linkage and steering gear be fore operating the vehicle 4 Check the brake lining wear on all vehicles in cluding those with automatic slack adjusters Proper brake operation is dependent on periodic maintenance and inspection of the brake linings 4 1 Check that brake linings are free of oil and grease 4 2 Inspect the thickness of the brake linings If the axle assembly is equipped with a dust shield or backing plate remove the inspection plugs If any brake linings are Pretrip Inspection and Daily Maintenance 4 3 4 4 wor
62. in a hazardous location the engine can be restarted after turning the key to the OFF position for a few seconds See Chapter 7 in this manual for the warning and shutdown modes associated with the exhaust after treatment system There is a progressive series of warnings for the aftertreatment system Controls Ignition Switch and Key The ignition switch has four positions ACCESSORY OFF ON and START The ignition key also locks and unlocks the cab doors baggage door s and if equipped the bunk door s In the OFF position the key slot is vertical the key can be inserted and removed only in this position The low beam headlights taillights brake lights road lights dome lights clearance lights turn signals hazard warning lights utility and baggage lights spotlights horn CB radio power mirrors cigarette lighter clock refrigerator fuel heater electric oil pan heater and electric or diesel fired engine coolant pre heaters can be operated in the OFF position regard less of whether the key is inserted In the ACCESSORY position the key is turned coun terclockwise The auxiliary bunk fan windshield fan s radio or stereo system mirror heat ether start system air dryer backup lights and all of the electri 2 5 cal systems that are operable in the OFF position are operable in the ACCESSORY position In the ON position the key is turned clockwise All electrical systems are operable Low air a
63. information screen press the down arrow key to display the vehicle information screen Press the right arrow key to display in order datalink activity datalink status and ICUAM ICUAM 2 data This sequence completes the vehicle information Screens From here press the right arrow key again to return to the vehicle information screen From any vehicle information screen press the left arrow key to return to the previous screen in the sequence Press the down arrow key to return to trip information Instrumentation Control Unit ICU3 Figure 2 38 shows the gauge portion of the dash for vehicles equipped with the ICU3 or ICU3 07 The ICU3 ICU3 07 electronic dashboard can accept information from the various sensors installed on the vehicle and feed it to electronic gauges Only air gauges operate mechanically There can be up to eight gauges on the driver s in strument panel six electronic and two mechanical The ICU3 ICU3 07 cannot drive gauges located on the auxiliary instrument panel The ICU3 is on vehicles with engines manufactured up until December 31 2006 and the ICU3 07 is on vehicles with engines manufactured January 1 2007 or later They can be differentiated by the ISO icons used on the ICU3 07 The dash message center is the heart of the ICU3 ICU3 07 It has a set of 26 warning and indicator lights similar to those found on a conventional light bar and a dash driver display screen The da
64. linch pin from the handle then push in on the handle and turn it toward you Open the pintle hook by pulling it down and toward you Release the handle lock ing the pintle hook open 6 Slowly drive the vehicle away from the trailer Holland Trailer Coupling General Information The Holland PH T 60 AL trailer coupling is de signed for use with trailers having a maximum gross weight of 10 000 pounds It is a rigid type pintle hook used only on truck applications and is fas tened to the rear closing crossmember of the vehicle See Fig 10 20 It is a non air adjusted coupling 01 20 95 1 Lock 2 Cotter Pin f310314a 3 Latch 4 Pintle Hook Fig 10 20 Holland PH T 60 AL Trailer Coupling Operation Trailer Hookup 1 Chock the front and rear tires of the trailer 2 Remove the cotter pin Then lift the lock and raise the latch Fifth Wheels and Trailer Couplings 3 Back up the vehicle until the drawbar eye is over the pintle hook 4 Lower the trailer until the drawbar eye rests on the pintle hook 5 Close the latch then insert the cotter pin NOTICE Always make sure the connect hanger support keeps the trailer air hoses and electrical cables positioned so that they do not rub on anything Rubbing may wear through hoses or cables re sulting in air leaks or exposed or broken wires potentially affecting trailer brake or electrical sys tems 6 Hook up the trailer s electrical an
65. occur when a vehicle with a turbo charged engine is started on a grade Do not disengage the clutch The rpm will recover and the vehicle will accelerate up the grade For city driving run in the highest gear possible and reduce engine speed This enables you to operate at a safe speed for traffic conditions while using less fuel and reducing noise Also when slowing down for reduced speed zones remain in your running gear and reduce engine rpm to stay within the speed limit Avoid downshifting until you are ready to return to highway cruising speed For highway cruising and for best fuel economy run the engine at 80 to 90 percent of rated rpm to main tain highway speed Engines with 1800 rpm ratings are exceptions and will provide fuel economy when run at their rated speed Proper gear selection 7 14 Engines and Clutches should permit cruising in the economy range with no appreciable sacrifice in desired highway speed It is okay to operate below rated rpm at full throttle if you are satisfied with the way the vehicle performs However there are times when hilly terrain high winds or other conditions make it impractical to op erate without reserve power Such conditions are bet ter met if the vehicle is operated in a lower gear with reserve power available for changes in terrain wind etc The proper use of gears will shorten time on hills and minimize the amount of shifting When starting up a hill gradually de
66. on the ICU If the vehicle is programmed for multiple drivers fol low the steps in Fig 2 62 to select identification of a driver SERVICE WARNING SCREEN PUSH ANY ARROW KEY PUSH Y ANY ARROW SELECT DRIVER 1 SELECT DRIVER 2 SET OK CHANGE SET OK lt CHANGE PUSH SET KEY or RELEASE PARK BRAKE Y FASTEN SEATBELTS e 123456 7 MILES PUSH SET KEY or RELEASE PARK BRAKE 09 12 2003 1610413 Fig 2 62 Driver Identification Setup Sequence SmartCruise Adaptive Cruise Control The Eaton VORAD EVT 300 Collision Warning System CWS with SmartCruise is intended solely as an aid for an alert and conscientious professional driver It is not intended to be used or relied on to operate a vehicle Use the system in conjunction with rearview mirrors and other instrumentation to safely operate the vehicle This system will not warn of many possible haz ards It will not adjust the vehicle speed for many 2 50 Instruments and Controls Identification possible hazards Do not assume it is all clear if no alert lights are illuminated and the Smart Cruise does not adjust vehicle speed Failure to drive safely and use the system prop erly could result in personal injury and or death and severe property damage On vehicles with SmartCruise the vehicle will not deactivate cruise control for stationary targets such as a car stopped in your traveling lane SmartCruise is an Adaptive Cruise
67. sources the operator accelerator pedal position engine brake switch etc other electronic control units for example the antilock brake system e the MOM oil pressure coolant temperature etc 1 5 California Engine Idle Limiting In order to meet the California engine idle limiting standard an engine idle shutdown feature has been built into the DDEC VI engine control strategy When the California engine idle limiting feature is enabled the engine will generally shut down after five minutes of continuous idling when the transmission is in neu tral or park and the parking brake is set or after fif teen minutes when the transmission is in neutral or park and the parking brake is not set Activating or momentarily changing the position of the service brake pedal the clutch pedal stop engine override switch the accelerator pedal or parking brake status during the final 30 seconds be fore a shutdown would otherwise occur will prevent the engine from shutting down and will reset the shutdown timer After an automatic shutdown the engine may be restarted and operated normally If a parked regen of the aftertreatment system is initi ated it will override the five minute idle shutdown The HEST lamp will flash every ten seconds indicat ing a regeneration is in progress and the driver is not controlling the engine idle The automatic shutdown feature is generally disabled on engines certified by the U
68. state and local regulations Replace damaged seat belts or seat belts that were worn in an accident and check all anchoring points Only qualified personnel familiar with air bag SPACE systems should replace the seat belts used in a vehicle with an air bag SPACE system The air bag SPACE system requires a spe cial seat belt Care must be taken to be sure the correct seat belt is used Keep all heavy objects in the cab secured 5 12 6 Steering and Brake Systems Staenmng SysISm eere tica kac RR ner E bbe EE AE CREE IEEE EEEREN cde REEF OHSS 6 1 Brake SYSE od o ebbe qe Kang hes Kusa uad iqq NOIRS A ue RI DEE E E ose 6 1 Steering and Brake Systems 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 centered 10 degrees as shown in Fig 6 1 See Group 46 of the Century Class Trucks Workshop Manual for steering adjustment procedures 1 es f F y 10 f q 10 Y oy 1 i 2 WC 10 10 N VA PA NS f s P4 N PN 10 15 98 1461694 1 9 o Clock 2 3 o Clock Fig 6 1 Proper Steering Wheel Position with tires pointed straight ahead CAUTION Never steam clean or high pressure wash the steering gear Internal damage to gear seals and ultimately the steering gear can result Power Steering System The power steering system consists of an integral steering gear
69. steering and loss of vehicle control possibly resulting in serious personal injury or death For lubrication instructions see Group 31 of the Century Class Trucks Maintenance Manual Premier Trailer Couplings General Information IMPORTANT Before operating the Premier cou pling refer to the Premier web site at www premier mfg com for complete safety operation and maintenance instructions Trailer couplings used only on trucks are attached to the rear closing crossmember Fifth Wheels and Trailer Couplings The Premier 260 and 460 trailer couplings Fig 10 18 have a rigid pintle hook and are air adjusted An air chamber mounted forward of the 1 coupling operates a push rod which pushes against 2 a shoe inside the coupling The shoe maintains con stant pressure on the eye of the trailer drawbar when it s over the pintle hook This takes up any slack in the trailer connection providing smoother towing and less wear on the pintle hook The air pressure is acti vated when the trailer brakes are released The Premier 690 trailer coupling Fig 10 19 has a moveable pintle hook and is nonair adjusted It is used for heavy duty applications Trailer Hookup Chock the front and rear tires of the trailer Open the coupling Models 260 and 460 Fig 10 18 Pull up on the pawl lock then while squeezing the pawl wedges together lift up the pawl assembly Lift up the latch and push it up against the pawl
70. symbol warning light and buzzer activate whenever the coolant temperature goes above Instruments and Controls Identification owe 3 10 11 12 13 e 5 6 HHHBHH 14 MI KM FASTEN SEAT BELTS 1 5 478 9 17 18 19 16 06 26 98 1601458 Typical installation shown Location and function of optional lights may vary 1 Left Turn Indicator 10 Message Display 2 Engine Protection Screen Warning Lamp 11 High Beam Indicator Indicator 12 Low Air Warning 3 Check Eng Indicator 13 Right Turn Indicator 4 Stop Engine Warning 14 Trailer ABS Warning 5 High Coolant Temp 15 Tractor ABS Warning Warning 16 Wheel Spin Warning 6 Low Oil Pressure 17 Park Brake On Warning Indicator 7 Optional Indicator 3 18 Recirc Air Warning 8 Optional Indicator 2 19 Optional Indicator 4 9 Optional Indicator 1 Fig 2 53 Dash Message Center ICU2L a maximum level specified by the engine manufacturer see the engine manual The red low oil pressure oil can symbol warn ing light and buzzer activate whenever the en gine oil pressure goes below a minimum level specified by the engine manufacturer see the engine manual The parking brake on PARK BRAKE warning light activates whenever the parking brake is engaged The recirculated air RECIRC AIR warning light activates whenever the ventilating system is switched to recirculated air Depending on options installed other warning and indicator lights can be installed in the spaces marke
71. target MPG feature allows quick and easy checking of fuel economy through the MPG Graph Target MPG Odometer screen See Fig 2 42 02ell 12 3MPG 9012 0MI R Fig 2 42 MPG Graph Target MPG Odometer Screen NOTE Use the LEFT ARROW key to lower the target MPG and the RIGHT ARROW key to raise it For more information on how to set tar get MPG adjust screen display brightness change languages or switch between USC and metric units of measure see Setup Information later in this chapter The Target MPG area is on the second line of the display to the left of the odometer It shows the ac tual target miles per gallon MPG Example A reading of 12 3 MPG indicates that the target MPG is 12 3 miles per gallon The MPG Graph on the first line of the display gives the same information in dynamic form The 0 mark in the center of the line gives the target MPG Bars showing to the right of the display indi cate that short term fuel economy is above the tar get bars showing to the left of the display indicate that short term fuel economy is below the target Brightness Control The panel light dimmer switch normally controls the brightness of all panel and gauge lights including the ICU2M message display screen With the parking brake set the ICU keypad can control the brightness of the message display screen independently of the other lights If the panel lights are set to maximum brightn
72. techniques On uphill grades begin downshifting when the en gine rpm falls to 1200 rpm for C 10 C 12 and 3406E electronic engines Fuel economy will be best if you let the engine lug back to around this speed before you downshift Downshift until a gear is reached in which the engine will pull the load Let the engine lug down if you can make it to the top of a hill without downshifting IMPORTANT Do not let C710 C 12 and 3406E electronic engines exceed 2300 rpm 2100 rpm if equipped with an exhaust brake On a downhill grade do not coast or put the trans mission in neutral Select the correct gear that does not allow the engine to exceed its maximum speed Use the brakes to limit the truck speed 7 13 A simple rule to follow is to select the same gear or one gear lower that would be needed to go up the grade As with any engine prolonged idling of Caterpillar engines is not recommended An idling engine wastes fuel and if left unattended is also unsafe Caterpillar engines can be programmed to shut off automatically after a specified idling time The vehicle transmission must be in neutral and the parking brake must be set for the automatic shutoff option to work Normal Operation Cummins Cummins CELECT Plus is an electronic fuel control system These electronic engines are controlled by a microprocessor based computer This computer con trols specific engine and vehicle speed modes of op eration to ma
73. the defrost mode This dries the air Heating 1 With the engine at operating temperature move the temperature control switch all the way clock wise for heat See Fig 4 5 Turn on the fan switch to the desired speed e Move the air selection switch to the desired set ting IMPORTANT If the windows start to fog move the air selection switch to defrost windshield and make sure the fan is on To defog the driv er s door window turn the extreme left dash face outlet to direct airflow to the upper left 4 2 Heater and Air Conditioner 9 07 95 1830719 1 Fan Switch 2 Air Selection Switch 3 Temperature Control Switch at Warm 4 Fresh Air Recirculation Switch Fig 4 5 Heating Settings NOTE In mild weather the fan switch can be kept off since forward motion of the vehicle will provide airflow through the heater 4 fthe vehicle has a sleeper with a rear climate control panel set the controls as desired For instructions refer to Heating Auxiliary Heater and Air Conditioner 5 When a comfortable temperature has been reached adjust the fan switch setting and tem perature control as needed to maintain the tem perature IMPORTANT To prevent the buildup of fumes or odors inside the cab for example from smok ing do not operate the heater and air condi tioning system in a recirculation mode for more than 20 minutes Air Conditioning IMPORTANT Operate the air conditioner at
74. the driver s identifi cation card has been successfully read One low tone will sound if the driver s card has been un successfully read If so configured a repeated low tone will sound if the system is on and the requested driver s card has not been inserted The yellow alert light illuminates when an object is detected within the system s maximum range of 350 feet 107 meters on a straight road Range is reduced in curves by the turn radius of the curve This light also illuminates when the proximity alarm threshold is crossed The orange alert light illuminates along with the yellow alert light when your vehicle is within a two to three second following interval behind another vehicle in the same lane If you are within a two second following interval and clos ing on the vehicle ahead a warning tone will also sound The red alert light illuminates along with the yel low and orange alert lights when you are less than one second behind a vehicle If the vehicle ahead is opening the interval no tone will sound If you are closing the interval double tones will sound Within a 1 2 second or less following in terval opening or closing the tones will repeat twice per second If a stationary vehicle or object or an object moving at least 20 percent slower than your ve hicle is detected within 220 feet 67 meters and within 3 seconds all three alert lights will illumi nate and the double tones will sound
75. the driver via the level III ICU Driver Message Center In automatic drive mode the number of the forward gear currently engaged appears continually on the message display screen when in drive D In manual shift mode the current gear is displayed until a new gear is re quested When neutral N is engaged N will ap pear on the message display screen When reverse R is engaged on 10 or 18 speed AutoShift trans missions either RL or RH will appear on the mes sage display screen AutoShift transmissions with fewer speeds do not have a dual range reverse gear and R will appear when reverse is engaged IMPORTANT The information shown on the message display screen indicates the state of the transmission only not the state of the SmartShift control Neutral Position Select neutral N by sliding the selector switch to the N position NOTE Neutral is always available during opera tion When in neutral upshift and downshift re quests are ignored If the mode selector switch is moved from neutral to drive D while the ve hicle is moving the transmission will shift into a gear causing the engine to go to a high torque level under the engine s rated torque Selecting a Starting Gear 1 In automatic mode select drive D by sliding the selector switch downward to the next position below the neutral position 2 Disengage the clutch to engage the gear se lected Engage the clutch and drive the vehicle NOT
76. the headlights are on high beam The yellow Check Engine CHK ENG light comes on to indicate an engine condition such as low coolant level high coolant temperature or low oil pressure It also comes on when a fault is detected or recorded The red Engine Protection ENG PROT light comes on to warn that the protection system available on the engine has been activated Installed on Cummins engines only the red Stop Engine STOP ENG light comes on to warn that the engine is not functioning nor mally The vehicle should be pulled over to the side of the road and the engine shut down im mediately The red low air pressure LOW AIR warning light and buzzer come on whenever air pres sure in the primary or secondary air reservoir falls below 64 to 76 psi 440 to 525 kPa Depending on options installed other warning and indicator lights can be installed in the spaces marked OPT Available optional indi cator lights include air bag warning alternator no charge warning automatic transmission overheat warning trailer ABS warning ECAS electronic suspension transfer indicator and ECAS failure warning NOTE The functions of the ABS warning lights are explained under Meritor WABCO Antilock Braking System ABS later in this chapter Keypad The ICU2M is controlled by a keypad located on the auxiliary dash panel See Fig 2 44 This keypad which has 10 keys can be used for the following tasks e Read and
77. the ignition switch back to the ON position and try again to start the engine 7 9 2 3 As soon as the engine starts release the ignition switch allowing the engine to run at a slow idle NOTICE If the oil pressure is less than 5 psi 35 kPa shut down the engine immediately to prevent serious damage If the vehicle is equipped with an auto matic shutdown system the engine will shut down after 30 seconds 3 Run Caterpillar C 10 C 12 C 15 C 16 engines at low load and speed once the engine oil pres sure has reached 10 to 20 psi 69 to 138 kPa Run a Caterpillar 3406E engine at low load and speed once the engine oil pressure has reached 18 psi 124 kPa 4 Operate the engine at full load when the engine has reached the normal operating temperature of 189 F 87 C Cummins Perform the steps in Prestart first 1 Turn the ignition switch to the ON position Fig 7 9 All the electronic gauges on the ICU instrumentation control unit complete a full sweep of their dials the warning and indicator lights light up and the buzzer sounds for three seconds 2 Turn the ignition switch to the START position After the engine starts release the key NOTE Some starters are equipped with op tional overcrank protection If overcranking oc curs a thermostat breaks the electrical circuit to the starter motor until the motor has cooled 3 Bring the engine up to operating speed gradually as it warms up and
78. the life of your vehicle s finish follow these guidelines Avoid washing your vehicle in the hot sun e Always use water After the cab is completely washed dry it with a towel or chamois Do not dust painted surfaces with a dry cloth as this will scratch the paint Do not remove ice or snow from a painted sur face with a scraper of any sort To prevent damage to the finish wax it regu larly Before waxing if the finish has become dull remove oxidized paint using a cleaner specifically designed for this purpose Remove all road tar and tree sap before waxing Freightliner recommends 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 with water To prevent rust have any nicks or other dam age on the finish touched up as soon as pos sible Park your vehicle in a sheltered area whenever possible Care of Fiberglass Parts Wash unpainted fiberglass air fairings and shields monthly with a mild detergent such as dishwashing liquid Avoid strong alkaline cleansers Apply a wax specifically designed for fiberglass 12 1 Care of Chrome Parts To prevent rust keep chrome parts clean and pro tected at all times This is especially important during winter driving and in coastal areas where there is exposure to salt air When cleaning chrome parts use clean water and a soft
79. the original position to remove it NOTE The cab door locks can be operated when the doors are open To lock a door from outside the cab insert the key in the lockset and turn it opposite the unlocking direc tion then close the door if it is open Or push down the inside lock button Fig 3 2 then close the door To lock either door from inside the cab push down the lock button Fig 3 2 then close the door if it is open Pull the integral grab bar Fig 3 2 when clos ing the door To open the door from the inside pull the door handle toward you Fig 3 2 This will unlatch the door whether or not it is locked To unlock the door without unlatching it pull the lock button up 3 1 C S Ne SON MON N DIT ACT N NS 3 Door Handle 4 Grab Handle 05 15 98 1720311 1 Lock Button 2 Integral Grab Bar Fig 3 2 Door Interior Cab Access WARNING Wet or dirty shoe soles greatly increase the chance of slipping or falling If your soles are wet or dirty be especially careful when climbing onto or down from the back of cab area Always maintain three point contact with the back of cab access supports while entering and exiting the back of cab area Three point contact means both feet and one hand or both hands and one foot on the grab handles steps and deck plates Other areas are not meant to sup port back of cab access and grabbing or step ping in the wrong place could lead to a fal
80. the panel lamps is activated by the headlight switch When the headlights are on the panel lamp switch controls the intensity of the instru ment panel lamps Slide the switch up to brighten them and down to dim them Headlight Switch and Daytime Running Lights A three position headlight switch is used to operate the exterior lights When the switch is up the head lights and all other vehicle lights are on All vehicle lighting is off when the switch is in the middle posi tion When down the switch activates only the clear ance instrument panel marker lights and the tail lights The switch for the headlight high beams is built into the turn signal lever When the headlights are on high beam a blue light in the warning and indicator light module goes on The ignition switch must be on for the high beams to operate 2 7 Switching on the ignition and releasing the parking brakes automatically activates the daytime running lights The daytime running lights will operate until the parking brakes are applied then they will switch off The vehicle must not be driven unless the day time running lights are activated Interrupt Switch A spring loaded interrupt switch temporarily deacti vates the marker lights and taillights With the vehicle lights on raise and release the interrupt switch to briefly turn off the marker lights and taillights To alert the driver that the switch is functioning the dash lights will flash with t
81. the vehicle such as a guard rail wall tunnel or bridge may cause the side sensor alert light to stay on In Case of Accident The accident reconstruction capability provides two segments of system data one of which can be stored in system memory Push and hold the DDU range knob for about 5 seconds to store the first seg ment Within 6 seconds the green SC indicator light will blink rapidly 8 times confirming that the data has been saved If the range knob is pushed again a fail tone will sound After the first segment is saved the second segment runs continuously but only contains the last 10 minutes approximately of system data NOTE Once the first memory segment is fro zen the other can t be frozen Only by discon necting the main CPU connector can the sec ond memory segment be preserved You must return the CPU to Eaton VORAD for download ing and interpretation of accident reconstruction data Maintenance and Diagnostics 1 Keep the antenna assembly and side sensor s free of a buildup of mud dirt ice or other debris that might reduce the system s range 2 46 Instruments and Controls Identification 2 The system tests itself continuously and evalu ates the results every 15 seconds If a problem is detected with the front radar system the red FAIL light on the DDU illuminates continuously as long as the failure is active The corresponding fault code is stored in the CPU s memory 3 Both active a
82. to be encountered requires Proper lubrication with low temperature lubri cating oils Protection from the low temperature air The metal temperature does not change but the rate of heat dissipation is affected Fuel of the proper grade for the lowest tem perature Heat to raise the engine block and component temperatures to at least 25 F 32 C for starting in lower temperatures Electrical equipment capable of operating in the lowest expected temperature All switches connections and batteries in the electrical sys tem should be inspected and kept in good con dition to prevent losses through poor contacts Arctic specifications refer to the design of material and specifications of components necessary for sat isfactory engine operation in extremely low tempera tures to 65 F 54 C Contact the nearest Freight liner dealer or Cummins engine dealer to obtain the special items required NOTICE Antileak antifreezes are not recommended for use in Cummins engines Although these anti freezes are chemically compatible with DCA water treatment the antileak agents may clog the coolant filters IMPORTANT Fuel heaters used on vehicles with Cummins CELECT Plus engine systems could cause high fuel temperatures that affect engine performance and operation of the elec tronic engine controls If a fuel heater is used make sure it has thermostatic controls If the fuel heater has a timer set the timer to a
83. to or disconnect from a trailer A control valve switch Fig 2 12 exhausts and fills the air sus pension To exhaust air from the suspension move the switch to LOWER A guard is positioned around the switch to minimize accidental activation SUSPENSION LOWER AIR AUTO TRAILER PARKING BRAKES MUST BE APPLIED 09 26 95 f350143 Fig 2 12 Air Suspension Dump Valve Instruments and Controls Identification NOTICE Do not operate the vehicle over uneven ground such as ramps speed bumps curbs etc with the air springs deflated Doing this may lead to air bag separation from the piston preventing the suspension air springs from reinflating NOTICE Never exhaust air from the suspension while driving If the air is exhausted the suspension will not absorb road shocks and could be dam aged Lane Guidance System Rocker Switch The lane departure warning system is controlled by a dash mounted rocker switch that toggles the system on and off Additional information is detailed later in this chapter Automatic Engine Idler Timer A Henke automatic engine idler timer allows the driver to select the idle time required for engine shut down The driver can turn off the ignition remove the ignition key lock the vehicle and leave it with the engine idling the automatic timer will shut the engine off at the end of the selected time Cigarette Lighter Push in the lighter to heat the element The li
84. to the cab forward outside grab handle Then move your right hand to the cab aft outside grab handle 7 Move your right foot to the bottom step 8 Step to the ground with your left foot 9 Let go of the grab handles Exiting the Cab When the Access Stairs Do not Fully Deploy Close the door Make sure the park brake is applied Look to see if there is an obstruction in the travel path of the steps e Start the engine to increase battery voltage e f the vehicle is parked at an incline greater than 3 5 degrees fore aft or side to side move it to a level surface if conditions permit Open the door If the steps will not fully deploy but will return to a fully stowed position the steps can be temporarily disabled by depressing the step toggle Switch on the dash panel and opening the door at the same time Exit the cab using the instructions for fixed access steps Exiting the Cab When the Access Stairs Do not Fully Stow Open and close the door If the steps do not fully stow check the following items Look to see if there is an obstruction in the travel path of the steps e Start the vehicle to increase the battery volt age e f the truck is parked at an incline of greater than 3 5 degrees fore aft or side to side move it to a level surface if conditions permit Vehicle Access Open and close the door If the steps will not stow after the above action items have been checked at tempt to st
85. to warn the driver of potentially dangerous situations A side sensor s mounted on the side of the vehicle also transmits and receives radar signals for a dis tance of 2 to 10 feet 0 5 to 3 meters alongside your vehicle The side sensor can detect unseen ve hicles and objects moving and stationary adjacent to your vehicle IMPORTANT Ensure that the B pillar door is closed and secured when the vehicle is in op eration Unintended motion of the B pillar door will affect the CPU s internal gyroscope The System may provide an incorrect or unneces sary warning or no warning when one is re quired The Eaton VORAD EVT 300 Collision Warning System CWS is intended solely as an aid for an alert and conscientious professional driver It is not intended to be used or relied on to operate a vehicle Use the system in conjunction with rear view mirrors and other instrumentation to safely operate the vehicle Operate this vehicle equipped with the EVT 300 Collision Warning System in the same safe manner as if the EVT 300 Collision Warning System were not present The EVT 300 Collision Warning System is not a substitute for safe normal driving procedures nor will it compensate for any driver impairment such as drugs alcohol or fatigue The EVT 300 Collision Warning System may pro vide little or no warning of hazards such as pe destrians animals oncoming vehicles or cross traffic On vehicles with SmartCruise the ve
86. turned off the engine should be shut down and the en gine brake repaired before continuing operation Failure to do so could result in damage to the en gine Turbo Brake MBE4000 only For high braking output the Mercedes Benz MBE4000 engine can be equipped with an optional turbo brake The turbo brake redirects the exhaust gas flow through the turbocharger to provide 600 brake horsepower The turbo brake can be operated either manually or automatically through the cruise control function Because the charge air pressure is maintained at a high level during braking full throttle response is available immediately if the operator desires it with out any turbo lag The turbo brake is maintenance free highly reliable and adds virtually no weight to the engine Constant Throttle Valves MBE4000 only To increase braking performance the Mercedes Benz MBE4000 engine can be equipped with con stant throttles in each combustion chamber Small valves built into the cylinder head allow a small amount of compressed air to escape through the ex haust port during the combustion stroke The constant throttle valves are open during the entire time that the engine brake is activated Although some braking ability is lost because the valves are constantly open constant throttle braking is quieter in operation than other types of engine brakes When both the exhaust brake and the constant throttles are installed a three position s
87. vehicle a certifica tion 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 1 1 s MFRDBY FRONT AXLE GAWR UNE e FIRST INTERMEDIATE AXLE GAWR E gwar SECOND INTERMEDIATE AXLE GAWR i VEHICLE ID NO 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 J 11 21 96 080053 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 for the system Fig 1 2 Certification Label U S 11 01 95 1601086 1 Tire and Rim Labels 2 Certification Label Fig 1 3 Labels Location CHAGSIS CAB MFD BY VEHICLE ID NUMBER THIS CHASSIS CAB CONFORMS TO FEDERAL MOTOR VEHICLE SAFETY STANDARD NOS 101 102 108 104 106 107 111 11 115 120 12 24 205 206207 208209210 300 THIS VEHICLE WILL CONFORM TO STANDARD NO IF TIS COMPLETED IN ACCORDANCE WITH THE INSTRUCTIONS CONTAINED IN THE INCOMPLETE VEHICLE DOCUMENT FURNISHED PURSUANT TO 49CFR PART S68 CONFORMITY TO THE OTHER SAFETY STANDARDS APPLICABLE TO THIS V
88. 0 1 2 TOWING ues selon mero et Dopo ku RES eme ges 13 1 Front Towing HOOKUP sex mk 13 1 Rear Towing Hookup 5 13 2 V Vehicle Specification Decal 1 1 Velour Upholstery Cleaning LL 12 2 Chewing Gum or Wax 0 0000 00 ee 12 3 Grease and Oil Based Stains 12 2 NOW iesu ceres hie Ait Tte duke i eR Backs Sot s 12 3 Sugar and Water Based Stains ss eee eee epee eS R3 RR UE R9 PUR 12 2 Vinyl Upholstery Cleaning liess 12 1 Ball Point Ink ass kem 12 2 Chewing GUM arosa i n RR mh Ru 12 2 Miscellaneous 20005 12 2 Nail Polish and Nail Polish FOMOVER ou zu mompa A eR Ae eo eee 12 2 Ordinary Dirt us eiu mom Pee eas 12 1 Paint Shoe Heel Marks 12 2 Shoe Polish 52i2453Bbee ex ne 12 2 Sulfide Stains 200020000 12 2 Tars Asphalts and Creosote 12 2 W Windshield Washer Reservoir 3 21
89. 1 J 3 01 06 95 f910068a A Pull on the loose end to shorten the belt 1 Buckle 3 Link 2 Belt Release Button Fig 5 12 Bunk Restraint Adjustment Bunk Restraint Operation 1 Starting at the foot of the bunk pull up the link end of the belt far enough to engage the buckle See Fig 5 13 2 A E ra 1 5 02 14 96 910150 1 Mattress 4 Belt Anchor 2 Sleeper Wall 5 Buckle 3 Restraint Fig 5 13 Bunk Restraint 2 Fasten the belt by pushing the link end into the buckle until they latch Make sure that the belt is not 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 re place the belt Repeat steps 1 and 2 for the 5 8 Seats and Seat Belts other two belts located in the middle and upper portion of the bunk to lock the restraint in place 3 To release the bunk restraint push the release button on the buckle at the head of the bunk and pull the link from the buckle Repeat this step for the other two buckles to completely release the bunk restraint Supplemental Restraint System Optional The supplemental restraint system can consist of an air bag and SPACE system or an air bag only sys tem Your vehicle may or may not have a supple mental restraint system Air Bag Optional The air bag when used with seat belts provides ad ditional protection to the driver in severe frontal colli
90. 1 D or winterized 2 D diesel fuel only A WARNING The addition of kerosene lowers the flash point of diesel fuel To prevent fire and risk of injuries due to burning do not smoke or use open flames around fuel mixed with kerosene Comply with all appropriate safety regulations NOTE Engine power may drop according to the proportion of kerosene For this reason never add more than 50 percent kerosene to the fuel High Altitude Operation 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 three percent for each 1000 feet 300 m altitude above sea level for a naturally aspirated engine Most turbocharged en gines are rated for higher altitudes than naturally as pirated engines An engine will have smoky exhaust at high altitudes unless a lower gear is used The engine will not de mand 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 7 19 Engine Shutdown CAT Cummins DDE S60 M B Caterpillar NOTICE Stopping the engine immediately after it has been working under load can result in overheating and accelerated wear of the engine components Ex cessive temperatures in the turbocharger center housing will cause oil coking problems Follow the procedure outlined below to allow the engine to cool 1 With the vehicle s
91. 17 16 12 01 2004 1610707a 1 Left Turn Signal 12 Wheel Spin Indicator 2 Check Engine Indicator 13 Check Transmission Indicator 3 Optional Indicator 14 Optimized Idle Indicator 4 Engine Protection Warning 15 Right Turn Signal 5 Intake Heater Indicator 16 Low Air System Pressure Warning 6 Air Filter Indicator 17 High Beam Indicator 7 Water in Fuel Indicator 18 Parking Emergency Brake Warning 8 Message Display Screen 19 Fasten Seat Belt Warning 9 Tractor ABS Indicator 20 No Charge Indicator alternator 10 Message Indicator 21 Low Vehicle Battery Voltage 11 Trailer ABS Indicator Fig 2 23 ICUAM Dash Message Center typical Pre 2007 3 4 5 6 7 8 9 e eN d 7 jorr emi OPT OPT OPT o ee E gt FASTEN SEATBELTS amp amp 1 opt 49 j IN d ic ia 0000432 MILES 8 oy IDLE 1 Qe ED MH pem 5 A 17 16 15 14 13 12 09 27 2006 161094 1 Left Turn Signal 10 Optimized Idle Indicator 2 Check Engine Indicator 11 Right Turn Signal 3 Stop Engine Warning 12 Low Air System Pressure Warning 4 High Exhaust System Temperature HEST Warning 13 High Beam Indicator 5 Diesel Particulate Filter DPF Status Lamp 14 Parking Emergency Brake Warning 6 Message Display Screen 15 Fasten Seat Belt Warning 7 Tractor ABS Indicator 16 Malfunction Indicater Lamp MIL 8 Trailer ABS Indicator 17 Low Vehicle Battery Voltage 9 Check Transmission Indicator Fig 2 24 ICUAM 2 Dash Message Ce
92. 2 to the middle posi tion The switch in the middle position gives full con trol of the auxiliary heater air conditioner to the sleeper bunk mounted control panel The sleeper bunk fan is turned off when the switch is in the bottom position The sleeper bunk fan is on high when the switch is in the top position NOTE Whenever the refrigerant compressor is operating the fan will always run at a very low speed even with the fan control knob in the Off position This prevents ice from forming on the evaporator especially during humid weather 2 Turn the temperature control knob all the way clockwise to HEAT Turn the fan control knob to position 3 See Fig 4 3 3 When the sleeper compartment heats to the de sired temperature turn the temperature control knob counterclockwise to adjust outlet air tem perature Then turn the fan control knob to ad just the air flow level The system will automatically maintain the se lected outlet air temperature 4 Whenever heat is not desired turn the tempera ture control knob counterclockwise as needed and turn off the fan IMPORTANT To prevent the buildup of fumes or odors inside the sleeper for example from smoking do not operate the heater and air con ditioning system in a recirculation mode for more than 20 minutes Air Conditioning Auxiliary Sleeper Bunk Heater and Air Conditioner 1 Turn on the cab air conditioner refer to Air Con ditioning and set th
93. 20 of the Century Class Trucks Workshop Manual for in structions or take the vehicle to an autho rized Freightliner dealer 5 Inspect the engine and chassis wiring Check for loose wiring chafed insulation and damaged or loose hold down clamps Tighten loose wires or hold down clamps replace dam aged wiring or clamps 6 Inspect the air intake system for leaks or dam age CAUTION Failure to maintain a sealed air intake system could allow the entry of dirt and contaminants into the engine This could adversely affect en gine performance and result in engine damage 6 1 Check the intake air restriction indicator 6 2 Replace the primary filter element in the air cleaner if the yellow signal stays locked at 25 inH2O for Caterpillar engines or 20 inH O for Mercedes Benz engines See Group 09 of the Century Class Trucks Workshop Manual for filter element replacement instructions or take the ve hicle to an authorized Freightliner dealer NOTE After replacing the filter element reset the restriction indicator by pressing the rubber reset button 6 3 Inspect the secondary or safety filter ele ment in the air cleaner when replacing the primary element and replace it when clogged or dirty This element should be replaced with every third primary element replacement 6 4 Check the engine air intake piping from the air cleaner to the engine intake In spect the piping for loose connections cracks torn or colla
94. 9 115B RSX9 115R RSX9 125A RSX9 125B RSX9 125R RSX9 135A RSX9 135B RSX9 135R RSX9 145A RSX9 145B RSX9 145R RSX9 155B and 10 speed M 11F10A E11 M 12F10A E12 M 13F10A E13 M 14F10A E14 M 15F10A E15 MO 11F10A E11 MO 12F10A E12 MO 13F10A E13 MO 14F10A E14 MO 15F10A E15 MO 16F10A E16 MO 11F10C E11 MO 12F10C E12 MO 13F10C E13 MO 14F10C E14 MO 15F10C E15 MO 16F10C E16 M 14F10A E16 MO 14F10A E16 MO 14F10C E16 MO 16F10C E18 RS10 115A RS10 125A RS10 135A RS10 145A RSX10 115A RSX10 115C RSX10 125A RSX10 125C RSX10 1354A RSX10 135C RSX10 145A RSX10 145C RSX10 155A RSX10 155C RSX10 165A and RSX10 165C transmissions do not require use of the clutch except to start and stop the vehicle NOTE Meritor M and MO series ESS transmis sions are available only on vehicles equipped with either Caterpillar or Cummins electronic engines Meritor RS and RSX series ESS trans missions are only available on vehicles equipped with Detroit Diesel electronic engines The ESS system works with the engine fuel control system to automatically synchronize en gine rpm to road speed during gear changes Use the clutch only to start and stop the vehicle and to shift into forward or reverse The HI and LO ranges are automated so the driver does not have to select ranges A break torque fea ture allows the driver to move the shift lever and take the transmission out of gear without chang ing
95. A i LAST OCCUR 123456 7 LAST OCCUR 123456 7 gt E 1234 TIMES AMT lt 1234 TIMES AMT 1 1 v FIRST OCCUR 123456 7 FIRST OCCUR 123456 7 D 1234 TIMES AMT 1234 TIMES AMT V V y vy ALL FAULTS CLEARED AMT a f040702 AMT Current gear information for automated manual transmissions NOTE With less than 254 miles on the odometer clearing historical faults also clears the memory of the electronic unit Fig 2 33 Diagnostic Information Screens IMPORTANT Do not attempt to clear active faults Bring the vehicle to an authorized Freightliner service facility as soon as possible From here press the right arrow again to return to the diagnostic information screen From any active fault diagnostic screen press the left arrow key to return to the previous screen in the sequence Press the down arrow key to go on to historical fault infor mation Historical Faults Historical faults dash faults only are kept in the ICU4M ICU4M 2 s memory after the active fault has been cleared The data are useful for situations where the same fault recurs over time to indicate an underlying problem that may otherwise escape atten tion From the diagnostic information screen press the down arrow key to display the historical faults infor mation screen Press the right arrow key again to display each individual historical fault in order until the end of the list
96. ACE Seats and Seat Belts 3 A B 07 29 97 LF 1910235 A Seat Tether Without the SPACE System B Seat Belt Assembly B Pillar Components 1 Height Adjuster 5 Buckle 2 Shoulder Loop 6 Buckle Cable 3 Seat Belt 7 SPACE Module 4 Latch 8 Seat Tether Fig 5 15 SPACE System Seat Belt Assembly system is designed for adults only Failure to fol low these instructions may result in personal in jury or death The operational readiness of the SPACE system is indicated by the supplemental restraint system SRS indicator on the dash The SRS indicator comes on when the engine is started and then goes off The indicator will remain on if there is a problem with the air bag or SPACE system The vehicle should be serviced if the SRS indicator does not come on when the engine is started or if the SRS indicator remains on Safety Guidelines for the SPACE System The SPACE system contains components that use combustible chemicals Because these chemicals are combustible care must be taken when replacing or handling system components Do not attempt to service the air bag SPACE sys tem Damaged or deployed air bag SPACE sys tems should be examined only by qualified per sonnel before any attempt is made to remove replace or handle the air bag SPACE system components All intentional deployments and testing of the system should be performed by trained personnel Unintentional or improper de ployment of the air bag SP
97. ACE system could cause severe bodily injury or death Do not attempt to service or to disassemble the SPACE module The SPACE module cannot be serviced Doing so could result in severe bodily injury or death Although the air bag SPACE system components will not likely explode self deploy or produce shrapnel care must be taken when it is neces sary to replace or perform work around the air bag SPACE system components Review and comply with the following list of warnings Fail ure to do so could result in severe injury or death Do not cut drill braze solder weld strike or probe any part of the air bag SPACE sys tem Keep all liquids acids halogens heavy metals and heavy salts away from the air bag SPACE system Do not expose the air bag SPACE system components to electricity Do not attempt to adapt reuse or install an air bag SPACE system in any vehicle other than the specific vehicle for which it is de signed Keep hands and tools away from the scis Sor points under the seats Do not cut wires or tamper with the connec tors between the vehicle wiring harness and the air bag SPACE system Cutting or removing the electrical connectors could cause unintentional deployment Do not expose the air bag SPACE system to electricity Never probe a circuit Seats and Seat Belts Store transport dispose and recycle de ployed air bag SPACE system components in accordance with all applicable federal
98. Avoid ultra deep discharging Repeated ultra deep discharging of a gel cell will sig nificantly reduce its life To protect against ultra deep discharging a low volt age warning alarm and indicator light activate when the battery voltage falls to 12 0 volts or less To si lence the alarm turn off all cab electrical loads or start the engine 2 6 Instruments and Controls Identification IMPORTANT To recharge a gel cell see an au thorized Freightliner dealer or the instructions in Group 54 of the Century Class Trucks Work shop Manual Road Light Switch The road light switch operates the road lights mounted on the bottom edge of the front bumper or recessed in the front bumper For vehicles built to operate in the United States the low beam headlights must be turned on before the road lights can be turned on The road lights will not go on if the high beam headlights are already on and switching from low beams to high beams will switch off the road lights For vehicles built to operate in Canada the marker lights must be on before the road lights can be turned on Utility Light Switch Utility lights can be swivel mounted on top of the cab mounted on the intake exhaust support or flush mounted in the back of the cab or sleeper box They are operated by the utility light switch which when turned on also illuminates a red indicator light in the switch if equipped Panel Lamp Control Switch The circuit to
99. Baggage Compartment Door Release Fig 3 18 Baggage Door Release Location Follow these rules for back of cab access Failing to follow these rules could lead to a fall and pos sible personal injury Never step on any exterior part unless it has a slip resistant surface meant for safe stepping If the surface is movable such as a battery box Vehicle Access 09 24 2007 1 Steps 2 Grab Handle 3 Deck Plate Fig 3 19 Back of Cab Access cover with a slip resistant surface be certain it is firmly secured Be careful not to trip on items such as chains or air lines in the back of cab area Always follow safety procedures for back of cab access maintaining three point contact both hands and one foot or both feet and one hand whenever moving around and always face in to ward the deck plate when climbing up or down Wet or dirty shoes steps or grab rails greatly increase the chance of slipping or falling If your shoes or the contact areas are wet or dirty clean and dry them as much as possible before ac cessing the back of cab area and be especially careful when climbing or standing on the vehicle Never jump onto or off of a vehicle doing so creates a very high likelihood of a fall and per sonal injury A grab handle and steps facilitate safe climbing up or down Accessing Back of Cab Area When climbing onto the deck plate use the grab handle and access steps as follo
100. Bolt Fig 10 19 Premier 690 Trailer Coupling Model 690 The pintle hook will automatically close and lock from the pressure of the drawbar eye against it Install the linch pin NOTICE Always make sure the connect hanger support keeps the trailer air hoses and electrical cables positioned so that they do not rub on anything Rubbing may wear through hoses or cables re sulting in air leaks or exposed or broken wires potentially affecting trailer brake or electrical sys tems 5 Hook up the trailer s electrical and air lines 6 Remove the chocks from the trailer s tires Trailer Release 1 Apply the truck and trailer parking brakes Do not use the trailer air supply for parking trail ers not equipped with spring parking brakes This applies the trailer service brakes only As air bleeds from the trailer brake system brake appli cation is lost This could allow the unattended vehicle to roll away possibly resulting in serious personal injury or death 2 Chock the front and rear tires of the trailer 3 Disconnect the trailer air and electrical lines Plug the air lines to keep out dirt 10 17 4 Take the weight of the trailer drawbar eye off the pintle hook 5 Open the coupling Models 260 and 460 Pull up on the pawl lock then while squeezing the pawl wedges together lift up the pawl assembly Lift up the latch and push it up against the pawl locking the latch in place Model 690 Remove the
101. Century Class Trucks Workshop Manual 22 Inspect the air brake chamber and the air brake chamber pushrods See Fig 11 11 1 pA 02 22 2000 1421352 A Do not remove this clamp ring 1 MGM TR T TR Series Brake Chamber shown Fig 11 11 Parking Brake Chamber Clamp Do not operate the vehicle with the front brakes backed off or disconnected Backing off or dis connecting the front brakes will not improve ve hicle handling and may lead to loss of vehicle control resulting in property damage or personal injury 11 10 Pretrip Inspection and Daily Maintenance 22 1 Check that the air brake chamber is mounted securely on its mounting bracket and that there are no loose or missing bolts 22 2 Look for worn clevis pins on brake cham ber pushrods and missing or damaged cotter pins on brake chamber pushrod cle vis pins Replace worn clevis pins and in stall new cotter pins if necessary 22 3 See if the chamber piston rod is in line with the slack adjuster Misalignment can cause the piston rod to rub on the non pressure chamber and cause a dragging brake See Group 42 of the Century Class Trucks Workshop Manual A CAUTION If the external breather tube or breather cap is missing or incorrectly installed road dirt and de bris can adversely affect the operation of the brake chamber Once inside of the chamber dirt and debris can cause the internal parts of the chamber to deteriorate faster 23 22 4
102. Control ACC system that uses the EVT 300 hardware and Smart Cruise software to maintain the vehicle s headway by interacting with the engine and requesting that the engine either de fuel or de fuel and apply the engine brakes Since SmartCruise does not apply the ser vice brakes or steer the vehicle the driver needs to be in control of the vehicle at all times Also because of the limitations of the EVT 300 system in distin guishing real targets from false targets when these targets are stationary and present in or near the ve hicle s path road signs in a curve or near the lane of travel overpasses parked vehicles on the side of the road center dividers retaining walls etc Smart Cruise ignores stationary targets when maintaining the headway The EVT 300 Collision Warning System CWS alerts the driver of a target in the vehicle s path SmartCruise works in conjunction with the engine s cruise control functions All of the cruise control func tions operate as usual when no targets are present in front of the vehicle When a valid target is present and SmartCruise de termines that the headway cannot be maintained it will request the engine to de fuel or to de fuel and apply the engine brake Once the correct headway has been achieved then SmartCruise will maintain the headway When the target vehicle accelerates beyond the vehicle set speed SmartCruise will ac celerate up to the set speed and will allow the engine to c
103. Cover the ends of the hubs with metal plates or plywood cut to fit the axle opening and drilled to fit the axle shaft studs This prevents lubricant from leaking out and will keep contaminants from getting into and damaging the wheel bear ings and axle lubricant In an Emergency CAUTION Failure to protect the frame rails from the chains could cause damage leading to eventual frame failure 4 On dual drive axles if the vehicle is to be lifted and towed chain the forward rear axle assembly to the vehicle frame use protection to keep the chains from damaging the frame 5 Remove the bumper extension and chrome bumper if so equipped Remove the bumper fair ing if so equipped 6 On vehicles equipped with an air fairing adjust the trim tab to the lowest position CAUTION Do not pass a sling for example a rope or chain from one tow hook to another to fasten for tow ing see Fig 13 2 Known as reeving this prac tice is not permissible in most industrial applica tions of towing and hoisting Reeving can overload the hooks and result in damage to the vehicle 7 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 8 On vehicles equipped with an air fairing mea sure the distance from the ground to the bumper or from the ground to a frame bracket 9 Lift the vehicle and sec
104. DC 20590 You can also obtain other information about motor vehicle safety from www safercar gov Canadian customers who wish to report a safety related defect to Transport Canada Defect Investi gations and Recalls may telephone the toll free hotline 1 800 333 0510 or contact 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 www tc gc ca roadsafety STI 385 11 10P A24 00879 000 Printed in U S A Foreword 1998 2010 Daimler Trucks North America LLC All rights reserved Daimler Trucks North America LLC is a Daimler company No part of this publication in whole or part may be translated reproduced stored in a retrieval system or transmitted in any form by any means electronic mechanical photocopying recording or otherwise without the prior written per mission of Daimler Trucks North America LLC For additional information please contact Daimler Trucks North America LLC Service Systems and Documentation P O Box 3849 Portland OR 97208 3849 U S A or refer to www Daimler TrucksNorthAmerica com and www FreightlinerTrucks com Chapter OONOOARWN Contents Page Introduction Environmental Concerns and Recommendations Event Data Recorder Customer Assistance Center Reporting Safety Defects ens use K E RPeed ek peas Gag a ado ge Med Pd
105. Disregarding this careful step by step procedure can result in your falling from the cab and pos sible personal injury or death 08 07 98 a 1720312 1 Bottom Step 4 Forward Grab Handle 2 Middle Step 5 Aft Grab Handle X 07 2098 f601695 A Remove this clip to remove the plastic cover 1 Plastic Cover Fig 3 6 Cab Access Stairs Underside Shown 3 Top Step Fig 3 5 Fixed Access Steps and Grab Handles Driver s Side IMPORTANT If the stairs do not stow automati cally you can stow them manually as follows 1 Remove the plastic cover on the underside of the stairs assembly See Fig 3 6 2 Remove the quick release pin by pulling its spring handle down and using the handle to un screw the pin If the pin is stuck you can use a 7 8 inch socket to remove it This disconnects the stairs assembly from its control arm See Fig 3 7 Press the stairs into the stowed position Secure the stairs in the stowed position See Fig 3 8 4 1 Locate the L rod mounted on the lower cab structure near where the V block on the inboard side of the stairs mates with the U bolt on the cab 4 2 Loosen the wheel nut around the L rod 3 3 07 20 08 1601694 A Unscrew the release pin 1 Cab Access Stairs Top Deck Fig 3 7 Removing the Quick Release Pin Vehicle Access 07 20 98 Cab Access Stairs Assembly Nut on Stairs Assembly Nut on L Rod Lower Cab Assembly Wheel Nut Thr
106. E In either the automatic or manual mode a starting gear other than the default starting gear may be selected by either pulling upward or pushing downward on the control while the vehicle is stopped and in drive Each pull up ward on the control increases the starting gear by one gear but no higher than fourth gear The number of the gear selected will flash on the message display screen until the driver engages the clutch This gear will be stored in memory 8 2 Transmissions as the default starting gear until either a differ ent starting gear is selected by the driver or the engine is shut down The transmission may also be programmed so that it is not possible to se lect a starting gear other than the prepro grammed default starting gear Upshifting NOTE With the transmission in drive D in the automatic mode upshifts require no driver inter action 1 With the transmission in drive in the manual mode request an upshift by pulling upward on the control If the requested gear is available the transmission will upshift NOTE A single momentary pull upward on the control selects the next higher gear when it is available Two consecutive momentary upward pulls will cause a skip shift when the next two higher gears are available and conditions are right 2 To skip shift move the control two times in less than 1 2 second The number of the gear en gaged will appear on the message display Screen NOTE T
107. EAR 1234567 FIRST m CLEAR DASH FAULTS R Y Y LAST OCCR LAST OCCR B l Y Y FIRST OCCR FIRST OCCR Lo d e YY R RESET PUSH RESET SET KEY TWICE 02 13 96 See applicable Figure S SET PUSH RESET SET KEY ONCE 1040325 Fig 2 51 Engine Information and Diagnostic Information Setup Information Setup information allows the user to change the tar get MPG the brightness of the screen display the language of the display English French or Span ish and the units of measurement English USC or metric When prompted by the screen press SET push the SET RESET key once The units that are setable will be blinking Use the arrow keys left right and down until the display shows the desired setup Press SET again when finished to save the new set tings See Fig 2 52 Vehicle Information Vehicle information displays important information including datalink activity and status ICU part num ber and software identification number The Datalink Active screen is a dynamic display that shows if the datalink unit is active at the given time If all the arrows are pointing down the ICU2M has not received any information on the datalink since the last time the ignition switch was turned on The Datalink Status screen is also dynamic show ing current datalink use and error rate The other screen which shows the ICU part number and the software identification number is informational onl
108. EHICLE WHEN COMPLETED IS NOT SUBSTANTIALLY AFFECTED BY THE DESIGN OF THE CHASSIS CAB 09 28 98 f080023 Fig 1 4 Incomplete Vehicle Certification Label U S Vehicle Identification that the vehicle conforms to all applicable FMVSS regulations in effect on the date of completion 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 5 which are attached to the left rear door post In addition tire and rim labels Fig 1 6 are also attached to the left rear door post EC ohNAD CMVSs o o OvASv 963 o o hA spo 10 10 2006 1080024 Fig 1 5 Canadian National Safety Mark 12 3 10 31 95 f080054 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 for the system Fig 1 6 Tire and Rim Label If purchased for service in Canada trucks built with out a cargo body and tractors built without a fifth wheel are certified by a Statement of Compliance label similar to Fig 1 2 This label must be attached by the final stage manufacturer after co
109. Foreword Introduction This manual provides information needed to operate and understand the vehicle and its components More detailed information is contained in the Owner s Warranty Information for North America booklet and in the vehicle s workshop and maintenance manuals Custom built Freightliner vehicles are equipped with various chassis and cab components Not all of the information contained in this manual applies to every vehicle For details about components in your ve hicle refer to the chassis specification pages in cluded in all new vehicles and to the vehicle specifi cation decal located inside the vehicle For your reference keep this manual in the vehicle at all times IMPORTANT Descriptions and specifications in this manual were in effect at the time of printing Freight liner Trucks reserves the right to discontinue models and to change specifications or design at any time without notice and without incurring obligation De scriptions and specifications contained in this publi cation provide no warranty expressed or implied and are subject to revisions and editions without no tice Environmental Concerns and Recommendations Whenever you see instructions in this manual to dis card materials you should first attempt to reclaim and recycle them To preserve our environment fol low appropriate environmental rules and regulations when disposing of materials Event Data Recorder This vehicle is
110. ID Fig 8 14 Allison Push Button Shift Selector should know the extent of the warning system in order to safely operate the vehicle See Chapter 2 for information on the warning system Operation CAUTION The engine should never be operated for more than 30 seconds at full throttle with the transmis sion in gear and the output stalled Prolonged operation of this type will overheat the transmis sion 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 Se lect at the top of the unit the display should al ways show 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 re verse R at engine speeds above idle The ve hicle will lurch forward or backward which could cause property 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 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 influen
111. KE A TRIP INFORMATION 9 APPLY PARK BRAKE PUSH RIGHT ARROW KEY 1040415 Fig 2 45 Ignition Sequence ICU2M 2 32 Instruments and Controls Identification to press the right arrow key will display all additional fault codes if any NOTE A list of fault codes and definitions can be found in Section 54 03 of the Century Class Trucks Workshop Manual To go on press the left arrow or if the engine is on release the parking brake to go on to the Fasten Seat Belts Odometer screen Unless the engine is running the ignition sequence ends with the Fasten Seat Belts Odometer screen IMPORTANT At this point if the vehicle has a communications system and an incoming mes sage is available it will be displayed To dismiss the incoming message press any key on the keypad With the engine idling the vehicle not moving the ignition sequence cycles on and displays the Idle Hours Idle Gallons Odometer screen See Fig 2 46 e ROY Er CN B N f N P Ww wv kd M N 07 29 97 Fig 2 46 ICU2M At the End of the Ignition Sequence The Message Display Screen To understand the information displayed on the mes sage display screen here is an example of screen layout On the Idle Hours Idle Gallons Odometer screen idle hours are displayed on the top line with the words Idle Hours on the left side of the screen and the number of hours on the right On the bottom line the n
112. Map and Clear Reading Lights Red Map Light Switches Red map lights are available on all cabs See Fig 2 15 and Fig 2 16 They are located next to the dome lights in the same fixture Like the dome lights the map lights can be turned on by pressing in on the light lens Instruments and Controls Identification 07 4 97 1541717 Fig 2 16 Dome Light with Red Map Light Clear Reading Light Switches SleeperCabs Only Clear reading lights are available on sleepers only See Fig 2 15 They are located next to the dome lights in the same fixture Like the dome lights the reading lights can be turned on by pressing in on the light lens Courtesy Light Switch Courtesy lights are available on all cabs They illumi nate the footwell area on both sides of the cab The driver s courtesy light Fig 2 17 is attached to the steering column and the passengers footwell light Fig 2 18 is located on the lower right dash panel To turn on the courtesy lights press the rocker switch on the dash When the lights are on the Switch is illuminated by a light inside it 07 4 97 1541716 Fig 2 17 Driver s Floor Courtesy Light Rear Wall Fluorescent Light Switches A rear wall fluorescent light Fig 2 19 is available on all raised roof cabs It is located on the rear wall where the wall meets the roof To turn on the rear wall fluorescent light press the rocker switch on ei ther the lower or upper bun
113. Meritor 10 Speed RM RMO and RMX Model 9 Speed i IA R IAL Bo ee i Transmissions Shift Patterns Overdrive lt an zu RMO Lw 5 73 t0W 5 53 er 9 speed models and 5th gear in 10 speed 1260327 1260327 1260328 models See Table 8 3 10 Speed z SS E a Direct or ye 4 T ep p 7 To upshift into high range with the transmission Overdrive JAA ZAKA pov still in the highest low range gear move the RMor Daw Dow C303 09 range selector lever up to put the transmission RMX 1260329 1260329 1260330 into high range then partially depress the clutch a c LM AA i R R R 7 10 pedal and move the shift lever into neutral As 10 Speed 223 VC Re Ce defe the shift lever passes through neutral the trans Overdrive a et v vg mission will automatically shift from low range to RMO VG CIA high range 1260331 1260331 260332 8 Release the clutch pedal and let the engine slow until the road speed and engine rpm match 9 Partially depress the clutch pedal and move the shift lever into the lowest gear in the high range Table 8 3 Meritor Shift Progressions Downshifting 5th gear in 9 speed models and 6th gear in 10 speed models 1 With the transmission in high range shift pro gressively downward to the bottom gear in high range 5th gear in 9 speed models and 6th gear Transmissions in 10 speed models Double clutch between shifts See Table 8 3 2 When in the bottom gear of the high range shift
114. NLOCK Button 2 LOCK Button Fig 3 25 Key Chain Fob radio transmitter A red system status LED light emitting diode mounted on the overhead panel above the clock The LED flashes slow or fast to indicate what state the system is in armed alert alarmed or violated It is off when the system is disarmed See Fig 3 26 1 secun ge TEM 2 S 3 07 01 96 1541288 1 System Status LED 3 Clock 2 Overhead Panel Fig 3 26 Red System Status LED A Meritor relay module mounted behind the right hand B pillar electrical compartment door that arms and disarms the system and pro grams the fobs Vehicle Access A program switch on the Meritor relay module that places the relay module in the learning mode which is the only state in which the sys tem can learn fob ID codes The switch is shown in its normal or OFF state toggle pointing up See Fig 3 27 11 15 96 1541501 1 Program Switch off position Fig 3 27 Program Switch A security system electronic control module ECM also mounted behind the right hand B pillar electrical compartment door that moni tors all the entry points controls the door locks operates the alarm and interrupts the power to the engine as necessary There is also a PDM power distribution module relay module mounted on top of the left hand side of the ECM How It Works The fob has three push buttons LOCK UNLOCK and ALERT When a b
115. Never attempt to start an electronic engine using ether or any other starting fluid Serious engine damage could result If using a cold weather start system be sure to follow the manufacturer s instructions regarding its use handling and storage Many starting flu ids are in capsules or pressure cans and im proper usage can be dangerous Do not attempt to use any type of vapor compound start system near heat or open flame Engine damage due to an explosion or fire in the intake manifold could result Do not breathe the ether fumes doing so could result in personal injury Caterpillar Turn the ignition switch to the ON position Fig 7 9 If the engine doesn t start after 30 seconds of crank ing turn the key to the OFF position and wait two minutes then repeat the starting procedure If the coolant temperature is less than 64 F 18 C the engine will start up in the cold start strategy This reduces the amount of fuel available to the injectors advances the timing and controls white smoke emis sions The engine remains in the cold start strategy until the coolant temperature rises above 64 F 18 C or until it has been running for 12 minutes IMPORTANT Do not move the vehicle when it is in the cold start strategy Power will be notice ably reduced 7 11 After a cold engine start of less than 64 F 18 C Caterpillar electronic engines automatically idle at 800 rpm for C210 and C 12 engines or 600
116. Push and hold the knob for 5 seconds to activate 13 Driver Display Unit DDU the accident reconstruction function and freeze 14 Antenna Assembly the most recent data in half of the allocated 15 Right Side Sensor memory 16 Left Side Sensor NOTE The system may be configured to pre 21 Right Turn Signal vent adjustment of the range levels 22 Left Turn Signal 5 The red system failure indicator light illuminates Speed if a system problem is detected Press and hold 25 Cruise the volume control knob for 5 seconds to display 31 71587 fault codes The fault codes will be blinked out as a pattern of flashes on this indicator light See 32 J1939 Table 2 2 for fault codes 33 VBUS a 34 DDU Communications 6 The green SC indicator light will flash 8 times if 35 Antenna Assembly Communications the range knob is pressed to store accident re 4i No Fault or End of Fault Codes construction information It will also flash 8 times after the system is activated after the power on LED test is finished and if accident reconstruc tion data was previously stored Table 2 2 Fault Codes 2 44 Instruments and Controls Identification The ambient light sensor senses lighting condi tions and automatically adjusts the intensity of the indicator and alert lights If the system s configuration requires insert the driver s identification card in the driver s card slot at the lower front edge of the DDU A high pitched tone will sound when
117. R E AO RR CRUCE RICE RO GER ROC do AO e ER en bedi 4 1 Defogging and Belrosung Using Fresh Air uooesesekieteek b RR RET RAS ERLEPERR E RS 4 2 He ting PTT 4 2 ote sug PMID P rPCTTPM ST 4 3 Fresh Air ccecdead caw ewas m RR OGERRATRORORTRORNDECARHOXORR GEAR ORA UL A RC Bk Vea a Are ale a CR ER s 4 4 Heating Auxiliary Sleeper Bunk Heater and Air Conditioner 0000 cece eee eee 4 4 Air Conditioning Auxiliary Sleeper Bunk Heater and Air Conditioner sss 4 4 Heater and Air Conditioner HVAC General Information A dash mounted climate control panel Fig 4 1 or Fig 4 2 allows you to control all of the heating air conditioning defrosting and ventilating functions Oy Moe Tis Z 4 2 we M N 3 4 Ww 4 9 07 95 1830716 1 Fan Switch 2 Air Selection Switch 3 Temperature Control Switch 4 Maximum Air Conditioning Fig 4 1 Climate Control Panel Heater and Air Conditioning 1 2 3 e 9 1 T p EM ve o 2 EZ N 3 jas 4 Ww 5 4 10 26 95 1830717 Fan Switch Air Selection Switch Temperature Control Switch Fresh Air Recirculation Switch Auxiliary sleeper bunk Switch OR ON Fig 4 2 Climate Control Panel Heater Only A four speed fan forces fresh or recirculated air to any selected air outlets at the windshield door win dows dashboard face and cab floor An air selection switch controls the direction of warm or cool air to the face and fe
118. RTANT On vehicles equipped with an in take air preheater the INTAKE HEATER indica tor stays on for a minimum of two seconds re gardless of coolant temperature Wait until the INTAKE HEATER indicator goes out before at tempting to start the engine 2 Turn the ignition switch to the START position Without touching the throttle pedal start the en gine NOTE Some starters are equipped with op tional overcrank protection If overcranking oc curs a thermostat breaks the electrical circuit to the starter motor until the motor has cooled 3 ldle the engine for one to three minutes at 600 to 850 rpm before operating the engine under load 4 Check the oil pressure gauge for any drop in lu bricating oil pressure or mechanical malfunction in the lubricating oil system Minimum oil pres sure at idle is 7 psi BO kPa NOTICE Do not rev the engine if the oil pressure gauge indicates no oil pressure Shut down the engine if no oil pressure appears within approximately 7 10 Engines and Clutches ten seconds Check to determine the cause of the problem Operating the engine with no oil pres sure will damage the engine Cold Weather Starting Electronic engines do not normally require special starting aids At low temperatures oil pan heaters or water jacket heaters are sometimes used to assist in starting Older vehicles with non electronic engines may be equipped with an automatic ether start system NOTICE
119. S EPA for use outside California Data Recording Capability DDEC VI contains the ability to extract detailed data on the engine use and performance using DDEC Reports software This data known as DDEC Data is stored in the CPC and contains information on en gine performance such as fuel economy idle time time in top gear and critical incidents such as de tailed diagnostic data records and hard braking events DDEC Data can be downloaded using DDEC Reports software to produce reports See the Detroit Diesel DD15 Engine Operator s Guide for complete details Flashing Malfunction Codes All malfunction codes are four digits The malfunction code recorded in the computer memory will remain until it is erased by a technician The flashing mal function code can also be obtained by the operator See the Detroit Diesel DD15 Engine Operator s Guide for complete details Engines and Clutches DDEC VI Driving Tips Accelerating the Vehicle The accelerator pedal was designed to communicate percentage of accelerator pedal travel to the engine MCM A throttle characteristic you may need time to get used to is the DDEC limiting speed governor This allows the driver to command total engine re sponse between idle and rated speed such as accel erating at half throttle an advantage when driving under slippery conditions To obtain 100 percent fuel ing at any speed the accelerator pedal must be de pressed to the fully press
120. S IN MOTION 9 07 95 1310489 Fig 10 6 Cab Control Fifth Wheel Slide 2 2 For manual release models pull the re lease lever Fig 10 3 using a release hook or other suitable tool Make sure both slide plungers have released See Fig 10 7 If the plungers haven t released haven t come out lower the trailer land ing gear to relieve pressure on the plungers 3 Lower the trailer landing gear just enough to re move the weight from the tractor 4 Pullthe trailer air supply valve to cut off the air supply to the trailer 5 Chock the front and rear of the trailer tires to prevent the trailer from moving 10 4 Fifth Wheels and Trailer Couplings 01 24 96 1310439 A Locked engaged B Unlocked released 1 Plunger Fig 10 7 Plunger Positions Do not use the trailer air supply for parking trail ers not equipped with spring parking brakes This applies the trailer service brakes only As air bleeds from the trailer brake system brake appli cation is lost This could allow the unattended vehicle to roll away possibly resulting in serious personal injury or death A CAUTION After moving the fifth wheel to the desired posi tion be sure the trailer landing gear will not at any time come in contact with the tractor frame or other components Make sure that the front of the trailer will not come in contact with the rear of the cab or with other components if they ex tend beyond
121. Switch Position Upshift Direction in manual mode pull upward Reverse Selector Position Mode Selector Switch Neutral Selector Position Drive Selector Position 0 Low Selector Position 1 Downshift Direction in manual mode push 270082 zi 0 NO C1 Gd NO downward Fig 8 1 SmartShift Control with Eaton AutoShift transmission SmartShift offers two main advantages over conven tional transmission control devices usable cab space is increased and access to the sleeper is improved by removing the shift lever from the floor Because of the steering column mounting the transmission con 8 1 4 EN 1 A S PULL R b Smart Shift N PUSH 5 1 smo F rd 6 11 23 99 1270081 SmartShift Control Upshift Direction pull upward Reverse R Selector Position Mode Selector Switch Neutral N Selector Position Forward F Selector Position Downshift Direction push downward NOoOBRON Fig 8 2 SmartShift Control with Meritor SureShift transmission trol is within fingertip reach of the steering wheel which enhances safety SmartShift is a true shift by wire system Manual gearshifts all SureShift shifts and AutoShift when in manual mode are accomplished by a momentary pull or push on the control in the plane perpendicular to the steering wheel See Fig 8 3 Pull upward to ward you on the control to upshift and push down ward away from you to downshift For the Eaton AutoShift trans
122. TED IN THE OWNER a MANUAL INCORPORATED INTO THIS VEHICLE IN COMPLIANCE WITH THE NOISE CONTROL ACT B THE USE THIS VEHICLE AFTER SUCH DEVICE OR ELEMENT OF DESIGN HAS BEEN REMOVED OR RENDERED INOPERATIVE 24 00273 020_ 10 06 98 f080026 Fig 1 7 Vehicle Noise Emission Control Label It is the owner s responsibility to maintain the vehicle so that it conforms to EPA regulations IMPORTANT Certain Freightliner incomplete vehicles may be produced with incomplete noise control hardware Such vehicles will not have a vehicle noise emission control information label For such vehicles it is the final stage manufac turer s responsibility to complete the vehicle in conformity to U S EPA regulations 40 CFR Part 205 and label it for compliance EPAO07 Exhaust Emissions Regulations To meet EPA07 emissions regulations engines manufactured after January 1 2007 are equipped Vehicle Identification with an emission aftertreatment device A warning label on the driver s sunvisor explains important new warning indicators in the driver s message display that pertain to the aftertreatment system See Chap ter 7 Vehicles domiciled outside of the USA and Canada may not have aftertreatment equipment de pending upon local statutory emissions guidelines It is a violation of federal law to alter exhaust plumb ing or aftertreatment in any way that would bring the engine out of compliance with certification require ments Re
123. This warn ing overrides all others and is not affected by the range control knob setting IMPORTANT The detection range will be re duced during a sharp turn 13 If your vehicle is traveling less than 5 mph 8 km h and an object is detected less than 15 feet 4 5 meters in front of your vehicle and the closing rate is less than 2 mph 3 km h but more than 1 2 mph 1 km h the yellow alert light will illuminate and a low frequency double tone will sound NOTE All warnings apply only to objects within the maximum detection range and in your lane Proximity alert tones and vehicle closing 1 to 2 second following interval tones are configured items All tones are disabled in sharp turns or when the brakes are applied If the configuration permits the 3 second alert level may be ad justed with the range control knob A single low frequency tone sounds when a system failure is detected A medium frequency tone sounds when the volume control level is changed Suc cessful downloading of Vehicle Information Man agement System VIMS data will cause a double tone to sound Unsuccessful download ing will cause a low frequency tone to sound 14 A failure of the side sensor s will cause a con tinuous red light on the side sensor display to appear Side Sensor Display 1 The yellow indicator light Fig 2 59 illuminates continuously when no vehicle is detected by the side sensor s c Ww Ns E A C 7 2 3
124. Understeer Condition B Turning Radius When Differential is Unlocked disengaged f350079a Fig 9 1 Turning Radius When the differential lock disengages the indicator light will go off and the buzzer will stop Meritor Tandem Drive Axles with Interaxle Differential Meritor tandem drive axles with an interaxle differen tial have a lockout feature Differential lockout is con trolled by a switch Fig 9 2 on the control panel LOCK UNLOCK INTER AXLE DIFFERENTIAL DO NOT ENGAGE DURING SPIN OUT 09 26 95 f350141 Fig 9 2 Interaxle Differential Control In the UNLOCK position there is differential action between the two axles The differential compensates for different wheel speeds and variations in tire size Keep the interaxle differential unlocked for normal driving on roads where traction is good In the LOCK position the interaxle differential is locked out and the driveshaft becomes a solid con nection between the two axles Power entering the forward axle is also transmitted straight through to the rear axle so both axles turn together at the same speed The LOCK position should be used when the vehicle encounters poor traction conditions however it also increases drivetrain and tire wear and should be used only when improved traction is required Meritor Interaxle Differential Lockout Operation To lock the interaxle differential and achieve maxi mum pulling power when approaching s
125. X R ratio transmissions have the 1st 5th shift positions where LO is in the A and B ratio transmis sions The top gear in the RTX R ratio transmissions is called 9th gear 10 Speed RT RTO and RTX Models Fuller RT 11710B RT 12710B RT 13710B RT 14710B RTO 15210C RTO 16210C RTLO 12610B RTLO 13610B RTLO 14610B RTLO 15710B C RTLO 16610B RTX 11710B C RTX 12710B C RTX 13710B C RTX 14710B C RTX 15710B C and RTX 16710B transmissions have ten selective evenly spaced forward ratios Each trans mission consists of a 5 speed front section and a 2 speed rear range section The ten forward speeds are obtained by twice using a 5 speed shift pattern the first time in low range the second time in high range See Fig 8 6 for the shift patterns noting that the 4th 9th and the 5th 10th shift positions in the RT direct ratio and RTX overdrive ratio transmissions are directly opposite in the RTO overdrive ratio transmissions Operation 1 When operating off highway or under adverse conditions always use low gear if so equipped when starting to move the vehicle When operating on highway with no load or under ideal conditions use 1st gear when start ing to move the vehicle except when equipped with a 9 speed RTO transmission then always start in low gear For all conditions use the highest gear that is still low enough to start the vehicle moving with engine idling and without slipping the clutch ex cessi
126. ac tor Incorrect fifth wheel adjustment could cause the trailer to disconnect possibly resulting in se rious personal injury or death 10 With the trailer wheels chocked and the brakes set check for clearance between 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 appli cable manufacturer s service information 11 Retract the trailer landing gear and secure the ratchet handle Remove the chocks from the trailer tires 12 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 weighing 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 instances should the axle load exceed the maximum axle weight rat ing given on the FMVSS or CMVSS label A WARNING Do not overload any tractor axle by improperly loading the trailer This could cause erratic steer ing and loss of vehicle control possibly
127. activates the control valve and un locks the fifth wheel slide mechanism allowing changes to the total length of the tractor trailer and changes to axle loads to comply with varying state or provincial laws A red indicator light if so equipped is illuminated whenever the fifth wheel slide is unlocked A guard is positioned around the Switch to minimize accidental activation UNLOCK LOCK FIFTH WHEEL E SLIDE MUST BE LOCKED WHEN VEHICLE IS IN MOTION 9 07 95 1310489 Fig 2 9 Fifth Wheel Air Slide Switch 2 8 Instruments and Controls Identification NOTICE Do not activate the fifth wheel slide control valve while the vehicle is in motion To do so could cause damage to the fifth wheel member the kingpin the cab or trailer and ultimately to the drivetrain Parking Brake Control Valve The yellow diamond shaped knob Fig 2 10 oper ates the parking brake valve Pulling the knob ap plies both the tractor and the trailer spring parking brakes Pushing in the knob releases the tractor spring parking brakes Before the spring parking brakes can be released the air pressure in either air brake system must be at least 65 psi 447 kPa f T amp N D lo wea Q4 c TRAILER AIR SUPPLY NOT FOR PARKING J amp lt E OOL a N o TO E 03 10 99 f610291 1 Trailer Air Supply Valve Knob 2 Parking Brake Control Valve Knob Fig 2 10 Brake Valve Knobs See Chapter
128. age shelves To open the sleeper access on vehicles with vinyl Sleeper curtains unzip the sleeper curtains If de sired unsnap the curtains all the way around the sides and top and remove the curtains To open the sleeper access on vehicles with velour sleeper curtains unfasten the snaps at one side then push the curtain to the opposite side Vehicle Access 04 09 98 680006 A Press this button 07 30 98 1601641 1 Compartment Door Fig 3 17 Baggage Compartment Door Driver s Side Fig 3 16 Circuit Breaker Relay Panel Sleeper Bunk Latches To move the lower or upper sleeper bunk if equipped disengage the latch at the front of the lower bunk or the latches on both sides of the upper bunk Lock the bunks into operating position down for the lower bunk and up or down for the upper bunk by engaging both the primary and secondary latches Baggage Compartment Doors To unlock the baggage compartment doors Fig 3 17 pull the release handle just inside the lower rear corner of the driver or passenger doors See Fig 3 18 To close the compartment doors press them flush with the cab skin Back of Cab Grab Handles Steps and Deck Plate When trailer air and electrical connections cannot be coupled from the ground Federal Motor Carrier Safety Regulations require commercial carriers to provide back of cab access Fig 3 19 SAWN 07 20 98 MEER CR 1601697 1 Driver s Seat 2
129. andle 03 08 99 1 Bottom Step 2 Middle Step 6 Forward Grab Handle 3 Top Step 7 Steering Wheel 4 Top Deck Fig 3 11 Right Hand Drive Optional Cab Access Stairs Driver s Side Shown 9 With your left foot securely in the cab and both hands gripping the steering wheel move your right foot into the cab Exiting the Driver s Side Using the Cab Access Stairs for Right Hand Drive Vehicles Fig 3 11 If the optional cab access stairs do not move into position or if there is not enough room for them to deploy use the fixed steps on the outside sur face of the moving stairs Fig 3 5 and follow the access instructions for the standard fixed step system Freightliner recommends you practice using the fixed steps until you are familiar with their use Enter the cab only as specified in the following steps Keep your body close to the cab and Vehicle Access maintain three point contact with the cab at all times This means one hand and two feet or two hands and one foot Do not lean out away from the cab Do not engage in horseplay Do not enter the cab with dirty or greasy hands or feet Disregarding this careful step by step procedure can result in your falling from the cab and pos sible personal injury or death IMPORTANT Do not attempt to exit the cab while carrying any items in your hands 1 Grasp the steering wheel tightly with both your hands and stand on the deck at the top of the stairs facing
130. ane Guidance lane departure warning system monitors the vehicle s position within the roadway lane markings and sounds a warning in the cab when the vehicle is about to stray outside its lane provided the turn signal is not on and the vehicle is traveling at least 40 mph 64 km h The system in cludes a digital camera mounted high near the center of the windshield inside the cab Fig 2 63 a central processing unit in the overhead console and a ste reo speaker above and behind each door that emits 2 52 Instruments and Controls Identification a sound similar to a rumble strip The sound is made on the side of the vehicle it s straying toward prompting the driver to respond and steer away from the sound and back into the center of the correct lane Z 3 1 SN p 11 18 1999 1610358 1 Clock 3 Digital Camera 2 Windshield Fig 2 63 Lane Departure Warning System Camera The lane departure warning system is intended only as an aid for a conscientious and alert driver The system may not indicate lane depar tures under certain conditions Read carefully the information in this manual to understand the cir cumstances under which this system may not provide adequate lane departure warnings Do not rely solely on the system to safely operate the vehicle The system does not warn of all pos sible hazards For example the system cannot prevent an accident if the driver is impaired or not driving safely The
131. ange preselection lever to low release and depress the throttle pedal quickly to increase 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 clutch and transmission to be sure the axle has completed the shift into the low range Some vehicle motion is required to ensure en gagement of the axle IMPORTANT Refer to Eaton Interaxle Differen tial Lockout Operation for precautions that must be taken when shifting axles in relation to the interaxle differential lockout Eaton Interaxle Differential Lockout Operation Interaxle differential lockout systems include a lock out control valve Fig 9 2 located in the cab and an air operated shift unit mounted on the forward rear axle When the interaxle differential lockout control valve is in the LOCK position the interaxle differential is locked out and the driveshaft becomes a solid con nection between the two axles Power entering the forward axle is also transmitted straight through to the rear axle so both axles turn together at the same speed The LOCK position should be used when ad ditional traction is needed A CAUTION Engage the lockout only when stopped or at slow speeds and never when the wheels are spinning Do not operate the axles on dry pavement with the lockout engaged for prolonged periods Use only when additional traction is needed under adverse road conditions Dise
132. ard operation shutting down the engine without idling may cause dam age to the turbocharger 2 Allow the engine to idle one to two minutes be fore shutting it down This allows the lubricating oil and the coolant to carry heat away from the combustion chambers bearings shafts and 7 20 Engines and Clutches seals The extreme heat may cause bearings to seize or oil seals to leak IMPORTANT Bearings and seals in the turbo charger are subjected to the high heat of com bustion exhaust gases While the engine is run ning this heat is carried away by oil circulation but if the engine is stopped suddenly the turbo charger temperature may rise as much as 115 F 63 C NOTICE Except in emergency do not shut down the MBE4000 engine when the coolant temperature is above 194 F 90 C To do so could damage the engine 3 Turn off the ignition switch and shut down the engine Optional Engine Systems Cruise Control IMPORTANT On vehicles with Eaton VORAD Collision Warning System CWS with Smart Cruise read the operating instructions in Colli sion Warning System in Chapter 2 before oper ating the cruise control The cruise control is activated by the SPD CNTL on off and RSM ACC SET CST switches on the dash Fig 7 11 or by optional PAUSE RESUME and SET buttons on the transmission shift knob Fig 7 12 The minimum speed at which cruise con trol can be used is 30 mph 48 km h The minimum and m
133. as sembly locking the latch in place Model 690 Fig 10 19 Remove the linch pin from the handle then push in on the handle and turn it toward you Open the pintle hook by pull ing it down and toward you Release the handle Operation locking the pintle hook open 3 Models 260 and 460 Back up the vehicle until A WARNING the drawbar eye is over the pintle hook then lower the trailer If at any time the 690 coupling is bound up jack Model 690 Back up the vehicle until the drawbar knifed the 294 bolt MUST be replaced immedi eye enters the open jaw contacts the back of the ately Do not use the coupling until the bolt has pintle hook and closes the coupling been replaced In addition carefully inspect the 690 coupling drawbar drawbar eye front end 4 Close the coupling assembly and tail board for damage Failure to Models 260 and 460 Push in on the pawl do so may result in trailer separation from the wedges and lift the pawl assembly The latch will truck while in use resulting in serious personal drop into the closed position Lock the latch by injury or property damage lowering the pawl assembly 2 6 pe a A 01 20 95 1310812a A Model 260 B Model 460 1 Pintle Hook 3 Pawl Assembly 5 Pawl Wedge 2 Latch 4 Pawl Lock 6 Shoe Fig 10 18 Premier 260 and 460 Trailer Couplings 10 16 Fifth Wheels and Trailer Couplings 07 13 2010 f310313a 1 Linch Pin 3 Pintle Hook 2 Handle 4 294
134. ast 20 percent slower than your vehicle is detected within 220 feet 67 meters and within 3 seconds the HDWY DETECT lamp will illuminate a message will be dis played and double tones will sound This warning overrides all others and is not affected by the headway setting If your vehicle is traveling less than 5 mph 8 km h and an object is detected less than 15 ft 4 5 m in front of your vehicle and the closing rate is less than 2 mph 3 km h but more than 1 2 mph 1 km h the HDWY DETECT lamp will illuminate a message will be displayed and a low frequency double tone will sound NOTE All warnings apply only to objects within the maximum headway range and in your lane Proximity alert tones and vehicle closing 1 to 2 second following interval tones are configured items All tones except the 1 2 second alert are disabled in sharp turns or when the brakes are applied If the configuration permits the 3 second alert level may be adjusted with the headway adjustment switch HDWY HDWY on the dash A single low frequency tone sounds when a system failure is detected A medium frequency tone sounds when the vol ume control level is changed Successful down loading of Vehicle Information Management Sys tem VIMS data will cause a double tone to sound Unsuccessful downloading will cause a low frequency tone to sound Driver Identification The EVT is capable of selecting two driver IDs This identification can be set
135. ature in the cab and in the sleeper With the valve shut off warm coolant is no longer available from the engine Heater and Air Conditioner and the outlet air temperature controls can t be used to change air temperature A fresh air recirculation switch Fig 4 2 is standard equipment when there is no air conditioning This control is an option when air conditioning is ordered It allows the cab to be ventilated with either fresh or recirculated air When the air selection switch is ro tated to the maximum air conditioning position Fig 4 1 the system uses only recirculated air re gardless of whether fresh or recirculated air has been selected When the air selection switch is set to air condition ing and recirculated air has been selected the sys tem functions the same as when the air selection Switch is set at maximum air conditioning The dash mounted auxiliary switch Fig 4 2 over rides the auxiliary sleeper control panel This switch should be set in the HI up position for increased ventilation in the bunk area the center middle posi tion for normal fan and temperature operation and the OFF lower position to cut power to the auxiliary unit NOTE When the auxiliary switch is in the OFF lower position the sleeper temperature control will default to the HEAT mode The sleeper fan will blow hot air when any air conditioning mode is selected To operate the temperature controls move the auxiliary sw
136. aximum speed cruise control set limits can be programmed by authorized personnel into the en gine electronics A WARNING Do not use the cruise control system when driv ing conditions do not permit maintaining a con stant speed such as in heavy traffic or on roads that are winding icy snow covered slippery or roads with a loose driving surface Failure to fol low this precaution could cause a collision or loss of vehicle control possibly resulting in per sonal injury or property damage 7 21 07 29 98 1 RSM ACC SET CST Switch 2 SPD CNTL On Off Switch 1541126 Fig 7 11 Cruise Control Switches Dash Mounted 05 23 95 1260316 Fig 7 12 Cruise Control Transmission Shift Knob Buttons NOTICE 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 temporarily uncontrolled increase in engine speed transmission damage and gear stripping could result 1 To cruise at a particular speed 1 1 Press the upper half of the SPD CNTL on off rocker switch on the instrument control panel 1 2 Hold the throttle down until the speedom eter reaches the desired speed Engines and Clutches 13 Momentarily flip the RSM ACC SET CST paddle switch on the instrument control panel down to SET CST or push the SET button on the transmission shift knob 2 To disengage the cruise control 2 1 Depre
137. can severely damage the clutch disc pressure plate and the flywheel During initial operation of a new vehicle or a vehicle with a new clutch check for clutch slippage during acceleration If the clutch slips decelerate until the clutch does not slip Allow the clutch to cool 15 to 30 seconds and then gradually accelerate again If the clutch continues to slip repeat the procedure If nec essary repeat the procedure up to five times If the clutch slips after five attempts stop the vehicle Allow the clutch to cool for at least one hour Notify your Freightliner dealer of the problem NOTICE Do not allow sustained slippage of the clutch this could severely damage the clutch disc pres sure plate or flywheel Damage caused by clutch slippage due to improper break in is not warrant able Starting the Vehicle in the Proper Gear An empty truck can be started in a higher transmis sion gear than a partially or fully loaded truck A good rule of thumb for the driver to follow is select the gear combination that allows you to start moving with an idling engine or if necessary just enough throttle to prevent stalling the engine After the clutch is fully engaged the engine should be accelerated to the correct rpm 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 proper speed This type of shi
138. carried through the engine and drivetrain slowing the vehicle and reducing the need for frequent service brake ap plications Exhaust brakes are not intended for use as the pri mary braking system during vehicle operation Before starting the engine make sure that the ex haust brake switch is in the off position Do not turn the exhaust brake on until the engine has reached normal operating temperatures While approaching a steep grade make sure that the exhaust brake switch is in the on position The ex haust brake comes on as soon as you remove your foot from the accelerator pedal While going down the grade use a low enough gear to safely descend with a minimum application of the service brakes As a general guideline use the same gear as you would to ascend the hill NOTICE Do not allow the engine to exceed its governed speed or serious engine damage could result Apply the service brakes to reduce the engine rpm or make a slower descent by using a lower gear A WARNING Do not use the exhaust brake when driving on slippery or low traction road surfaces Failure to follow this precaution could result in a loss of vehicle control and possible personal injury or property damage Make sure the exhaust brake is turned off before shutting off the engine 7 25 Exhaust Brake Operating Characteristics When you remove your feet from both the accelera tor and clutch pedals and the exhaust brake switch is in the o
139. cated on the auxiliary instrument panel The dash message center is the heart of the ICU2L It has two parts a set of 18 warning and indicator lights similar to those found on a conventional light bar and a message display screen The message display screen is a one line by six character vacuum fluorescent display Warning and Indicator Lights There can be up to 18 warning and indicator lights installed in the ICU2L See Fig 2 53 The green right and left turn signal lights flash on and off whenever the outside turn signal lights are flashing e The blue high beam indicator light comes on when the headlights are on high beam The yellow Check Engine ENG CHK light comes on if an engine condition exists such as low coolant level high coolant temperature or low oil pressure It also comes on when a fault is detected or recorded The red Engine Protection ENG PROT light comes on to indicate that the protection system available on the engine has been activated Installed on Cummins engines only the red Stop Engine STOP ENG light comes on to warn that the engine is not functioning nor mally The vehicle should be pulled over to the side of the road and the engine shut down immediately The red low air pressure LOW AIR warning light and buzzer activate whenever air pressure in the primary or secondary air reservoir falls below 64 to 76 psi 440 to 525 kPa The red high coolant temperature thermom eter
140. cates the system is on If the system is equipped with SmartCruise the switch is not installed Headway Control HDWY CNTL This switch is installed on vehicles with SmartCruise When this switch is pressed the light comes on to indicate that the vehicle is in SmartCruise mode It has the same function as the SPD CNTL switch which is installed on vehicles without SmartCruise The switch is backlit by a green light when the Headway Control is on Resume Accelerate Set Coast RSM ACC SET CST This switch works the same as it does on conventional cruise control On ve hicles with SmartCruise the speed will change if necessary to maintain the set headway Headway Volume HDWY VOL This switch adjusts the volume of the headway alerts and other audible alerts from the CWS The speaker volume resets to maximum vol ume when the system turned off and back on again or the ignition is turned off and back on Headway Adjustment Switch HDWY HDWY This switch will adjust the headway for alerts When the system power is reset the headway will default back to the maximum dis tance For vehicles with SmartCruise the headway adjustment will determine the headway the ve hicle will maintain from other moving vehicles in the same traveling lane of your vehicle Cruise control must be set for the headway to adjust 1 2 3 4 5 05 08 2000 1 Headway Control Switch 2 Resume Accelerate Set Coast Switch 3 Headway
141. cause serious injury or death if improperly handled Do not smoke where starting fluid is in use Keep sparks flames and arc welding equip ment away from starting fluid NOTICE Protect the turbocharger during the start up by not opening the throttle or accelerating the en gine above 1000 rpm until minimum engine idle oil pressure registers on the gauge Failure to do so could damage the turbocharger Engines and Clutches Caterpillar NOTE Perform the steps in Prestart first 1 Turn the ignition switch to the ON position Fig 7 9 All the electronic gauges on the ICU instrumentation control unit complete a full sweep of their dials the warning and indicator lights light up and the buzzer sounds for three seconds OFF ON ACC amp START 03 22 2001 1602079 Fig 7 9 Ignition Switch Positions NOTE The engine electronics supply the cor rect amount of fuel for starting the engine Pedal pressure is unnecessary 2 Turn the ignition switch to the START position Do not press down on the throttle pedal Release the switch the moment the engine starts 2 1 If the engine does not start after 30 sec onds of cranking turn the ignition switch OFF NOTE Some starters are equipped with op tional overcrank protection If overcranking occurs a thermostat breaks the electrical circuit to the starter motor until the motor has cooled 2 2 Wait two minutes to allow the starter motor to cool Turn
142. ces 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 a lower range The lower the gear range the greater the engine braking power Use the up or down arrow buttons on the shift selector to reach the desired gear The Select indicator will display your choice and the Moni tor indicator will show the selected gear once it is reached NOTE In the lower gear ranges the transmis sion will not upshift above the highest gear se lected unless the engine governed speed is ex ceeded 5 Use neutral N and apply the parking brake when the vehicle is parked with the engine run ning CAUTION Do not allow the vehicle to coast in neutral This can result in severe transmission damage Also no engine braking is available 8 18 Transmissions Meritor Engine Synchro Shift ESS Automated Models General Information 9 Speed and 10 Speed M MO RS and RSX Models Meritor 9 speed M 11F9A E11 M 12F9A E12 M 13F9A E13 M 14F9A E14 M 15F9A E15 MO 12F9A E12 MO 13F9A E13 MO 14F9A E14 MO 11F9B E11 MO 12F9B E12 MO 13F9B E13 MO 14F9B E14 MO 15F9B E15 RS9 115A RS9 125A RS9 135A RS9 145A RS9 155A RSX
143. ch gear the ve hicle is operating in When a flashing blinking indi cation is present in the right position s it indicates which gear the transmission is attempting to reach The arrow indication will also be flashing with either an up or down arrow indicating the need to increase or decrease input shaft speed Fuel Use Efficiency Level FUEL If so equipped the FUEL system continuously moni tors fuel usage efficiency and instantly transmits ac tion messages through the Driver Message Center to help the driver get better mileage The system may suggest a different speed gear or throttle position and will calculate and transmit estimated fuel savings based on the suggested action It also calculates and displays a bar graph that shows a fuel efficiency Score as a percentage of optimum efficiency The messages this system displays are Drive 60 MPH Gain X MPG Shift to Next Gear Gain X MPG End Idling Save X Gal Hr Drive Steady Speed Gain X MPG Move Throttle Slower Gain X MPG In each example the X value in the statement is variable The system will estimate and display a nu merical savings gain in place of the X NOTE The information provided by the FUEL efficiency system is different than and should not be confused with the information available by pressing the FUEL key on the 10 key key pad The keypad and its direct access keys are described in more detail later in this chapter Target MPG The
144. cision screen appears displaying the decision choices with the current selection flashing To change the selection move the left or right arrow key as many times as required until the desired se lection is flashing Then press the down arrow key to leave the decision screen and go to the next setup feature screen See Fig 2 36 Service Interval Programming For service intervals only there is an extra program ming step From the service interval feature screen press the set reset key to display a decision screen for setting service interval units the choices are miles hours or off If you select miles or hours on this decision screen press the down arrow key to go to a second decision screen This decision screen allows you to select the length of the interval in the units you have chosen either miles or hours Once you have selected the interval length press the down arrow key again to go to the next setup feature screen target mpg If on the other hand you select off at the selection screen for service interval units meaning you have turned off service interval information you go di rectly to the next setup feature screen target mpg Vehicle Information Vehicle information allows you to view datalink activ ity in a dynamic graph format datalink usage and error rate datalink status and ICU4M ICUAM 2 data including ICUA4M ICUAM 2 serial number and software revision level See Fig 2 37 From the setup
145. ck for the cause of abrasion such as loose or damaged hose clamps Have the clamps repaired or replaced as needed 23 5 Observe the hose cover condition espe cially hoses exposed to water splash and ice If dried out or ragged the wire or liner is showing through the cover have the hose s replaced 23 6 Inspect the air tubing especially tubing made of nylon In cold weather nylon tub ing is sensitive to damage such as nicks or cuts Have nicked or cut tubing re placed even if it is not leaking 23 7 Check for kinked or twisted hoses A Seven percent twist in the hose can re duce its life by up to 90 percent A twisted hose under pressure tends to untwist which may loosen the fitting Reconnect hoses that are twisted NOTE The front brake lines flex continu ously in vehicle operation so they require special examination Give particular attention to the areas near where they connect to the front air brake chambers This inspection requires two people one in the driver seat and another to inspect the brake line con nections at the wheels 23 8 Both wheel air lines must be inspected with the emergency brake set engine idling air pressure at 80 to 90 psi 550 to 620 kPa and the brake pedal held down Pretrip Inspection and Daily Maintenance 24 25 23 9 Turn the wheels to full lock in one direc tion and inspect both air lines where they connect to the air chambers then turn the wheels to full lock
146. clog the injector spray holes and piston rings and may result in stuck valves 3 If the engine coolant temperature becomes too low raw fuel will wash the lubricating oil off the cylinder walls and dilute the crankcase oil there fore all moving parts of the engine will suffer from poor lubrication 4 Turn off the ignition switch and shut down the engine DDE S60 1 With the vehicle stopped apply the parking brakes and place the transmission in neutral 2 Allow the engine to run at idle for four to five minutes This allows the engine to cool and the turbocharger to slow down NOTICE After high speed operation shutting down the engine without idling may cause damage to the turbocharger as it will continue to turn without an oil supply to the bearings 3 Turn off the ignition switch and shut down the engine Mercedes Benz If any of the following occur shut down the engine immediately The oil pressure swings back and forth or falls sharply Engine power and rpm fall even though the throttle pedal remains steady The exhaust pipe gives off heavy smoke The coolant and or oil temperature climb ab normally e Abnormal sounds suddenly occur in the engine or turbocharger 1 With the vehicle stopped apply the parking brakes and place the transmission in neutral NOTICE Idle the engine one to two minutes before shut ting it down if this can be done without damage to the engine After h
147. cloth or sponge A mild detergent may also be used Sponge gently then rinse If necessary use a non abrasive chrome cleaner to remove stubborn rust or other material Do not use steel wool To help protect the chrome after cleaning apply a coat of polishing wax to the surface Never use wax on parts that are exposed to high heat such as ex haust pipes Dashboard Care Periodically wipe the dashboard with a water dampened cloth A mild detergent can be used but avoid using strong detergents CAUTION Do not use Armor All Protectant STP Son of a Gun or other equivalent treatments These cleaners contain vinyl plasticizers that can cause stress crazing in the interior plastic panels which can result in cracking of the panels Vinyl Upholstery Cleaning To prevent soiling frequent vacuuming or light brush ing to remove dust and dirt is recommended Harsh cleaning agents can cause permanent damage to vinyl upholstery To preserve the upholstery and pre vent damage carefully review the following sections for recommended cleaning procedures Waxing or refinishing improves soil resistance and cleanability for all vinyls 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 repeate
148. code is stored in all four memory locations Taken together these ensure that only the vehicle owner s fobs can be pro grammed into the system If additional fobs are programmed they overwrite the original code in locations two three and four in that order The ECM provides a 20 second time period to pro gram each fob If the fob is not programmed within this time span the system will exit the programming sequence After each valid code storage sequence the system LED will indicate the completion of a learning cycle by turning off the LED for approximately 0 5 second and unlocking the doors To program a fob do the following steps 1 With the ignition key switch turned off turn the program switch ON flip the toggle DOWN See Fig 3 27 2 Now turn the ignition key switch on Note that the system LED illuminates continuously See Fig 3 26 This indicates that the ECM is ready to begin the learning sequence NOTE If the LED does not illuminate continu ously at this point repeat the first two steps 3 On the fob press down both the LOCK and UN LOCK buttons at the same time and hold them down for at least three seconds See Fig 3 25 If the code was learned the system LED flashes and the doors unlock IMPORTANT If no valid code was received the system does not erase any stored data in that memory location This is a security measure to ensure that a fob ID cannot be erased acciden tally 4 Repeat th
149. connect the gel cell battery and use only an external battery charger that has been approved for gel cell batteries Turbocharger Boost Pressure Gauge A turbocharger boost pressure gauge Fig 2 65 measures the pressure in the intake manifold in ex cess of atmospheric pressure being created by the turbocharger Pyrometer A pyrometer registers the exhaust temperature near the turbocharger Normal exhaust temperatures are 700 to 1100 F 370 to 595 C Variations in engine load can cause exhaust tem peratures to rise as high as 1100 F 600 C If the pyrometer reading shows that exhaust temperature exceeds normal reduce fuel to the engine until the exhaust temperature is reduced Shift to a lower gear if the engine is overloaded Instruments and Controls Identification Primary and Secondary Air Pressure Gauges Air pressure gauges Fig 2 66 register the pressure in the primary and secondary air systems Normal pressure with the engine running is 100 to 120 psi 689 to 827 kPa in both systems A low air pressure warning light and buzzer connected to both the pri mary and secondary systems activate when air pres sure in either system drops below a minimum pres sure of 64 to 76 psi 441 to 524 kPa When the engine is started the warning light and buzzer re main on until air pressure in both systems exceeds minimum pressure oe DAN E A A WY Ye We Primary Air Pressure Ta Secondary Air Pressure
150. ctivate only for a limited period of time before the en gine starts Make sure the fuel heater is used only for starting the engine For more information see the Cummins engine op eration manual supplied with the vehicle DDE S60 Preparations made in advance of winter and mainte nance performed during the cold months will help to ensure efficient engine starting and operation Engine oil thickens as it gets colder slowing cranking speed When cold multi grade oil of fers less resistance to the cranking effort of the engine and permits sufficient rpm to be devel oped to start the engine See How to Select Lubricating Oil in the Detroit Diesel Engine Operator s Guide for specific recommenda tions When an engine equipped with a DDEC sys tem is started at temperatures below 25 F 4 C the idle speed automatically increases to 900 rpm The injection timing is also ad vanced to decrease white smoke As the en gine oil warms up the idle speed gradually de creases When the oil temperature reaches 122 F 50 C both the idle speed and the in jection timing return to normal A winterfront may be used to improve cab heating while idling At least 2596 of the grille opening should should remain open in sec tioned stripes that run perpendicular to the charge air cooler tube flow direction This as sures even cooling across each tube and re duces header to tube stress and possible fail ure Winterfronts should on
151. curves dips and hills and these can provide an unexpected result NOTE A warning may sound when an object is detected in front of the vehicle even though the driver intends to turn away or stop before reach ing the object When an object is detected in a very sharp right or left hand turn the audible alarm will not sound When approaching a curve before turning into it alarms may sound and lights illuminate be cause of an object off the road directly in line with your vehicle This will not occur when the brakes are applied Elevated obstacles such as overpasses and overhead signs may be detected when ap proaching a roadway descending to a lower elevation Vehicles cannot be detected on the other side of a hill An alarm will not sound until the object is within the antenna assembly s field of view On approaching a steep hill objects above the beam cannot be detected Generally the beam hitting the road surface does not cause an alarm The side sensor only detects objects within its field of view next to the tractor A vehicle far ther back behind the field of view will not be detected The side sensor range is set to detect average sized vehicles 2 to 10 feet 0 5 to 3 meters away in the adjacent lane The radar beam of the CWS will detect near range cut ins of approximately 30 feet 9 meters or less depending on the angle of en trance into the lane in front of your vehicle Heavy rain or
152. d OPT The optional indicator lights that are available include low voltage warning alternator no charge warning auto matic transmission overheat warning trailer ABS warning ECAS electronic suspension transfer indicator and ECAS failure warning NOTE The functions of the ABS warning lights are explained under Meritor WABCO Antilock Braking System ABS later in this chapter ICU2L Ignition Sequence If the headlights are turned on the screen displays the odometer and waits for the ignition to be turned on See Fig 2 54 When the ignition is turned on all the electronic gauges complete a full sweep of their dials the warning and indicator lights light up and the buzzer sounds for three seconds NOTE The air gauges and voltmeter do not sweep The following lights go on during the ignition se quence High Coolant Temperature Warning Low Engine Oil Pressure Warning Low Air Pressure Warning Park Brake On Indicator All engine warning lights including Engine Pro tection Check Engine and Stop Engine Cum mins only All ABS warning lights including Wheel Spin Tractor ABS and Trailer ABS if installed NOTE While the engine and ABS warning lights go on during the ignition sequence they are not controlled by the ICU2L but by their own sys tem ECU electronic control unit Once the ignition switch has been turned on the ICU2L performs a self test looking for active faults During t
153. d accessories Most standard and optional instrument gauges and switches can be mounted in either of these dashes The instrumentation control unit ICU houses most warning and indicator lights most gauges and a message display screen Warning messages and diagnostic fault codes will appear in the message display screen The dash light bars have warning and indicator lights that may be comprised of letter ing icons or both Until December 31 2006 the warning and indicator lights are a mixture of ISO icons and lettering Since January 2007 ISO icons are used for all standard warning and indicator lights on the dash light bar For more information see the appropriate heading in this chapter depending on the ICU installed in the vehicle See Table 2 1 for descriptions of the standard warn ing and indicator lights used on the lightbars Warning and Indicator Lights Check Engine Lamp amber o Indicates an undesirable engine condition is detected or recorded The vehicle can still be driven If the condition gets worse the stop engine or engine protection light will illuminate Stop Engine or Engine Protect Lamp red fe Indicates a serious fault which requires the engine shut down immediately The engine ECU will reduce the maximum engine torque and speed and if the condition does not improve will shut down the engine within 30 seconds of the light illuminating The driver must safely bring the vehicl
154. d air lines 7 Remove the chocks from the trailer s tires Trailer Release 1 Apply the truck and trailer parking brakes Do not use the trailer air supply for parking trail ers not equipped with spring parking brakes This applies the trailer service brakes only As air bleeds from the trailer brake system brake appli cation is lost This could allow the unattended vehicle to roll away possibly resulting in serious personal injury or death 2 Chock the front and rear tires of the trailer 3 Disconnect the trailer air and electrical lines Plug the air lines to keep out dirt 4 Take the weight of the trailer drawbar off the pintle hook 5 Open the latch by first removing the cotter pin then lift up the lock and raise the latch 6 Slowly drive the vehicle away from the trailer 10 18 11 Pretrip Inspection and Daily Maintenance Pretrip and Post Trip Inspection Checklists 0 0 0 c cece eee eee e 11 1 Pretrip and Post Trip Inspection and Maintenance Procedures 0 000ee eee eee 11 3 Pretrip Inspection and Daily Maintenance Pretrip and Post Trip Inspection Checklists Regulations in both Canada and the United States clearly indicate that it is the driver s responsibility to perform an inspection and ensure the complete road worthiness of a vehicle before placing it into service for the day Commercial vehicles may be subject to inspection by authorized inspectors and an unsafe vehicl
155. d several times as necessary Cab Appearance 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 per manent dull appearance Chewing Gum Harden the gum with an ice cube wrapped in a plas tic bag then scrape it off with a dull knife Any re maining traces of gum can be removed with an all purpose light oil peanut butter will also work and wiped off Tars Asphalts and Creosote Each of these items stains vinyl after prolonged con tact They should be wiped off immediately and the area carefully cleaned using a cloth dampened with naphtha Paint Shoe Heel Marks Paint should be removed immediately Do not use paint remover or liquid type brush cleaner on vinyl An unprinted cloth dampened with naphtha or tur pentine 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 con tact with vinyl These stains can be removed by plac ing a clean unprinted piece of cloth over the spotted area and pouring a liberal amount of 6 percent hy drogen peroxide onto the cloth Allow the saturated clot
156. datalink through which all necessary data and infor mation is exchanged The CPC broadcasts informa tion on the J1587 and J1939 datalinks where it is read by the diagnostic tool The MCM monitors both the engine and datalink When a malfunction is de tected the system selects an appropriate response for example the emergency running mode may be activated Motor Control Module MCM The MOM is located on the left hand side of the en gine See Fig 7 7 The MCM processes the data received from the CPC for example the position of the accelerator pedal engine brake etc This data is evaluated to gether with the data from the sensors on the engine such as coolant and fuel temperature and oil and charge pressure The data is then compared to the characteristic maps stored in the MCM From this data the quantity and timing of fuel injection are cal culated 7 4 Engines and Clutches 02 19 2008 1545236 Fig 7 7 Motor Control Module MCM Common Powertrain Controller CPC The CPC is located in the vehicle cab See Fig 7 8 The CPC communicates with the MCM over the J1939 datalink Data for specific applications is stored in the CPC These include idle speed maxi mum running speed and speed limitation 02 19 2008 1545235 Fig 7 8 Common Powertrain Controller CPC The CPC receives data from the following
157. de reduced engine idle time fuel savings reduction of exhaust emis sions and noise increased starter and engine life and less chance of dead batteries due to electrical loads Engines and Clutches Optimized Idle operates in two modes the engine mode or the thermostat mode The engine mode keeps the battery charged and the engine oil tem perature within factory set limits The thermostat mode is the same as the engine mode but also keeps the cab and sleeper at a constant preset tem perature The engine mode is always activated when the sys tem is operated The thermostat mode is activated when the thermostat is turned on The thermostat mode controls the set point which is the desired temperature of the cab and sleeper and the comfort zone which is the number of degrees from the set point before the engine needs to heat or cool the cab There are three comfort zones 4 F 2 C 7 F 4 C or 10 F 6 C Vehicles equipped with Optimized Idle have a label and a dash light The dash light is on the dash mes sage center or the Driver Message Center on the A panel See Fig 7 13 See Fig 7 14 for the dash label detail If equipped with the thermostat mode a thermostat is located in the sleeper above the bunk See Fig 7 15 1 FASTEN SEATBELTS 0000432 MILES 02 11 97 1601264 1 Optimized Idle Light Fig 7 13 Optimized Idle Light d OPTIMIZED IDLE e ACAUTION TO AVOID
158. der 4 Electrical Access Panel Fig 3 29 Cab Amenities Ash Tray and Cigar Lighter The driver s ash tray and cigar lighter assembly is on the right side of lower dash panel See Fig 3 29 Map Holder An elastic topped pouch is located above each door These are intended for holding maps and other items Glove Box Some vehicles have two glove boxes and two small overhead bins all located in the overhead console assembly See Fig 3 30 Above the sun visors on both the driver s and the passenger s sides are the glove boxes with latched doors or netted openings In the middle section of the console assembly are two small bins The driver s side bin is often removed and replaced with a CB radio The grille underneath this portion of the console allows the radio s speaker to be heard 05 15 98 1680007 Fig 3 30 Glove Boxes and Overhead Storage Overhead Lights Above both the driver s and the passenger s seats are three oval shaped lights mounted to the bottom of the overhead console A red light and two white lights The red light is mounted nearest to the wind shield Each light is activated by pushing on the lens cover Also the center light a white light activates when the doors to the vehicle are opened Courtesy Lights There are optional red lights mounted underneath the dash on the driver s and the passenger s sides of the vehicle These lights are activated by a rocker switch on the lower
159. develops stable oil pressure NOTE When the engine is started it takes a short time to build up a lubricating oil film be tween the shafts and bearings and between the pistons and liners The oil pressure gauge indi cates any drop in lubricating oil pressure within 15 seconds of engine start up 4 lf a minimum engine oil pressure at idle of 10 psi 69 kPa does not register within 15 seconds shut down the engine Engines and Clutches NOTICE Protect the turbocharger during the start up by not opening the throttle or accelerating the en gine above 1000 rpm until minimum engine idle oil pressure registers on the gauge Failure to do so could damage the turbocharger 5 Idle the engine for three to five minutes at 1000 rpm before operating the engine under load DDE S60 NOTE Perform the steps in Prestart first 1 Turn the ignition switch to the ON position see Fig 7 9 All the electronic gauges on the ICU instrumentation control unit complete a full sweep of their dials the warning and indicator lights light up and the buzzer sounds for three seconds 2 When all the indicators go out turn the ignition switch to the START position Without touching the throttle pedal start the engine If the engine won t start within 15 seconds release the ignition switch and allow the starter motor to cool IMPORTANT If the engine won t start check the main engine power fuses The fuses are located along the main en
160. different governed speeds below the governed speed Depress the clutch pedal enough to release the torque then shift into neutral Engage the clutch and bring the engine rpm up to governed speed While holding full throttle disengage the clutch shift into 4th gear engage the clutch smoothly Follow the same sequence to downshift from 4th into 3rd 3rd into 2nd and from 2nd into 1st gear Never use the clutch brake when downshifting or as a brake to slow the vehicle Fuller Range Shift Models General Information 9 Speed RT RTO and RTX Models Fuller RT 8608L RT 8609 RT 11609A RT 11709H RT 12609A RT 12709H RT 13609A RT 13709H RT 14609A RT 14709H RTO 11909MLL RTO 14909MLL RTX 11609B R RTX 11709H RTX 12609B R RTX 12709H RTX 13609B R RTX 13709H RTX 14609B R RTX 14709H and RTX 16709B H transmissions have a 5 speed front section and a 2 speed rear range section The low gear in the front sections of the RT 8609 and A and B ratio transmissions is used only as a starting ratio The high gear in the front section of the R ratio transmissions is used only as the top gear The re maining gear positions of the above transmissions are used once in the low range and once in the high range See Fig 8 5 for the shift patterns noting that the 3rd 7th and 4th 8th shift positions in the RT direct ratio and RTX B overdrive ratio transmissions are opposite of the RTO overdrive ratio transmissions The RT
161. ds After three seconds the lights go out only if all of the tractors ABS components are working IMPORTANT If any of the ABS warning lights do not work as described above or come on while driving repair the ABS system immedi ately to ensure full antilock braking capability The wheel spin indicator light WHEEL SPIN comes on if one of the drive wheels spins under power The light goes out when the wheel stops spinning A label Fig 2 57 on the dash explains what actions should be taken when the WHEEL SPIN indicator light comes on NOTICE Axle lock should only be engaged when the ve hicle is moving slowly at low throttle Engage ment at high speed or power can damage the axle s Vehicles with electronic engines and ABS may have automatic traction control ATC On these vehicles the ATC system automatically limits wheel spin when power is applied to the drive axles during reduced traction situations FASTEN SEATBELTS 0000432 MILES 1 2 1601125 2 Wheel Spin Indicator 04 02 96 1 Tractor ABS Warning Fig 2 56 ABS Warning and Wheel Spin Indicator Lights IF REAR WHEEL SPIN OCCURS PARTIALLY RELEASE THROTTLE PEDAL UNTIL WHEEL SPIN AMBER LIGHT EXTINGUISHES THEN ENGAGE AXLE LOCK 09 22 98 1600311a Fig 2 57 Dash Label If the vehicle has ATC there will be a momentary contact rocker switch on the dash labeled NORM SPIN and ATC When the ATC system is in
162. ds and place your right foot on the door threshold while standing up from the seat facing inward 2 Move your right hand to the cab forward outside grab handle 3 Carefully place your right foot on the top access step 4 Move your left hand to the cab forward outside grab handle Then move your right hand to the cab aft outside grab handle 5 Place your left foot on the middle step 6 Place your right foot on the bottom step 7 Step to the ground with your left foot 8 Let go of the grab handles Door Windows The windows in both doors operate manually or elec trically if so equipped Use the crank handle or the appropriate switch to raise or lower a door window Sleeper Compartment Vents To open any sleeper compartment vent push the vent handle outward and forward with your fingertips To close the vent turn your hand so that your fingers are pulling on the handle from the front edge then pull in and back on the handle Use care to avoid pinching your fingers Circuit Breaker Relay Panel The circuit breaker relay panel is located in front of the passenger s seat under the top cover of the in strument panel To access the compartment press the button labeled PRESS and lift the top dash panel See Fig 3 16 Cab to Sleeper Access A WARNING Place rigid or heavy objects in storage areas on the floor or under the bunk Sudden stops or swerves could cause personal injury if items fall from overhead stor
163. e the ICU2M conducts a roll call of all the elec tronic control units ECUS installed on the vehicle looking for active faults If there are no active faults the screen displays the Fasten Seat Belts Odometer screen If however the ICU2M has received active fault codes or an electronic control unit ECU fails to re spond to the roll call it shows the Active Faults screen and displays the number of active faults up to a total of eight If desired press the right arrow Fig 2 44 to see the active fault codes Continuing POWER ON HEADLIGHTS ON Y FASTEN SEATBELTS IGNITION ON 123456 7 MILES B FREIGHTLINER IGNITION ON ELECTRONIC GAUGE NEEDLES SWEEP AND WARNING INDICATOR LIGHTS COME ON IF FAULT DETECTED AND OR AN ECU DID NOT RESPOND DURING ICU ROLL CALL Y IF NO FAULTS ICU ROLL CALL WERE DETECTED TRANSMITS REQUEST AND ALL EDS FOR FAULT ONTO RESPONDED THE DATALINK DURING ICU ROLLCALL IF MESSAGE AVAILABLE Y Y FASTEN SEATBELTS INCOMING MESSAGE TEXT p 123456 7 MILES IF MESSAGE DUNG AVAILABLE INCOMING MESSAGE IDLE HOURS 1234 56 TEXT p gt 12 3 GAL 123456 7 MI PARK BRAKE IF MESSAGE RELEASED AVAILABLE MOVING INCOMING MESSAGE 74 O Illllllll TEXT pe 12 3 TMPG 123456 7 MI 03 18 98 ACTIVE FAULTS 8 FAULT CODE SCREEN PRESS KEY OR Y KEY OR RELEASE PARK BRA
164. e 11 2 Weekly Post Trip Inspection and Maintenance Checklist P n Monthly Post Trip Inspections Checks sessi Clean the battery terminals M1 Inspect radiator hoses and heater hoses M2 Check fluid level in the hydraulic clutch reservoir if applicable and if necessary fill with DOT 4 brake fluid Check steering wheel play M3 Check outer surfaces of the hood and body for visible surface breaks and damage Check hood tilt damper attached at both ends Inspect brake lining wear M4 Inspect driveshaft Inspector Date Table 11 3 Monthly Post Trip Inspection and Maintenance Checklist Pretrip and Post Trip Inspection and Maintenance Procedures Whenever equipment requires adjustment replace ment repair addition of lubricants or a change of lubricants see the Century Class Trucks Workshop Manual for procedures and specifications and see the Century Class Trucks Maintenance Manual for lubricant recommendations specifications and main tenance intervals Daily Pretrip Inspection and Maintenance Procedures 1 Drain manually drained air reservoirs Water and oil normally enter the air reservoir in the form of vapor because of the heat generated 11 3 during compression After the water and oil con dense drain the resulting emulsion as follows 1 1 Open the wet tank valve The drain cock or pull chain drain is located on the for ward end of the supply air reservoir which is connected directly to t
165. e Distance traveled beyond the Y set Service Interval set Service Interval 4 SERVICE gt lt INTERVAL IS SET TO gt lt 12345 MILES OR SERVICE WAS DUE INFORMATION AMT XXXXX MILES AMT TO NEXT SERVICE AMT 12345 MILES AGO AMT R R V V Y Y LY j j Go to Set up Information Screens Time prior to reaching the Time accumulated beyond the set Service Interval set Service Interval SERVICE INTERVAL IS SET TO 1234 HOURS SERVICE WAS DUE lt I INFORMATION amt lt I xxxxHoURS AMT TO NEXT SERVICE AMT D OR 1234 HOURS AGO AMT R R V V V y y LY Go to Setup Information Screens 12 17 2004 AMT Current gear information for automated manual transmissions 040703 NOTE Service information screens only appear if the service interval is set to MILES or HOURS in Setup Information Metric unit screens are similar Fig 2 34 Service Information Screens 2 23 Instruments and Controls Identification parameters From the service information screen press the down arrow key to display the setup information screen See Fig 2 35 Press the right arrow key to display the setup screen for changing the service interval feature Press the down arrow key to scroll among the various setup feature screens This sequence completes the setup feature screens From any setup feature screen press the left arrow key to return to the setup information screen To set any feature press the set reset key when prompted A de
166. e Layout typical all ABS warning lights including wheel spin tractor ABS and trailer ABS if installed NOTE Although the engine and ABS warning lights illuminate during they are not controlled the ignition sequence by the ICU but by their own system ECU electronic control unit When the ignition switch has been turned on the ICU performs a self test looking for active faults During the first half of the self test all segments of the display illuminate as follows 888888 8 The ICU voltmeter display also illuminates but with the value 18 8 During the second half of the self test the software revision level is displayed If there are no active faults the ICU displays the odometer However if the ICU has received active fault codes from other devices it displays them one after the other until the parking brake is released or the ignition switch is turned off Once the parking brake is released the ICU displays the odometer again See Fig 2 41 for the ICU3 ICU3 07 ignition sequence Instrumentation Control Unit ICU2M NOTE The ICU2M is not available on vehicles built after January 1 2007 It is replaced with the ICUAM The ICU2M is an advanced programmable electronic dashboard It can accept information from the sen sors and electronic control units installed on the ve hicle and feed it to electronic gauges Only air gauges operate mechanically There can be up to 14 removable gauge
167. e above step to program additional fobs up to a total of four 5 When the programming sequence is over return the system to normal operation by turning the program switch OFF flip the toggle UP Fob Battery Replacement 1 Open the battery cover on the back of the fob with a suitable coin or other thin piece of metal Twist off the cover See Fig 3 28 1 2 3 UA 10 22 96 541446 1 Fob 3 O Ring 2 Battery 4 Battery Cover Fig 3 28 Fob Battery 2 Remove the battery and the O ring installed in side the cover Save the O ring for later installa tion IMPORTANT The battery may contain perchlor ate material special handling may apply see www dtsc ca gov hazardouswaste perchlorate 3 Install the new battery as follows 3 1 Insert the new battery into the fob Make sure the battery is right side up 3 2 Install the O ring as removed If the O ring is damaged or there are signs of moisture inside the fob replace the O ring 3 3 Twist on the battery cover and check it to make sure it is tight 4 Check the fob for correct operation Vehicle Access Cab Amenities Cup Holders The Century Class vehicle features two cup holders The driver s cup holder is located above the ash tray on the lower dash panel See Fig 3 29 The passen ger s cup holder is on the lower dash panel near the passengers seat 04 07 98 1610210 1 Ash Tray 2 Drivers Cup Holder 3 Passenger s Cup Hol
168. e air restriction indicator Check oil and air pressure warning systems Check ICU fault codes Check horn windshield wipers and windshield washer Check heater defroster and optional mirror heat controls Check backup alarm Check panel lights and interior lights Check exterior lights and reflectors Check tire pressure Inspect tire condition Inspect rims and wheels Check automatic transmission fluid level Inspect air brake chambers and pushrods Inspect air brake lines Inspect slack adjusters Check air brake system operation Inspect frame rails missing bolts crossmembers bent or loose Check mud flaps aren t damaged at least 10 inches above the ground and brackets u are secure Check exhaust system mounted securely connected tightly no signs of leaks such as u soot trails Remove chocks and test service brakes D26 Inspector Date Table 11 1 Daily Pretrip Inspection and Maintenance Checklist 11 2 Pretrip Inspection and Daily Maintenance dico P Weekly Post Trip Inspections Checks Deria Manually drain air reservoirs that are equipped with automatic drain valves Inspect batteries and battery cables W1 Check wheel bearing lubricant level W2 Inspect steering components W3 Check serpentine drive belt condition W4 Check V belt tension W5 Inspect seat belts and tether belts W6 Inspector Date Tabl
169. e can be put out of service until the driver or owner repairs it Use the inspection checklists to ensure that vehicle components are in good working condition before each trip A driver that is familiar with the vehicle and drives it regularly can perform the daily inspec tions then add the weekly and monthly post trip in spections as scheduled If the driver does not oper ate the vehicle on a consistant basis all three of the inspection procedures should be performed before the trip NOTE Procedure reference numbers in the the checklists reference the corresponding detailed instructions found under the pretrip and post trip maintenance procedures Pre and post trip inspections cannot be done quickly However careful inspections save time by eliminating stops later to adjust items overlooked or forgotten If any system or component does not pass this in spection it must be corrected before operating the vehicle Whenever equipment requires adjustment replacement repair addition of lubricants or a change of lubricants see the Century Class Trucks Workshop Manual for procedures and specifications and see the Century Class Trucks Maintenance Manual for lubricant recommendations specifica tions and maintenance intervals IMPORTANT The pre and post trip checklists and inspections and maintenance procedures detailed in this chapter are not all inclusive Also refer to other component and body manu facturers in
170. e 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 10 5 Lockguard Mechanism rear view sulting in air leaks or exposed or broken wires A WARNING potentially affecting trailer brake or electrical sys tems Adjust the locks correctly to a maximum clear ance of 1 8 inch 3 mm Incorrect adjustment of 7 After lockup is completed connect the tractor to the lock could cause the trailer to disconnect trailer air system lines and electrical cable to the possibly resulting in serious personal injury or trailer Take care to prevent dirt or foreign mate death rial from entering the air lines 6 Make a visual check for proper kingpin lockup 8 Charge the air brake system with air Make sure Release the tractor parking brakes Test for king that the air connections do not leak pin lockup by pulling on the trailer against the 9 Retract the trailer landing gear and secure the chocks Check for correct maximum clearance ratchet handle between the lock halves If more than 1 8 inch 3 2 mm clearance exists between the lock 10 Remove the chocks from the trailer tires halves the lock must be adjusted See Group 11 The load distribution on the front steering axle 31 of the Century C
171. e only after the transmission has shifted 11 To shift from 5th overdrive to 6th direct partially disengage the clutch shift into 6th but before engaging the clutch flip the splitter control but ton down into the direct drive position then en gage the clutch and accelerate the engine Do not move the control button while the shift lever is in neutral 12 Shift upward through each of the high range gears alternating the procedures in steps 10 and 11 above Downshifting 1 Downshift from 8th overdrive to 8th direct without moving the shift lever Flip the splitter control but ton down to the direct drive position then imme diately release the accelerator and press and release the clutch pedal Accelerate the engine only after the transmission has shifted 2 To downshift from 8th direct to 7th overdrive flip the splitter control button up to the overdrive po sition then immediately double clutch through neutral moving the shift lever from 8th to 7th gear 3 Downshift through each of the high range gears alternating the procedures in steps 1 and 2 above until reaching 5th direct 4 While in 5th direct and ready for the next down shift push the range selection lever down into low range Double clutch through neutral and shift into 4th gear See Fig 8 13 As the shift lever passes through neutral the transmission will automatically shift from high range to low range 5 With the transmission in lo
172. e return to base idle The active light will turn off Optimized Idle is now disabled and all the DDEC features are available Clutches General Information The major reason clutches wear out too soon is ex cessive heat Clutches are designed to absorb and dissipate more heat than encountered in typical op eration The heat generated in typical operation will not break down the clutch friction surfaces However if a clutch is slipped excessively or asked to do the job of a fluid coupling high temperatures develop quickly and destroy the clutch Temperatures gener ated between the flywheel driven discs and pres sure plates can be high enough to cause the metal to flow and the friction facing material to char and burn Heat and wear are practically nonexistent when a clutch is fully engaged But during the moment of Engines and Clutches engagement when the clutch is picking up the load it generates considerable heat An improperly 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 in clude starting in the right gear clutch malfunctions and when to adjust a clutch Clutch Operation Valeo Clutch Break In With a new or newly installed Valeo clutch the clutch may slip for a short time while the friction surfaces break in However allowing the clutch to slip for more than two seconds
173. e three position switch on the main climate control panel on the dash Fig 4 2 to the middle position The switch in the middle position gives full con trol of the auxiliary heater air conditioner to the sleeper bunk mounted control panel The sleeper bunk fan is turned off when the switch is in the bottom position The sleeper bunk fan is on high when the switch is in the top position 2 Turn the temperature control knob all the way counterclockwise to COOL Turn the fan control knob to position 3 See Fig 4 3 3 When the sleeper compartment cools to the de sired temperature turn the temperature control knob clockwise to adjust outlet air temperature Then turn the fan control knob to adjust the air flow level The system will automatically maintain the se lected outlet air temperature 4 Whenever air conditioning is not desired turn the temperature control knob clockwise as needed and turn off the fan IMPORTANT To prevent the buildup of fumes or odors inside the sleeper for example from 4 4 Heater and Air Conditioner smoking do not operate the heater and air con ditioning system in a recirculation mode for more than 20 minutes NOTE Whenever the refrigerant compressor is operating the fan will always run at a very low speed even with the fan control knob in the Off position This prevents ice from forming on the evaporator especially during humid weather 4 5 Seats and Seat Belts ccc
174. e to a stop on the side of the road and shut down the engine as soon as the red light is seen If the engine shuts down while the vehicle is in a hazardous location the engine can be restarted after turning the key to the OFF position for a few seconds 1 err De High Exhaust System Temperature HEST Lamp amber Slow 10 second flash indicates a regeneration is in progress and the driver is not controlling the engine idle speed Solid illumination indicates a regeneration is in progress with high exhaust temperatures at the outlet of the tail pipe if the speed is below 5 mph 8 km h It does not signify the need for service it only alerts the vehicle operator of high exhaust temperatures See the engine operation manual for details Diesel Particulate Filter DPF Lamp amber Solid illumination indicates a regeneration is required Change to a more challenging duty cycle such as highway driving to raise exhaust temperatures for at least 20 minutes or perform a parked regeneration See the engine operation manual for details Blinking indicates that a parked regeneration is required immediately An engine derate and shutdown will occur See the engine operation manual for details on how to perform a stationary regeneration Malfunction Indicator Lamp MIL amber o Indicates an engine emissions related fault including but not limited to the aftertreatment system See the engine operation manual f
175. e to sup port it specific vehicle information can be transmitted wirelessly over the Internet Transmitted information includes Global Positioning System GPS coordinates instant messages vehicle mileage diagnostics in the form of active fault codes Transmitted information is viewed by going to the vehicle s web page using an Internet browser With 2 28 Instruments and Controls Identification the exception of instant messages all of the informa tion mentioned above is transmitted to the web page without any action required of the vehicle operator Instant Messages The ICU2M is capable of transmitting and receiving instant messages to and from the vehicle s web page for vehicles equipped with Truckweb IMPORTANT The parking brake must be set in order to send instant messages or to retrieve instant messages from memory Bring the ve hicle safely to a stop out of the flow of traffic and set the parking brake before sending mes sages or retrieving them from memory Receiving Messages Incoming messages are displayed as they are re ceived and will be interrupted only by higher priority messages If interrupted the instant message being received will display after the higher priority message is dismissed Instant messages are stored in memory after being received and dismissed Up to three mes sages can be stored in memory at any one time If a new message arrives and three messages are al ready in memo
176. e 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 causing personal injury and property damage NOTE On some vehicles the differential lock system is connected through the low speed range of the transmission If this system is used the transmission must be in the low speed range for the differential to fully lock If the vehicle is moving maintain a constant vehicle speed while engaging the differential lock Briefly let up on the accelerator to relieve torque on the gear ing allowing the differential to fully lock The indica tor light should come on and the buzzer should sound on vehicles so equipped When the differential is fully locked the turning radius will increase be cause the vehicle understeers See Fig 9 1 Drive cautiously and do not exceed 25 mph 40 km h To unlock the main differential move the control Switch to the unlock position Briefly let up on the accelerator to relieve torque on the gearing allowing the differential to fully unlock NOTE If the differential lock system is con nected through the low speed range of the transmission shifting out of low speed range will also unlock the differential Rear Axles o Ld a 02 09 96 A Turning Radius When Differential is Locked engaged
177. each side of under side of the lower bunk and illuminates the baggage compartment Both lights turn on when either bag gage compartment door is opened The lights also come on when the lower bunk is raised See Fig 2 21 Tilt Steering Wheel The tilt steering wheel control button Fig 2 22 is located to the left of the brake automatic transmis sions or clutch manual transmissions pedal After adjusting the seat to the desired ride position unlock the steering column by pushing and holding the control button all the way down Tilt the steering column to the desired position then release the con trol button to lock the steering column in place 3 G 09 29 95 1541139 1 Under Bunk Light 3 Switch 2 Bunk Fig 2 21 Baggage Compartment Light Y Lo 1 2 09 14 99 1601698 1 Control Button 2 Clutch Pedal Fig 2 22 Tilt Steering Wheel Control Button Instruments and Controls Identification Make sure that the steering column is locked be fore driving the vehicle Never tilt the column while driving the vehicle Doing so could cause loss of vehicle control personal injury and prop erty damage Instrumentation Control Unit ICUAM General Information The ICUAM is used on pre EPAO07 engines and the ICUAM 2 is used on vehicles with engines that are EPAO07 compliant They can be differentiated by the exhaust icons in the middle row of the dash message center on the ICUAM 2 See Fig
178. eaded L Rod 1601696 OV om Fig 3 8 Manually Securing the Access Stairs 4 3 Turn the L rod until it extends out and en gages the nut in the stairs assembly Keep turning the L rod until the nut on the L rod is flush with the inboard surface of the stair assembly 4 4 Tighten the wheel nut 5 f you can t secure the stairs using the L rod use wire tie straps or bungee cords to hold the stairs in the stowed position NOTE When replacing the quick release pin you must fold the pin s spring handle back up against the pin This will hold the pin in place after it s installed See Fig 3 9 Entering the Driver s Side Using the Cab Access Stairs Fig 3 3 A WARNING If the optional cab access stairs do not move into position or if there is not enough room for them to deploy use the fixed steps on the outside sur face of the moving stairs Fig 3 5 and follow the f610230 07 20 98 3 1 Pin Handle in correct stowed position 2 Release Pin 3 Underside of Access Stairs Fig 3 9 Quick Release Pin Cab Access Stairs access instructions for the standard fixed step System Freightliner recommends you practice using the fixed steps until you are familiar with their use Enter the cab only as specified in the following steps Keep your body close to the cab and maintain three point contact with the cab at all times This means one hand and two feet or two hands and one foot Do not lean out a
179. ed If the calculations indicate wheel lockup the main circuit signals the appropriate solenoid control valve to reduce braking pressure During emergency braking the solenoid control valve alternately reduces increases or maintains air pres sure supply in the brake chamber to prevent front and rear wheel lockup If equipped with Automatic Traction Control an addi tional solenoid valve is installed During reduced traction situations the valve increases or reduces air pressure supply in the brake chamber to provide bet ter traction whenever wheel spin occurs The electronic control unit also has a safety circuit that constantly monitors the wheel sensors traction control valve if equipped solenoid control valves and the electrical circuitry After the ignition switch is turned on the tractor warning light TRACTOR ABS and if equipped with Automatic Traction Control the wheel spin WHEEL SPIN indicator light come on for about three sec onds If a compatible trailer is connected the trailer ABS lamp will also illuminate After three seconds the warning lights go out only if all of the tractor and trailer if equipped ABS components are working The wheel spin WHEEL SPIN indicator light comes on if one of the drive wheels spins during accelera tion The light goes out when the wheel stops spin ning When the light comes on partially release the throttle pedal until the light goes out If slippery road conditions
180. ed Position C Locked B Locking 1 Wedge 3 Trailer Kingpin 2 Jaw Fig 10 15 Fontaine Kingpin Lock Mechanism 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 dur ing release of the kingpin During lockup the jaw is moved first with the spring loaded wedge being allowed to slip in place against the jaw A timing bracket ensures that the wedge and jaw are moved at the proper time Placing the lock control handle in the unlocked posi tion moves the wedge away from the jaw This action unlocks the jaw so that it can be moved by the trailer kingpin 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 un locked position the lock control handle will remain in the unlocked position until manually moved by the operator During coupling Fig 10 15 the motion of the king pin entering 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 Op
181. ed gear is not available an audible warning will sound and the message display screen will indicate that the requested gear is not available Unlike upshifting an unavailable requested downshift is stored in memory and the shift will be made when the gear is avail able The time limit for this memory is a pro grammable parameter Reverse 1 To engage reverse R slide the selector switch upward to the next position above the neutral position and disengage the clutch NOTE AutoShift 10 and 18 speeds transmis sions have a dual range reverse Reverse low RL is the default reverse gear 2 On AutoShift 10 and 18 speed transmissions select reverse high RH by pulling upward on the control NOTE Reverse may be engaged below a pro grammable forward speed in order to rock the vehicle If reverse is selected above the pro grammed forward speed an audible warning will sound and a message indicating that the gear is not available will appear on the message dis play screen Transmissions Low Gear Operation Use low L when descending steep hills and using compression braking Engine speed will be increased by 200 rpms and shift points will be offset by 200 rpms The efficiency of the exhaust brake will be maximized Using the Clutch Use the clutch to start and stop the vehicle Operation Meritor SureShift Transmission Manual Mode There is no slide switch on the Meritor control as only the manual mode is
182. ed on after the engine is idling If it was 7 26 Engines and Clutches previously turned on turn off the cruise con trol then turn it on again 1 6 The dash light will begin blinking indicat ing that Optimized ldle is active The sys tem is now in the engine mode and after an initial phase in which the idle speeds up to 1000 or 1500 rpm depending on the outside temperature the engine will stop and start automatically to keep the battery charged and the engine oil warm The dash light stays on and shines steadily at this point 2 Activate the thermostat mode if so equipped as follows NOTE When the system is in the thermostat mode it is also in the engine mode It will continue to operate in the engine mode even if the thermostat mode is turned off 2 1 With the system in the engine mode set the cab and sleeper heater or air condi tioner controls to the highest setting 2 2 Turn on the thermostat by touching any of the four buttons See Fig 7 15 The display will flash the current sleeper temperature and the previous mode cool ing or heating selected If the cab needs to be cooled or heated the cool heat icon will flash 2 3 Choose either cool or heat by pressing the Cool Heat button Make sure the selection matches that of the cab controls IMPORTANT If the heat or cool selection of the thermostat does not match that of the cab the system will idle and cycle exces sively 2 4 Select Fah
183. ed position Shifting Depending on your transmission model the gear split may vary from 400 to 500 rpm The electronic gover nor provides almost no overrun capability if the transmission is downshifted too early you will experi ence a temporary loss of pulling power until the en gine speed falls below rated speed In general when using a 9 speed transmission you should always downshift between 1000 and 1100 rpm This is true even on steep grades with heavy loads When using an 18 15 or 13 speed transmission you will need to downshift at an rpm that allows less than rated rpm before throttle application in the next gear down You may want to limit engine speed to 1900 rpm in all gears The Detroit Diesel HD engines provide horsepower through 2100 rpm but fuel economy is not as effi cient above 1800 rpm If you decide to drive at lower rpm for improved fuel economy don t let different engine noises throw you off guard The Detroit Diesel HD engine sounds quiet at 1400 rpm almost as if it had quit pulling If you had a boost gauge to look at while driving you would notice the turbocharger maintaining steady intake manifold pressure even as rpm falls Depending on the air intake arrangement you may also hear a chuffing sound as the engine starts to pull hard at lower rpm This is normal and caused by the velocity changes of the air flow within the air intake plumbing Electronic engines can actu ally deliver more fuel a
184. ed with fuel tank shutoff valves be sure the valves are fully open Never operate the engine with the fuel tank shut off valves partly closed This could damage the fuel pump causing sudden loss of engine power possibly resulting in serious personal injury due to reduced vehicle control 9 Check the fuel level in the fuel tank s To keep condensation to a minimum fuel tanks should be filled at the end of each day Federal regulations prohibit filling a fuel tank to more than 95 percent of its liquid capacity Never fill 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 resulting in serious personal injury or death by burning Do not mix gasoline or alcohol with diesel fuel This mixture could cause an explosion possibly resulting in serious personal injury or death Do not fill the fuel tanks in the presence of sparks open flames or intense heat These could ignite the fuel possibly causing severe burns 9 1 Fuel should always be strained or filtered before being put into the tanks This will lengthen the life of the engine fuel filter and reduce the chances of dirt getting into the engine 9 2 Before installing the fuel cap clean the area with a rag or if necessary clean the cap with solvent 9 3 If needed prime the fuel system For priming procedures see the applicable engine manufacturer s manual 10 f equipped
185. eed rear range sec tion They also have five additional deep reduction ratios The 5 speed front section and the low and high range sections provide ten evenly and progres sively spaced forward speeds The five deep reduc tion ratios are also evenly and progressively spaced however they do overlap the low range ratios and should be used only when operating under adverse conditions See Fig 8 10 for the shift patterns noting that the 4th 9th and the 5th 10th shift positions in the RT direct ratio and RTX overdrive ratio transmis sions are directly opposite in the RTO overdrive ratio transmissions f260026a 2omnmmoeomgs Operation IMPORTANT The shifter knob has an interlock feature that prevents the deep reduction button from being moved forward when the range pre selection lever is up in high range when in low range and the deep reduction button is in the forward position the range preselection lever cannot be moved up Transmissions A Y 9 Lo Hi 7 gt 9 8 1 22 4 7 DR DR Lo DR Lo 5 4 N 3 2 5 2 4 1 s p 3 C 6 8 gt 10 A 171 3 3 55 DR Lo DR Lo DR Lo 1 z 13 03 13 96 A Fuller RT and RTX transmissions shift pattern 1 High Range 4 High Range 2 Low Range 5 Low Range 3 Deep Reduction B Fuller RTO transmissions shift pattern B Lo Hi lt 7 gt 10 22 DR DR Lo DR Lo 4 i N 1 T 5 8 gt 9 171 33 6 lt 7 DR Lo DR Lo DR Lo f260045a 6
186. een displays See Fig 2 27 for the idle hours screen odometer display IDLE HOURS 1234 56 123456 7 MI a 12 17 2004 1610754 NOTE On vehicles with automated manual transmis sion the three digits on the lower right are reserved for current gear information 12 3 GAL Fig 2 27 Idle Hours Screen Alert Screens Alert screens come on whenever the condition oc curs They appear when the vehicle is moving they override the regular screen display They are warn ings cautions or other messages that require the driver s attention but not all of them are critical to the operation of the vehicle Warning messages always display at full brightness More important messages take priority over less im portant messages The order of importance or prior ity is 1 Eaton VORAD and RSA warnings if so equipped Park brake on with the vehicle moving Park brake off with door open Low oil pressure high coolant temperature Hard brake warnings if equipped with RSA Low voltage Turn signal on Incoming instant or Qualcomm messages o 0 N Oar wo DP Service warnings 10 No datalink activity Incoming Message Screen On vehicles with an onboard communications system like Truckweb or Qualcomm this screen activates whenever a message is received Incoming Mes sage appears on the message display screen NOTE The Incoming Message screen also displays during the ignition sequence if a mes
187. efore descending hills and do not exceed a safe control speed Driving on Wet or Slippery Pavement To avoid injury from loss of vehicle control do not activate the engine brake system under the following conditions on wet or slippery pavement when driving without a trailer bobtailing or pulling an empty trailer if the tractor drive wheels begin to lock or there is fishtail motion after the engine brake is activated NOTE On single trailers or combinations a light air application of the trailer brakes may be desir able to help keep the trailer stretched out Fol low the manufacturer s recommended operating procedure when using the trailer brakes On wet or slippery pavement start with the master switch in the OFF position and use the gear you would normally use under these conditions If the vehicle is maintaining traction place the selective braking switch in the LOW position and turn ON the engine brake system If the drive wheels are main taining traction and you desire greater slowing power move the braking switch to the next higher position However if the tractor drive wheels begin to lock or there is a fishtail motion turn the engine brake sys tem OFF immediately and do not activate it until road conditions improve Check your progressive engine braking switch often for proper position since road conditions can change quickly Never skip a step when operating the pro gressive braking system Always
188. egree grip around the shoul der and neck of the kingpin positioning sliding yokes between the lock halves and tapered rib members of the fifth wheel understructure The kingpin can be released only by manually operating the kingpin lock Fifth Wheels and Trailer Couplings 07 11 2000 A Closed Position Locked 1 Release Handle and Spring 2 Adjustment Nut 3 Lock Halves 4 Lock Pivot 1310841 B Open Position Unlocked 5 Sliding Yoke Fig 10 4 Type B Kingpin Lock Mechanism bottom view control handle The adjustment nut will compensate for wear on the lock or kingpin Lockguard The Holland lockguard is a device that prevents a false lockup and is used on all models See Fig 10 5 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 de press the tongue the locks are unable to close Fifth Wheel Locking Operation Locking the Fifth Wheel Mechanism CAUTION Before attempting to lock or unlock the fifth wheel lock mechanism of a sliding type fifth wheel the slide release plungers must be in the locked position This prevents the sliding mem ber from moving rapidly to the far forward or rearward position which could damage the fifth wheel or kingpin
189. eight adjust ment feature EzyRider Seat For seat adjustment controls on vehicles built before November 28 2005 see Fig 5 2 For seat adjust ment controls on vehicles built on or after November 28 2005 see Fig 5 3 Back Cushion Tilt To tilt the back cushion raise the back cushion tilt lever and lean forward or backward Release the lever to lock the cushion in place Lumbar Support To adjust the amount of support for your lower back use the lumbar support switch or lever on the side of the seat Isolator To engage the isolator push in on the isolator lever To lock out the isolator pull the isolator lever out to the first stop Fore and Aft Seat Adjustment Pull the fore and aft seat adjustment lever out to the second stop and slide the seat forward or backward to the desired position Height Adjustment To raise or lower the seat use the height adjustment switch or lever on the side of the seat Seats and Seat Belts 10 26 2000 Back Cushion Tilt Lumbar Support Isolator Feature Height Adjustment PON gt CONDON 1910149a Bottom Cushion Angle fore and aft cushion height Fore and Aft Seat Adjustment seat track adjustment Seat Tilt Upper Back Cushion Fig 5 1 Seat Adjustments Bottom Cushion Angle To adjust the bottom cushion angle pull the bottom cushion up and forward or down and back The bot tom cushion angle is controlled by the guides on each side of the seat
190. el 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 back ward motion until positive lockup occurs 6 Apply the tractor parking brakes 7 Make a visual check even if equipped with the Touchloc air operated system for positive king pin lockup The trailer bed plate must be flush on the fifth wheel plate surface When positive lockup has occurred the fifth wheel operating rod will have moved inward to the locked posi tion and the safety latch will swing freely over the operating rod See Fig 10 12 NOTE Only when the operating rod is fully re tracted in the locked position will the safety latch be freely rotated down 8 Release the tractor parking brakes Test for king pin lockup by pulling on the trailer against the chocks NOTICE Always make sure the connect hanger support keeps the trailer air hoses and electrical cables positioned so that they do not rub on anything Rubbing may wear through hoses or cables re sulting in air leaks or exposed or broken wires potentially affecting trailer brake or electrical sys tems 9 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 mate rial from entering the air system lines 10 Charge the air brake system with air Make sure that the air connection
191. en imme diately release the accelerator and disengage the clutch Engage the clutch and accelerate the engine only after the transmission has shifted 8 10 Transmissions 2 Start the downshift from 8th direct to 7th over drive by flipping the splitter control button to the overdrive forward position then immediately double clutch through neutral moving the shift lever from 8th to 7th gear 3 Shift downward through each of the high range gears alternating the procedures in steps 1 and 2 above until reaching 5th direct 4 While in 5th direct and ready for the downshift to 4th 13 speed transmissions or 4th overdrive 18 speed transmissions push the range prese lection lever down Then double clutch through neutral and move the shift lever to the 4th gear position On 18 speed transmissions move the splitter control button to the overdrive forward position before engaging the clutch Do not move the control button while the shift lever is in neu tral 5 Continue downshifting from 4th to 1st as follows For 13 speed transmissions Downshift through the low range gears as condi tions require Never use the clutch brake when downshifting or as a brake to slow the vehicle For 18 speed transmissions Continue downshifting from 4th overdrive to 4th direct then 4th direct to 3rd overdrive 3rd over drive to 3rd direct etc Single clutch when split shifting direct to overdrive overdrive to direct D
192. eneral Information 13 Speed RTO Models Fuller RTLO 12713A RTLO 14713A and RTLO 16713A transmissions have thirteen forward speeds and two reverse speeds Each transmission consists of a 5 speed front section and a 3 speed auxiliary section The auxiliary section contains low and high range ratios plus an overdrive splitter gear See Fig 8 7 for the shift pattern P Hi 55 7 7 1 R Dir OD Dir OD Lo 1 3 N b La 1 B 6 6 8 8 LOW Dir OD Dir OD 2 4 mi 03 13 96 P B f 260044a A High Range C Overdrive forward B Low Range D Direct Drive rearward 1 Splitter Control Button Fig 8 7 Fuller 13 Speed RTO Transmissions Shift Pattern All of the thirteen speeds are controlled with one shift lever Built into the shift knob of the lever are a range preselection lever and a splitter control button on the side of the shift knob that control range se lection and gear splits respectively Low gear in the front section is used only as a start ing ratio The remaining four forward positions are used once in the low range and once in the high range However each of the four high range gear positions can be split with the underdrive ratio RT models or overdrive ratio RTO models of the split ter gear Ratios cannot be split while the transmis sion is in low range 18 Speed RTO Models Fuller RTLO 14718B RTLO 16718B and RTLO 18718B transmissions have eighteen forward speeds and four reverse co
193. engine since installation NOTE Engine information is supplied by the engine Electronic Control Module ECM It can be reset using engine diagnostic tools For more information see the engine manufacturer s manuals Engine Gallons and PTO Gallons displays the gal lons of fuel used by the engine and PTO since instal lation Diagnostic Information Diagnostic information provides two sets of data Screens Active Faults followed by a separate screen for each fault until all have been shown and Historical Dash Faults also followed by a separate screen for each fault until all have been shown See Fig 2 51 Active Faults cannot be reset Active faults can be cleared only by correcting the fault Historical Dash Faults displays all dash faults since the last reset The second line of the display shows the mileage the last time faults were cleared Instruments and Controls Identification IDLE HOURS 123456 12 3 GAL 1234567 MI FASTEN SEATBELTS 1234567 MILES See applicable Figure for trip and fuel information A IGNITION ON ONLY Y Y IDLING ENGINE ENG MILES 1234567 8 ENG GALLONS 123456 7 a INFORMATION ENG HOURS 123456 78 PTO GALLONS 123456 7 Y Y Y Y Foreach fault display fault codes and description DIAGNOSTIC ACTIVE FAULTS INFORMATION 1234 or NONE FIRST SECOND LAST A Y Y Y Y Y For each fault display fault codes and description 123 HIST DASH FAULTS PUSH RESET TO LAST CL
194. er sonal injury always wash your hands after han dling battery parts and related accessories 1 Clean the batteries 1 1 Remove any corrosion from the hold down and the top of the battery CAUTION Take care to keep the vent plugs tight so that the neutralizing solution does not enter any of the battery cells and damage the battery 1 2 Use a soda solution to neutralize the acid present then rinse off the soda solution with clean water 1 3 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 terminals to the battery posts then apply a thin coat of petroleum jelly to the posts and terminals to help retard corro sion 2 Inspect the radiator and heater hoses including the clamps and support brackets 2 1 Make sure the radiator inlet and outlet hoses are pliable and are not cracking or ballooning Replace hoses that show signs of cracking weakening or ballooning 11 15 2 2 X Make sure the heater hoses are pliable and are not cracking or ballooning Re place hoses that show signs of cracking weakening or ballooning 2 3 Tighten hose clamps as necessary but do not overtighten as hose life can be ad versely affected 2 4 Be sure the hose support brackets are securely fastened Make sure the hoses are not located near sources of wear abrasion or high heat IMPORTANT Replace all
195. er the tractor axles Slots are evenly spaced along the slide rails and retractable tapered wedges are positioned through the slots to hold the fifth wheel in the desired posi tion See Fig 10 13 or Fig 10 14 The slide portion of the sliding model may be at tached to either an air operated release slide or a manual release slide The air operated release slide contains an air cylin der that locks and unlocks the fifth wheel slide See 10 11 4 Oy i191 Lg 9j 190 ul oL Qi vag 19 19 i rol ro 07 25 95 1310189 1 Locking Wedge 2 Air Cylinder Fig 10 13 Air Operated Sliding Fifth Wheel Mount AWB Model 1 W X9 aJ ey Sy 3 9 qus uy XQO4 ad m m sae 7 rv tor Tg ryt o Tol r rol rol Fr et 07 25 95 1 Locking Wedge 2 Slide Release Pull Handle 310190 Fig 10 14 Manual Release Sliding Fifth Wheel Mount MWS Model Fig 10 13 The air cylinder is activated by a two position air control valve in the tractor cab The manual release slide contains a slide release pull handle located on the left side of the fifth wheel Fifth Wheels and Trailer Couplings which locks or unlocks the fifth wheel slide See Fig 10 14 Fifth Wheel Lock Mechanism for Trailer Kingpin The Fontaine fifth wheel lock mechanism Fig 10 15 for the trailer kingpin consists of a spring loaded jaw and a sliding wedge 01 04 95 1310184c A Unlock
196. eration Locking the Fifth Wheel Lock Mechanism CAUTION Before attempting to lock or unlock the fifth wheel lock mechanism of a sliding type fifth wheel the slide release pull handle if so equipped and the slide locking wedges must be in the locked position This prevents the sliding member from moving rapidly to the far forward or rearward position which could damage the fifth wheel member or kingpin 1 Chock the front and rear of the trailer tires to prevent the trailer from moving 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 personal injury or death 2 The kingpin lock mechanism must be fully open the fifth wheel plate must be completely lubri cated with chassis grease For lubrication in structions see Group 31 of the Century Class Trucks Maintenance Manual 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 mechanism Fig 10 15 Adjust the trailer landing gear to give enough alignment height for positive kingpin lockup 4 With the fifth wheel lock opening aligned with the trailer kingpin back the tractor slowly toward the 10 12 Fifth Wheels and Trailer Couplings trailer making sure that the king
197. erential Meritor WABCO Antilock Braking System ABS Optional Engine Systems Cruise Control Engine Braking Systems Exhaust Braking System CAT Cummins DDE S60 MB Latus users Optimized Idle Power Takeoff PTO Governor Premier Trailer Couplings General Information Operation Pretrip and Post Trip Inspection and Maintenance Procedures Daily Pretrip Inspection and Maintenance Procedures Monthly Post Trip Inspection and Maintenance Procedures Weekly Post Trip Inspection and Maintenance Procedures Pretrip and Post Trip Inspection Checklists Seat Belts and Tether Belts General Information Seat Belt Inspection Seat Belt Operation Seats Dura Form Fleetcruiser Seat EzyRider Seat Freightliner Bostrom Seat General Information National 2000 Series Seat Sleeper Bunk Latches Index Subject Page Sleeper Compartment Restraints 22 nR349ve6ibebeet RPSL ads 5 8 Bunk Restraint Adjustment 5 8 Bunk Restraint Operation 5 8 General Information lll 5 8 Sleeper Compartment Vents 3 12 SPACE System Optional 5 10 Safety Guidelines for the SPACE Syslem l c b R pes 5 11 Steering System 0 0000 llis 6 1 General Information lll 6 1 Power Steering System issus 6 1 Supplemental Restraint System Optional 62 00 2 Rr c e m YS 5 9 T Tire and Rim Labels 0
198. es when the vehicle is in mo tion In addition to seat belt assemblies tether belts are installed on suspension type seats Tether belts help secure the seat to the floor and are intended to re strain 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 replacement as needed are the only assurance of adequate seat belt security over the life of the vehicle Seat Belt Inspection A WARNING Inspect and maintain seat belts and tethers as instructed below Seat belts and tethers that were damaged or stressed in an accident must be re placed and their anchoring points must be checked When any part of a seat belt system needs replacement the entire seat belt must be replaced both the retractor and the buckle side Do not attempt to modify the seat belt system doing so could change the effectiveness of the system Failure to replace damaged or stressed Seats and Seat Belts seat belts or any modifications to the system may result in personal injury or death Inspect the seat belts and tether belts if so equipped 1 Check the web for fraying cuts or extreme wear especially near the buckle latch plate and in the D loop guide area 2 Check the web for extreme dirt or dust and for severe fading from exposure to sunlight 3 Check the buckle and latch for operation and for wear or damage
199. eselection lever must be made prior to moving the shift lever out of gear into neutral 10 After your shifting ability improves you may want to skip some of the ratios This may be done only when operating conditions permit depend ing on the load grade and road speed Upshifting There are several patterns of upshifting depending on the vehicle load and the road conditions See Table 8 2 for suggested shifting sequences Deep reduction gears are best suited for heavy loads and steep inclines Low gear in 10 speed transmissions is best suited for off highway use The following instructions are recommended for start ing a loaded vehicle moving under adverse condi tions 1 Position the gear shift lever in neutral Start the engine and bring the vehicle air system pressure up to 100 to 120 psi 689 to 827 kPa 2 Position the range preselection lever down into low range 8 12 Transmissions Fuller Shift Progressions DEEP REDUCTION LOW RANGE HIGH RANGE TRANSMISSION zm z z Adverse Conditions Off Highway and On Highway and Ideal vag MODEL ih un All Conditions Only Adverse Conditions Conditions Mie 7 WT RT W V RTS d I 10 Speed RTO o o rua e ar e We aS um 1260335 1260333 260336 1260337 BAT R RO cg Ritts ROC p S A NE Pi Y PA 10 Speed RTX oi co 668 y Vy 2 4 1260335 1260338 1260339 1260340 E dd R br R Wish Lo R ts Lo R y 9 15 Speed RTO Lo JA d ad 2 Spee ph
200. ess the message display screen cannot be brightened any further 2 30 Instruments and Controls Identification NOTE Use the left arrow key to dim the mes sage display screen and the right arrow key to brighten it For more information on how to set the brightness of the message display screen see Setup Information later in this chapter When the parking brake is released the arrow keys no longer work to change the brightness of the mes sage display screen but the settings stay in effect unless the headlights are turned on With the head lights on the message display screen dims slightly to adjust to nighttime conditions Warning and Indicator Lights There can be up to 18 warning and indicator lights installed in the ICU2M see Fig 2 43 The turn signal lights flash green on and off whenever the outside turn signal lights are flashing 1 2 3 6 7 8 9 FASTEN SEATBELTS 1O 0000432 MILES 11 4 5 5 2 04 02 96 f600996a Typical installation shown Location and function of optional lights may vary 1 Left Turn Indicator 6 2 Engine Protection Warning Lamp vie Indicator 8 3 Check Engine 9 Message Display Screen High Beam Indicator Low Air Warning Right Turn Indicator Indicator 10 Air Bag Warning 4 Stop Engine Warning 11 Tractor ABS Warning 5 Optional Indicator 12 Wheel Spin Indicator Fig 2 43 Driver Message Center ICU2M e The blue high beam indicator light comes on when
201. et face only feet only feet and windshield or windshield only defrost A temperature control switch is used to select the desired temperature Turn the switch counterclock wise for cool air or clockwise for warm air 4 1 All of the dash face outlets have adjustable louvers that pivot right and left and up and down The out lets can be closed by moving the louvers all the way down Windshield defrost outlets and the passenger s door window defrost outlet have nonadjustable lou vers The bunk outlet at the right hand rear corner of the bunk has two sets of vertical louvers that oper ate like the horizontal dash face louvers An auxiliary heater and air conditioner unit is stan dard when there is a sleeper compartment The unit is installed in the right side sleeper baggage com partment and uses the cab s refrigerant liquid system for air conditioner operation The unit is equipped with a separate evaporator coil expansion valve and fan It is also equipped with its own heater core and water valve independent of the cab heater The aux iliary unit s climate control panel Fig 4 3 is mounted on the right rear wall or the rear overhead storage compartment 10 04 95 1 Temperature Control Knob 2 Fan Control Knob 1830728 Fig 4 3 Auxiliary sleeper bunk Control Panel NOTE Shutting off the heater supply gate valve if equipped on the engine limits the ability to control air conditioning temper
202. etween noon and midnight the small letters PM will appear in the lower left corner of the display no PM indicates an A M setting 1 2 X Advance the hour setting to the correct number by pushing and releasing the hour button as many times as needed Or if the button is pressed and held in for longer than two seconds the numbers will con tinue to advance until the button is re leased 1 3 Advance the minute setting by repeatedly pushing or pushing and holding the minute button as needed 1 4 Push the Run Set switch to the middle RUN position 2 To set the alarm time 2 1 Push the Run Set switch to the left ALARM SET position 2 2 Set the alarm time by using the same pro cedure that you used to set the time of day Remember to set the hour for A M no letters in the corner of the display or P M as desired Instruments and Controls Identification 2 3 Return the Run Set switch to the middle RUN position The readout will return to the time of day setting 3 To operate the alarm 3 1 With the alarm time set push the alarm upper switch to the left An alarm wave symbol and the letters AL will appear in the upper left corner of the display when the alarm is on 3 2 When the displayed time of day coincides with the alarm time the alarm will sound If the snooz button is not pushed or the alarm switch is not moved the alarm will automatically stop sounding after one minute and will not sound a
203. f 42 U S C S7522 a 3 It is the own er s responsibility to maintain the vehicle so that it conforms to EPA regulations Instruments and Controls Identification Instrument and Control Panel eeeeeeee RR RR RR Rr 2 1 Gora CP NM PD TEE 2 5 Instrumentation Control Unit ICU4M sseeeee trasa sederma nera 2 14 lnsirumentation Control Unit CUS cues serER RUE GUe A EDOE EGG E adware weed Ena 2 24 Instrumentation Control Unit ICU2M sseeee ee arts 2 26 Instrumentation Control Unit ICU2L oor rU ERR RR EID IRE See ERU EX 2 38 Meritor WABCO Antilock Braking System ABS 000 cece een eens 2 42 Collision Warning System CWS Eaton VORAD EVT 300 Stand Alone 2 42 Collision Warning System CWS Eaton VORAD EVT 300 with ICU Integrated display 2 47 Lane Guidance Systemi usesscere ts eee e ere wey E Ries evs tees UE ERARE rers 2 52 NYS WUD DER RECETTE TTE an ane 48 Soe ice Gn ILE 2 54 S at do gets k 1 1S Uc iuro entrer EM M Md M MAREM M MEM UE 2 58 Instruments and Controls Identification Instrument and Control Panel Figure 2 1 and Fig 2 2 represent a portion of a typi cal Freightliner left hand drive LH DR dash Figure 2 3 and Fig 2 4 represent a portion of a typical Freightliner right hand drive RH DR dash The left hand drive and right hand drive dashes are shown equipped with all of the standard and many of the optional instruments an
204. fault codes and to the right to blink inac tive codes 3 Fault codes can only be reviewed tested and cleared by using a Pro Link 9000 diagnostic tool Collision Warning System CWS Eaton VORAD EVT 300 with ICU Integrated display The Eaton VORAD EVT 300 is a computerized colli sion warning system CWS that uses front mounted and side mounted radar to continuously monitor ve hicles ahead and alongside your vehicle The system warns of potentially dangerous situations by means of visual and audible alerts The system performs in fog rain snow dust smoke and dark ness To be detected objects must be within the radar beam field of view and provide a surface area that can reflect back to the radar beam The front looking antenna assembly transmits radar signals to and receives them back from vehicles and objects ahead This allows the determination of the distance to relative speed of and angle to the target of vehicles and objects ahead The system uses this information to warn the driver of potentially dangerous situations Vehicles with SmartCruise also use this system to maintain consistent headway A side sensor s mounted on the side of the vehicle also transmits and receives radar signals for a dis tance of 2 to 10 feet 0 5 to 3 meters alongside your vehicle The side sensor can detect vehicles and objects moving and stationary adjacent to your vehicle WARNING The Eaton VORAD EVT 300 Collisi
205. for them to deploy use the fixed steps on the outside sur face of the moving stairs Fig 3 5 and follow the access instructions for the standard fixed step system Freightliner recommends you practice using the fixed steps until you are familiar with their use Enter the cab only as specified in the following steps Keep your body close to the cab and maintain three point contact with the cab at all times This means one hand and two feet or two hands and one foot Do not lean out away from the cab Do not engage in horseplay Do not enter the cab with dirty or greasy hands or feet Disregarding this careful step by step procedure can result in your falling from the cab and pos sible personal injury or death IMPORTANT Do not attempt to exit the cab while carrying any items in your hands 1 Grasp the steering wheel tightly with both your hands and stand on the deck at the top of the stairs facing into the cab 2 With your right hand grasp the forward grab handle 3 5 3 Move your right foot very carefully to the top step 4 Move your left hand to the forward grab handle and grip it tightly At this point both your hands should be gripping the forward grab handle 5 Move your left foot to the next step 6 Maintaining three point contact with the cab at all times very carefully move your right hand to the aft grab handle 7 Move your right foot to the bottom step 8 Step to the ground with your left foo
206. forward position then immediately release the accelerator Press and release the clutch pedal After releasing the clutch accelerate again For 13 speed transmissions Shift upward from low to 1st gear 2nd etc until 4th gear double clutching between shifts and accelerating to 80 percent of engine governed speed See Fig 8 7 For 18 speed transmissions Shift upward from low overdrive to 1st direct by first moving the splitter control button into the direct rearward position Fig 8 8 Move the shift lever double clutching to the 1st gear posi tion Continue upshifting through the shift pattern Double clutch during lever shifts 1st to 2nd to 3rd to 4th single clutch during split shifts 1st direct to 1st overdrive etc When in 4th gear 13 speed transmissions or 4th overdrive 18 speed transmissions and ready to shift up to 5th gear use the range shift lever as follows For 13 speed transmissions While in 4th gear pull the range shift preselec tion lever up into high range The transmission will automatically shift from low to high range as the shift lever passes through neutral Then dis engage the clutch double clutch through neutral move the shift lever to 5th gear engage the clutch and accelerate the engine For 18 speed transmissions While in 4th overdrive pull the range shift prese lection lever up into high range The transmis sion will automatically shift from low to high ran
207. ft Models 0 20 e eee m m 8 6 Fuller Splitter and Range Shitt Models 2c ccucsereesd kee ee ee ed bbe be Reed ERETR RERERREE 8 8 Fuller Deep Reduction and Range Shift Models 0 0 00 c cece eee eee eee 8 11 Meritor Bange Shit Models lt a css exeos 6 onse404e 6H404 058 be esas EAS Hee OEE Ee Heese RE SS KE 8 14 Meritor Splitter and Range Shift Models 0 00 cece eee 8 16 Alison Automati Models sips xn dd RA ERE 645 ce 64848 PRO EEEE RE bw wes CARS ES 8 17 Meritor Engine Synchro Shift ESS Automated Models Transmissions Freightliner SmartShift Transmission Shift Control General Information The SmartShift transmission shift control is an elec tronic transmission control device It is applicable to both automated mechanical and automatic transmis sions but must be mated to an Eaton AutoShift or Meritor SureShift transmission It replaces either the typical floor mounted shift lever or dash mounted push button control The SmartShift control mounts to the right hand side of the steering column and is operated by the driver s right hand See Fig 8 1 and Fig 8 2 SmartShift accepts driver requests for trans mission functions and transmits them through hard wiring to the transmission control unit TCU Refer to the Eaton website for additional information www roadranger com 11 23 99 SmartShift Control Forward Driving Mode Switch slide switch MAN Switch Position AUTO
208. ft grab handle 5 Step to the middle step with your left foot 6 Step to the bottom step with your right foot 7 Step to the ground with your left foot 8 Let go of the grab handles Entering the Passenger s Side Fig 3 13 1 3 2 J4 5 6 Z 7 8 N 08 07 98 N 1720308 1 Aft Grab Handle 5 Passenger Door 2 Forward Grab Handle Threshold 3 Upper Inside Grab 6 Top Step Handle 7 Middle Step 4 Lower Inside Grab 8 Bottom Step Handle Fig 3 13 Passenger s Side Steps and Grab Handles 1 Open the passengers door and place anything that you are carrying in the cab 2 Grasp the aft grab handle with your left hand 3 Place your left foot on the bottom step 4 Grasp the forward grab handle with your right hand 5 Place your right foot on the middle step and step up to the top step with your left foot 6 Carefully move your left hand to the forward grab handle Then move your right hand to the upper inside grab handle Vehicle Access 7 Place your right foot on the door threshold and step up 8 Step into the cab with your left foot first Exiting the Passenger s Side Fig 3 10 IMPORTANT Do not attempt to exit the cab while carrying any items in your hands 1 Grasp the upper inside grab handle with both hands and place your right foot on the door threshold while standing up from the seat facing inward Move your left hand to the forward grab handle 3 Carefully place your
209. fting is almost as bad as starting off in a gear that is too high since the engine rpm and vehicle speeds are too far apart requiring the clutch to absorb the speed difference with friction creating heat For transmis sion operating instructions refer to Chapter 8 in this manual The clutch brake is applied by fully depressing the clutch pedal Its purpose is to stop the transmission gears from rotating in order to engage the transmis sion gears quickly in making an initial start NOTICE Never apply the clutch brake when making down shifts or upshifts The clutch pedal should never be fully depressed before the transmission is put in neutral If the clutch brake is applied with the transmission still in gear a reverse load will be put on the gear At the same time it will have the effect of trying to stop or decelerate the vehicle with the clutch brake Rapid wear of the friction discs will take place necessitating frequent re placement Considerable heat will be generated which will be detrimental to the release bearings and transmission front bearings Proper Clutch Usage NOTICE Overloading will result in damage to the clutch and possibly to the entire powertrain Clutches are designed for specific vehicle applica tions and loads These limitations should not be ex ceeded Riding the clutch pedal is very destructive to the clutch since partial clutch engagement permits slip page generating excessive heat Rid
210. g but in no instances should the axle load exceed the maximum axle weight rat ings given on the FMVSS or CMVSS label Do not overload any tractor axle by improperly loading the trailer This could cause erratic steer ing 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 10 9 2 Pull the trailer air supply valve to cut off the air supply to the trailer WARNING Do not use the trailer air supply for parking trail ers not equipped with spring parking brakes This applies the trailer service brakes only As air bleeds from the trailer brake system brake appli cation is lost This could allow the unattended vehicle to roll away possibly resulting in serious personal injury or death 3 Chock the front and rear of the trailer tires to prevent the trailer from moving 4 Lower the trailer landing gear until the trailer rises about 1 2 inch 13 mm 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 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 personal injury or death 6 If equipped with a manual kingpin lock release Release the kingpin lock mechani
211. g the shift lever out of gear into neutral 11 After your shifting ability improves you may want to skip some of the ratios This may be done only when operating conditions permit depend ing on the load grade and road speed Upshifting 1 Position the gear shift lever in neutral Start the engine and bring the air system pressure up to 100 to 120 psi 689 to 827 kPa 2 Position the range preselection lever down into low range See Fig 8 7 or Fig 8 8 3 Make sure the splitter control button is in the di rect rearward position See Fig 8 7 or Fig 8 8 4 For 13 speed transmissions Depress the clutch to the floor shift into low or 1st gear then engage the clutch with the engine at or near idle speed to start the vehicle moving Accelerate to 80 percent of engine governed speed For 18 speed transmissions Transmissions ATE 3 Dir OD Dir OD R 1 1 3 3 Dir OD Dir OD A N i L N 6 6 8 8 E LOW LOW Dir op Dir op pir QD Dir OD Dir OD i C D 03 13 96 1260157a A High Range C Overdrive forward B Low Range D Direct Drive rearward Splitter Control Button 5 Fig 8 8 Fuller 18 Speed RTO Model Transmissions Shift Pattern Depress the clutch to the floor shift into low then engage the clutch with the engine at or near idle speed to start the vehicle moving To shift from low direct to low overdrive move the splitter control button Fig 8 8 into the over drive
212. g a three point seat belt while driving creates a haz ard 1 Slowly pull the link end of the three point seat belt out of the retractor and pull it across your lap from outboard to inboard far enough to en gage the buckle If the retractor locks too soon A B C allow the belt to retract slightly then slowly pull it 08 09 2010 f910634 out again A Correct Belt is centered on your shoulder and chest away from your face and neck B Wrong Belt must not rub against face or neck C Wrong Belt must not hang off shoulder 2 Fasten the three point seat belt by pushing the link into the buckle until it latches Fig 5 7 Give the belt a tug at the buckle If the buckle un latches repeat this step If the problem contin Fig 5 8 Proper Shoulder Strap Fit ues replace the three point seat belt 5 6 Seats and Seat Belts f910048a 01 06 95 A 1 Inch 2 5 cm Maximum Fig 5 9 Adjusting Shoulder Harness Clearance N 11 02 95 910144 Fig 5 10 Locking Komfort Latch 4 To unbuckle the three point seat belt push the button on the buckle as shown in Fig 5 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 Kom fort Latch will release by itself unde
213. g ability improves you may want to skip some of the ratios This may be done only when operating conditions permit depend ing on the load grade and road speed 8 7 Upshifting 1 Position the gear shift lever in neutral Start the engine and bring the air system pressure up to 100 to 120 psi 689 to 827 kPa Position the range preselection lever down into low range Depress the clutch pedal to the floor shift into low or 1st gear Table 8 1 then engage the clutch with the engine at or near idle speed to start the vehicle moving Accelerate to 80 per cent of engine governed speed Shift progressively upward from low or 1st gear to the top gear in low range Table 8 1 double clutching between shifts and accelerating to 80 percent of engine governed speed While in the top gear of the low range shift pat tern and ready for the next upshift flip the range preselection lever up into high range Double clutch through neutral and shift into the bottom gear in high range Table 8 1 As the shift lever passes through neutral the transmission will au tomatically shift from low range to high range With the transmission in high range shift pro gressively upward through each of the high range gears Table 8 1 double clutching be tween shifts Downshifting 1 With the transmission in high range shift pro gressively downward to the bottom gear in high range double clutching between shifts Transmissi
214. g the ignition se quence fasten seat belt warning low battery voltage warning high coolant temperature warning low engine oil pressure warning low air pressure warning parking brake on indicator all engine warning lights including engine pro tection check engine and stop engine Cum mins only Instruments and Controls Identification Return to Idle Hours From Setup Screen Information f lt VEHICLE INF ORMATION AMT DATALINK ACTIVE gt lt I settee am DATA LINK STATUS USAGE 12 ERR1 AMT gt lt V 4 1 1 lt Return to Trip Information Screens gt lt DASH XXX XXXXX XXX SW P1 2 3 AMT J 01 11 2005 AMT Current gear information for automated manual transmissions 1040706 Fig 2 37 Vehicle Information Screens V2 4 20 25 TRANS 06 02 99 1 Transmission Temperature Gauge 2 Water Temperature Gauge Engine Oil Pressure Gauge Dash Message Center Fuel Gauge at O KENN 5 8888888 N j igo voLTs NE F NZ Fue 4 ED Z 6 OS AB 0 100 L5 s 95 os A 30 705 o gs 159 v T pe Za f A C WATER S 10 m 110 s pt 07 f 1 1 5 N ds ET ne o AS 85 Z RPM 10 oS 9 SY 2 8 N y 99 X100 Ww MPH Cf 1610205b 6 Primary Air Pressure Gauge 7 Mode Reset Push Button 8 Secondary Air Pressure Gauge 9 Speedometer 10 Tachometer Fig 2 38 ICU3 ICUS 07 Gaug
215. gain for 24 hours 3 3 If desired press the snooz button while the alarm is sounding to shut the alarm off for three minutes The alarm symbol will flash in the display when the button is pushed and will continue to flash until the alarm switch is moved or the alarm has sounded for one minute The snooze pro cedure can be done as many times as desired 3 4 Move the alarm switch to the right when you wish to shut off or cancel the alarm the alarm symbol will disappear Kysor Digital Clock A Kysor digital clock has a constant red display which automatically adjusts the brightness for day or night The clock features a 24 hour alarm 1 To set the time of day 1 1 Depress both of the time Set push but tons labelled Fast and Slow 12 00 A M will appear as the readout NOTE A small illuminated red dot in the upper left side of the clock above PM in dicates P M no dot indicates A M 1 2 Advance to the correct time by pushing either the Fast or Slow push button 2 To set the alarm 2 1 Depress the alarm Set push button Ob serve that a red lamp above the word Alarm illuminates 2 2 Set the alarm time by using the same pro cedure that you used to set the time of day Remember to select either A M no red dot or P M red dot illuminates when setting the alarm time 2 3 After the desired alarm time appears de press the alarm Set push button again The readout will return to the time
216. gallons and PTO gallons This sequence completes the fuel information screens From here press the right arrow again to return to the fuel information screen From any fuel informa tion screen press the left arrow key to return to the previous screen in the sequence Press the down arrow key to go on to engine information Engine Information Engine information allows you to view total engine mileage and hours fuel consumption for the engine and PTO and engine oil level where installed See Fig 2 32 NOTE Engine oil level is an optional function available on vehicles with Mercedes Benz en gines From the fuel information screen press the down arrow key to display the engine information screen Press the right arrow key to display in order engine miles hours engine PTO gallons of fuel used and when installed engine oil level This sequence com pletes the engine information screens Instruments and Controls Identification L S Push Once gt When in Setup this brings up a screen where a SET N selection can be made C RESET J di cess PUSH RESET AGAIN R j Push Once gt ro CONFIRM CLEAR to get this screen R Push Again gt This resets the value on the screen 12 17 2004 1040707 AMT Current gear information for automated manual transmissions Fig 2 29 Set Reset Key Functions FASTEN SEATBELTS 123456 7 MILES AMT Engine Idling P
217. ge as the shift lever passes through neutral Move the shift lever double clutching to the 5th gear position Just before making final clutch en gagement move the splitter control button to the direct rearward position then engage the clutch and accelerate Do not move the control button while the shift lever is in neutral Shift up through the high range gears as follows For 13 speed transmissions To shift from 5th direct to 5th overdrive move the splitter control button Fig 8 7 into the overdrive forward position then immediately release the accelerator Press and release the clutch pedal After releasing the clutch accelerate again Continue upshifting through the shift pattern Double clutch during lever shifts 6th to 7th to 8th single clutch during split shifts 6th direct to 6th overdrive etc For 18 speed transmissions To shift from 5th direct to 5th overdrive move the splitter control button Fig 8 8 into the overdrive forward position then immediately release the accelerator Press and release the clutch pedal After releasing the clutch accelerate again Continue upshifting through the shift pattern Double clutch during lever shifts 6th to 7th to 8th single clutch during split shifts 6th direct to 6th overdrive etc Downshifting 1 Downshift from 8th overdrive to 8th direct without moving the shift lever Flip the splitter control but ton to the direct rearward position th
218. gers and shackles 11 2 Inspect the shock absorbers for loose fas teners and leaks 11 3 Tighten all loose fasteners and have any component s replaced that are worn cracked or otherwise damaged 11 4 On vehicles with air suspensions check for leaks Check air suspension compo nents for cuts and bulges 12 Clean the windshield side and rear windows then check the condition of the windshield wiper arms and blades 12 1 Replace the wiper arms if the wiper blades are not tensioned against the wind shield 12 2 Replace damaged or deteriorated wiper blades A WARNING When cleaning windshields and windows always stand on the ground or on a secure ladder or platform Use a long handled window cleaner Do not use the cab steps tires fenders fuel tanks engine or under hood components to access the windshield or windows Doing so could cause a fall and result in an injury 13 Check the oil and air pressure warning systems 13 1 Check if the warning systems come on when the ignition is turned on and if not have the systems repaired 14 15 16 17 13 2 Start the engine then check that the oil and air pressure warning systems are op erating The buzzer should stop sounding when the preset minimum is reached If the air pressure in both systems is above the preset minimum when the engine is started test the low air pressure warning system by lowering the pressure to below
219. ght hand to the forward outside cab grab handle Then move your left hand to the aft grab handle Step to the middle step with your right foot Step to the bottom step with your left foot N 9 0 Step to the ground with your right foot 8 Let go of the grab handles Entering the Passenger s Side for Right Hand Drive Vehicles Fig 3 15 1 Open the passenger s door and place anything that you are carrying in the cab 2 Grasp the cab aft outside grab handle with your right hand Place your right foot on the bottom step Grasp the cab forward outside grab handle with your left hand 5 Place your left foot on the middle step and step up to the top step with your right foot Vehicle Access N 03 08 99 1720308a 1 Aft Grab Handle 5 Passenger Door 2 Forward Grab Handle Threshold 3 Upper Inside Cab 6 Top Step Handle 7 Middle Step 4 Lower Inside Cab 8 Bottom Step Handle Fig 3 15 Right Hand Drive Passenger s Side Steps and Grab Handles 6 Carefully move your right hand to the cab for ward outside grab handle Then move your left hand to the upper inside cab handle 7 Place your left foot on the door threshold and step up 8 Step into the cab with your right foot first Exiting the Passenger s Side for Right Hand Drive Vehicles Fig 3 15 IMPORTANT Do not attempt to exit the cab while carrying any items in your hands 1 Grasp the upper inside cab handle with both han
220. ghter will stay in then will automatically pop out when the element is hot CB Radio Connections An antenna connection and positive and negative power connections are provided for a CB radio Turn Signal Lever The turn signal lever Fig 2 13 is mounted on the steering column Pushing the lever counterclockwise turns on the left turn signal lights pushing it clock wise turns on the right turn signal lights When one of the signal lights is on a green indicator light flashes at the far left or far right of the warning and indicator light panel To cancel the signal return the lever to the neutral position 1 2 3 9 26 95 1461056 1 Turn Signal Lever 2 Trailer Brake Hand Control Valve Lever 3 Hazard Warning Light Switch Tab Fig 2 13 Steering Column Mounted Controls Hazard Warning Light Switch Tab The hazard warning light switch tab Fig 2 13 is located below the lever on the turn signal switch Hazard warning lights are operated by pulling the tab out When the hazard warning light switch tab is pulled out all of the turn signal lights and both of the indicator lights on the control panel will flash To can cel the warning lights move the turn signal lever up or down Headlight Dimmer Pull the turn signal lever toward the steering wheel to change from low beam to high beam headlights or from high beam back to low beam When the headlights are on high beam a blue light on the indica
221. gine and set the parking brake Turn the ignition switch to the ON position Turn the cruise control on cruise control on off switch See Fig 2 55 With the cruise control on press and hold down the cruise control set switch until the odometer display begins to blink After about five seconds the MI dis play at the bottom of the screen will change to KM or KM will change to MI depending on what units were previously set 1 2 CI Ges 07 29 98 1541126 To switch from miles to kilometers turn the cruise control on Then press and hold down the set switch until the MI display starts to blink 1 On Off Switch 2 Set Switch Fig 2 55 Cruise Control Switches Instruments and Controls Identification Alert Screen The NODATA screen comes on whenever the datalink is not receiving data It appears when the vehicle is moving and overrides the regular screen display If the condition persists take the vehicle in for ser vice as soon as possible to discover the cause of the problem Meritor WABCO Antilock Braking System ABS The Meritor WABCO Antilock Braking System ABS has a tractor warning light TRACTOR ABS Fig 2 56 and if equipped with automatic traction control ATC a wheel spin indicator light WHEEL SPIN After the ignition switch is turned on the tractor warning light TRACTOR ABS and if equipped the wheel spin WHEEL SPN indicator light come on for about three secon
222. gine electrical harness on the left frame rail near the batteries If the fuses are blown replace the fuses Be sure to find the cause of the blown fuses as soon as possible NOTE Some starters are equipped with op tional overcrank protection If overcranking oc Curs a thermostat breaks the electrical circuit to the starter motor until the motor has cooled Never pour fuel or other flammable liquid into the air inlet opening in the air intake in an attempt to start the vehicle This could result in a flash fire causing serious personal injury or property dam age 3 Check the oil pressure gauge immediately after starting the engine 4 f no pressure registers within 10 to 15 seconds or the ENGINE PROTECT indicator comes on shut down the engine and check the lubricating oil system NOTICE Protect the turbocharger during the start up by not opening the throttle or accelerating the en gine above 1000 rpm until minimum engine idle oil pressure registers on the gauge Failure to do so could damage the turbocharger 5 Idle the engine for about five minutes at 1000 rpm before operating the engine under load Mercedes Benz NOTE Performs the steps in Prestart first 1 Turn the ignition switch to the ON position Fig 7 9 All the electronic gauges on the ICU instrumentation control unit complete a full sweep of their dials the warning and indicator lights light up and the buzzer sounds for three seconds IMPO
223. h to remain on the spot for 30 to 60 minutes For stubborn spots allow the hydrogen peroxide satu rated cloth to remain on the area overnight Use cau tion 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 liquid during removal 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 procedure used for sulfide stains Ball Point Ink Ball point ink can sometimes be removed if rubbed immediately with a damp cloth using water or rub bing alcohol If this does not work try the procedure used for 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 undam aged Velour Upholstery Cleaning To prevent soiling frequent vacuuming or light brush ing to remove dust and dirt is recommended Spot clean with a mild solvent or an upholstery shampoo or the foam from a mild detergent When using a sol vent or a dry clean
224. has cooled to normal operating temperature 5 To stop a parked regen at any time during the process engage the clutch brake or throttle pedal or turn off the engine Diesel Particulate Filter Maintenance When diesel particulate filter servicing is needed it must be performed by an authorized technician and a record must be maintained for warranty purposes The record must include date of cleaning or replacement vehicle mileage particulate filter part number and serial number Detroit Diesel Heavy Duty Engine DD13 15 IMPORTANT Always refer to your engine opera tor s manual supplied with the vehicle for com plete details of engine operation DDEC VI Because the DDEC VI system is electronic vehicle battery power must be available to operate the com puter The system operates at 12 volts however in the event of a power supply malfunction the system will continue to operate at reduced voltage When this occurs the amber warning lamp Check Engine will come on The engine will operate only at reduced rpm When the battery reaches a point where the Motor Control Module MCM hasn t enough power to function the engine will shut down Besides the engine and its related sensors the DDEC VI system has two control modules a Motor Control Module MCM located on the engine a Common Powertrain Controller CPC lo cated in the vehicle cab The two control units are connected by a proprietary
225. he Eaton AutoShift 18 speed transmis sion is able to perform triple upshifts when the next three higher gears are available and condi tions are right To triple shift this transmission move the control three times in less than 1 2 second If a requested gear is not available an audible warning will sound and the message display screen will indicate that the gear is not avail able An unavailable requested upshift is not stored in memory The upshift must be re quested again Downshifting NOTE With the transmission in drive D in the automatic mode downshifts require no driver interaction 1 With the transmission in drive in the manual mode request a downshift by pushing downward 8 3 on the control If the requested gear is available the transmission will downshift NOTE A single momentary push downward on the control selects the next lower gear when it is available Two consecutive momentary down ward pushes will cause a skip shift when the next two lower gears are available and condi tions are right 2 To skip shift move the control two times in less than 1 2 second The number of the gear en gaged will appear on the message display Screen NOTE The Eaton AutoShift 18 speed transmis sion is able to perform triple downshifts when the next three lower gears are available and conditions are right To triple shift this transmis sion move the control three times in less than 1 2 second If a request
226. he air compres sor Block the valve open When draining the air reservoir do not look into the air jets or direct them toward anyone Dirt or sludge particles may be in the airstream and could cause injury 1 2 Exhaust the remaining air and moisture from the system by opening the drain cocks on the bottoms of the remaining air reservoirs Block the valves open Pretrip Inspection and Daily Maintenance 1 3 Water and oil emulsion often form pockets that will not drain while compressed air is in the reservoirs Because of these pock ets leave the valves blocked open during the first part of the pretrip inspection 1 4 If the drained water is cloudy or oily it may indicate a problem with the compres Sor If oil is allowed to contaminate the air dryer it will not remove the water from the air brake system which could adversely affect braking A CAUTION Step back from the front access panel when opening it The access panel can open quickly and could hit a person possibly resulting in per sonal injury 2 Check that the windshield washer reservoir is filled Add washer fluid as needed See Fig 11 1 The windshield washer reservoir is located on the left hand side of the frontwall behind the ac cess panel 03 26 98 1820313 1 Washer Reservoir Fig 11 1 Windshield Washer Reservoir Washer fluids may be flammable and poisonous Do not expose washer fluid to an open flame or any burning material
227. he first half of the self test all segments of the display illuminate During the second half of the self test the software revision level is displayed If there are no active faults the screen displays the odometer However if the ICU2L has received active fault codes from other devices it displays them one after the other until the parking brake is released or the ignition switch is turned off A list of fault codes and definitions can be found in Section 54 14 of the Century Class Trucks Work shop Manual Once the parking brake is released the ICU2L displays the odometer again 2 40 Instruments and Controls Identification HEADLIGHTS ON A 123456 MI ODOMETER SCREEN IF NO FAULTS WERE DETECTED Y 123456 MI PARK BRAKE RELEASED MOVING POWER ON IGNITION ON ICU PERFORMS SELFTEST ELECTRONIC GAUGE NEEDLES SWEEP WARNING INDICATOR LIGHTS COME ON BUZZER SOUNDS IF FAULT DETECTED Y A C 190 FAULT CODE SCREEN 123456 MI RELEASE PARK BRAKE 10 03 97 1040395 Fig 2 54 Level Il ICU Ignition Sequence Setting the Units for the Odometer The ICU2L odometer is a six digit display without a decimal point It can display the distance the vehicle has traveled in either miles or kilometers but it can not display tenths of miles or kilometers The choice of units is selectable using the cruise control switches To change the display shut down the en
228. he jaw eccentric pin can be removed and ro tated to compensate for wear and maintain an approximate 1 16 inch 1 6 mm clearance during service Placing the operating rod in the lockset position moves the lock away from the jaw This action un locks the jaw so that it can be rotated by movement of the kingpin When the tractor is moved out from under the trailer the kingpin will rotate the jaw until the jaw is in the unlocked position allowing the king pin to move out of the mechanism With the jaw in the fully open position the operating rod drops out of the lockset position and the fifth wheel is ready for coupling See Fig 10 11 1 2 amp 1 3 y gt AO 04 08 96 i 1310447 1 Safety Latch 2 Operating Rod locked 3 Operating Rod unlocked Fig 10 11 Simplex Kingpin Locking Mechanism Locking and Unlocking During coupling the kingpin contacts and rotates the jaw into the locked position This action automatically moves the operating rod into the locked position This securely locks the jaw around the kingpin In the locked position the safety latch swings freely over the operating rod See Fig 10 12 Fifth Wheels and Trailer Couplings 11 18 94 1 Safety Latch 1310448 2 Operating Rod Fig 10 12 Simplex Kingpin Locking Mechanism Safety Latch locked position Fifth Wheel Locking and Unlocking Locking the Fifth Wheel Lock Mechanism 1 Chock the front and rear of the trai
229. he marker lights when the switch is actuated Windshield Wiper Washer Controls The wipers are operated by a double paddle switch mounted on the auxiliary instrument panel See Fig 2 6 The top paddle when pushed in turns the wipers on if they are off or off if they are on When it is pushed up the top paddle switches the wipers to high speed when it is pushed down it switches them to low speed TRAILER BRAKE 11 15 95 1 Windshield Wiper Washer Switch 1541127 Fig 2 6 Instrument Panel The bottom paddle when pushed in turns the washers on When pressed for less than 1 2 second the wipers will perform a single low speed dry wipe mist function When pressed for more than 1 2 second the wash cycle begins and continues for three cycles or until the paddle is released When the bottom paddle is pushed up the wipers operate in fast delay When the bottom paddle is pushed down the wipers operate in slow delay With the wipers in Instruments and Controls Identification delay mode fast or slow push the bottom paddle up to shorten the delay period or push the paddle down to lengthen it NOTICE Do not move the wiper arms manually Wiper motor damage will occur if the arms are moved Left and Right Windshield Fan Switches Ceiling mounted defogger fans are operated by Low Off High toggle switches located in the base of the fan Heater Air Conditioner Controls Heater ai
230. he primary system oper ates the service brakes on the rear axle the second ary system operates the service brakes on the front axle Service brake signals from both systems are sent to the trailer Do not operate the vehicle with the front brakes backed off or disconnected Backing off or dis connecting the front brakes will not improve ve hicle 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 second ary system air pressure causes the front axle brakes to become inoperative rear service brakes and trailer brakes will be operated by the primary system Before driving your vehicle allow time for the air compressor to build up a minimum of 100 psi 689 Steering and Brake Systems kPa pressure in both the primary and secondary Systems Monitor the air pressure system by observ ing 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 below 64 to 76 psi 441 to 524 kPa in either system If this happens check the dual system air pres
231. he warning signs sudden drop in oil pressure unusual noises etc and immediately shut down the engine NOTE Long periods of idling are not good for an engine because the combustion chamber temperatures drop so low that 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 caus ing all moving parts of the engine to suffer from poor lubrication Cold Weather Operation CAT Cummins DDE S60 M B Satisfactory performance of a diesel engine operating in low ambient temperatures requires modification of the engine surrounding equipment operating prac tices and maintenance procedures The lower the temperatures the greater the amount of modification required and yet with the modifications applied the engines must still be capable of operation in warmer climates without extensive changes The following information is provided to engine own ers operators and maintenance personnel on how the modifications can be applied to get satisfactory performance from their diesel engines There are three basic objectives e Reasonable starting characteristics followed by practical and dependable warm up of the en gine and equipment e A unit or installation which is as independent as possible from externa
232. hicle will not deactivate cruise control for stationary targets such as a car stopped in your traveling lane Failure to drive safely and use the system prop erly could result in personal injury and or death and severe property damage Driver Display Unit DDU NOTE All system controls are located on the DDU Indicators to inform the driver about the system s operation are located on both the DDU and the side sensor display See Fig 2 58 The DDU controls system power range for vehicle warnings and speaker volume At the lower front edge of the DDU a slot is provided to insert the driv er s identification card Alert and indicator lights advise of multiple warning levels system power sys tem failure and if so configured failure of the driver to enter the identification card A light sensor automatically adjusts alert and indica tor light brightness depending on lighting conditions A small speaker provides audible alert tones to warn of closing on an object ahead and when equipped with a side sensor of objects alongside when the turn signal is activated in preparation for a lane change Additional tones indicate speaker volume system failure driver s card status and data extrac tion pass or fail 1 The green power on driver s card status indicator light illuminates when the system is activated and the power on LED test is complete If the system is configured to require that the driver s card be read and it i
233. ht hand to the lower inside grab handle See Fig 3 10 Hold on very tightly and maintain three point contact with the cab at all times 1 3 2 4 6 5 7 i P 08 20 98 8 1720321 1 Aft Grab Handle 5 Passenger Door 2 Forward Grab Handle Threshold 3 Upper Inside Grab 6 Top Step Handle 7 Middle Step 4 Lower Inside Grab 8 Bottom Step Handle Fig 3 10 Passenger s Access Stairs and Grab Handles 6 Then slowly move your right foot to the thresh old of the door 7 Holding tightly to the lower inside grab handle with your right hand move your left hand to the upper inside grab handle See Fig 3 10 8 With both of your hands gripping the inside grab handles tightly step into the cab with your left foot 9 With your left foot securely in the cab and both hands gripping the inside grab handles move your right foot into the cab Exiting the Passenger s Side Using the Cab Access Stairs Fig 3 10 If the optional cab access stairs do not move into position or if there is not enough room for them to deploy use the fixed steps on the outside sur face of the moving stairs Fig 3 5 and follow the access instructions for the standard fixed step system Freightliner recommends you practice using the fixed steps until you are familiar with their use Enter the cab only as specified in the following steps Keep your body close to the cab and maintain three point contact with the cab at all times This means
234. icator Back Cushion Tilt Lever Height Adjustment and Lumbar Support Lever Fore Aft Seat Position Indicator NOOBRON Fig 5 2 EzyRider Seat Adjustment Controls Vehicles Built Before November 28 2005 Bottom Cushion Tilt Adjustment Rotate the bottom cushion tilt knob to increase or decrease bottom cushion tilt Lumbar Support To increase lumbar support on LSO models press the plus sign on the lumbar support switch To de crease lumbar support on LSO models press the minus sign on the switch To increase lumbar support on non LSO models rotate the lumbar support knob forward To decrease lumbar support on non LSO models rotate the knob rearward Damper Adjustment Press the damper adjustment switch to adjust the damper Dura Form Fleetcruiser Seat See Fig 5 5 for seat adjustment controls 5 3 udi 3 SS 2 2 4 5 6 01 06 2006 1910565 Isolator and Fore Aft Seat Adjustment Lever Armrest Adjustment Knob Bottom Cushion Angle Guide Back Cushion Tilt Lever Lumbar Support Switch Height Adjustment Switch OO com Fig 5 3 EzyRider Seat Adjustment Controls Vehicles Built on or After November 28 2005 Back Cushion Tilt To tilt the back cushion through a range of 10 de grees push down on the back cushion tilt handle Move the back cushion to the desired position and release the handle Height Adjustment Push the height adjustment knob in to inflate the sus pe
235. ift down as Engines and Clutches desired to maintain the maximum vehicle speed The higher torque of Cummins engines may permit top ping some grades without shifting Cummins engines are designed to operate over a wide speed range More frequent shifting than neces sary does not allow proper utilization of this flexibility The driver who stays in top gear and uses the wider speed range will achieve the best fuel economy 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 it 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 prevent it from opening when the ignition key is turned on NOTICE Engine overspeed engine speed exceeds high idle no load rpm can damage the engine Use a combination of brakes and gears to keep the ve hicle under control at all times and to keep the engine speed below the rated governed rpm Normal Operation Detroit Diesel S60 DDEC Ill The DDEC III system uses a computer that is pro grammed to automatically control engine timing and fuel injection providing maximum engine perfor mance and fuel economy Individual driving habits can make a difference in the performance and economy of any engine The rec ommendation
236. in the other direction and inspect both lines If a hose is leak ing have it replaced IMPORTANT ABS equipped vehicles operat ing in regions where especially corrosive ice removal chemicals are used may experience higher than normal rotor corrosion Tone rings should be routinely inspected for corro sion Severe corrosion of the integral ABS tone ring may cause the ABS warning lamp in the dash to illuminate due to false wheel speed readings If the ABS warning lamp illuminates at any time other than at vehicle start up have the problem repaired immedi ately Inspect the slack adjusters 24 1 Meritor Slack Adjusters Check the boot for cuts tears or other damage Have it replaced if necessary 24 2 Gunite Slack Adjusters Inspect the slack adjuster for any signs of damage If dam aged have the slack adjuster replaced Inspect the slack adjuster boot for cuts or tears If the boot is damaged have it re placed See Fig 11 12 Haldex Slack Adjusters Inspect each slack adjuster and anchor strap for dam age See Fig 11 13 Have any damaged components replaced 24 3 Check that the control arm nut is fully re leased If the control arm is in the wrong position the brakes will drag Check the air brake system for proper operation 25 1 Check the air governor cut in and cut out pressures as follows Run the engine at fast idle The air gover nor should cut out the air compressor at approximately 120 p
237. inactivated so they do not display at all For pro gramming service intervals look under the heading Setup Information Service Information From here press the right arrow key again to return to the service information screen From any service information screen press the left arrow key to return to the previous screen in the sequence Press the down arrow key to go on to setup information From the diagnostic information screen press the i down arrow key to display the service information Setup Information screen if activated See Fig 2 34 Setup information allows you to program various fea NOTE If the service information screen is not tures of the ICU4M ICU4M 2 environment Some of activated the ICUAM ICUAM 2 will instead dis the features which can be programmed include play the setup information screen which can be service intervals used to activate service information e target miles per gallon From the service information screen press the right a i e i i arrow key to display in order the service interval LCD lighting screen and the miles time remaining before the next display brightness service interval This sequence completes the service information screens language units of measurement Return to Idle Hours From Diagnostic Screen Information 4 1 rm Distance prior to reaching th
238. ing product follow the instructions carefully and clean only in a well ventilated area Avoid any product that contains carbon tetrachloride or other toxic materials With either method pretest a small area before proceeding Use a professional upholstery cleaning service when extensive cleaning is needed Grease and Oil Based Stains Dampen a small absorbent cloth with dry cleaning solvent or spot remover Apply the cloth carefully to the spot from the outer edge to the center Pat and blot the spot with a clean dry cloth Repeat several times as necessary turning the cloths so that the stain does not redeposit on the fabric Sugar and Water Based Stains Apply water based detergent or cleaner working in circular motions Pat and blot as dry as possible Re peat if necessary before drying thoroughly 12 2 Cab Appearance Chewing Gum or Wax Harden the gum or wax with an ice cube wrapped in a plastic bag then scrape it off with a dull knife Ex cess 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 proce dure for grease and oil based stains Mildew Brush the dry fabric with a soft brush Sponge with detergent and blot If the fabric is colorfast dilute a teaspoon of bleach in one quart one liter of cool water Apply with a swab directly on the mildew stain Dab repeatedly with clear cool water and blot dry 12 3
239. ing the clutch pedal will also put a constant thrust load on the re lease bearing which can thin out the lubricant Re lease bearing failures can be attributed to this type of misuse A slipping clutch accumulates heat faster than it can be dissipated resulting in early clutch failures Never use the clutch as a hill holder 7 28 Engines and Clutches 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 persons in the cab Engaging the clutch while coasting can result in tre mendous shock loads and possible damage to the clutch as well as to the entire drivetrain Reporting erratic clutch operation as soon as pos sible will give maintenance personnel a chance to inspect and lubricate the clutch components make necessary internal clutch and linkage adjustments etc Free pedal should be included and commented on daily in the driver s report since clutch free pedal is the maintenance department s guide to the condition of the clutch and the release mechanism Clutch free pedal is a decreased resistance felt at the top of the clutch pedal stroke See Fig 7 16 With the clutch pedal in this range the clutch is fully engaged and the only resistance to clutch pedal movement is the force of the return spring If clutch free pedal is 3 4 inch 20 mm or less measured at the
240. into the cab 2 With your left hand grasp the forward grab handle Move your left foot very carefully to the top step Move your right hand to the forward grab handle and grip it tightly At this point both your hands should be gripping the forward grab handle 5 Move your right foot to the next step 6 Maintaining three point contact with the cab at all times very carefully move your left hand to the aft grab handle 7 Move your left foot to the bottom step 8 Step to the ground with your right foot 9 Let go of the grab handles Entering the Passenger s Side Using the Cab Access Stairs for Right Hand Drive Vehicles Fig 3 12 If the optional cab access stairs do not move into position or if there is not enough room for them to deploy use the fixed steps on the outside sur face of the moving stairs Fig 3 5 and follow the access instructions for the standard fixed step system Freightliner recommends you practice using the fixed steps until you are familiar with their use Enter the cab only as specified in the following steps Keep your body close to the cab and maintain three point contact with the cab at all 03 08 99 a 1720321a 1 Aft Grab Handle 5 Passenger Door 2 Forward Grab Handle Threshold 3 Upper Inside Cab 6 Top Step Handle 7 Middle Step 4 Lower Inside Cab 8 Bottom Step Handle Fig 3 12 Right Hand Drive Passenger s Access Stairs and Grab Handles times This mean
241. ionary access screens can be seen only when the vehicle is not moving and the parking brake is applied Each set of stationary access screens has a title screen followed by one or more data screens To move forward and backward through these screens use the three arrow keys as shown in Fig 2 50 Fig 2 51 and Fig 2 52 Trip Information Trip information provides three data screens Trip Miles and Hours Idle Hours and Average MPH and Leg Miles and Hours See Fig 2 50 Trip Miles and Hours displays the number of miles and hours driven since the start of the trip At the start of a trip press RESET SET RESET twice to set trip miles and hours back to zero NOTE Resetting Trip Miles and Hours also resets Idle Hours and Average MPH Idle Hours and Average MPH displays the hours spent idling and the average miles per hour Leg Miles and Hours records the number of miles and hours driven since the start of the leg At the start of a new leg press RESET to set leg miles and hours back to zero NOTE Resetting Trip Miles and Hours also resets Leg Miles and Hours Fuel Information Fuel information provides two data screens Fuel Used and Average MPG and Idle Gallons and PTO Gallons See Fig 2 50 Fuel Used and Average MPG displays the gallons of fuel used since the last reset At the start of a trip after refueling or whenever desired press RESET SET RESET twice to set fuel used and average
242. ir can be selected either with the switch or by setting the air selection switch to maximum air conditioning 5 Move the temperature control switch counter clockwise for cool air In this position no heat is given off by the heater 6 Turn the fan switch to the highest speed 4 7 As soon as cool air is flowing from the dash board outlets close the windows Adjust the fan switch setting as desired Heater and Air Conditioner 8 Ifthe air from the vents is too cold move the temperature control switch clockwise for warmer air flow IMPORTANT To prevent the buildup of fumes or odors inside the cab for example from smok ing do not operate the heater and air condi tioning system in a recirculation mode for more than 20 minutes Fresh Air 1 Move the fresh air recirculation switch to the fresh air position See Fig 4 2 Move the air se lection switch to the desired position 2 Move the temperature control switch counter clockwise for no heating or move it clockwise for heat 3 Set the fan switch at the desired speed IMPORTANT To prevent the buildup of fumes or odors inside the cab for example from smok ing do not operate the heater or ventilation System in a recirculation mode for more than 20 minutes Heating Auxiliary Sleeper Bunk Heater and Air Conditioner 1 With the engine at operating temperature set the three position switch on the main climate control panel on the dash Fig 4
243. is reached From any historical fault screen press the down arrow key to scroll through the occurrence data for each fault This se quence completes the historical fault diagnostic screens It is possible to clear historical fault data from the ICU4M ICU4M 2 s memory when the information is no longer needed When there are less than 254 miles on the odometer clearing historical faults also clears the memory of the electronic unit reporting the fault IMPORTANT Do not reset historical faults un less you are sure that the data will not be needed in the future It is not possible to clear particular historical faults either all the data are cleared or none To clear historical faults press the set reset key When the message all faults cleared appears all the historical fault data have been cleared From this message press the left arrow key to return to the diagnostic information screen the right arrow key to 2 22 Instruments and Controls Identification return to the historical faults information screen or NOTE If the vehicle has gone past the service the down arrow key to go on to service information interval the miles hours remaining screen is replaced by the service was due screen fol lowed by the number of miles hours since the Service information allows you to view the next re service fell due curring service interval Service intervals can be ex pressed in either miles or hours They can also be
244. it The word Warning flashes on the message display screen above the message Low Voltage This message follows the same rules of dismissal and display as Low Oil Pressure Faulty Speedo Gauge Screen This message is displayed when the system detects a faulty speedometer This becomes the default Screen and vehicle speed is displayed as a digital readout at the bottom left of the screen All other screens and functions operate normally Recirc Mode Engaged and Provide Fresh Air Screens The Recirc Mode Engaged screen comes on when ever recirculated air is selected on the fresh air recir culation switch or the air circulation switch is rotated to the maximum air conditioning position It displays one time only for seven seconds It notifies the driver that recirculated air is being used and that fresh air needs to be provided after 20 minutes If fresh air is not provided after 20 minutes the Pro vide Fresh Air message is displayed It displays for seven seconds every 254 seconds about every four minutes until the driver switches to fresh air either by selecting fresh air on the fresh air recirculation Switch or by rotating the air circulation switch away from maximum air conditioning and to one of the other positions See Chapter 4 for detailed operating instructions for the heater air conditioner Low Fuel Level Screen Fuel level is continuously monitored by the ICU When the fuel level drops to 1 8th full
245. itch to the center middle position A cab exhaust system is included with sleepers When the climate control unit is set for fresh air 300 cubic feet per minute of air is provided to the sleeper and exhausted through a vent in the left rear area of the sleeper When the system is activated fresh air rapidly displaces stale air as the cab pressurizes IMPORTANT To prevent the buildup of fumes or odors inside the cab for example from smok ing do not operate the heater and air condi tioning system in a recirculation mode for more than 20 minutes Defogging and Defrosting Using Fresh Air 1 Turn the temperature control switch all the way clockwise for warm air the fan switch to OFF and if so equipped the bunk fan switch to OFF before starting the engine 2 Remove any ice or snow from the outside of the windshield door windows and fresh air inlet grille 3 With the engine at operating temperature turn the fan switch to 4 the highest speed See Fig 4 4 Leave it in this position for 30 seconds This will clear the system of moist air 9 07 95 1830718 1 Fan Switch at Highest Speed 2 Air Selection Switch at Defrost 3 Temperature Control Switch at Warm Fig 4 4 Defogging and Defrosting Settings 4 Move the air selection switch to the defrost windshield position In this position warm dry air is directed to the windshield NOTE The air conditioner if equipped is auto matically engaged in
246. its exces sive input force to the brake components which could damage or cause eventual failure of brake actuating components Meritor WABCO Antilock Braking System ABS Fig 6 4 FASTEN SEATBELTS 0000432 MILES 1 2 04 02 96 601125 1 Tractor ABS Warning Light 2 Wheel Spin Indicator Light Fig 6 4 ABS Dash Lights The Meritor WABCO Antilock Braking System ABS is an electronic wheel speed monitoring and control system that works with the standard air brake sys tem ABS passively monitors vehicle wheel speed at all times and controls wheel speed during emer gency stops If equipped with Automatic Traction Control wheel spin is controlled during reduced traction situations 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 installed during production are programmed into the electronic control unit Installing different sized tires could result in a reduced braking force leading to longer stopping distances ABS includes signal generating tone wheels and sen sors located in the wheel hubs of each sensed wheel The sensors transmit vehicle wheel speed information to an electronic control unit located in a panel behind the driver s seat The control unit s main circuit interprets the speed sensor signals and calculates wheel speed wheel retardation and a ve hicle reference spe
247. ized 9 2 Rear Axles TRACTION CONTROL DIFFERENTIAL LOCK UNLOCK DO NOT ENGAGE DURING SPIN OUT 09 26 95 1350142 Fig 9 3 Traction Control Differential Control NOTE The controlled traction differential can be engaged at any speed except during spinout Eaton 2 Speed Tandem Axles Each axle of the 2 speed tandem contains a high range single reduction gear set and a low range double reduction gear set The operator selects the desired axle range by moving the range preselection lever located on the shifter knob See Fig 9 4 U gt 01 19 95 A High Range f260056a B Low Range Fig 9 4 Range Preselection Lever Dual Range 2 Speed Tandem Axle Operation with Multispeed Transmissions NOTE Refer to Chapter 8 Transmissions for detailed information on how to use the range preselection lever On multispeed transmission applications the 2 speed axle should be used as a dual range Use the low range when operating off highway or when starting out with a heavy load on highway After the vehicle is 9 3 moving on the highway the axle can be shifted to high range To shift the axle to the high range Make sure the interaxle differential lockout is disengaged keep the throttle pedal down move the range preselection lever to high release the throttle pedal until the axle shifts then accelerate To shift the axle to the low range Keep the throttle pedal down move the r
248. jury or death Normal Operation Caterpillar The Caterpillar C 10 C 12 and 3406E electronic engines use a computer electronic control module to automatically control engine timing and fuel injec tion The electronic features of these engines include an electronic governor fuel to air ratio control pro grammable engine ratings injection timing control fault analysis and recording and a datalink used for programming the electronic control module and troubleshooting the system Proper operation and maintenance are key factors in obtaining the maximum life and economy of a vehicle engine Refer to the instructions in the Caterpillar Operation and Maintenance Management Manual and this manual for trouble free economical engine operation When starting out operate the engine at low load After normal oil pressure is reached and the tem perature gauge begins to move the engine may be operated at full load Caterpillar electronic engines automatically idle at 900 to 1000 rpm for the correct warm up time after a cold engine start less than 40 F 5 C These elec tronic engine systems will reduce the idle speed to 600 rpm when the engine is warm enough to drive the truck IMPORTANT Fuel heaters used on vehicles with Caterpillar electronic engines could cause 7 12 Engines and Clutches excessive fuel temperatures that affect engine performance and operation of the electronic en gine controls If a fuel heate
249. k control panels Fig 2 20 a 1601053 06 10 98 Fig 2 18 Passenger s Footwell Courtesy Light 09 29 95 1541133 1 Fluorescent Light 2 Fluorescent Light Lens Fig 2 19 Mid Roof Fluorescent Mid Roof Fluorescent Light Switches SleeperCabs Only A mid roof fluorescent light curtain bow light is stan dard on sleepers only It is located on the ceiling in the middle of the cab where the curtain is drawn to separate the bunk area from the rest of the cab See Fig 2 19 To turn on the mid roof fluorescent light press the rocker switch on the dash or on either the lower or upper bunk control panels Fig 2 20 Bunk Reading Light Switches SleeperCabs Only Bunk reading lights are high intensity reading lights for use when reading in the bunk They are located on the bunk control panel for each bunk To turn on the bunk reading lights press the rocker switch on 2 12 Instruments and Controls Identification 8 4 7 5 6 NW 11 06 98 Sy 1830811 Reading Light Switch Clock Volume Control Knob Dome Light Switch Fan Control Knob Reading Light A T C Control Knob Dome Light Switch Cigarette Lighter oR woh oND Fig 2 20 Bunk Reading Light and Control Panel the bunk control panel that holds the light See Fig 2 20 Baggage Compartment Light Switches SleeperCabs Only Baggage compartment lights are installed in all Slee perCabs One light is located on
250. l and personal injury Be careful not to get hands or feet tangled in hoses or other back of cab equipment Careless ness could cause a person to trip and fall with possible injury Vehicle Access Cab Access Stairs Optional Fig 3 3 7 6 5 L 3 2 08 10 98 1720309 1 Bottom Step 5 Aft Grab Handle 2 Middle Step 6 Forward Grab Handle 3 Top Step 7 Steering Wheel 4 Top Deck Fig 3 3 Optional Cab Access Stairs Driver s Side Shown The optional cab access stairs will move into position when you open the cab door from the inside or the outside As the stairs deploy an alarm outside the vehicle will sound If anything prevents deployment of the stairs for example if the parking brake is not set or something is blocking the stairs or the cab is tilted a buzzer will sound and an indicator light will activate on the dash If the interior buzzer and light activate the exterior alarm will also sound You can open the door without activating the stairs as follows f you re outside the cab press the button on the cab side directly above the stairs before opening the door See Fig 3 4 e f you re inside the cab press the dash rocker switch labeled RH STEP or LH STEP while opening the cab door NOTE You must press the disable button each time you don t want the stairs to deploy Press 05 18 98 1 Stairs Disable Button 1500313 Fig 3 4 Stairs Disable Button Cab Right
251. l influences Modifications which maintain satisfactory oper ating temperatures with a minimum increase in maintenance of the equipment and accesso ries 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 7 16 Engines and Clutches minimum of revision Most of the accessories should be designed in such a way that they can be discon nected so there is little effect on the engine when they are not in use IMPORTANT If a winterfront is used on a ve hicle with an electronic engine equipped with a charge air cooler make sure that there are slit openings distributed across the face of the win terfront to allow airflow through the entire charge air cooler core Do not use a winterfront with closed areas that block uniform air flow across all sections of the charge air cooler crossflow tubes This will adversely affect the operation and durability of the charge air cooler On all engines the following steps are necessary when operating in cold weather Check for cracks in the battery cases for cor rosion of the terminals and for tightness of the cable clamps at the terminals Charge the batteries to full capacity Replace any battery that is unable to hold full charge or is physically damaged Check the alter
252. 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 rat ing given on the FMVSS or CMVSS label Fifth Wheels and Trailer Couplings Do not overload any tractor axle by improperly loading the trailer This could cause erratic steer ing and loss of vehicle control possibly resulting in serious personal injury or death Fifth Wheel Lubrication A WARNING Keep the fifth wheel plate lubricated to prevent binding between the tractor and trailer A binding fifth wheel could cause erratic steering and loss of vehicle control possibly resulting in serious personal injury or death For lubrication instructions see Group 31 of the Century Class Trucks Maintenance Manual ASF Castloc Il and Simplex Series Fifth Wheels General Information The ASF Castloc Il and Simplex series fifth wheels are used for pulling trailers having the standard 2 inch diameter kingpin When installed as a station ary fifth wheel Fig 10 8 they are bracket mounted to the tractor frame in a position that best distributes the trailer load over the tractor axles When used as a Sliding fifth wheel Fig 10 9 they are mounted on the Taperloc sliding mount air operated or manual release The fifth wheel lock mechanism for the
253. lamp with a steadily illumi nated yellow Check Engine lamp indicates that a parked regen must be performed because the filter has reached maximum capacity The vehicle must be parked and a parked regen must be performed or the engine will begin derate A flashing yellow DPF lamp with a steadily illumi nated yellow Check Engine lamp and a steadily illu minated red Stop Engine lamp indicates that a parked regen is required or the engine will shut down because the filter has exceeded maximum ca pacity The vehicle must be parked and a parked regen or service regen must be performed Check your engine operation manual for details 7 2 Engines and Clutches EXHAUST AFTERTREATMENT SYSTEM INFORMATION A WARNING INDICATOR LAMP S Indicator Lamp Filter Regeneration Filter Regeneration Parked Regeneration Parked Regeneration Required HEST High Exhaust Message s Recommended Necessary Required Engine Engine Shut Down System Temperature Derate Diesel Particulate Filter is reaching Filter is now Filter Condition capacity Required Action Bring vehicle to To avoid engine highway speeds to allow for an Automatic J to highway speeds Regeneration or to allow for an perform a Parked Automatic Regeneration perform a Parked Regeneration as soon as possible For a driver performed Parked Regeneration vehicle must be equipped with a dash mounted Regeneration Switch See Engine Operator s Manual for complete Rege
254. lane departure warning system is not a sub stitute for safe driving procedures Failure to drive safely and use the system prop erly could result in personal injury and or death and severe property damage IMPORTANT It is still the responsibility of the driver to change driving styles depending on existing traffic and road conditions Starting the vehicle activates the system On start up the system performs a self test then sounds two chirps through the speakers to indicate the system is ready The rocker switch on the B instrument panel turns the system on and off Once the vehicle is started and the system is ready the ON light at the bottom of the switch illuminates Pushing the top of the rocker switch turns the system off pushing the switch again turns the system on The top portion of the switch reads LANE ALERT and is backlit with the dash lights on The LANE SRCHNG amber warning light illuminates to indicate the system is not fully functional When the warning light is on the system audible alert may not indicate a lane departure Conditions that can cause the warning light to come on include The system is unable to detect lane markings Vehicle speed is less than 40 mph 64 km h Lane width is greater than 13 feet 4 m A dirty windshield or a similar problem is ob scuring the camera A system problem is detected While the system is capable of detecting a number of different types of lane marker
255. lar screen dis play at any time by pressing the keypad to display one of the direct access screens Press the TRIP key for the Trip Miles and Trip Hours screen Press the FUEL key for the Fuel Used and Average MPG screen Press the LEG key for the Leg Miles and Leg Hours screen Data for each of the above screens can be reset cleared To reset display the screen and push the Set Reset key twice within six seconds a confirma tion screen will display after you press the key once NOTE Resetting Trip Miles and Hours also resets Leg Miles and Hours Press the TEMP key to display the outside air tem perature If the vehicle has a data logging unit press the EVENT key to record data about a significant driving event engine problem driving problem unusual ve hicle operation etc Normally the screen displays Data Being Recorded NOTE If the memory in the data logger is full the screen instead displays Memory Full Data Not Recorded If the data logger is not con nected or not responding the screen displays Data Recorder Not Responding If the EVENT key was pressed recently within the last two minutes the screen displays Still Recording Last Event Stationary Access Screens Used With Parking Brake Applied The stationary access screens are a series of infor mational displays that give trip fuel engine diagnos tic setup and vehicle information For reasons of safety stat
256. lass Trucks Workshop i i i ff Manual for adjustment procedures 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 NOTICE weighing the vehicle on scales designed for this Always make sure the connect hanger support purpose keeps the trailer air hoses and electrical cables The maximum axle weight ratings are shown on positioned so that they do not rub on anything the Federal Motor Vehicle Safety Standard Rubbing may wear through hoses or cables re FMVSS label or Canadian Motor Vehicle Safety 10 3 Fifth Wheels and Trailer Couplings 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 rat ing given on the FMVSS or CMVSS label A WARNING Do not overload any tractor axle by improperly loading the trailer This could cause erratic steer ing and loss of vehicle control possibly resulting in serious personal injury or death Unlocking the Fifth Wheel Lock Mechanism Apply the tractor parking brakes 2 Pull the trailer air supply valve to cut off the air supply to the trailer 3 Chock the front and rear of the trailer tires to prevent the trailer from moving Do not use the trailer air supply for parking trail ers not equipped with spring parki
257. left foot on the top access step 4 Move your right hand to the forward grab handle Then move your left hand to the aft grab handle 5 Place your right foot on the middle step 6 Place your left foot on the bottom step 7 Step to the ground with your right foot 8 Let go of the grab handles Entering the Driver s Side for Right Hand Drive Vehicles Fig 3 14 1 Open the driver s door and place anything that you are carrying in the cab 2 Grasp the aft grab handle with your left hand and grab the forward grab handle with your right hand Reach up as far as you re comfortable 3 Place your left foot on the bottom step and care fully pull yourself up Slowly place your right foot on the next step Place your left foot on the top step 6 Grasp the steering wheel with your right hand and step up into the cab Exiting the Driver s Side for Right Hand Drive Vehicles Fig 3 14 IMPORTANT Do not attempt to exit the cab while carrying any items in your hands 1 Grasp the steering wheel tightly with both hands and stand on the door threshold facing into the cab J 1720312a 4 Forward Grab Handle 5 Aft Grab Handle 1 03 08 99 1 Bottom Step 2 Middle Step 3 Top Step Fig 3 14 Right Hand Drive Fixed Access Steps and Grab Handles Driver s Side 2 With your left hand grasp the forward grab handle at the aft edge of the door Move your left foot to the top step Move your ri
258. ler tires to prevent the trailer from moving A CAUTION Before attempting to lock the fifth wheel lock mechanism of a sliding type fifth wheel the slide operating rod Fig 10 9 must be in the locked position This prevents the sliding member from moving rapidly to the far forward or rearward po sition which could damage the fifth wheel mem ber or kingpin 2 The fifth wheel jaw must be fully open Make sure that the operating rod is in the unlocked po sition The fifth wheel must be completely lubri cated with chassis or multi purpose grease For lubrication instructions see Group 31 of the Century Class Trucks Maintenance Manual 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 personal injury or death 3 Make sure the fifth wheel top plate is tilted so the ramps are as low as possible If equipped with an air suspension make sure the air bags are completely inflated 4 Position the tractor so that the center of the fifth wheel is in line with the trailer kingpin The king pin should be in a position to enter the throat of the locking mechanism See Fig 10 10 Adjust the trailer landing gear so that the lower front trailer edge contacts the top surface of the tilted fifth wheel plate approximately 8 inches 20 cm before the fifth wheel center 5 With the fifth whe
259. lippery or poor road conditions move the lockout control valve to LOCK while maintaining vehicle speed before en countering the poor road conditions Let up momen tarily on the accelerator to engage the differential lock Proceed over poor road conditions with caution Do not wait until traction is lost and the tires are spinning before locking the interaxle differential CAUTION Do not actuate the interaxle differential control valve while the tires are slipping Do not operate the vehicle continuously with the interaxle differ ential locked during extended good road condi tions To do so could result in damage to the axle gearing and excessive tire wear To unlock the interaxle differential move the lockout control valve to UNLOCK while maintaining vehicle speed after leaving the poor road conditions Let up momentarily on the accelerator to allow the shift then resume driving at normal speed Eaton Single Reduction Axles with Controlled Traction Differential The controlled traction differential system is a differ ential assembly designed to transfer torque from the slipping wheel to the one with traction A control valve Fig 9 3 in the cab is actuated by the driver to engage and disengage the controlled traction feature Disengaged the axle has differential action all the time One wheel will spin independently of the other if slippery conditions are encountered Engaged wheel slippage and spinout are minim
260. lllsslnn 2 17 Keypad sy baraa gineo RARE qx RE 2 14 Stationary Access Screens 2 19 Instruments llle 2 54 AMIMC IER uua Sb a hor mote Vie x a e zn 2 57 Index Subject Application Air Pressure Gauge Borg Indak Analog Clock Coolant Temperature Gauge Engine Oil Pressure Gauge Engine Oil Temperature Gauge Forward and Rear Axle Oil Temperature Gauges Fuel Gauge Intake Air Restriction Gauge Intake Air Restriction Indicator Kysor Digital Clock Pana Pacific Digital Clock Primary and Secondary Air Pressure Gauges Pyrometer Speedometer Tachometer Transmission Oil Temperature Gauge Turbocharger Boost Pressure Gauge Voltmeter Keyless Security System optional Fob Battery Replacement Fob Programming General Information How It Works Lane Guidance System Meritor Drive Axles with Main Differential Lock Meritor Engine Synchro Shift ESS Automated Models General Information Operation Meritor Interaxle Differential Lockout Operation Meritor Main Differential Lock Operation Meritor Range Shift Models General Information Operation Page 2 56 2 57 2 55 2 54 2 55 2 56 2 56 2 56 2 57 2 58 2 57 2 56 2 55 2 54 2 54 2 56 2 55 2 55 3 18 3 20 3 20 3 18 3 19 2 52 Subject Meritor Single Drive Axles with Traction Equalizer Meritor Splitter and Range Shift Models General Information Operation Meritor Tandem Drive Axles with Interaxle Diff
261. ln 8 8 Opetatigh Jia aene dees ac ee URL RR ES 8 9 Fuller Straight Shift Models LL 8 5 General Information 8 5 ODGFatlGlT 33 xe esas sos pape awe ane ode d oe 8 5 H Hazard Warning Lights 13 1 Heating Auxiliary Sleeper Bunk Heater and Air GONGIWIONER ccc eatin ck a ak erie eee eed ctm 4 4 Heating md eee Abas EELS qwe 4 2 Holland Fifth Wheels 10 1 Fifth Wheel Locking Operation 220 5082 c4 b REY GS 10 2 Fifth Wheel Lubrication 10 6 Fifth Wheel Slide Operation 10 4 General Information 10 1 Holland Trailer Coupling 10 17 General Information 10 17 Operation see 6 4 e pose p eee baked 10 17 HVAC General Information 4 1 Hydraulic Cab Tilt System llus 3 15 Hydraulic LOCKUP x aneio trast rasa 3 15 Returning the Cab from a Tilted Position id 25 4 2246 ooo eb E e 3 17 Tilting the Cab on seve fe RS ERR ns 3 16 Subject Page Ignition and LOCK Key 2e ES RR 3 1 Instrument and Control Panel llus 2 1 Engine Protection Warning and Shutdown sus ex ae qox RR Og ors 2 3 Instrumentation Control Unit CUE ni ais Sie dodi RUE ea thi S Reds 2 38 Alert Screen 2222482 RR ERR 2 42 ICU2L Ignition Sequence ls 2 40 Setting the Units for the Odometer 66 coss x 2 41 Warning and Indicator Lights
262. ly be used when the ambient temperature remains below 10 F 12 C During cold weather the batteries should be tested more frequently to ensure ample power for starting All electrical connections should be tight and in good condition to prevent losses through loose or corroded connections Ethylene glycol based antifreeze is recom mended An inhibitor system is included in this type of antifreeze and the corrosion protection is sufficient as long as the recommended con centration range of 30 to 67 percent antifreeze to water by volume is employed If the engine is to be operated in arctic tem peratures consult the nearest Freightliner dealer or an authorized Detroit Diesel engine dealer for information regarding availability of special cold weather equipment 7 18 Engines and Clutches Mercedes Benz IMPORTANT At outside temperatures below 4 F 20 C a coolant preheater is recom mended For service products to use in cold weather see the M B Engine Operator s Manual supplied with the vehicle for details Periodically check the coolant mixing ratio concen tration of antifreeze in the coolant Add more if nec essary The coolant mixing ratio should never rise above 60 percent antifreeze Use low viscosity lubricating oils for adequate lubri cation At temperatures below 32 F 0 C do not use summer grade 2 D diesel fuel To avoid fuel prob lems due to paraffin separation use winter grade
263. m away from the batter ies of the vehicle needing the start The vehicle frame is usually a good ground Do not connect the cable to or near the discharged batteries 4 Start the engine of the vehicle with the booster batteries and let the engine run a few minutes to charge the batteries of the other vehicle 5 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 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 8 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 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 de spite this most materials will burn The cab of this vehicle contains urethane foa
264. m which is of concern in this respect A WARNING Urethane foam is flammable Do not allow any flames sparks or other heat sources such as cigarettes or light bulbs to contact urethane foam Urethane foam in contact with such heat Sources could cause a serious rapid fire which could result in death severe burns or gas poi soning as well as damage to the vehicle In Case of a Cab Fire As quickly as possible bring the vehicle to a safe stop apply the parking brake turn off the ignition and get out of the vehicle 13 4 Index Subject Page Air Bag Optional o soc ceee tia Ln mu 5 9 Air Bag Safety Guidelines 5 9 Air Conditioning Auxiliary Sleeper Bunk Heater and Air GOMGIUIONER sos uk soe hos ox dod ck Rs eta tees 4 4 Air Conditioning l llle 4 3 Allison Automatic Models 8 17 General Information 8 17 Operation uui ges Rn xy ER 8 18 ASF Castloc Il and Simplex Series Fifth Wheels eee 10 6 Fifth Wheel Locking and Unlocking i essem RES SS 10 8 Fifth Wheel Lubrication 10 11 Fifth Wheel Slide Operation 10 10 General Information 10 6 Back of Cab Grab Handles Steps and Deck Plate 3 13 Accessing Back of Cab Area 3 14 Exiting the Back of Cab Area 3 14 Baggage Compartment Doors 3 13 Battery Box Co
265. mended engine braking speed is above 1800 rpm and below the rated speed IMPORTANT Maximum retarder performance is obtained when you use the lowest possible gear without exceeding the recommended engine braking speed Control speed is the speed at which the engine brake performs 100 percent of the required downhill braking resulting in a constant speed of descent The control speed varies depending on vehicle weight and the downhill grade Below a set engine speed set at the factory to 700 rpm the engine control unit ECU will not engage the engine brake The engine brake will not work below the set engine speed For faster descent select a higher gear than that used for control speed Service brakes must then be used intermittently to prevent engine overspeed and to maintain desired vehicle speed IMPORTANT When descending a grade re member that frequent use of service brakes causes them to become hot which results in a reduction of their stopping ability Grade descent speed should be such that the service brakes are used infrequently and that they remain cool thus retaining their effectiveness A driver may descend slower than control speed by selecting a lower gear one that will not overspeed the engine The engine brake retarding force will Engines and Clutches then be sufficient to cause vehicle deceleration Oc casional deactivation of the engine brake may be necessary to maintain the designated road s
266. ment Lever Seat Cushion Adjustment Lumbar Support Lever aroNw gt Fig 5 5 Dura Form Fleetcruiser Seat Adjustment Controls Fore and Aft Seat Adjustment To adjust the fore and aft position of the entire seat move the fore and aft seat adjustment lever to the left and slide the seat forward or backward to the desired position Move the lever back to its original position to lock the seat in place Rear Cushion Adjustment To adjust the height of the rear of the seat cushion remove your weight from the seat and turn the rear cushion adjustment knob to one of three positions Isolator Also called a Chugger Snubber the isolator reduces the amount of road shock by isolating the occupant from the motion of the vehicle and allowing the seat to move in a simple pendulum motion To use the isolator feature turn the isolator handle to the hori zontal position Turn the isolator handle down when the isolator feature is not desired 5 4 Seats and Seat Belts 11 14 2000 Back Cushion Tilt Knob Lumbar Support Switch Height Adjustment Switch Fore and Aft Seat Adjustment Lever Bottom Cushion Front Height Adjustment Handle Isolator Handle 910445 NOoORONN Rear Cushion Adjustment Knob Fig 5 6 National 2000 Series Seat Adjustment Controls Lumbar Support To adjust the lumbar support use the lumbar support switch on the side of the seat to give more or less support to your lower back
267. mission a four position R N D L linear mode selector switch Fig 8 1 is located at the end of the control For the Meritor SureShift transmission a three position R N F linear mode selector switch Fig 8 2 is located at the end of the control The control is spring loaded and returns to mid position when released after an upshift or downshift Operation Eaton AutoShift Transmission Automatic and Manual Modes A two position forward driving mode switch slide switch is located near the end of the control Fig 8 4 The switch positions are labelled MAN manual shift mode and AUTO automatic drive mode Transmissions 06 03 99 X 1270065 Upshift in manual mode pull upward Steering Wheel Reverse Position Neutral Position Drive Position Downshift in manual mode push downward Steering Column NO OVP Oh Fig 8 3 SmartShift Control Operation Eaton AutoShift control showing only R N D positions 03 13 96 f260055a Fig 8 4 Fuller Straight Shift Model Transmissions Shift Pattern NOTE In automatic drive mode upshifts and downshifts require no driver interaction Move the selector switch to the drive D position dis engage the clutch to engage the gear selected engage the clutch and drive the vehicle In manual shift mode upshifts and downshifts re quire either a pull upward or push downward on the control Driver Message Center Gear information is presented to
268. module or connecting an electric priming pump to the priming port on the fuel filter module See the engine operation manual for complete instructions Prestart NOTE These prestart steps apply to all en gines 1 Perform the engine pretrip inspection and daily maintenance checks in Chapter 11 2 Apply the parking brake NOTE On vehicles equipped with a neutral start switch the transmission must be in neutral be fore the engine can be started For air start sys tems check the air supply before starting the engine There must be 100 psi 689 kPa of air pressure available 3 For manual transmissions place the transmis sion in neutral and disengage the clutch For automatic transmissions make sure the transmission shift control is in neutral or park Starting Precautions NOTICE Do not crank the engine for more than 30 sec onds at a time Wait two minutes after each try to allow the starter to cool Failure to do so could cause starter damage NOTE Some starters are equipped with op tional overcrank protection If overcranking oc curs a thermostat breaks the electrical circuit to the starter motor until the motor has cooled A WARNING Never pour fuel or other flammable liquid into the air inlet opening in the air intake in an attempt to start the vehicle This could result in a flash fire causing serious personal injury or property dam age Starting fluid is highly flammable and explosive It can
269. mpletion of the vehicle The label is located on the left rear door post and certifies that the vehicle conforms to all applicable CMVSS regulations in effect on the date of completion Tire and Rim Labels Tire and rim labels certify suitable tire and rim combi nations that can be installed on the vehicle for the given gross axle weight rating Tires and rims in stalled on the vehicle at the time of manufacture may have a higher load capacity than that certified by the tire and rim label If the tires and rims currently on the vehicle have a lower load capacity than that shown on the tire and rim label then the tires and rims determine the load limitations on each of the axles See Fig 1 6 for U S and Canadian tire and rim la bels EPA Emission Control Labels EPA Vehicle Noise Emission Control Label A vehicle noise emission control label Fig 1 7 is attached either to the left side of the dashboard or to the top right surface of the frontwall between the dash and the windshield VEHICLE NOISE EMISSION CONTROL ee FREIGHTLINER CORPORATION E OF MANUFACTURE 596 THIS VEHICLE CONFORM U S EPA REGULATIONS FOR NOISE EMISSION APPLICABLE TO MEDIUM AND HEAVY TRUCKS THE FOLLOWING ACTS OR THE CAUSING THEREOF BY ANY PERSON ARE PROHIBITED BY THE NOISE CONTROL ACT OF 1972 A THE REMOVAL OR RENDERING INOPERATIVE PIRNER THAN FOR PURPOSES D s MAINTENANCE REPAIR OR REPLACEI ANY NOISE CONTROL DEVICE Ol ELEMENT OF DESIGN LIS
270. n 6 Inspect the seat belts and tether belts Inspect and maintain seat belts as instructed below Worn or damaged seat belts could fail during a sudden stop or crash possibly resulting in serious injury or death IMPORTANT Seat belts have a finite life which may be much shorter than the life of the vehicle Regular inspections and re placement as needed are the only assur ance of adequate seat belt security over the life of the vehicle NOTE When any part of a seat belt needs replacement the entire seat belt must be replaced both retractor and buckle side 6 1 Check the web for fraying cuts or ex treme wear especially near the buckle latch plate and in the D loop guide area 6 2 Check the web for extreme dirt or dust and for severe fading from exposure to sunlight 6 3 Check the buckle and latch for operation and for wear or damage 6 4 Check the Komfort Latch for function and cracks or other damage 11 14 Pretrip Inspection and Daily Maintenance 6 5 Check the upper seat belt mount on the door pillar for damage 6 6 Check the web retractor for function and damage 6 7 Check the mounting bolts for tightness and tighten any that are loose Monthly Post Trip Inspection and Maintenance Procedures A WARNING 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 p
271. n the right rear axle If during vehicle operation the safety circuit senses a failure in any part of the ABS System a sensor solenoid control valve wiring con nection short circuit etc the tractor warning light TRACTOR ABS comes on and the control circuit where the failure occurred is switched to normal braking action The remaining control circuit will re tain the ABS effect Even if the ABS system is com pletely inoperative normal braking ability is main tained An exception would be if a solenoid control valve or combination solenoid control valve is dam aged and inoperative As these components are an integral part of the air brake system normal braking may be impaired or inoperative IMPORTANT If any of the ABS warning lights do not work as described above or come on while driving repair the ABS system immedi ately to ensure full antilock braking capability During emergency or reduced traction stops fully depress the brake pedal until the vehicle comes to a safe stop do not pump the brake pedal With the brake pedal fully depressed the ABS system will control all wheels to provide steering control and a reduced braking distance Although the ABS system improves vehicle control during emergency braking situations the driver still has the responsibility to change driving styles de pending on the existing traffic and road conditions For example the ABS system cannot prevent an ac cident if the driver is
272. n accident that could result in personal in jury or property damage CAUTION On the 90 inch cabs with stairs on the right hand side you must deploy the stairs before tilting the cab Tilting the cab with the stairs stowed will cause damage to the vehicle IMPORTANT Before tilting or lowering the cab read the warning label on the tilt pump and the tilt instructions label on the exhaust stack 1 If equipped with an air hydraulic tilt system build the system air pressure to 100 psi 689 kPa Then with the vehicle parked on level ground shut down the engine and place the shift lever in the neutral position Objects falling in the cab or a door flying open could damage the vehicle or cause personal in jury 2 Secure all loose articles in the cab and bunk and make sure the doors are securely latched 3 Apply the parking brakes 4 fthe vehicle is equipped with an electric hydraulic tilt system activate the tilt system power switch on the dash Check the cab travel path for obstructions Move the pump control lever to the Tilt position Stand clear of the cab travel path ON OO Using either the air or electric motor control but ton if so equipped or the pump handle located in the baggage compartment operate the tilt pump to disengage the hold down latches IMPORTANT Check the indicator pin on each cab latch The latches have disengaged if the pins are out See Fig 3 22 NOTE If air is prese
273. n or in an emergency situation When the brake pushrod stroke exceeds the legal brake adjustment limit on a vehicle there is likely a mechanical problem with the foundation brake com ponents 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 prema ture wear of the adjuster itself Further the im proper adjustment of some automatic slack ad justers may cause internal damage to the adjuster thereby preventing it from properly functioning Engines and Clutches EPAO07 Exhaust Aftertreatment System ATS ssesleseseeseeeeeeeel eee 7 1 Detroit Diesel Heavy Duty Engine DD13 15 ccssicteecisceatiersdesepiac aban pee RR ERES 7 4 Engine Starting CAT Cummins DDE S60 M B 0 cece eee ne eee 7 8 Engine Operation CAT Cummins DDE S60 M B 0 0 00 e eee 7 12 Engine Shutdown CAT Cummins DDE S60 M B 0c ee ee eens 7 19 Opti nal Engine Sys DITS eresse sse hp sete FETTE BU RACE V RE e BUR HERE oed 7 21 DIUIEnBS veszpexarkFIRSEXATRERP RE EURE EKE EEIE EEROR E REEE ENEE sees Sepeud e584 7 27 Engines and Clutches EPA07 Exhaust
274. n position the exhaust brake is applied The following conditions should exist if the brake is operating properly A slight change in the sound of the engine may be noticed when the exhaust brake is applied Exhaust smoke should appear normal Engine temperature should remain in the nor mal operating range Road speed usually decreases when the ex haust brake is applied during a descent When the vehicle is carrying a heavy load or the grade is extremely steep you may need to apply the service brakes occasionally Do not expect a retarding effect similar to sud den hard application of the service brakes The exhaust brake retards the vehicle with a smooth braking effect During a descent the tachometer usually shows a drop in rpm depending on the grade and the vehicle load Depending on the grade and vehicle load you may or may not feel the retarding force acting against your body when the brake is applied The retarding force of the brake may not al ways be noticed but it is actually preventing the vehicle from going much faster Optimized Idle The Optimized Idle option on Detroit Diesel vehicles is a system that automatically stops and restarts the engine to accomplish the following keep the engine oil temperature between 60 to 104 F 16 to 40 C e keep the battery charged keep the cab or sleeper at a constant desired temperature if equipped with a thermostat The benefits of the system inclu
275. n to less than approximately 1 4 inch 6 4 mm at the thinnest point have the linings replaced on all brake assemblies on that axle See Group 42 of the Century Class Trucks Workshop Manual for lining replacement instructions and camshaft end play inspection Check the brake drums for wear and cracks Check that the inspection plugs in the dust shields or backing plates if so equipped are installed 11 16 12 Cab Appearance Cab Washing and Polishilg iu x RR EE ERR ttti nere EENETI E UR RR GCER ORE deers 12 1 Gare OF Fiberglass PAIS 2 2issats tue itae tiet ietis bepa eE eea E P p DeR PES P ES 12 1 Care of Chrome Pans vuosxeeescterueesxesubiReneREg p Ra ke REX E E ERU RR Rd E EERE qx 12 1 Dashboard Care 3 6 up 24d DP edu Obi bE HUN TR I CRT P PEOR e f ed UR CR e UCRC S hd d 12 1 Vinyl Upholstery Cleaning xesswepxek se RERO REX REX paw heed eh hee oe rs Save ke 12 1 Velour Upholstery Cleaning lt i eire S4 oue REV bese bER E RR ERAS PERRA RO seen eens k 12 2 Cab Appearance Cab Washing and Polishing To protect the finish of your new vehicle follow these guidelines carefully 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 During the first 120 days do not wax your vehicle To extend
276. nator output e Check the condition and tension of the drive belts Caterpillar If the engine is in good mechanical condition and the precautions necessary for cold weather operation are taken ordinary cold weather will not cause difficulty in starting or loss of efficiency If the engine does not start prime the fuel system When the use of unblended No 2 diesel fuel in win ter cannot be avoided install a thermostatically con trolled fuel heater Fuel heaters can prevent wax from clogging the fuel filters and formation of ice crystals from water in the fuel IMPORTANT If a fuel heater is used make sure it has thermostatic controls to prevent excessive heating of the fuel in warm weather Excessive heating of fuel can cause a loss of engine power For cold weather operation use the following guide lines 7 17 e When starting the engine in temperatures below 32 F 0 C use engine lubricants of lower viscosity Refer to the Caterpillar Opera tion and Maintenance Manual for specifica tions When the temperature is below freezing use sufficient antifreeze solution in the cooling sys tem to prevent freezing During cold weather give more attention to the condition of the batteries Test them frequently to ensure sufficient power for starting See Group 15 of the Century Class Trucks Work shop Manual for detailed information e f so equipped turn off the battery disconnect switch after the engine i
277. nd the pressure in both air systems is at least 65 psi 448 kPa the red knob must be pushed in It should stay in to charge the trailer air supply system and to release the trailer spring parking brakes it must be pulled out before disconnecting a trailer It must also be pulled out when operating a vehicle without a trailer If pressure in both air systems drops to 35 to 45 psi 242 to 310 kPa the red knob automatically pops out exhausting the trailer air supply and apply ing the trailer service or spring parking brakes The yellow diamond shaped knob Fig 6 3 in the control panel actuates the parking brake valve Pull ing out the knob applies both the tractor and trailer spring parking brakes and automatically causes the trailer air supply valve knob to pop out CAUTION Do not use the spring parking brakes if the ser vice brakes are hot such as after descending a steep grade Also do not use the spring parking brakes during freezing temperatures if the ser vice brakes are wet To do so could damage the 6 3 P 4 TO Se 1 2 o8 EZ e X TRAILER AIR SUPPLY N PARKING k NOT FOR PARKING BRAKE g N EN SU l y Na gt e N X TO P N we f S J 03 10 99 1610291 1 Trailer Air Supply Valve Knob 2 Parking Brake Control Valve Knob Fig 6 3 Brake Valve Knobs 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 b
278. nd TX 14607B transmissions have seven forward speeds and one reverse speed They are designed for use with on highway fuel economy engines where a minimum of shifting is desired and less gear reduction is acceptable See Fig 8 4 for the shift pattern 8 5 Operation 1 Always use 1st gear when starting to move the vehicle forward 2 Use the clutch brake to stop gear rotation when shifting into 1st or reverse when the vehicle is stationary The clutch brake is actuated by de pressing the clutch pedal all the way to the floor For normal upshifts and downshifts only a partial disengagement of the clutch is necessary to break engine torque 3 Use double clutching between all upshifts and downshifts 4 After your shifting ability improves you may want to skip some of the ratios This may be done only when operating conditions permit depend ing on the load grade and road speed Never use the clutch brake when downshifting or as a brake to slow the vehicle Upshifting 1 Position the gear shift lever in neutral then start the engine Bring the air system pressure up to 100 to 120 psi 689 to 827 kPa 2 Depress the clutch pedal to the floor shift into 1st gear then engage the clutch with the engine at or near idle speed to start the vehicle moving Accelerate to engine governed speed 3 Once governed speed has been reached disen gage the clutch and shift the lever to neutral Engage the clutch allow
279. nd inactive fault codes can be indi cated by the DDU when the system is placed in failure display mode Inactive faults are those that have occurred and have cleared Active faults are still present Fault codes provide the driver the ability to record the system faults dur ing a trip and to notify his maintenance depart ment or Eaton VORAD See Failure Display Mode Fault Codes below In this mode specific fault codes are indicated by the pattern of blinks of the driver display unit red FAIL light 4 Each fault code is a 2 digit number as shown in Table 2 2 The red FAIL light blinks the same number of times as the first digit a pause of ap proximately 3 4 of a second follows then the light blinks the same number of times as the sec ond digit 5 Additional fault codes are blinked out at intervals of approximately eight seconds After all the fault codes have been displayed a code 41 will be flashed Failure Display Mode Fault Codes 1 Press and hold the DDU volume control and power ON OFF knob Continue pressing the knob until the FAIL light begins to blink in ap proximately five seconds If so configured the system will turn off if you release the knob before five seconds After five seconds the DDU FAIL light begins to blink out the failure flash codes A code 41 will be displayed either if no faults are found or when all fault codes have been dis played 2 Position the DDU range knob to the left to blink active
280. nd indicates poor fuel economy 09 25 95 1600993 1 Tachometer 2 Speedometer Fig 2 64 Instrument Panel center Speedometer The speedometer Fig 2 64 registers speed in both miles per hour mph and kilometers per hour km h Engine Oil Pressure Gauge The engine oil pressure gauge Fig 2 65 should read as shown in Table 2 4 02 12 96 5 d d 601126 Engine Oil Pressure Gauge Coolant Temperature Gauge Engine Oil Temperature Gauge Voltmeter Turbocharger Boost Pressure Gauge Pyrometer oggi ON Fig 2 65 Instrument Panel Gauges left side Oil Pressure At Idle Speed At Rated RPM Engine Model psi kPa psi kPa Caterpillar C 10 10 20 69 138 30 45 207 310 Caterpillar C 12 10 20 69 138 30 45 207 310 Caterpillar 3406E 15 100 min 40 275 min Cummins M11 10 69 min 35 45 241 310 Cummins N14t 10 69 min 35 45 241 310 Cummins ISX 15 103 min 35 241 min Detroit Diesel S60 12 83 50 345 min MBE 4000 7 50 36 250 min DD13 DD15 14 97 55 350 min Oil pressures are given with the engine at operating temperature With the engine cold oil pressure may be higher t Individual engines may vary from the listed pressures observe and record pressures when the engine is new to create a guide for checking engine condition Table 2 4 Oil Pressure NOTICE A sudden decrease or absence of oil press
281. nd oil pressure warning lights or messages and buzzer operate until the engine is started and pressure is built up The engine can be started and operated only when the ignition switch is ON Switching ON the ignition and releasing the parking brakes automatically activates the daytime running lights The daytime running lights will operate until the parking brakes are applied then they will switch off The vehicle must not be driven unless the day time running lights are activated Idle Shutdown Timer This feature is a 1 to100 minute idle shutdown sys tem Its purpose is to conserve fuel by eliminating excessive idling and allowing a turbocharger cool down period To activate the shutdown the transmis sion must be in neutral with the vehicle parking brakes set and the engine in idle or fast idle mode Mirror Heat Switch One or both outside door mirrors can be heated to keep them defrosted Whenever the mirror heat Switch is on an amber indicator light illuminates in the switch Instruments and Controls Identification Power Mirrors Both outside mirrors can be equipped with an electri cal remote control Operate the driver door mounted switch to adjust the mirror Exhaust Aftertreatment Regen Switch A parked regen of the aftertreatment system can be initiated with the regen switch Refer to Chapter 7 for instructions on how to perform a parked regen An optional regen requeSt inhibit switch provides ad di
282. nditions use the highest gear that is still low enough to start the vehicle moving with the engine at or near idle speed and without slipping the clutch excessively 2 Use the clutch brake to stop gear rotation when shifting into low or 1st or reverse when the ve hicle is stationary The clutch brake is actuated by depressing the clutch pedal all the way to the floor For normal upshifts and downshifts only a partial disengagement of the clutch is necessary to break engine torque 3 Use double clutching between all upshifts and downshifts that require movement of the shift 8 9 lever Splitting of the high range gears does not require movement of the shift lever 4 Never move the shift lever into low gear while in high range 5 Never move the splitter control button while in neutral 6 Do not preselect with the splitter control button after moving the control button complete the shift immediately 7 Except when downshifting from 5th direct to 4th gear never push the range preselection lever down into low range while operating in high range the splitter will become inoperative 8 Do not shift from high range to low range at high vehicle speeds 9 Do not make range shifts with the vehicle moving in reverse gear 10 Never attempt to move the range preselection lever with the gear shift lever in neutral while the vehicle is moving Preselection with the range preselection lever must be made prior to movin
283. neration Instructions 06 29 2009 ter has reached Filter has exceeded ni reaching maximum maximum capacity maximum capacity A regeneration is in capacity progress Vehicle must be derate bring vehicle parked and a Parked Parked Regeneration or Service Solid Regeneration must be performed engine will begin Regeneration or derate zF 9 Flashing Vehicle must be parked and a Regeneration must be performed I Exhaust Components Check engine operator s manual and exhaust gas are for details engine will shut down ff at high temperature When stationary keep away from people and flammable materials or vapors 24 01583 000B 1080147 Fig 7 4 Exhaust Aftertreatment Warnings Reference Card The regen switch located on the dash is used to initiate a parked regen of the aftertreatment device The regen switch can start a parked regen only after the engine software calls for it and the DPF light is illuminated The regen switch cannot initiate a regen otherwise See Fig 7 5 10 02 2006 1610848 07 30 2009 f610944 Fig 7 5 Regen Switch A regen inhibit switch allows additional control over the aftertreatment regen process When activated the inhibit switch will stop a regen cycle in progress and prevent the start of a regen cycle until the switch is no longer active See Fig 7 6 7 3 Fig 7 6 Regen Inhibit Switch Parked Regen During parked regenera
284. ng brakes This applies the trailer service brakes only As air bleeds from the trailer brake system brake appli cation is lost This could allow the unattended vehicle to roll away possibly resulting in serious personal injury or death 4 Lower the trailer landing gear until the weight is removed from the fifth wheel e 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 Ay CAUTION Before attempting to lock or unlock the fifth wheel lock mechanism of a sliding type fifth wheel the slide release plungers must be in the locked position This prevents the sliding mem ber from moving rapidly to the far forward or rearward position which could damage the fifth wheel or kingpin 6 Release the kingpin locking mechanism by pull ing the kingpin lock control handle Fig 10 1 to the outward position 7 Slowly drive the tractor away from the trailer Fifth Wheel Slide Operation 1 Connect the trailer kingpin to the tractor fifth wheel For instructions refer to Holland Fifth Wheel Locking Operation in this chapter 2 After positive lockup of the fifth wheel lock mechanism has been accomplished release the sliding member using one of the following meth ods 2 1 For air operated models set the cab operated control switch Fig 10 6 to UNLOCK FIFTH WHEEL SLIDE UNLOCK LOCK MUST BE LOCKED WHEN VEHICLE I
285. ng the time required to reach the same sign If the count reaches 3 then the headway is a 3 second headway A more precise method of determining the headway would be to use a stopwatch rather than counting Instruments and Controls Identification For example If the headway is 3 seconds and the vehicle speed is 55 mph 88 5 km h then the dis tance to the vehicle ahead is 242 ft 74 m If the ve hicle speed is reduced to 40 mph 64 km h the dis tance is 176 ft 53 5 m for a 3 second headway Audible and visual headway alerts are as follows When a moving object is detected in the travel lane and is less than 350 ft 107 m from the front of the vehicle the HDWY DETECT light will illuminate on the ICU No warning tone will sound When a moving object is detected in the travel lane and it has a headway between one and two seconds the HDWY DETECT light will illu minate and a message will appear on the ICU A warning tone will sound e When a moving object is detected in the travel lane and it has a headway between 1 2 second and 1 second the HDWY DETECT light will illuminate and a message will appear on the ICU Warning tones will sound also If the headway is increasing no tone will sound If the headway is decreasing double tones will sound Within a 1 2 second or less following interval opening or closing the tones will repeat twice per second If a stationary vehicle or object or an object moving at le
286. ng the vehicle forward on a grade are equal to the forces holding it back without using the vehicle service brakes In other words this is the speed the vehicle will maintain without using the ser vice brakes or throttle Do not over apply the vehicle service brakes when descending a long steep grade Excessive use of the vehicle brakes will cause them to heat up reducing their stopping ability This condi tion referred to as brake fade may result in loss of braking which could lead to loss of con trol of the vehicle resulting in personal injury or property damage Use the following guidelines when descending a long steep grade Before beginning the descent determine if your engine brake system is operating properly by lifting your foot briefly off the accelerator pedal You should feel the system activate Check the progressive braking switch often for proper position since road conditions can change quickly Never skip a step when oper ating the progressive braking switch Always go from OFF to LOW and then to a higher posi tion when on slippery roads Do not exceed the safe control speed of your vehicle Example You could descend a 6 per cent grade under control at 10 mph 16 km h without an engine brake but at 25 mph 40 T km h it requires an engine brake You could not descend that same hill at 50 mph 80 km h and remain under control Know how much slowing power your engine brake can provide b
287. ngage the interaxle differential lockout before shifting the axle to a higher range Rear Axles When the interaxle differential lockout control valve is in the UNLOCK position the interaxle differential al lows differential action between the axles thereby compensating for different wheel speeds and varia tions in tire size Keep the interaxle differential lock out in the UNLOCK position for normal driving on roads where traction is good On 2 speed axles the interaxle differential must be in the UNLOCK position before attempting to shift the axles out of low or high range 9 4 10 Fifth Wheels and Trailer Couplings Holland Fifth Wheels ess sea sme RR em hehe iet hk aca y kie Redes eren i Rhea RIRs 10 1 ASF Castloc I and Simplex Series Fifth Wheels 0 00 cece eee eee eee eae 10 6 Fontaine Fifth Wheels 0 0 0 tenet teen rn 10 11 Premier Trailer Couplings i22i c 2s6e4e025400es805 60804 000248 0470264 RO 3E be Ree SS 10 15 Holland Trailer Coupling Fifth Wheels and Trailer Couplings Holland Fifth Wheels General Information The 2535 sliding fifth wheel models incorporate a Model 3500 fifth wheel Fig 10 1 equipped with either an air operated release slide or a manual re lease slide Sliding fifth wheel assemblies are mounted on a baseplate which permits forward and rear movement along notched rails Plungers are meshed into teeth on the baseplate to lock the slid ing mechanism Dise
288. ngagement of the sliding mem ber is accomplished when the plungers are with drawn manually or air operated releasing the fifth wheel assembly so that it can be positioned for opti mum weight distribution over the tractor axles 01 19 95 b l 310046a 1 Kingpin Lock Mechanism 2 Kingpin Control Handle 3 Mounting Bracket Fig 10 1 Holland Fifth Wheel The air operated release slide assembly Fig 10 2 contains a double ended air cylinder which locks and unlocks both sides of the sliding member at the same time The air cylinder is activated by a two position air control valve in the tractor cab The manual release slide assembly Fig 10 3 is equipped with a single release lever Pulling on the release lever unlocks both plungers Type B Kingpin Lock Mechanism Fig 10 4 The Type B kingpin lock mechanism utilizes two spring loaded lock halves The final forward motion of the kingpin into the open lock halves forces the 10 1 3 05 19 93 1310369 NOTE Baseplate rails not shown 1 Kingpin Lock Control Handle 2 Double Ended Air Cylinder 3 Slide Plunger Release Fig 10 2 Air Operated Release Slide Assembly Y CN BVASN Ww S a N d SN EN 2 QS Fu 4 02 01 96 f310438 NOTE Baseplate rails not shown 1 Kingpin Lock Control Handle 2 Plunger Release Handle 3 Plunger Release Spring 4 Plunger Fig 10 3 Manual Release Slide locks to close in a 360 d
289. ning and Shutdown When the red stop engine or engine protection light illuminates most engines are programmed to shut down automatically within 30 seconds The driver must immediately move the vehicle to a safe location at the side of the road to prevent causing a hazardous situation that could cause bodily injury property damage or severe damage to the engine 2 3 Certain engine conditions that are programmed for your engine will activate an engine protection shut down sequence The shutdown sequence can be activated by readings from the following sensors engine coolant temperature engine coolant level engine oil pressure engine oil temperature engine intake air temperature diesel particulate filter for the exhaust after treatment system Instruments and Controls Identification 02 09 96 1 Ignition Switch 2 Heater Air Conditioner Controls 3 1541100 NOTE Instruments and controls and their locations may vary from those shown AM FM Stereo Radio Cassette Player Clock Fig 2 2 Instrument and Control Panel Layout lower LH DR dash shown my 4 qo vel y 03 02 99 Trailer Air Supply Valve Parking Brake Control Valve Controlled Traction Differential Control Valve Switch Fifth Wheel Air Slide Control Valve Switch Interaxle Differential Lockout Control Switch Air Suspension Dump Valve 10 Key Keypad Windshield Wiper Washer Controls Oil Pressure Gauge 10
290. nses a severe life threatening frontal impact the module triggers two gas cylinders mounted at the base of the seat See Fig 5 14 The gas cylinders activate the power cinches that then tighten the lap and shoulder belts against the occu pant of the seat and lower the seat suspension mov ing the occupant down and away from the steering wheel and ceiling See Fig 5 15 The air bag is acti vated simultaneously This sequence of actions oc curs in about a tenth of a second j lt a 09 03 97 Pretensioning Cable Tether SPACE Module Suspension Seat Gas Cylinder Sensor Bracket 910172 aOPoNs Fig 5 14 SPACE System Components A WARNING The SPACE system will activate during a severe frontal collision even if the seat belts are not fas tened but the SPACE system only provides pro tection to the occupant when the seat belts are fastened Always use the seat belts when operat ing the vehicle Failure to do so can result in se vere personal injury or death A WARNING Damaged seat belts or seat belts that were worn in an accident must be replaced and their an choring points must be checked Do not attempt to modify the SPACE system Doing so could change the effectiveness of the system The SPACE system must be replaced after being acti vated Failure to do so may result in personal in jury or death Infants and children must not be placed in seats equipped with the SPACE system The SP
291. nsion and raise the seat Pull the knob out to de flate the suspension and lower the seat Isolator and Fore Aft Seat Adjustment Move the fore aft adjustment lever to the left to ad just the seat to the desired fore aft position Move the same lever to the center position to lock out the isolator feature Move the lever to the right to engage the isolator Seats and Seat Belts 10 10 96 Mi Back Cushion Tilt Lever Lumbar Support Switch LSO models Damper Adjustment Switch Weight and Height Adjustment Switch Bottom Cushion Tilt Knob Fore and Aft Adjustment and Isolator Lever Lumbar Support Knob non LSO models 1910131 NO OT SO N Fig 5 4 Freightliner Bostrom Seat Adjustment Controls Seat Cushion Adjustment To put the seat cushion in the upper position lift up ward on the front of the cushion then push rearward To put the seat cushion in the lower position pull for ward and then push downward Lumbar Support Move the lumbar support lever to any of the three positions as desired National 2000 Series Seat See Fig 5 6 for seat adjustment controls Back Cushion Tilt To tilt the back cushion turn the back cushion tilt knob until the desired position is reached Height Adjustment To raise or lower the height of the seat use the height adjustment switch on the side of the seat 02 09 95 f910003a Back Cushion Tilt Handle Height Adjustment Knob Isolator and Fore Aft Adjust
292. nsisting of a 5 speed front sec tion and a 3 speed auxiliary section The auxiliary 8 8 Transmissions section contains low and high range ratios plus an overdrive splitter gear One ratio in the front section low is used as a start ing ratio it is never used when the transmission is in high range The other four ratios in the front section are used once in low range and once again in high range however each of the five ratios low 1 2 3 4 in low range and each of the four ratios 5 6 7 8 in high range can be split with the overdrive splitter gear All of the eighteen speeds are controlled with one shift lever Built into the shift knob of the lever are a range preselection lever and a splitter control button on the side of the shift knob that control range se lection and gear splits respectively Operation IMPORTANT On 13 speed transmissions the shifter knob has an interlock feature that pre vents the splitter control button from being moved forward when the range preselection lever is down in low range when in high range and the splitter control button is in the forward position the range preselection lever cannot be moved down 1 When operating off road or under adverse condi tions always use low gear when starting to move the vehicle forward When operating on highway with no load or under ideal conditions use 1st gear when start ing to move the vehicle forward For all co
293. nt in the hydraulic tilt sys tem pump operation will seem spongy or inef fective If this happens bleed the air from the system For instructions see Group 60 of the Century Class Trucks Workshop Manual Make sure the safety stop is engaged on the right tilt cylinder rod If the safety stop isn t engaged and the cab should drop the result could be seri ous injury or death 9 When the cab reaches a 30 degree angle stop working the pump Engage the safety stop on the right tilt cylinder rod See Fig 3 23 The safety stop prevents the cab from accidently dropping below this position IMPORTANT If the cab stops moving while it is being raised don t force it to move with the tilt pump The velocity fuses have locked up the tilt cylinders To unlock them see Hydraulic Lockup 3 16 Vehicle Access 10 19 94 310441 Fig 3 22 Indicator Pin 04 15 93 1310357a 1 Tilt Cylinder Rod 2 Safety Stop Fig 3 23 Safety Stop Engaged 10 To tilt the cab all the way continue working the pump until the cab nears a 45 degree angle the balance point Reduce pumping speed Once the cab goes beyond 45 degrees stop working the pump The cab will gently descend to a full tilt position To slow cab descent reverse the tilt pump lever after the cab passes the balance point IMPORTANT If the cab stops after it has gone beyond 45 degrees don t force it down with the tilt pump The velocity fuses
294. nter the locked position When the slide re lease pull handle returns to the fully locked position visually and physically check the locking wedges to make sure they are fully inserted into the slots in the slide rails Make sure the slide release pull handle is locked in position against the guide plate 10 15 The amount of load distribution on the front steering axle and rear drive axle s will have a direct effect on the steering control of the vehicle Determine the front and rear axle weights by weighing the vehicle on scales designed for this purpose 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 instances should the axle load exceed the maximum axle weight rat ing given on the FMVSS or CMVSS label A WARNING Adjust the fifth wheel slide correctly and do not overload any tractor axle by incorrectly loading the trailer Incorrect slide adjustment or improper axle loading could cause erratic steering and loss of vehicle control possibly resulting in seri ous personal injury or death Fifth Wheel Lubrication A WARNING Keep the fifth wheel plate lubricated to prevent binding between the tractor and trailer A binding fifth wheel could cause erratic
295. nter typical EPA07 Compliant Move from screen to screen while the vehicle is stationary using the general keys left right and down arrow keys tion of the SET RESET key Program on screen service intervals screen brightness language units of measurement and other display functions using the set func Instruments and Controls Identification 8 coco aan eebe uuum No gogg 2 TION 09 29 2010 1610706b 1 Engine Oil Pressure Gauge 9 Tachometer 2 Engine Coolant Temperature Gauge 10 Speedometer 3 Engine Oil Temperature Gauge 11 Primary Air Pressure Gauge 4 Battery Voltage Gauge 12 Secondary Air Pressure Gauge 5 Turbo Boost Air Pressure Gauge 13 Fuel Level Gauge 6 Pyrometer 14 Transmission Fluid Temperature Gauge 7 Dash Message Center 15 Tandem Rear Axle Temperature Gauge Forward 8 Warning and Indicator Lights 16 Tandem Rear Axle Temperature Gauge Rear Fig 2 25 ICUAM ICUAM 2 Instrument Cluster typical Buzzer and Chime SET Co PURG Bl BES me neser EVENT The buzzer sounds for three seconds during the self test at start up and when the following conditions Neate SIGNORA NOTI PP eet ie Spee eee ty exist Dedicated Keys General Keys Control Keys 10 17 2006 16010092 low air pressure low oil pressure Fig 2 26 10 Key Keypad
296. ntil the Message Information screen appears 4 Press the right arrow key until the Send Mes sage Information screen appears 5 Press the down arrow key until the first choice message appears 6 Press the down arrow key again to scroll through the choices The five programmable messages appear first the next five messages are the fixed messages The fixed messages are Message Received Destination Confirmed Please Provide Return Load Please Provide Directions e Send Help 7 Once the correct message appears to send it press the Set Reset key When the message has been sent the display will revert to the Send Message Information screen 8 To return to the default screen press the left arrow key as necessary Instruments and Controls Identification AMT Display The ICU2M replaces the gauge display on vehicles built with Eaton AutoShift or Meritor SureShift trans missions and Freightliner SmartShift column mounted shifter The ICU receives information from the Trans mission Control Unit TCU and displays it in the last three positions in the bottom right corner of the ICU The two right hand positions are dedicated to alpha numeric characters N for neutral R for Reverse and 1 through 10 or 18 depending on the transmission configuration The left hand position is for the up down arrow When a solid non blinking indication is present in the right position s it indicates whi
297. nual Instruments and Controls Identification BN Pitti ee Pid a i EEEEEEN ununu i ANC Controller NoRESPONSE190s254 07 07 29 97 1601413 Fig 2 48 ICU2M Roll Call Fault Code and Message ICU2M Odometer The ICU2M odometer is a seven digit display with one decimal point after the sixth digit allowing it to display tenths of miles or kilometers When first installed the odometer starts at 0 0 miles or kilometers When replaced the odometer does not start with the engine miles but starts again from 0 0 and cannot be changed up or down IMPORTANT Although the odometer uses data supplied by the engine ECM to update its count it keeps its own mileage starting from the zero point which marks where it was first installed Alert Screens Alert screens come on whenever the condition oc curs They appear when the vehicle is moving they override the regular screen display They are warn ings cautions or other messages that require the driver s attention but not all of them are critical to the operation of the vehicle Warning messages always display at full brightness More important messages take priority over less im portant messages The order of importance or prior ity is 1 Eaton VORAD warnings if so equipped 2 Parking Brake On with the vehicle moving 3 Low Oil Pressure High Coolant Temperature Low Coolant Level and Low Voltage Alternate Speed
298. nufacturer whether the vehicle is idling or in motion The word Warning flashes on the message display screen above the message Low Oil Pressure To dismiss the message press any key on the keypad NOTE If there is more than one alert message to display pressing any key takes you to the next message and so on until all the messages have been received If low oil pressure is detected during the ignition se quence it displays as an active fault and the alert Screen does not appear After 30 seconds this message displays again and can be dismissed as before by pressing any key Low Coolant Level Screen This warning message and alarm tone activate whenever the coolant level falls below a preset point The word Warning flashes on the message display screen above the message Low Coolant Level This message follows the same rules of dismissal and display as Low Oil Pressure High Coolant Temp Screen This message and alarm tone come on whenever the engine coolant temperature exceeds a preset point specified by the engine manufacturer see the engine manual for this temperature The word Warning flashes on the message display screen above the message High Coolant Temp This message follows the same rules of dismissal and display as Low Oil Pressure Low Voltage Screen On some vehicles this message and alarm tone come on whenever a low voltage condition is de tected by the instrumentation control un
299. o add them to axle lubricants A CAUTION Tire sizes on both rear wheels should be the same on axles equipped with a traction equalizer If not excessive wear may occur in the traction equalizer Meritor Drive Axles with Main Differential Lock The Meritor main differential lock is a driver controlled traction device operated from the vehicle cab A switch allows the driver to lock or unlock the differential An indicator light comes on when the dif ferential lock is engaged An optional buzzer can also be used to indicate differential lock engagement The main differential lock provides maximum traction under slippery conditions When the differential lock is engaged the clutch collar completely locks the differential 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 9 1 Be especially careful when driving under slippery conditions with the differential locked Though forward traction is improved the vehicle can still slip sideways causing possible loss of vehicle control personal injury and property damage Meritor Main Differential Lock Operation To lock the main differential and obtain maximum traction under slippery conditions move the control switch to the lock position A WARNING Lock the main differential only when th
300. of the clutch pedal is needed Do not push the clutch pedal all the way to the floor and engage the clutch brake instead partially depress the clutch pedal and move the shift lever into neu tral 4 Release the clutch and allow the engine to de celerate until the road speed and the engine rpm match 5 Partially depress the clutch pedal and move the shift lever into first gear 6 Double clutch and continue upshifting until you reach the top gear in the low range 4th gear in 8 14 Transmissions A B C Hi 7 i 5 1 8 Hi 6 8 y RJ G 3 Ms Xp 4 kb 2 4 1 N f N N j e 6 W AFN EN LOW Co Xa Low Xe ey 47 G 2 03 13 96 12601562 A All RM and RMX Transmissions B All RMO Transmissions C All RMX R Transmissions 1 High Range 2 Low Range Fig 8 11 Meritor 9 Speed RM RMO and RMX Model Transmissions Shift Patterns E 10 Double clutch to continue upshifting n T 4 2 R 7 1 Meritor Shift Progressions c TRANS LOW RANGE HIGH N i N MODEL Off Highway On Highway RANGE Y 9 Speed mic a SiON et D Direct or aa mae See NS a ves 4 6 8 10 6 8 9 Overdrive 1AA AT 4 i 1 7 X3 V 5 1 7 3 4 RM or LOW g 8 4 R MX 1260322 1260321 260320 03 13 96 f260155a A AEN EV A All RM and RMX Transmissions 9 Speed pha RR dui B All RMO Transmissions Direct Cane uae ET C High Range RMX R 14 X37 14 X37 9 D Low Range 260325 260325 260326 5 8 Fig 8 12
301. of day and the red lamp will go out 2 4 To set the alarm depress the alarm On push button Observe that a red dot on the right side of the time of day readout is illuminated The alarm is now set and when the displayed time of day coincides with the alarm time the alarm will sound 2 5 To cancel or shut off the alarm depress the alarm On push button again The red dot on the face of the clock will go out Exterior Switches Battery Disconnect Switch A battery disconnect switch Fig 2 68 cuts off all battery power to the vehicle The switch is used whenever service operations require that the batter ies be disconnected It is also used whenever the vehicle is placed out of service for extended periods to prevent battery discharge 2 58 Instruments and Controls Identification 04 15 98 1542521 1 Disconnect Switch Fig 2 68 Battery Disconnect Switch 2 59 Vehicle Access Ignition and Lock Key 54b ry RR A RENE DRAK RR ER wuld bos brine ERG ERST 3 1 Gab Door Locks and Handles i ccaceentdceeeeedsg REOS ATE SR dei de basa qas ps 3 1 COD ACCESS MR MMC 3 1 DSor WIBHONS estilo kd AR DURS RACER dE Up ER RES CONROE He ee OS DORE PERE D CEOS 3 12 Sleeper Compartment Vents isleseseseseeseeeeee m mun 3 12 Circuit Breaker Relay Panel ioc0 24660565 EE S nuteka mit COTRA S E TERR BEEE AER RN T PPS 3 12 Cab to Sleeper Access isses xke RR EFL RE eee SEE eek es wes dees we Seed K E REEE 3 12 Sleeper B
302. ol unit ECU e Sounds the horn in pulses of 0 5 second on 0 5 second off Flashes the cab marker lights in pulses of 0 5 second on 0 5 second off Changes the blink rate of the LED from slow to fast If the UNLOCK button is pressed the ECM disarms the system if armed It unlocks all the entry points discontinues its monitoring of the entry points in structs the relay module to stop flashing the system LED and restores ignition power to the engine if in terrupted If the ALERT button is pressed the ECM executes the unlock sequence and also activates the vehicle alarm functions see above To cancel an ALERT to turn off the alarm press the UNLOCK button Once activated the alarm sequence continues for 30 seconds unless deactivated by pressing the UN LOCK button on the fob After 30 seconds in the alarmed state the system automatically enters the violated state In the violated state the horn does not sound and the cab marker lights do not flash but the engine is Vehicle Access still immobilized and the LED continues to blink at the fast rate The vehicle remains in this state until the UNLOCK button is pressed Fob Programming The security system ECM can store up to four fob identification codes Once the first fob has been pro grammed there are never any vacant memory loca tions IMPORTANT As a security measure all fobs must be coded during the same programming sequence The first fob
303. om gear of the high range shift pattern and ready for the next downshift push the range preselection lever down into low range Double clutch through neutral and shift into the top gear of the low range shift pattern As the shift lever passes through neutral the transmis sion will automatically shift from high range to low range 3 With the transmission in low range downshift through the low range gears as conditions re quire Never use the clutch brake when downshifting or as a brake to slow the vehicle Meritor Range Shift Models General Information 9 Speed RM RMO and RMX Models Meritor RM9 115A RM9 125A RM9 135A RM9 145A RM9 155A RMO9 115B RMO9 125A B RMO9 135A B RMO9 145A B RMX9 115B RMX9 125A B RMX9 135A B RMX9 145A B RMX9 155B RMX9 115R RMX9 125R RMX9 135R and RMX9 145H transmissions have a 5 speed front section and a 2 speed auxiliary sec tion The low gear in the front sections of the A and B ratio transmissions is used only as a starting ratio The high gear in the front section of the R ratio transmissions is used only as the top gear The remaining gear positions of the above transmissions are used once in the low range and once in the high range See Fig 8 11 for the shift patterns noting that the 3rd 7th and 4th 8th shift positions in the RM and RMX direct ratio are opposite of the RMO over drive ratio transmissions The RMX R ratio transmis sions have the 1st 5th shift p
304. om the trailer Fifth Wheel Slide Operation 1 Connect the trailer kingpin to the tractor fifth wheel For instructions refer to Fontaine Fifth Wheel Locking Operation in this chapter 2 After positive lockup of the fifth wheel lock mechanism has been accomplished release the slide using one of the following methods 2 1 For air operated release models set the cab operated control switch Fig 10 6 to UNLOCK 2 2 For manual release models lift the slide release pull handle to disengage it from the guide plate Then pull out the handle Fig 10 17 until it is in the unlocked posi tion and can be positioned against the guide plate to hold it out The slide re lease pull handle will stay in the unlocked position until it is manually disengaged from the guide plate 05 19 94 1310050 Fig 10 17 Fontaine Sliding Fifth Wheel Manual Release 3 Lower the trailer landing gear just enough to re move the weight from the tractor 4 Pullthe trailer air supply valve to cut off the air supply to the trailer A WARNING Do not use the trailer air supply for parking trail ers not equipped with spring parking brakes This applies the trailer service brakes only As air bleeds from the trailer brake system brake appli cation is lost This could allow the unattended vehicle to roll away possibly resulting in serious personal injury or death 5 Chock the front and rear of the trailer tires to prevent the traile
305. ometer Recirc Mode Engaged and Provide Fresh Air Low Fuel Level Turn Signal On Incoming instant or Qualcomm messages 9 599 S3 COS gr de Service warnings 10 No Datalink Activity Incoming Message Screen On vehicles with an onboard communications system like Truckweb or Qualcomm this screen activates whenever a message is received Incoming Mes sage appears on the message display screen NOTE The Incoming Message screen also displays during the ignition sequence if a mes sage is available This message displays for a preset time period and then disappears It returns after the preset interval until it is dismissed by pressing any key on the key pad Parking Brake On Screen This warning message and alarm tone come on whenever the parking brake is applied and the ve hicle is moving faster than 2 5 miles per hour or the clutch has been depressed The word Warning flashes on the message display screen above the message Parking Brake On The screen and alarm tone go away only when the parking brake is re leased See Fig 2 49 WARNING PARK BRAKE ON 06 21 2007 601414 Fig 2 49 Parking Brake On Screen The Parking Brake On screen overrides any other screen message 2 34 Instruments and Controls Identification Low Oil Pressure Screen This warning message and alarm tone come on whenever the oil pressure falls below the minimum oil pressure specified by the engine ma
306. on When the tractor is towing a trailer the rear brake chambers will receive full normal appli cation air pressure NOTE If equipped with main and auxiliary transmissions do not shift both transmissions into neutral while the vehicle is rolling Shifting both transmissions back into gear would be diffi cult while the vehicle is rolling The trailer brake hand control valve Fig 6 2 actu ates the trailer service brakes independently from the vehicle chassis service brakes The valve can be partially or fully applied but in any partially on posi tion it will be overridden by a full application of the foot brake control pedal Moving the valve handle clockwise actuates the trailer brakes while moving it counterclockwise releases the trailer brakes The valve handle is spring loaded and returns to it s origi nal no air application position when released 6 2 Steering and Brake Systems 9 26 95 f461056 1 Turn Signal Lever 2 Trailer Brake Hand Control Valve 3 Hazard Warning Light Tab Fig 6 2 Steering Column Mounted Controls Do not use the trailer service brakes for parking they are not designed for this purpose If air bleeds out of the trailer air tank during parking the vehicle could roll causing serious personal injury or property damage The red octagonal shaped knob Fig 6 3 in the con trol panel actuates the trailer air supply valve After the vehicle s air hoses are connected to a trailer a
307. on If any of the gauge bulbs the dome light bulbs or the right and left turn indicator bulbs are not working replace them Pretrip Inspection and Daily Maintenance 18 Make sure all the exterior lights are working properly Check that all the lights and reflectors are clean See Fig 11 6 04 09 98 1601640 Identification Lights Road Light Headlight and Daytime Running Light Turn Signal and Side Marker Light Marker Light o ROom Fig 11 6 Exterior Lights 18 1 Check that the brake lights taillights headlights parking lights turn signals marker lights identification lights road lights if so equipped and front clearance lights are working properly and are clean 18 2 Test the high and low beams of the head lights 18 3 Replace light bulbs or sealed beam units that are not working 18 4 Be sure all reflectors and lenses are in good condition and are clean Replace any broken reflectors or lenses 19 Check tire inflation pressures using an accurate tire pressure gauge Tires should be checked when cool For inflation pressures and maximum loads per tire see the tire manufacturer s guidelines A weekly pressure loss of 4 psi 28 kPa or more in a tire may indicate damage The tire should be inspected and if necessary repaired or replaced 19 1 Be sure valve stem caps are on every tire and that they are screwed on finger tight 19 2 Inflate the tires to the applicable press
308. on Warning System CWS is intended solely as an aid for an alert and conscientious professional driver It is not intended to be used or relied on to operate a vehicle Use the system in conjunction with rear view mirrors and other instrumentation to safely operate the vehicle Operate this vehicle equipped with the EVT 300 Collision Warning System in the same safe manner as if the EVT 300 Collision Warning System were not present The EVT 300 Collision Warning System is not a substitute for safe normal driving procedures nor will it compensate for any driver impairment such as drugs alcohol or fatigue Instruments and Controls Identification The EVT 300 Collision Warning System may pro vide little or no warning of hazards such as pe destrians animals oncoming vehicles or cross traffic On vehicles with SmartCruise the vehicle will not deactivate cruise control for stationary targets such as a car stopped in your traveling lane Failure to drive safely and use the system prop erly could result in personal injury and or death and severe property damage Dash Switches The following dash switches Fig 2 60 are used to control the collision warning system and Smart Cruise Headway Alert HDWY ALERT This switch turns on the collision warning system On most Systems the collision warning system will turn on automatically when the ignition is turned on The switch is backlit by a green light that indi
309. on to keep the chains from damaging the vehicle frame chain the forward rear drive axle to the frame 4 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 5 Lift the vehicle and secure the safety chains If extra clearance is needed remove the bumper extension if equipped 6 Connect the clearance lights taillights and sig nal lights Also connect any special towing lights required by local regulations 13 2 In an Emergency QS Sa ee S Su o 01 11 2006 IMPORTANT Do not reeve when towing 1 Tow Hook L ud 2 Chain ok rS XD MAE VH S5 ESSE E H AA AS 1880694 Fig 13 2 Reeving Emergency Starting with Jumper Cables When using jumper cables follow the instructions below Batteries release explosive gas Do not smoke when working around batteries Put out all flames and remove all sources of sparks or intense heat in the vicinity of the battery Do not allow the ve hicles to touch each other Do not lean over the batteries when making connections and keep all other persons away from the batteries Failure to follow these precautions could lead to severe personal injury as a result of an explosion or acid burns CAUTION Make sure both starting sys
310. one hand and two feet or two hands and one foot Do not lean out away from the cab Do not engage in horseplay Do not enter the cab with dirty or greasy hands or feet Disregarding this careful step by step procedure can result in your falling from the cab and pos sible personal injury or death IMPORTANT Do not attempt to exit the cab while carrying any items in your hands 1 Grasp the upper inside grab handle Fig 3 10 and stand in the threshold of the door facing into the cab 2 With your left hand grasp the forward grab handle 3 Move your left foot very carefully to the top step 4 Move your right hand to the lower inside grab handle and grip it tightly 5 Move your right foot to the next step 6 Maintaining three point contact with the cab at all times very carefully move your right hand to the forward grab handle Then move your left hand to the aft grab handle 7 Move your left foot to the bottom step 8 Step to the ground with your right foot 9 Let go of the grab handles 3 6 Vehicle Access Entering the Driver s Side Using the Cab Access Stairs for Right Hand Drive Vehicles Fig 3 11 If the optional cab access stairs do not move into position or if there is not enough room for them to deploy use the fixed steps on the outside sur face of the moving stairs Fig 3 5 and follow the access instructions for the standard fixed step system Freightliner recommends you practice using the
311. ons Fuller Shift Progressions TRANS LOW RANGE HIGH MODEL Off Highway On Highway RANGE 55 7 R R R 8 Speed 1 234 17 237 k TE Direct UA nS ACH RT 2 4 2 4 1260321 1260321 260320 9 Speed EUR 55 7 R R Direct or A Piera RS Overdrive LAA QUNM O RT or LOW aa ANAT AN RTX 1260322 1260323 260324 PES 85 8 R R R 9 Speed ye co yh V e Hen Direct e LIRE gt RTX P 1 3 1 3 Y 1260325 1260325 260326 5 8 R R R 9 Speed pine HM 7 ry Overdrive oa EC Fk deem RTO LOW Ca C3 LOW Ca 7 3 n ws 1260327 1260327 1260328 10 Speed A S l R R R Direct or Sa 4 wt SBD ND Ye ye Overdrive Se NT AA eek T 6 8 10 RT or VOUS Vos o NL NA RTX 1260329 1260329 260330 ATA R R 10 Speed SI 225 b pw ae Overdrive EE E 64 Bed RTO JD 374 Wd 34 1260331 1260331 1260332 Table 8 1 Fuller Shift Progressions 2 When in the bottom gear of the high range shift pattern and ready for the next downshift push the range preselection lever down into low range Double clutch through neutral and shift into the top gear of the low range shift pattern As the shift lever passes through neutral the transmis sion will automatically shift from high range to low range 3 With the transmission in low range downshift through the low range gears as conditions re quire Never use the clutch brake when downshifting or as a brake to slow the vehicle Fuller Splitter and Range Shift Models G
312. ontinue with the normal cruise control functions The driver may override the system at any time and the system will relinquish control anytime the clutch or service brake pedals have been pressed or the fuel pedal is pressed to accelerate the vehicle If the vehicle speed drops below 30 mph 48 km h minimum cruise set speed the engine will change from cruise control to throttle control The message WARNING CRUISE OFF will display in the ICU The message will not display if the brake clutch or panel switches were used to deactivate cruise con trol IMPORTANT If SmartCruise is not functioning due to a failure conventional cruise control can be used instead To enable conventional cruise control toggle the headway control HDWY CNTL switch twice within 10 seconds Toggling of the switch twice only activates con ventional cruise control after SmartCruise has failed Accident Reconstruction The EVT 300 system has a continuously operating memory segment that records target and vehicle data for the purpose of reconstructing an accident The memory will record as much data as possible When the memory is full the earliest information is recorded over To activate the accident reconstruction and freeze the most recent action in memory hold the volume adjustment switch HDWY VOL and headway adjustment switch HDWY up simultaneously for five seconds The ICU will confirm that the data was saved with an audible
313. or details 2 1 Instruments and Controls Identification Warning and Indicator Lights Indicates a problem with the ABS is detected Repair the Tractor ABS amber tractor ABS immediately to ensure full antilock braking capability Trailer ABS Lamp amber Indicates a fault is detected with the trailer ABS Flashes on and off whenever the outside turn signal lights Left Turn Signal green are flashing Flashes on and off whenever the outside turn signal lights Right Turn Signal green are flashing High Beam Indicator blue Indicates the headlights are on high beam Activates with a buzzer when air pressure in the primary or Low Air Pressure Warning red secondary air reservoir falls below 64 to 76 psi 440 to 525 kPa Activates with a buzzer when the coolant temperature goes above a maximum level specified by the engine manufacturer see the engine manual High Coolant Temperature Warning red Activates with a buzzer when engine oil pressure goes below a minimum level specified by the engine manufacturer see the engine manual Low Engine Oil Pressure Warning red Indicates the parking brake is engaged or hydraulic brake fluid pressure is low A buzzer activates when the vehicle is moving over 2 mph 3 km h with the parking brake set Parking Emergency Brake BRAKE red Illuminates for 15 seconds when the ignition key is turned to Fasten Seat Belt red the ON po
314. or location of the fifth wheel along the baseplate Retractable spring actuated lockpins are positioned through the slots to 10 6 Fifth Wheels and Trailer Couplings hold the fifth wheel in the desired position The lock pins are retracted either manually or by an air operated cylinder controlled from the cab The manually operated slide contains an operating rod Fig 10 9 which unlocks both sides of the plate at the same time The air operated sliding saddle plate contains an air cylinder which moves the operating lever to unlock both sides of the plate at the same time The air cyl inder is activated by a two position air control valve in the tractor cab Fifth Wheel Lock Mechanism for Trailer Kingpin Fig 10 10 04 08 96 1310446 A Locked Position B Jaw movement compresses spring C Fully open 1 Operating Lever 4 Jaw Eccentric Pin 2 Safety Latch 5 Lock 3 Jaw 6 Spring Fig 10 10 ASF Castloc Il and Simplex Series Kingpin Locking Mechanism Operation The Castloc Il and Simplex Series fifth wheel lock mechanism consists of a rotating jaw and a spring actuated lock that grips the trailer kingpin The jaw rotates on an eccentric pin during coupling and un coupling operations The spring actuated lock holds the jaw in the locked position once kingpin lockup has occurred 10 7 In the locked position there is approximately 1 16 inch 1 6 mm clearance between the jaw and king pin T
315. ositions where low is in the A and B ratio transmissions The top gear in the RMX R ratio transmissions is called 9th gear 10 Speed RM and RMX Models Meritor RM10 115A RM10 125A RM10 135A RM10 145A RMX10 115A RMX10 125A RMX10 135A RMX10 145A RMX10 155A and RMX10 165A transmissions have ten evenly spaced forward ratios Each transmission consists of a 5 speed front section and a 2 speed auxiliary section The ten for ward speeds are obtained by twice using a 5 speed shift pattern the first time in low range the second time in high range See Fig 8 12 for the shift pattern Operation Reverse To drive in reverse push the range selector lever down to put the transmission in the low range Push the clutch pedal to the bottom of travel so the clutch brake slows the transmission for initial gear engage ment Holding the clutch pedal at the bottom of travel shift into reverse Slowly release the clutch pedal to move the vehicle in reverse Upshifting 1 To drive forward make sure the vehicle is com pletely stopped and the range selector lever is pushed down to put the transmission in the low range Push the clutch pedal to the bottom of travel so the clutch brake slows the transmission for initial gear engagement holding the clutch pedal at the bottom of travel shift into low 2 Slowly release the clutch pedal to begin moving the vehicle forward 3 To upshift into 1st gear only partial depression
316. ouble clutch when making lever shifts 4th to 3rd 3rd to 2nd etc Fuller Deep Reduction and Range Shift Models General Information 10 Speed RT RTO and RTX Models Fuller RT 7608LL RT 8908LL RTO 11708LL RTO 11908LL RTO 14708LL RTO 14908LL RTX 11708LL and RTX 14708LL transmissions have a 5 speed front section and a 2 speed rear range sec tion with a deep reduction gear The low low deep reduction gear is used only when operating under adverse conditions Low gear in the front section is used only for rough off highway conditions as a starting ratio The remaining four forward positions are used once in the low range and once in the high range See Fig 8 9 for the shift pattern noting that 8 11 the 3rd 7th and 4th 8th shift positions in the RT and RTX LL transmissions are opposite of the RTO LL transmissions o gt oo 5 7 o H R SDR on ga4 0O LOW SLOW E LOW LOW LOW N 0 Z o w N 6 2 on 8 4 E gt F 03 13 96 All RTO Transmissions All RT and RTX Transmissions High Range Low Range Deep Reduction IN forward Deep Reduction OUT rearward Deep Reduction Button Fig 8 9 Fuller 10 Speed RT RTO and RTX Model Transmissions Shift Patterns 15 Speed RT RTO and RTX Models Fuller RT 14715 RT 14915B RT 15715 RTO 14715 RTO 14915B RTO 15715 RTO 16915B RTX 14715 and RTX 15715 transmissions have a 5 speed front section and a 2 sp
317. ound and lights illuminate be cause of an object off the road directly in line with your vehicle This will not occur when the brakes are applied Elevated obstacles such as overpasses and overhead signs may be detected when ap proaching a roadway descending to a lower elevation Vehicles cannot be detected on the other side of a hill An alarm will not sound until the object is within the antenna assembly field of view On approaching a steep hill objects above the beam cannot be detected Generally the beam hitting the road surface does not cause an alarm The side sensor only detects objects within its field of view next to the tractor A vehicle far ther back behind the field of view will not be detected The side sensor range is set to detect average sized vehicles 2 to 10 feet 0 5 to 3 meters away in the adjacent lane The radar beam of the CWS will detect near range cut ins of approximately 30 feet 9 meters or less depending on the angle of en trance into the lane in front of your vehicle Heavy rain or water spray at the side sensor may cause both the yellow and red lights on the side sensor display to illuminate at the same time Under these conditions the system is temporarily unable to provide adequate warnings Failure to drive safely and use the system prop erly could result in personal injury and or death and severe property damage NOTE A continuous fixed object on the right side of
318. ow the steps as follows 1 Leave the door open and exit the cab from the opposite side 2 Place a hand on the exterior surface of the step then apply light pressure to the step and close the door 3 If the step stows press the yellow disable button next to the grab handle This will disable the step for one deploy and stow cycle 4 fthe steps will not fully stow follow the instruc tions on the inside of the baggage door to safely stow the steps Exterior Cab Grab Handles and Fixed Access Steps Entering the Driver s Side Fig 3 5 1 Open the driver s door and place anything that you are carrying in the cab 2 Grasp the aft grab handle with your right hand and grab the forward grab handle with your left hand Reach up as far as you re comfortable 3 Place your right foot on the bottom step and carefully pull yourself up Slowly place your left foot on the next step Place your right foot on the top step 6 Grasp the steering wheel with your left hand and step up into the cab Exiting the Driver s Side Fig 3 5 IMPORTANT Do not attempt to exit the cab while carrying any items in your hands 1 Grasp the steering wheel tightly with both hands and stand on the door threshold facing into the cab 2 With your right hand grasp the forward grab handle at the aft edge of the door Move your right foot to the top step Move your left hand to the forward grab handle Then move your right hand to the a
319. p Inspection and Daily Maintenance 10 11 2005 A Q9 OIN 1421397 Rotate the control arm toward the brake chamber until you can feel it contacting the internal stop Clevis 6 Control Arm Washers Slack Adjuster and Nut Clevis Pin 7 Anchor Strap Slot Manual Adjusting Nut 8 Anchor Strap Control Arm 9 Brake Chamber If leakage exceeds the limits shown in Table 11 4 repair all areas of leakage be fore driving the vehicle Maximum Allowable Service Brake Air Leakage 25 4 11 13 Fig 11 13 Haldex Automatic Slack Adjuster drop If it drops more than 25 psi 172 kPa all areas of leakage must be elimi nated before operating the vehicle Check the air leakage in the system as follows With the parking brake spring brake ap plied the transmission out of gear and the tires chocked charge the air system until cut out pressure of 120 psi 827 kPa is reached With the service brakes released shut down the engine wait one minute and note the air pressure gauge reading Ob serve the air pressure drop in psi kPa per minute Charge the air system until cut out pres sure of 120 psi 827 kPa is reached With the parking brakes released and the ser vice 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 Air Leakage in psi Description kPa Per Minute
320. p bracket if equipped The shoulder strap must be centered on your shoulder and chest away from your face and neck See Fig 5 8 6 To unbuckle the three point seat belt press the release button on the buckle see Fig 5 11 NOTE Make sure the three point seat belt is completely retracted when it is not in use Sleeper Compartment Restraints General Information On vehicles equipped with a sleeper compartment bunk restraints should be used whenever the sleeper compartment is occupied and the vehicle is moving Restraints are designed to lessen the chance of in jury or the amount of injury resulting from accidents or sudden stops For this reason Daimler Trucks North America LLC urges the use of bunk restraints when the sleeper compartment is occupied in a mov ing vehicle Do not use the sleeper compartment while the vehicle is in motion unless a bunk restraint is installed and used Not using the bunk restraint increases the chance of injury or the degree of injury from accidents or sudden stops to all oc cupants of the vehicle Bunk Restraint Adjustment 1 Make sure the belt is attached to the bunk sup port and sleeper wall 2 To lengthen the belt tip the link end downward and pull the link until it connects with the buckle 3 After the belt is connected shorten it by pulling on the loose end until the belt is snug but com fortable Be sure the belts are not twisted See Fig 5 12 2 Fd A
321. pattern and ready for the next downshift push the range selection lever down into low range Double clutch through neutral and shift into the top gear of the low range shift pattern As the shift lever passes through neutral the transmis sion will automatically shift from high range to low range 3 With the transmission in low range downshift through the low range gears as conditions re quire Never fully depress the clutch pedal to use the clutch brake when downshifting or as a brake to slow the vehicle Meritor Splitter and Range Shift Models General Information 13 Speed RMO Models The Meritor RMO13 145A transmission has thirteen forward speeds and two reverse speeds Each trans mission consists of a 5 speed front section and a 3 speed auxiliary section The auxiliary section con tains low and high range ratios plus an overdrive splitter gear See Fig 8 13 Hi 55 777 1 R Dir OD Dir OD N Lo 1 7 lt 3 ENTS A S N Y A B oy N 6 6 8 8 X LOW Dir OD Dir OD x 2 4 D 03 13 96 1260154a A High Range C Overdrive B Low Range D Direct Drive 1 Splitter Control Button Fig 8 13 Meritor 13 Speed RMO Model Transmission Shift Pattern All of the thirteen speeds are controlled with one shift lever Built into the shift knob of the lever are a range selection lever and a splitter control button on the side of the shift knob that control range selec tion and gear splits res
322. pectively Low gear in the front section is used only as a start ing ratio The remaining four forward positions are used once in the low range and once in the high range However each of the four high range gear positions can be split with the overdrive ratio of the splitter gear Ratios cannot be split while the trans mission is in low range Operation IMPORTANT The shifter knob has an interlock feature that prevents the splitter control button from being moved up when the range selection lever is down in the low range when the trans mission is in the high range and the splitter control button is up the range selection lever cannot be moved down Reverse To drive in reverse push the range selector lever down to put the transmission in the low range Push the clutch pedal to the bottom of travel so the clutch brake slows the transmission for initial gear engage ment holding the clutch pedal at the bottom of travel shift into reverse Slowly release the clutch pedal to move the vehicle in reverse Upshifting 1 To drive forward make sure the vehicle is com pletely stopped and the range selector lever is pushed down to put the transmission in the low range Push the clutch pedal to the bottom of travel so the clutch brake slows the transmission for initial gear engagement holding the clutch pedal at the bottom of travel shift into low 2 Slowly release the clutch pedal to begin moving the vehicle forward
323. pedal have the clutch adjusted Operating the vehicle with incorrect free pedal could result in clutch damage Clutch brake squeeze is an increased resistance greater than the force of the clutch spring felt as the clutch pedal approaches the end of its stroke If the gears grind when shifting into first or reverse gear with the clutch pedal fully depressed the clutch is out of adjustment or the clutch brake is worn and needs to be replaced Clutch Adjustments Clutches have an internal adjustment and external linkage adjustment Refer to Group 25 in the Century Class Trucks Workshop Manual for clutch adjustment procedures and specifications NOTICE Operating the vehicle with the clutch improperly adjusted could result in clutch or clutch brake failure 7 29 02 09 96 A Free Pedal 1250306 Fig 7 16 Clutch Free Pedal Lubrication On vehicles equipped with a greaseable release bearing the release bearing and linkage should be lubricated at frequent intervals Refer to Group 25 in the Century Class Trucks Maintenance Manual for intervals and procedures NOTICE Failure to lubricate the release bearing and link age as recommended could result in release bearing and clutch damage Transmissions Freightliner SmartShift Transmission Shift Control 0 00 c cece eee ee eee eee 8 1 Fullar Straight SMIE MOUGIS 24 o Rauch CERE RE ienee tee Cowes TAS PER RET REPSU PLE 8 5 Fuller Range Shi
324. peed under these conditions Using the engine brake as a primary braking sys tem when the service brakes are operable is dan gerous This can cause long unpredictable stop ping distances possibly resulting in personal injury or property damage Whenever vehicle braking is required the engine brake may be used with the service brakes There is no time limit for operation of the engine brake 1 After the engine is warmed up and the vehicle is in motion move the paddle switch to the desired position LO or HI Depending on the engine model LO will provide 1 3 or 1 2 of the full brak ing capacity of the engine HI will provide maxi mum engine braking 2 The engine brake activates when the dash switch is in LO or HI position and the driver s feet are removed from both the clutch and throttle pedals If it fails to activate take the ve hicle to an authorized Freightliner dealer for ser vice 3 To obtain maximum retarding maintain the top governed speed of the engine through appropri ate selection of gears when the engine brake is in use 4 When either the clutch or throttle pedal is de pressed the engine brake is deactivated NOTICE If the engine brake fails to shut off when either the throttle or clutch pedal is depressed place the dash switch in the OFF position and do not use the engine brake until the throttle or clutch switch system is repaired If the engine brake fails to shut off when the dash switch is
325. pin enters the throat of the locking mechanism Continue back ward motion until positive lockup occurs Apply the tractor parking brakes Make a visual and physical check for positive kingpin 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 10 16 This will hold the control handle in the locked position 02 09 95 D f310110a NOTE Make sure the safety latch is down when the control handle is locked A Unlocked 1 Safety Latch B Locked 2 Lock Control Handle Fig 10 16 Fontaine Fifth Wheel Locking and Unlocking 7 Release the tractor parking brakes Test for king pin lockup by pulling on the trailer against the chocks NOTICE Always make sure the connect hanger support keeps the trailer air hoses and electrical cables positioned so that they do not rub on anything Rubbing may wear through hoses or cables re sulting in air leaks or exposed or broken wires 10 13 potentially affecting trailer brake or electrical sys tems 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 material from entering the air system lines 9 Charge the air brake system with air Make sure that the air connections do not leak Eliminate slack between the trailer and the tr
326. press the accelerator pedal all the way and keep it there as the vehicle moves up the grade If the engine continues to maintain a satisfac tory road speed remain in that gear for the entire grade If the hill causes a steady decline in engine rpm downshift as required until the engine can maintain a stable uphill speed Make full use of each gear be fore going to a lower gear By remaining in a gear until arriving at the speed of the next lower gear the vehicle will top the grade in the best possible time on less fuel and fewer shifts Because of their constant torque over a wide speed range Detroit Diesel engines can be operated at full throttle at lower rpm than other engines This offers benefits in fuel economy and engine life And more than likely it will be possible to top most grades with out downshifting When the vehicle starts into a grade allow the en gine to lug down to maximum torque rpm before downshifting Downshift if required at maximum torque rpm also or at the predetermined road speed for the next lower gear Do not be afraid to lug the engine down It has more than enough torque at low rpm to keep a loaded ve hicle moving against a grade and it won t harm the engine The driver who is not familiar with the vehicle s shift points can greatly improve driving skill by learning them for all gears By knowing rather than guessing where the shift points are it is possible to avoid over speeding the engine by
327. psed hoses punc tures and other damage Tighten loose connections and have damaged compo nents replaced Make sure the piping sys tem is airtight so that all intake air passes through the air cleaner 11 5 7 Check the engine oil level If the oil level is at or below the minimum fill or add mark on the dipstick add enough oil to maintain the level between the minimum fill or add and the maximum fill or full marks on the dipstick See Fig 11 3 Engine lube oil must have a sulfated ash level less than 1 0 wt 96 currently referred to as CJ 4 oil Use the proper SAE viscosity rating for the temperature and time of year 2 1 n 05 18 98 l 1500310 1 Dipstick 2 Coolant Fill Cap Fig 11 3 Oil Level Checking CAUTION Operating the engine with the oil level below the minimum fill or add mark or above the maxi mum fill or full mark could result in engine damage 8 Inspect the fuel tanks fuel lines and connections for leaks 8 1 Check that the fuel tanks are secured to their mounting brackets and that the mounting brackets are secured to the frame 8 2 Replace leaking fuel tanks 8 3 If lines or connections are leaking have them repaired or replaced Pretrip Inspection and Daily Maintenance For repair and or replacement procedures see Group 47 of the Century Class Trucks Workshop Manual or take the ve hicle in to an authorized Freightliner dealer 8 4 f equipp
328. pump control lever 2 Two tilt cylinders 3 Tilt strut on the right side tilt cylinder 4 Two hydraulic cab latches On vehicles equipped with an optional electric hydraulic system an electric motor activates the hy draulic tilt pump On vehicles equipped with an op tional air hydraulic system an air motor assembly activates the pump The tilt pump can also be manually operated if necessary The hydraulic cab latches are plumbed into the cab tilt system and open automatically when the cab is tilted When the cab is returned to the operating posi tion latch pins on the underside of the cab engage the latch hooks which lock automatically Spring force keeps the hooks locked An indicator pin on the outboard side of each latch protrudes when the latch is unlocked and recedes when the latch is locked CAUTION Do not use either the telescoping tube assembly or the hydraulic tilt cylinder as a step or hand hold you could damage the transmission tele scoping tube assembly or the tilt cylinder The tilt cylinders lift the cab to a 45 degree angle and from a full tilt position back to 45 degrees See Fig 3 21 The rate of cab descent beyond over center in either direction is controlled by the tilt pump 03 27 98 A Upright or Operating Position B 45 Tilted Position balance position C Full Tilt Position 1000896 Fig 3 21 Cab Tilt Positions A pump handle is located in the baggage
329. r lower back area This adjustment is either mechanical or air con trolled depending on make and model of the seat 3 Isolator This feature also referred to as back slap isolator or Chugger Snubber reduces the amount of road shock by isolating the occupant from the motion of the vehicle and allowing the upper seat to move in a simple pendulum mo tion A lockout feature is used whenever the iso lator is not desired 4 Height Adjustment The entire seat moves up or down when adjusting the height The adjustment is either manually or air controlled depending on the make of the seat 5 Bottom Cushion Angle or Fore and Aft Bottom Cushion Height This feature enables the occu pant to raise or lower the front or back of the 5 1 bottom cushion This adjustment is easier to per form when all weight is removed from the seat 6 Fore and Aft Seat or Seat Track Adjustment The entire seat moves forward or backward when this adjustment is made 7 Seat Tilt When this adjustment is made the seat assembly back and bottom cushions tilts for ward or backward 8 Upper Back Cushion Adjustment When this ad justment is made the upper back cushion changes angle to provide upper back support 9 Weight Adjustment On those seats with weight adjustment the feature is fully automatic When you sit on the seat a leveling valve places you in the center of the ride zone Additional adjust ments are possible by using the h
330. r conditioner controls consist of a four speed fan switch an air selection switch a tempera ture control switch and a fresh air recirculation switch See Fig 2 7 See Chapter 4 for detailed op erating instructions of the heater air conditioner 1 2 3 o cm e e 2 NK 6 N we E n x 4 Sy 5 4 10 26 95 830717 Fan Switch Air Selection Switch Temperature Control Switch Fresh Air Recirculation Switch Auxiliary sleeper bunk Switch OV No Fig 2 7 Heater Air Conditioner Controls Interaxle Differential Lockout Control Valve Switch Differential lockout standard on all dual drive ve hicles is driver actuated by means of a Lock Unlock control valve switch Fig 2 8 mounted on the control panel A red indicator light comes on whenever the interaxle differential is locked out switch is in the lock position no differential action between the drive axles A guard around the switch minimizes accidental activation LOCK UNLOCK INTER AXLE DIFFERENTIAL DO NOT ENGAGE DURING SPIN OUT 09 26 95 1350141 Fig 2 8 Interaxle Differential Lockout Switch Fifth Wheel Air Slide Control Valve Switch The fifth wheel air slide valve permits repositioning of the sliding fifth wheel from inside the cab Moving the air slide control valve switch Fig 2 9 to the lock position deactivates the control valve and locks the fifth wheel to the baseplate Moving the switch to the unlock position
331. r from moving 10 14 Fifth Wheels and Trailer Couplings CAUTION After moving the fifth wheel to the desired posi tion be sure the trailer landing gear will not at any time come in contact with the tractor frame or other components Make sure that the front of the trailer will not come in contact with the rear of the cab or with other components if they ex tend beyond the rear of the cab 6 Slowly move the tractor forward or backward until the fifth wheel is in the desired location 7 Apply the tractor parking brakes NOTE The fifth wheel may have to be moved slightly to enable the locking wedges to enter the fully locked position 8 Lock the sliding member in position using one of the following methods Check to be sure that the lockpins are seated in the holes Failure to achieve complete lockup may cause the trailer to detach from the tractor possibly resulting in serious personal injury or death 8 1 For air operated release models set the cab operated slide control switch to LOCK Visually inspect the locking wedges to make sure that they are fully inserted in the slide rail slots 8 2 For manual release models disengage the slide release pull handle from the guide plate The slide release pull handle is spring loaded in the locked position and will seek the locked position when disen gaged from the guide plate The fifth wheel may have to be moved slightly to enable the locking wedges to fully e
332. r is used make sure it has thermostatic controls 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 start ing the engine Select a gear that allows a smooth easy start with out increasing engine speed above low idle or slip ping the clutch Engage the clutch smoothly Jerky starts waste fuel and put stress on the drivetrain It is not necessary to accelerate Caterpillar electronic engines to governed speed in the lower gears to get the vehicle moving except in a high power demand situation such as starting on a grade Continue to upshift until cruising speed is reached Use only the rpm needed to make an upshift into the next gear The engine speed needed to make an up shift increases as the truck speed increases or if up shifts are made on uphill grades If the truck can be operated in a higher gear after reaching the desired speed select the highest gear available that will pull the load Experience with your truck will show you what rpm is needed to make upshifts under various conditions This progressive shifting technique will lower fuel costs because the engine will be operating at the lowest rpm needed to pull the load Caterpillar electronic engines can be programmed to limit engine rpm while the truck is operated in the lower and higher gears This feature assists the driver in following progressive shifting
333. r rough road or other abnormal conditions Make sure the three point seat belt is completely retracted when it is not in use 5 7 uon Nunc Saar 7 f910049a 01 18 95 Fig 5 11 Releasing the Three Point Seat Belt Three Point Seat Belt NOTE For vehicles equipped with the Komfort Latch see the seat belt operation under the heading Three Point Seat Belt With Komfort Latch A WARNING Wear three point seat belts only as described below Three point seat belts are designed to be worn by one person at a time In case of an acci dent or sudden stop personal injury or death could result from misuse Fasten the seat belts before driving Fastening a three point seat belt while driving creates a haz ard 1 Slowly pull the link end of the three point seat belt out of the retractor and pull it across your lap from outboard to inboard far enough to en gage 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 latch into the buckle Listen for an audible click See Fig 5 7 3 Tug on the seat belt to make sure it is securely fastened If the buckle unlatches repeat this step If the problem continues replace the three point seat belt Seats and Seat Belts 4 Snug the seat belt to your waist 5 Position the shoulder strap diagonally across your chest with the adjustable D loo
334. r sprung rings and rims replaced Be sure that the rim base lockring and side ring are matched according to size and type 21 4 Make sure all wheel nuts are tightened 450 to 500 Ibf ft 610 to 678 N m for Ac curide wheels with unlubricated threads AZ io 02 09 95 1400001 Fig 11 8 Worn Stud Holes 11 9 Pretrip Inspection and Daily Maintenance Use the tightening pattern in Fig 11 9 for 10 hole wheels and the tightening pattern in Fig 11 10 for 8 hole wheels See Group 40 of the Century Class Trucks Workshop Manual for more information ee 8 08 23 93 f400081a Fig 11 9 Tightening Pattern 10 Hole Wheels A 08 20 93 f400052a Fig 11 10 Tightening Pattern 8 Hole Wheels CAUTION Insufficient wheel nut torque can cause wheel shimmy resulting in wheel damage stud break age and extreme tire tread wear Excessive wheel nut torque can break studs damage threads and crack discs in the stud hole area Use the recommended torque values and follow the proper tightening sequence Do not loosen or remove the parking brake clamp ring for any purpose The parking emergency brake section of the brake chamber is not in tended to be serviced Serious injury or death may result from sudden release of the power spring Before doing any repairs or adjustments on a service parking brake chamber read the appli cable warnings and instructions in Group 42 of the
335. rakes to heat and dry them Allow hot brakes to cool before using the spring parking brakes Always chock the tires If the trailer is not equipped with spring parking brakes pulling out the yellow knob applies the tractor spring parking brakes and the trailer service brakes When the tractor and trailer parking brakes or trailer service brakes are both applied the trailer brakes are released by pushing in the red knob leaving the tractor parking brakes applied Air pressure in the primary or secondary reservoir must be at least 65 psi 447 kPa before the tractor spring parking brakes or the trailer service or spring parking brakes can be released On trailers not equipped with spring parking brakes chock the trailer tires before disconnecting the truck or tractor when parking just the trailer When parking a truck or tractor with a trailer combi nation vehicle and the trailer is not equipped with spring parking brakes apply the truck or tractor spring parking brakes If a trailer is not equipped with spring parking brakes do not park it or a combination vehicle by pulling out only the trailer air supply valve knob This would apply only the trailer service brakes If air were to bleed from the trailer brake system the trailer brakes would release possibly causing an unattended runaway vehicle Steering and Brake Systems CAUTION Never apply the service and spring parking brakes simultaneously To do so transm
336. renheit or Celsius by pressing and holding the Mode button until either the F or C is displayed 2 5 Select the temperature set point by press ing either the UP button or the DOWN button as applicable Holding the button will cause the display to count up or down rapidly When the desired set point is dis played release the button The set point is stored in memory 7 27 2 6 Select the temperature comfort zone by pressing the MODE button until the upper and lower temperature limit icon is dis played Then use the UP or DOWN button to select one of the three comfort zones of 4 F 2 C 7 F 4 C or 10 F 6 C To change the display to either Fahrenheit or Celsius press the MODE button until only the F or C icon is flashing Press the UP or DOWN button to change to the desired value The main display will appear five seconds after the button is released 4 To deactivate the thermostat mode and return to just the engine mode press the MODE button and hold it for three seconds 5 To shut down Optimized Idle completely either turn off the ignition or use the drive away feature The drive away feature allows the use of all the DDEC features Use the drive away feature as follows 5 1 If the engine is running release the park ing brakes or put the transmission in gear If the engine is not running start the en gine then release the parking brakes or put the transmission into gear 5 2 Letthe engin
337. ress Right Arrow Key and Set the Parking Brake 100 RPM or more IDLE HOURS 1234 56 S 12 3GAL123456 7MI AMT 7 v TRIP gt lt TRIP MILES 123456 7 D A IDLE HOURS 1234 56 INFORMATION AMT TRIP HR 1234 56 AMT AVG MPH 12 3 AMT V V R R V R lt LEG MILES 123456 7 LEG HR 1234 56 AMT 4 y v 12 01 2004 Go to Fuel Information Screens 1040699 AMT Current gear information for automated manual transmissions NOTE Metric unit screens are similar Fig 2 30 Trip Information Screens From here press the right arrow key again to return tive fault code on display push the left arrow key to to the engine information screen From any engine go to the active faults screen gives the total number information screen press the left arrow key to return of active faults and again to go to the diagnostic to the previous screen in the sequence Press the information screen From here any of the diagnostic down arrow key to go on to diagnostic information information can be obtained including information about any fault active or historical Prag nostic MOnnalar NOTE Historical faults are dash faults only Diagnostic information allows you to view any J1587 fault codes transmitted on the vehicle datalink The complete fault code is displayed both as a text mes sage and in numbers Specific fault code information can be displayed only wi
338. resulting in serious personal injury or death Fifth Wheels and Trailer Couplings Unlocking the Fifth Wheel Lock Mechanism 1 Apply the tractor parking brakes 2 Pull the trailer air supply valve to cut off the air supply to the trailer Do not use the trailer air supply for parking trail ers not equipped with spring parking brakes This applies the trailer service brakes only As air bleeds from the trailer brake system brake appli cation is lost This could allow the unattended vehicle to roll away possibly resulting in serious personal injury or death 3 Chock the front and rear of the trailer tires to prevent the trailer from moving 4 Lower the trailer landing gear until the weight is removed 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 CAUTION Before attempting to lock or unlock the fifth wheel lock mechanism of a sliding type fifth wheel the slide release pull handle if so equipped and the slide locking wedges must be in the locked position This prevents the sliding member from moving rapidly to the far forward or rearward position which could damage the fifth wheel member or kingpin 6 Release the kingpin locking mechanism by lifting the safety latch and pulling the lock control handle to the unlocked position See Fig 10 16 7 Slowly drive the tractor away fr
339. row key Fig 2 35 Setup Information Screens for service intervals mL Go to Setup Information Screens A PUSH SET KEY TO TARGET MPG 12 3 nas CHANGE TARGET MPG AMT S lt LESS MORE gt AMT lt gt V A m v PUSH SET KEY TO lel LCD LAMP K CHANGELCD LAMP AMT SI lt oFF ON gt AMT I V V y PUSH SET KEY TO Fel DISPLAY BRIGHTNESS A inne CHANGE BRIGHTNESS AMT SP lt DARK LIGHT sAMT lt gt h y Y PUSH SET KEY TO LANGUAGE ENGLISH A Ie CHANGE LANGUAGE AMT isp FRENCH SPANISH AMT lt I gt k y v A PUSH SET KEY TO UNITS K CHANGE UNITS AMT LSH ENGLISH METRIC AMT lt D Q y y PUSH SET KEY TO RESET PARAMETERS CHANGE PARAMETERS AMT S lt YES NO gt AMT lt b M Y y Go to Vehicle Information Screens 1217 2004 1040705 The current selection flashes Press the left and or right arrow key s to change the selection To store the changes and exit the screen press the down arrow key Fig 2 36 Other Setup Information 2 25 ICU Ignition Sequence If the headlights are turned on the screen displays the odometer and waits for the ignition to be turned on When the ignition is turned on all the electronic gauges complete a full sweep of their dials the warning and indicator lights light up and the buzzer sounds for three seconds NOTE The air gauges do not sweep The following lights illuminate durin
340. rpm for 3406E C 15 and C 16 engines These elec tronic engine systems will adjust the idle speed to 700 to 750 rpm when the engine is warm enough to drive the vehicle Cummins The cold start system approved for use on Cummins engines has been based upon starting aid capabili ties to 25 F 32 C For more information see the Cummins Operation and Maintenance Manual Turn the ignition switch to the ON position Fig 7 9 If the engine doesn t start after 30 seconds of crank ing turn the key to the OFF position and wait two minutes then repeat the starting procedure 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 one minute then repeat the starting procedure DDE S60 The engine may require the use of a cold weather starting aid if the outside temperature falls below 40 F 4 C Turn the ignition switch to the ON position and start the engine If the engine doesn t start after 30 seconds of crank ing turn the key to the OFF position and wait two minutes then repeat the starting procedure 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 one minute then repeat the starting procedure Mercedes Benz The intake air preheater i
341. ry the newest message replaces the oldest message The size of each incoming message is limited to the total characters that can be displayed on three Screens or 111 total characters Press the down arrow key on the 10 key keypad located on the B panel to scroll through a message if necessary To acknowledge to the sender that an incoming mes sage has been received press the Set Reset but ton The message then goes into memory replacing the oldest message there To recall a message from memory 1 Safely stop the vehicle and set the parking brake 2 With the parking brake set press the right arrow key on the 10 key keypad to display the Trip Information screen 3 Press the down arrow key until the Message Information screen appears 4 Press the right arrow key until Read Message appears 5 Press the down arrow key until the first message is displayed 6 Press the down arrow key to continue scrolling through incoming messages stored in memory 7 To return to the default screen press the left arrow key as necessary after reading messages Sending Messages Up to 10 different messages can be stored for send ing 5 are fixed and 5 are programmable using Ser viceLink To send a message 1 Safely stop the vehicle and set the parking brake 2 With the parking brake on press the right arrow key on the 10 key keypad until the Trip Informa tion screen appears 3 Press the down arrow key u
342. s its performance may be compromised or degraded by certain conditions including the following e Weather conditions such as snow heavy rain ice or standing water Damaged worn or faded lane markings Broken pavement dirt sand salt gravel or skid marks Poor lighting such as heavy glare or an inop erable headlight e A cracked dirty or streaked windshield The lane guidance system is not meant for use in city traffic or in heavy highway traffic System alerts are automatically disabled when vehicle speed drops below 40 mph 64 km h The system may be manu ally turned off with the instrument panel rocker switch if an unacceptable level of false alerts is reached NOTE If the green light on the LANE ALERT rocker switch remains off despite depressing the switch and the LANE SRCHNG amber warning light remains on the system is not fully func tional and needs service at an authorized ser vice facility Instruments and Controls Identification Instruments Tachometer The tachometer Fig 2 64 indicates engine speed in revolutions per minute rpm and serves as a guide for shifting the transmission and keeping the engine in the appropriate rpm range For low idle and rated rpm see the engine identification plate The green color band on the tachometer indicates the best fuel economy range The yellow band indicates lower fuel economy the orange band indicates much lower fuel economy and the red ba
343. s Due X Mi Ago and Service Was Due X Hr Ago The letter X represents the number of miles or hours programmed The ICUAM ICUAM 2 can be programmed using Servicel ink to generate service warnings in either miles or hours but not both No Datalink Activity Screen The No Datalink Activity screen comes on when ever the datalink is not receiving data If the condition persists take the vehicle in for ser vice as soon as possible to discover the cause of the problem Automated Manual Transmissions The ICUAM ICUAM 2 can display current gear infor mation for vehicles with automated manual transmis sions AMT The last three digits at the far right on the lower line are reserved for this information On the diagrams for the stationary access screens this is indicated by the legend AMT If there is a need to shift one digit displays an arrow either up or down depending on the shift direction The other two digits display the current gear On vehicles with conventional manual or automatic transmissions these three digits do not display Direct Access Screens The driver can also override the regular screen dis play at any time by pressing the keypad to display one of the direct access screens Press the TRIP key for the Trip miles and Trip Hours screen and Roll Count and Hard Brake Count screen Press the FUEL key for the Fuel Used and Average MPG screen 2 18 Instruments and Controls Identification
344. s activated by turning the ignition switch to the on position Fig 7 9 If the en gine is at normal temperature the INTAKE HEATER indicator goes out after two seconds If the temperature is low enough to require the heater the INTAKE HEATER indicator stays on while the intake air preheater warms up After the indicator goes out start the engine If the engine doesn t start Engines and Clutches after about 30 seconds of cranking turn the key to the off position and wait two minutes then repeat the starting procedure NOTE If the engine doesn t start on the second try wait at least five minutes before using the intake air preheater again Starting After Extended Shutdown or Oil Change An engine in storage for an extended period of time over winter for example may accumulate water in the oil pan Oil diluted by water cannot provide ad equate bearing protection at start up For this reason change the engine oil and filters after extended stor age Perform the following steps after an oil change or after the engine has been shut down for more than three days 1 Make sure the transmission is filled with the cor rect type of fluid as recommended by the trans mission manufacturer 2 Make sure the fuel tank is full If air has entered the fuel system prime the fuel system using the engine manufacturer s instructions 3 If the engine is equipped with a fuel water sepa rator drain off any accumulated wa
345. s before by pressing any key High Coolant Temp Screen This message and an alarm tone come on whenever the engine coolant temperature exceeds a preset point specified by the engine manufacturer see the engine manual for this temperature The word Warning flashes on the message display screen above the message High Coolant Temp This message follows the same rules of dismissal and display as Low Oil Pressure Low Voltage Screen On some vehicles this message and an alarm tone come on whenever a low voltage condition is de tected by the instrumentation control unit The word Warning flashes on the message display screen above the message Low Voltage Turn Signal On Screen This warning message the alarm tone is optional comes on whenever the turn signal remains on be yond a preset time or distance traveled The word Warning flashes on the display screen above the message Turn Signal On To dismiss this message either turn off the turn sig nal or press any key on the keypad Service Warnings Service warning screens display during the ignition sequence and indicate that a service interval has been reached or exceeded and maintenance is re quired The messages may indicate the number of miles or hours until the next service or once passed the number of miles or hours ago that maintenance should have been performed The messages read X Miles To Next Service X Hours To Next Service Service Wa
346. s below call attention to the techniques that can be employed to save fuel and extend the operating efficiency and life of a new Detroit Diesel engine for the longest possible time All engines have an operating range in which the en gine performs most efficiently The operating range extends from maximum torque rpm at the low end to engine rated speed at the high end Detroit Diesel engines deliver best fuel economy when operated in the low and mid speed segments of the efficiency range and produce maximum horsepower at rated speed which is also the recommended maximum speed of the engine It is seldom necessary to accelerate the engine to governed speed in the lower gears to get the vehicle moving except in a high power demand situation such as starting on a grade To conserve fuel start off in low gear and develop only the engine speed needed to get rolling Then increase engine speed gradually as upward gear shifting progresses As described by Detroit Diesel this progressive shifting technique will get the vehicle up to the de sired cruising speed while minimizing noise emission and maximizing fuel economy A progressive shift pattern is illustrated in Fig 7 10 0 10 20 30 40 50 60 16 32 48 64 80 97 4 11 02 95 1250319 1 Governed RPM 2 Engine RPM 3 Idle RPM 4 Miles Kilometers Per Hour Fig 7 10 Progressive Shift Pattern NOTE A momentary hesitation in throttle re sponse will
347. s do not leak 10 8 Fifth Wheels and Trailer Couplings Adjust the jaw pin if there is more than 1 8 inch 3 mm clearance between the kingpin and the lock Incorrect adjustment could cause the trailer to disconnect possibly resulting in serious per sonal injury or death 11 With the trailer wheels chocked and the brakes set check for clearance between the kingpin and the fifth wheel jaws by moving the tractor forward and backward against the locked kingpin A clearance of approximately 1 16 inch 1 6 mm between the jaw and kingpin is allowable When clearance between the jaw and kingpin exceeds 1 8 inch 3 mm adjust the jaw to restore the 1 16 inch 1 6 mm clearance between the jaw and kingpin For instructions see Group 31 of the Century Class Trucks Workshop Manual 12 Retract the trailer landing gear and secure the ratchet handle 13 Remove the chocks from the trailer tires 14 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 weighing 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 ratin
348. s not the ON light blinks continuously 2 Push in the volume control and power ON OFF knob to turn power on or off Turn the knob left or right to increase or decrease speaker volume Press and hold the knob for five seconds and then release it to activate the failure display mode NOTE The system may be configured to have no on off capability 3 The speaker is located under the top cover of the DDU It sounds audible tones to alert the driver to potential hazards Volume may be re stricted to a range above a minimum level Instruments and Controls Identification 3 4 5 2 f N 6 f IN lt IN f ON FN VN SC FAIL j J S Nena CALL so pma 1 7 EATON VORAD 11 10 9 TECHNOLOGIES S A 12 8 10 15 98 1610258 1 Red System Failure Indicator Light 7 Ambient Light Sensor 2 Green Power ON Driver s Card Status Indicator Light 8 Drivers Card Slot 3 Volume Control and Power ON OFF Knob 9 Red Alert Light 4 Speaker on top of unit 10 Orange Alert Light 5 Range Knob 11 Yellow Alert Light 6 Green SC Indicator Light 12 Distance Danger Alert Lights Fig 2 58 Driver Display Unit EVT 300 NOTE This electronic parameter can be config Fault Codes ured Fault Code Suspect Failure 4 Rotate the range knob to adjust the first alert de 11 Central Processing Unit CPU tection range to between 3 and 2 25 seconds 12 CyberCard
349. s on the driver s instrument panel 11 electronic one electro mechanical and two mechanical The Driver Message Center is the heart of the ICU2M It has three parts 2 26 Instruments and Controls Identification 7 8 14 1 9 10 f Pio f s 13 11 15 i L 1 L i i i ENGINE PROTECT CHARGE 8888888 ABS TEMP AB El g MI CD gg eta E 188 VOLTS i e E fie b e d 16 17 18 cel 19 20 21 11 10 2006 22 23 24 25 26 27 16102312 1 Stop Engine Warning 11 Engine Protection Warning 19 Parking Brake On Warning 2 Engine Fan On Indicator 12 No Charge Indicator 20 Recirculated Air Indicator 3 Do Not Shift Indicator 13 Tractor ABS Warning 21 Air Restriction Indicator 4 ECAS Failure Warning 14 Transmission Temperature 22 Left Turn Signal 5 ECAS Transfer Indicator Warning 23 Low Battery Voltage Warning 6 Low Washer Fluid Indicator 15 Trailer ABS Warning 24 Dash Driver Display Screen 7 Wheel Spin Indicator 16 Low Oil Pressure Warning 25 High Beams Indicator 8 EBS Warning optional 17 High Coolant Temperature 26 Low Air Pressure Warning 9 Water In Fuel Indicator Warning 27 Right Turn Signal 10 Check Engine Indicator 18 Fasten Seat Belt Warning Fig 2 39 ICU3 Dash Message Center Pre 2007
350. s one hand and two feet or two hands and one foot Do not lean out away from the cab Do not engage in horseplay Do not enter the cab with dirty or greasy hands or feet Disregarding this careful step by step procedure can result in your falling from the cab and pos sible personal injury or death 1 Open the passenger s door and place anything that you are carrying in the cab 2 Grasp the aft grab handle with your right hand and grab the forward grab handle with your left hand Reach up as far as you re comfortable 3 Very carefully place your right foot on the bottom step and pull yourself up 4 Place your left foot on the next step and care fully pull yourself up 5 Place your right foot on the top step and care fully move your right hand to the forward grab handle and your left hand to the lower inside cab grab handle See Fig 3 12 Hold on very tightly 3 8 Vehicle Access and maintain three point contact with the cab at all times 6 Then slowly move your left foot to the threshold of the door 7 Holding tightly to the lower inside cab grab handle with your left hand move your right hand to the upper inside cab grab handle See Fig 3 12 8 With both of your hands gripping the inside cab grab handles tightly step into the cab with your right foot 9 With your right foot securely in the cab and both hands gripping the inside cab grab handles move your left foot into the cab Exiting the
351. s shut down to prevent battery discharge For starting below 0 F 18 C an optional cold weather starting assist is recommended For temperatures below 10 F 23 C consult your Caterpillar dealer for recommendations When customer parameters include cold mode operation and the coolant temperature is below 82 F 28 C the system puts the engine into cold mode It adjusts the low idle to 600 rpm for the 3406E C 15 and C 16 engines and 800 rpm for the C 10 and C 12 engines It also advances the timing to reduce white smoke emissions and improve warm up time The system will keep the engine in cold mode until the coolant temperature rises above 82 F 28 C After cold mode has been completed operate the vehicle at low load and low rpm until the engine coolant reaches normal operat ing temperature of 189 F 87 C Fuel cloud point is the temperature at which wax crystals become visible which is generally above the pour point of the fuel To keep the fuel filter elements from plugging with wax crystals the cloud point should be no higher than the lowest ambient temperature at which the engine must start Cummins The two most commonly used terms associated with preparation of equipment for low temperature opera tion are winterization and arctic specifications Engines and Clutches Winterization of the engine and or components so that starting and operating are possible in the lowest temperature
352. sage is available This message displays for a preset time period and then disappears It returns after the preset interval until it is dismissed by pressing any key on the key pad Parking Brake On Screen This warning message and an alarm tone come on whenever the parking brake is applied and the ve hicle is moving faster than 2 5 miles per hour or the clutch has been depressed The word Warning flashes on the message display screen above the message Parking Brake On The screen and alarm tone go away only when the parking brake is re leased See Fig 2 28 Low Oil Pressure Screen This warning message and an alarm tone come on whenever the oil pressure falls below the minimum oil pressure specified by the engine manufacturer whether the vehicle is idling or in motion The word Warning flashes on the message display screen Instruments and Controls Identification WARNING PARK BRAKE ON 06 21 2007 f601414 Fig 2 28 Parking Brake On Screen above the message Low Oil Pressure To dismiss the message press any key on the keypad NOTE If there is more than one alert message to display pressing any key takes you to the next message and so on until all the messages have been received If low oil pressure is detected during the ignition se quence it displays as an active fault and the alert screen does not appear After 30 seconds this message displays again and can be dismissed a
353. same Foreword beraten ae ae wee Gace Pale wae paar a 1 1 Instruments and Controls Identification llle 2 1 Vence ACCESS d p seep Gaye Shane ae eos te dag aid ag ae a are 3 1 Heater and Air Conditioner 0 ccc ee eee eee ene eens 4 1 Seatsand Seat DONS Ree 5 1 Steering and Brake Systems 0 0000 cece eee 6 1 Engines Sd UNCKGS nooosadq ed arde er OR neon b act adeo EA Ea a aE Ep 7 1 Bride CM 8 1 PRCA PANS uuodaescs tei oram tea Mee e Rot e m asa ag fa Atc aUe and GLA Der rar eae 9 1 Fifth Wheels and Trailer Couplings 02 00 e eee eee eee eee 10 1 Pretrip Inspection and Daily Maintenance 00 cece eee ees 11 1 Cab AppearaNCe ais cake dea deco deam ode de non UR eden de sc Ru ded tig a PHA dien D Gd de NR CR a 12 1 luec um qe P akiai a arada aE REN a aa g arh EE a aE 13 1 ner A LUTTE 1 1 Vehicle Identification Federal Motor Vehicle Safety Standard FMVSS Labels Canadian Motor Vehicle Safety Standard CMVSS Labels 0 0000 cee eee eee 1 2 Tire and Rim Labels EPA Emission Control Labels Vehicle Identification Vehicle Specification Decal The vehicle specification decal lists the vehicle model identification number and major component models It also recaps the major assemblies and in stallations shown on the chassis specification sheet One copy of the specification decal is attached to the inside of the sliding storage waste drawer Ano
354. screens are similar Fig 2 32 Engine Information Screens Active Faults Active faults are current problems that require atten tion If active fault codes display during start up or at any other time make a note of the fault code and text message Then call an authorized Freightliner service facility for assistance 2 21 From the diagnostic information screen press the right arrow key to display the number of active faults then each individual fault in order until the end of the list is reached This sequence completes the ac tive fault diagnostic screens Instruments and Controls Identification Return to Idle Hours From Engine Screen Information C 3 m v A Fault 1 Fault n q DIAGNOSTIC gt ACTIVE FAULTS INFORMATION AMT a 7 iS 12 or NONE AMT gt lt MID text PID SID text FMi text MID sPID FMI AMT MiD text PID SID text FMI text MIDZsPIDZFMIZZAMT gt gt lt Y y v 12 HIST DASH FAULTS lt LAST CLR 123456 7AMT gt ls MID text PID SID text lt j FMI text MID sPID FMI AMT Hist Fault 1 Hist Fault n MiD text PID SID text FMI text MID sPIDZFMIZAMT gt PUSH RESET TO CLEAR DASH FAULTS AMT V d 4 x Y T Go to Service Information Screens 12 17 2004 reporting the fault R y
355. send instant messages on vehicles equipped with Truckweb Call up information onto direct access screens Move about from screen to screen while the vehicle is stationary e Set up the display SET TEMP FUEL TRIP LEG RESET EVENT Dedicated Keys General Keys Control Keys 08 08 96 1601009 Fig 2 44 10 Key Keypad Instruments and Controls Identification e Set a target MPG to monitor fuel economy while driving Press the left arrow key to lower the target MPG and the right arrow key to raise it Set the brightness of the message display screen independently of the panel dimmer switch Use the left arrow key to dim the dis play and the right arrow key to brighten it Record significant data using the EVENT key if a data logging unit is installed NOTE One key is blank and is not usable at this time ICU2M Ignition Sequence If the headlights are turned on the screen displays the odometer and waits for the ignition to be turned on See Fig 2 45 When the ignition is first turned on all the electronic gauges complete a full sweep of their dials the warning and indicator lights light up for five seconds and the buzzer sounds for two seconds NOTE The air gauges and voltmeter do not sweep Once the ignition has been turned on the screen displays the Freightliner message At the same tim
356. sh driver display screen is a one line by seven character liquid crystal display LCD that normally shows odometer readings Warning and Indicator Lights There can be up to 26 warning and indicator lights installed in the ICU3 or ICU3 07 See Fig 2 39 and Fig 2 40 There are four rows of lights in the dash message center Lights installed in the top row are optional and their positions may vary The lights in the bottom three rows are installed in fixed positions on all ve hicles 2 24 Instruments and Controls Identification Return to Idle Hours Screen From Service Information 1 yY SETUP 1 INFORMATION AMT a E id Go to Vehicle Information Screens 12 17 2004 PUSH SET KEY TO s gt SERVICE INTERVAL m CHANGE SERVICE AMT OFF MILESIHOURS AMT V y If Service Interval is set to MILES A PUSH SET KEY TO INTERVAL XXXXXMILES s lt CHANGE SERVICE MI AMT S EP lt LESS MORE gt AMT lt L gt y i OR SERVICE INTERVAL TPS 7 OFF MILES HOURS AMT SIP V Y If Service Interval is set to HOURS PUSH SET KEY TO INTERVAL XXXXHOURS lt CHANGE SERVICE HR AMT s gt LESS MORE gt AMT lt gt i ii v To more Setup Information 1040704 The current selection flashes Press the left and or right arrow key s to change the selection To store the changes and gt exit the screen press the down ar
357. si 827 kPa With the engine idling apply the brake pedal sev eral times The air governor should cut in the air compressor at approximately 100 psi 689 kPa If the air governor does not cut in and out as described above it must 5 6 7 3 8 2 a 9 1 10 06 17 2003 1421398 1 7 16 inch Adjusting 6 Clevis Nut 7 1 2 inch Clevis Pin 2 Grease Fitting 8 1 4 inch Clevis Pin 3 Boot 9 Grease Relief 4 Link Opening 5 Brake Chamber Piston 10 Slack Adjuster Spline Rod Fig 11 12 Gunite Automatic Slack Adjuster be adjusted to these specifications If the air governor cannot be adjusted or re paired replace it before operating the ve hicle 25 2 Check the air pressure buildup time as follows With the air system fully charged to 120 psi 827 kPa make one full brake appli cation 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 required to raise the air pressure to 120 psi 827 kPa from the pressure noted after one brake application is more than 30 seconds eliminate any leaks or replace the air compressor before operat ing the vehicle 25 3 Check the air pressure reserve as follows With the air system fully charged to 120 psi 827 kPa stop the engine and note the air pressure Then make one full brake application and observe the pressure 11 12 Pretri
358. sions The operational readiness of the air bag sys tem is indicated by the supplemental restraint system SRS indicator on the dash The SRS indicator comes on when the engine is started and then goes off The indicator will remain on if there is a problem with the air bag system The vehicle should be ser viced if the SRS indicator does not come on when the engine is started or if the SRS indicator remains on Air bags are designed to inflate only in severe frontal collisions The driver and the passenger should always wear seat belts For maximum pro tection in a collision or rollover always be in a normal seated position with your back against the seat back and your head upright Fasten your seat belt and ensure that it is properly positioned on your body as described under the Seat Belt Operation heading Since the air bag inflates with considerable speed and force a proper seat position will keep you a safe distance from the inflating air bag Do not place objects on the steering wheel or be tween you and the steering wheel Keep your hands on the sides and lower portion of the steering wheel Any objects may cause harm dur ing an accident 5 9 Failure to follow these instructions may result in death or personal injury Air Bag Safety Guidelines The air bag system contains components that use combustible chemicals Because these chemicals are combustible care must be taken when replacing or handling system componen
359. sition Intake Heater amber Indicates the intake air heater is active Water in Fuel amber Indicates that the fuel could contain water Fuel Filter Restricted amber Indicates that the fuel could contain water Low Battery Voltage red Indicates battery voltage is 11 9 volts or less 2 2 Instruments and Controls Identification Warning and Indicator Lights No Charge amber Indicates an alternator charge output failure Table 2 1 Warning and Indicator Lights 04 08 96 541099 NOTE Instruments and controls and their locations may vary from those shown Oil Pressure Gauge Engine Oil Temperature Gauge Turbocharger Boost Pressure Gauge Coolant Temperature Gauge Voltmeter Pyrometer Dash Message Center or Driver Message Center Tachometer Speedometer Primary Air Pressure Gauge 11 Fuel Gauge 12 Forward Axle Oil Temperature Gauge CONOR OD i o 13 Secondary Air Pressure Gauge 14 Transmission Oil Temperature Gauge 15 Rear Axle Oil Temperature Gauge 16 Windshield Wiper Washer Controls 17 10 Key Keypad 18 Controlled Traction Differential Control Valve Switch 19 Fifth Wheel Air Slide Control Valve Switch 20 Interaxle Differential Lockout Control Switch 21 Air Suspension Dump Valve 22 Trailer Air Supply Valve 23 Parking Brake Control Valve Fig 2 1 Instrument and Control Panel Layout upper LH DR dash shown Engine Protection War
360. sm by raising the safety latch to the rear and pulling the lock operating rod out and up into the lockset posi tion See Fig 10 11 The offset of the lock con trol upper rod should bottom against the plate casting above the hole If the operating rod can not be pulled to the lockset position back the tractor slightly to release the kingpin force against the jaw If equipped with an air operated kingpin lock re lease Pull the air release knob on the dash From outside the cab visually check that the op erating rod has bottomed out against the plate casting above the hole See Fig 10 11 If the operating rod isn t in the unlocked position back the tractor slightly to release the kingpin force against the jaw IMPORTANT If equipped with an air operated lock release you still must make a visual check Fifth Wheels and Trailer Couplings of the operating rod to make sure it is in the un locked position 7 Slowly drive the tractor away from the trailer Fifth Wheel Slide Operation 1 Chock the front and rear of the trailer tires to prevent the trailer from moving 2 Connect the trailer kingpin to the tractor fifth wheel For instructions refer to Fifth Wheel Locking Operation in this chapter 3 After positive lockup of the fifth wheel lock mechanism has been accomplished release the slide using one of the following methods 3 1 For air operated models set the cab operated control switch Fig 10 6 to UN
361. spect each tire for bulges cracks cuts and penetrations Pretrip Inspection and Daily Maintenance 20 3 Inspect each tire for oil contamination Fuel oil gasoline and other petroleum derivatives if allowed to contact the tires will soften the rubber and destroy the tire 21 Check the wheel nuts or rim nuts for indications of looseness Examine each rim and wheel com ponent 21 1 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 Fig 11 7 and Fig 11 8 0209 95 A 1400058 Fig 11 7 Dirt and Rust Streaks from the Stud Holes 21 2 Examine the rim and wheel assembly components including rims rings flanges studs and nuts for cracks or other dam age See Group 33 or Group 35 of the Century Class Trucks Workshop Manual for service procedures on the studs and hubs and see Group 40 in the same manual for wheel and tire servicing or take the vehicle to an authorized Freight liner dealer Have any worn or damaged wheel components replaced by a qualified person using the wheel manufacturer s instructions and the wheel indus try s standard safety precautions and equipment Otherwise a vehicle or workshop accident could occur possibly resulting in serious personal in jury or death 21 3 Have broken cracked badly worn bent rusty o
362. speeding or following too closely Trailer ABS Lamp Operation Antilock braking systems on tractors are designed to communicate with trailer ABS systems if they are compatible Compatibility will result in the illumination of the trailer ABS lamp during vehicle start up and fault detection 6 5 The dash mounted lamp will operate as follows when a compatible trailer is properly connected to a tractor When the ignition key is turned to the ON posi tion the trailer ABS lamp will illuminate mo mentarily then turn off If the lamp comes on momentarily during ve hicle operation then shuts off a fault was de tected and corrected If the lamp comes on and stays on during ve hicle operation there is a fault with the trailer ABS Repair the trailer ABS system immedi ately to ensure full antilock braking capability The Trailer ABS lamp will not illuminate unless a compatible trailer is connected to the tractor IMPORTANT If a compatible trailer is con nected and the lamp is not illuminating momen tarily when the ignition key is turned to the ON position it is possible that the lamp is burnt out 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 dur ing slack adjuster installatio
363. ss the brake pedal or clutch pedal Or 2 2 Press the lower half of the SPD CNTL rocker switch on the instrument control panel or push the PAUSE button on the transmission shift knob 3 To resume a preselected cruise speed 3 1 If the SPD CNTL rocker switch on the in strument control panel is off turn it on 3 2 Momentarily flip the RSM ACC SET CST paddle switch on the instrument control panel to RSM ACC or push the RESUME button on the transmission shift knob Cruise will return to the last speed se lected NOTE The resume vehicle speed memory is not maintained if the ignition is shut off 4 To adjust cruise speed up or down hold the paddle switch on the instrument control panel at RSM ACC to accelerate or at SET CST to decel erate until the desired speed is reached or press the SET button on the transmission shift knob to accelerate or the RESUME button to decelerate until the desired speed is reached Power Takeoff PTO Governor The vehicle must be parked before engaging the PTO The PTO mode is activated by the SPD CNTL and RSM ACC SET CST switches on the dash Fig 7 11 or by optional PAUSE RESUME and SET buttons on the transmission shift knob Fig 7 12 1 To engage the PTO 1 1 Press the upper half of the SPD CNTL rocker switch on the instrument control panel 1 2 Hold the throttle down until the tachometer reaches the desired engine speed 1 3 Momentarily flip the paddle switch on the instr
364. structions for specific inspection and maintenance instructions See Table 11 1 for a list of procedures that should be perfomed daily before the first trip See Table 11 2 for a list of procedures that should be performed weekly post trip See Table 11 3 for a list of procedures that should be performed monthly post trip IMPORTANT Before performing any checks apply the parking brake and chock the tires Pretrip Inspection and Daily Maintenance iiio P i Daily Pretrip Inspections Checks iig Drain manually drained air reservoirs that are not equipped with automatic drain D1 valves Check windshield washer reservoir fluid Inspect wheel seal and hub cap for leakage Check surge tank coolant level Inspect radiator and charge air cooler Check engine for fuel oil or coolant leaks Inspect engine and chassis wiring Inspect air intake system Check intake air restriction indicator mounted on air intake Check engine oil level Check power steering fluid level Inspect fuel tank s fuel lines and connections Check fuel level Check fuel water separator Inspect front and rear suspension components Inspect headlights mirrors and window glass and windshield wipers Check doors open without difficulty and close securely Adjust driver s seat then align rearview and downview mirrors Check dash mounted intak
365. sure gauge to determine which system has low air pressure Although the vehicle s speed can be reduced using the foot brake control pedal either the front or rear service brakes will not be operating causing a longer stopping distance Bring the vehicle to a safe stop and have the air system repaired be fore continuing IMPORTANT In the event of a total loss of ser vice brakes with full system air pressure use the parking brake control valve yellow knob to bring the vehicle to a complete stop in the saf est location possible On tractor trailer vehicles if both the primary and secondary systems become inoperative the trailer service brakes or spring parking brakes will automati cally apply when air pressure drops below 35 to 45 psi 242 to 310 kPa The tractor spring parking brakes will automatically apply when air pressure drops below 20 to 30 psi 138 to 207 kPa On straight trucks spring parking brakes will apply when air pressure drops below 20 to 30 psi 138 to 207 kPa Do not wait for the brakes to apply automati cally when the warning light and buzzer first come on immediately bring the vehicle to a safe stop Be fore continuing operation of the vehicle correct the cause of the air loss Before the vehicle can be moved the spring parking brakes must be released by applying an external air source at the gladhands or by manually caging the parking brake springs WARNING Do not release the spring parking
366. t 9 Let go of the grab handles Entering the Passenger s Side Using the Cab Access Stairs Fig 3 10 A WARNING If the optional cab access stairs do not move into position or if there is not enough room for them to deploy use the fixed steps on the outside sur face of the moving stairs Fig 3 5 and follow the access instructions for the standard fixed step system Freightliner recommends you practice using the fixed steps until you are familiar with their use Enter the cab only as specified in the following steps Keep your body close to the cab and maintain three point contact with the cab at all times This means one hand and two feet or two hands and one foot Do not lean out away from the cab Do not engage in horseplay Do not enter the cab with dirty or greasy hands or feet Disregarding this careful step by step procedure can result in your falling from the cab and pos sible personal injury or death 1 Open the passengers door and place anything that you are carrying in the cab 2 Grasp the aft grab handle with your left hand and grab the forward grab handle with your right hand Reach up as far as you re comfortable 3 Very carefully place your left foot on the bottom step and pull yourself up Vehicle Access 4 Place your right foot on the next step and care fully pull yourself up 5 Place your left foot on the top step and carefully move your left hand to the forward grab handle and your rig
367. t lower engine speeds than at rated speed The Detroit Diesel HD engine has been designed for a very quiet operation but the air flow may be no ticeable to the tuned attentive ear The turbocharger operates at higher boost pressure forcing exhaust to flow through the exhaust gas recirculation plumbing In some situations the driver may believe they have experienced a charge air cooler system leak Even while connecting trailer lights and air hoses the driver may hear a different tone exhaust and under hood with the engine idling If equipped with a turbo boost gauge the driver may occasionally note the intake manifold pressure exceeds 35 psi 241 kPa Idling The common belief that idling a diesel engine causes no engine damage is wrong Idling produces sulfuric acid that is absorbed by the lubricating oil and eats into bearings rings valve stems and engine sur faces If you must idle the engine for cab heat or cooling the high idle function of the cruise control switches should be used An idle speed of 900 rpm should be enough to provide cab heat in above freezing ambient temperatures Cold Weather Operation Precautions must be taken during cold weather to protect your engine Special cold weather handling is required for fuel engine oil coolant and batteries The engine does not require starting aids down to 50 F 10 C A grid heater is included for tempera tures between 50 F 10 C and 4 F 20 C Tem
368. tch brake stops the transmission switch input shaft from rotating 1 2 Apply pressure with the shift lever toward 8 Move the shift lever and engage reverse the neutral position 9 Slowly release the clutch pedal and move the 1 3 Press the bottom portion of the shift intent vehicle in the reverse direction switch again far enough so that the _ See Fig 8 18 for two ESS 9 speed shift patterns switch goes into a second position inside and one ESS 10 speed shift pattern the body of the shift knob Then release the switch See Fig 8 17 This will break torque 1 4 Immediately move the shift lever to the neutral position 1 5 Allow engine rpm to speed up enough to synchronize with road speed 1 6 Move the shift lever to the next lower gear 2 To downshift through the rest of the gears re peat the substeps above Before each downshift push the bottom of the shift intent switch into the shift handle body to break torque The range shift is automatic Transmissions R 5 R 6 8 R 7 9 H 1 3 H 2 4 H 2 4 N N N Lo 2 4 1 3 B 1 3 5 5 7 6 8 10 02 17 98 c 1270061 A 9 Speed Shift Pattern with LO B 9 Speed Shift Pattern C 10 Speed Shift Pattern Gear Fig 8 18 Meritor ESS 9 and 10 Speed Shift Patterns 8 22 Rear Axles Meritor Single Drive Axles with Traction Equalizer E E A EEE 9 1 Meritor Drive Axles with Main Differential Lock llli 9 1 Meritor Main Differential Lock Operation
369. ted governed speed Essential information regarding the operation and care of Allison automatic transmissions is contained in the Allison Driver s Handbook Applying the knowl edge presented will not only make driving easier but will give the maximum benefits from an Allison equipped vehicle Maintenance literature is also available for drivers of Allison equipped vehicles who desire trouble free performance and maximum life from their equipment These maintenance books are available from any authorized Detroit Diesel engine distributor As with all engines prolonged idling of Detroit Diesel engines is not recommended An idling engine wastes fuel and if left unattended is also unsafe A Detroit Diesel Electronic Control DDEC engine can be equipped to shut off automatically after five minutes of idling The vehicle transmission must be Engines and Clutches in neutral and the parking brake must be set for the automatic shutoff option to work To start the engine follow the normal start up procedure Engines equipped with DDEC will idle fast when cold As the engine warms up to operating tempera ture the idle speed will decrease Warm the engine until idle speed is normal before operating the ve hicle Normal Operation Mercedes Benz While you are driving watch for any signs of engine problems If the engine overheats uses excessive fuel or lubricating oil vibrates misfires makes un usual noises or shows an
370. tems 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 isolated deep cycle batteries with jumper cables Follow the battery manufacturer s instructions when charging 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 posi tive 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 dis charged battery or jump start post if equipped See Fig 13 3 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 In an Emergency A 10 18 94 2 1540027b A To Ground E To Starter B Connect 3rd F Connect 2nd C To Frame ground G Connect 1st D Connect Last 1 Booster Battery 2 Discharged Battery Fig 13 3 Jumper Connections 3 Connect one end of the second jumper cable to the negative terminal of the booster battery and connect the other end of the cable to a ground at least 12 inches 300 m
371. ter 4 Check the drive belts to make sure they are in good condition and properly adjusted Replace any drive belts that are cracked worn or glazed 5 Check the turbocharger for signs of oil or ex haust leaks Correct any problems before starting the engine 6 Check the engine mounting bolts for tightness Retighten them if necessary 7 Make sure the battery cable connections are clean and tight Check that the batteries are charged 8 Start the engine normally Engine Operation CAT Cummins DDE S60 M B Each engine must pass a full load operating test on a dynamometer before shipment thereby eliminating the need for a break in period Before running the engine for the first time follow the instructions in the engine manufacturer s operation manual specific to your engine Operating vehicles with diesel engines in areas where there are concentrated flammable vapors such as diesel gasoline or propane fumes can cre ate a hazardous situation These vapors can be drawn into the engine through the air intake and cause engine overspeed Be especially cautious of low lying or closed in areas and always check for signs that flammable vapors may be present Do not 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 in
372. th the vehicle stopped and the parking brake set Diagnostic information can also be obtained at any time From the odometer screen press the right arrow key once and the down arrow key three times to display the diagnostic information screen See Fig 2 33 During vehicle start up with the parking brake set the ICU4M ICU4M 2 displays active fault codes if any until the parking brake is released With an ac 2 20 Instruments and Controls Identification Return to Idle Hours From Trip Screen Information 1 1 4 A la A FUEL D gt lt FUEL USED 12345 6 4 IDLE GALLONS 12 3 N INFORMATION AMT AVG MPG 12 34 AMT PTO GAL 12345 6 AMT R R V V V 4 v Y Y i Go to Engine Information Screens 12 17 2004 3 1040700 AMT Current gear information for automated manual transmissions NOTE Metric unit screens are similar Fig 2 31 Fuel Information Screens Return to Idle Hours From Fuel Screen Information i m A ENGINE ENG MILES 123456 7 ENG GALLONS 123456 7 ENG OIL LEVEL lt INFORMATION AMT gt lt ENG HOUR1234 78AMT N PTOGAL 12345 6 AMT lt lt LO 1QTS AMT gt ENG OIL LEVEL If Oil Level Low LO 1QTS AMT l ENG OIL LEVEL Go to Diagnostic Information Screens Ir OllLevel Oi OK AMT g P ENG OIL LEVEL If Oil Level High Hl 1QTS AMT 12 01 2004 1040701 AMT Current gear information for automated manual transmissions NOTE Metric unit
373. the NORMAL mode it will apply gentle braking to the spinning wheel to feed power to the wheel s with better traction If both wheels are spinning the system will signal the electronic engine to reduce power Pressing NORM SPIN will temporarily allow more drive wheel spin to help burn through a thin layer of ice or to help throw off accumulated mud or snow SPIN mode is indicated by a flashing WHEEL SPIN light Pressing NORM SPIN again will cycle the sys tem back to normal operation See the brake system operating instructions in Chap ter 6 for more information Collision Warning System CWS Eaton VORAD EVT 300 Stand Alone The Eaton VORAD EVT 300 is a computerized colli sion warning system CWS that uses front mounted and side mounted radar to continuously monitor ve hicles ahead and alongside your vehicle 2 42 Instruments and Controls Identification The system warns of potentially dangerous situations by means of visual and audible alerts The system performs in fog rain snow dust smoke and dark ness To be detected objects must be within the radar beam s field of view and provide a surface area that can reflect back the radar beam The front looking antenna assembly transmits radar signals to and receives them back from vehicles and objects ahead This allows the determination of the distance to relative speed of and angle to the target of vehicles and objects ahead The system uses this information
374. the engine speed to drop about 800 rpm the rpm drop may vary with engines of different governed speeds then dis engage the clutch Move the shift lever to 2nd gear then engage the clutch and accelerate to engine governed speed Continue shifting upward from 2nd to 3rd gear 3rd to 4th gear and 4th to 5th gear using the same sequence See Fig 8 4 for the shift pat tern 4 Again at governed speed disengage the clutch and shift into neutral Engage the clutch allow the engine speed to drop about 500 rpm rpm drop may vary with engines of different governed speeds then disengage the clutch Move the shift lever to 6th gear then engage the clutch and accelerate to engine governed speed Transmissions Shift into 7th gear using the same sequence Downshifting When downshifting shift down from 7th gear through each lower gear as follows 1 Allow the engine speed to drop about 500 rpm rpm drop may vary with engines of different gov erned speeds below the governed speed De press the clutch pedal enough to release the torque then shift into neutral Engage the clutch and bring the engine rpm up to governed speed While holding full throttle disengage the clutch shift into gear engage the clutch smoothly Follow the same sequence to downshift from 6th into 5th gear 2 When in 5th gear and ready for the next down shift allow the engine speed to drop about 800 rpm rpm drop may vary with engines of
375. the fuses see Hydraulic Lockup 10 Leave the pump lever in the return position 11 If the vehicle is equipped with an electric hydraulic tilt system switch off the tilt system dash switch 12 Push the transmission shift lever forward to lock the shift tube latch mechanism Vehicle Access 04 15 93 1 Safety Stop 2 Tilt Cylinder Rod f310358a 2 Tilt Cylinder Fig 3 24 Safety Stop Disengaged 13 Check the indicator pin on each cab latch The latches are locked when the pins have moved back into the piston and cylinder spring assem bly NOTE Maintain the hydraulic oil level at the oil fill plug Add oil only when the cab is in the op erating position Use only Freightliner approved hydraulic oil See Group 60 of the Century Class Trucks Maintenance Manual Keyless Security System optional General Information The optional Meritor keyless security system is a complete vehicle security system If installed it locks and unlocks the doors protects against theft and provides security for the driver while sleeping or rest ing inside the vehicle The system consists of the following components A hand held radio frequency transmitter that looks like a key chain fob It acts as a remote control for locking the doors unlocking the doors or placing the system on alert Each system allows as many as four different fobs See Fig 3 25 08 30 96 1541289 1 ALERT Button 3 U
376. the rear of the cab 6 Slowly move the tractor forward or backward until the fifth wheel is in the desired location 10 5 7 Apply the tractor parking brakes NOTE The fifth wheel may have to be moved slightly to enable the locking plungers to enter the fully locked position 8 Lock the sliding member into position using one of the following methods Check to be sure that the slide plungers are in the locked position Failure to achieve complete lockup may allow disengagement of the tractor from the trailer possibly resulting in serious per sonal injury or death 8 1 For air operated models set the cab operated control switch to LOCK Visually check the slide plungers to make sure they are engaged in the fully locked posi tion See Fig 10 7 8 2 For manual release models trip the re lease lever Fig 10 3 using a release hook or other suitable tool Make sure that both plungers have locked retracted into their pockets and are fully engaged in the rack teeth See Fig 10 7 It may be necessary to move the tractor slightly while keeping the trailer brakes locked 9 The amount of load distribution on the front steering axle and rear drive axle s will have a direct effect on the steering control of the vehicle Determine the front and rear axle weights by weighing the vehicle on scales designed for this purpose The maximum axle weight ratings are shown on the Federal Motor Vehicle Safety Standard FMVSS
377. ther copy is inside the rear cover of the Owner s Warranty Information for North America booklet An illustration of the decal is shown in Fig 1 1 COMPONENT INFORMATION MANUFACTURED BY USE VEHICLE ID NO WHEN ORDERING PARTS MODEL VEHICLE ID NO 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 IMRON PAINT CAB PAINT MFR CAB COLOR A WHITE 4775 PAINT NO CAB COLOR B BROWN 3295 CAB COLOR C BROWN 29607 CAB COLOR D DARK BROWN 7444 FOR COMPLETE PAINT INFORMATION SEE VEHICLE SPECIFICATION SHEET PART NO 24 00273 010 11 21 96 1080021 Fig 1 1 Vehicle Specification Decal U S Built Vehicle Shown NOTE Labels shown in this chapter are ex amples only Actual specifications may vary from vehicle to vehicle 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 as shown in Fig 1 3 If purchased for service in the U S trucks built with out a cargo body have a certification label Fig 1 4 attached to the left rear door post See Fig 1 3 In addition after completion of the
378. this range or until the warning system comes on The air pressure in both the primary and secondary air reservoir systems must be above 65 psi 448 kPa on most vehicles For vehicles with an optional Bendix dryer reservoir module DRM the cut out pres sure is 130 psi 896 kPa Check the instrumentation control unit ICU for fault codes During the ignition sequence if an active fault is detected in any device that is connected to the ECU the message display screen will show the active fault codes one after the other until the parking brake is released or the ignition switch is turned off See Chapter 2 for detailed operating instructions for the ICU Make sure that the horn windshield wipers and windshield washers are operating properly These devices must be in good working order for safe vehicle operation 15 1 Make sure that the horn works If a horn is not working have it repaired before trip departure 15 2 Check the wiper and washer control on the multifunction turn signal switch If the wipers and or washers are not working have them repaired before trip departure During cold weather make sure the heater de froster and optional mirror heat controls are op erating properly If so equipped turn on the mir ror heat switch and make sure the system is working Check the operation of all the panel lights and interior lights Turn on the headlights dash lights and four way flashers and leave them
379. throttle position Throttle position can be maintained while braking and downshifting through the gears when stopping the vehicle as well as on steep grades The major components of the ESS system are the system switch shift intent switch input and output shaft speed sensors a neutral position sensor and an electro pneumatic solenoid Operation The ESS system collects and relays information per taining to the positions of the shift intent and system switches Fig 8 15 transmission input and output shaft speeds and shift lever position The informa tion is received by the engine Electronic Control Module ECM which signals the fuel control system to increase or decrease engine rpm to match road speed The ECM also controls HI and LO range se lection in the auxiliary case on the rear of the transmission 02 17 98 1 Shift Intent Switch f270058 2 System Switch Fig 8 15 ESS Shift Handle The system switch Fig 8 15 is the lower switch lo cated on the driver s side of the shift handle It con trols ESS system operation When in the down posi tion the system is operating and the word ON is visible on the switch In the up position the word OFF is visible the system is not operating and the transmission can be shifted manually The shift intent switch Fig 8 15 is the upper switch on the driver s side of the shift handle It has four positions and controls upshifting and downshifting by comm
380. tigate the cause to prevent further damage Do not operate the engine until the cause has been determined and corrected Application Air Pressure Gauge An application air pressure gauge registers the air pressure being used to apply the brakes and should be used for reference only The gauge will not regis ter air pressure until the foot brake pedal is de pressed or the trailer hand brake is applied Intake Air Restriction Gauge An intake air restriction gauge measures the vacuum on the engine side of the air cleaner at the air cleaner outlet Vacuum is measured in inH O inches of water When the vacuum reading in normal op eration equals the applicable level shown under Ser vice in Table 2 6 the air cleaner needs to be ser viced 2 56 Instruments and Controls Identification NOTE Rain or snow can wet the filter and cause a temporarily higher than normal reading Intake Air Restriction Indicator An intake air restriction indicator Fig 2 67 mea sures 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 2 6 after the engine is shut down the air cleaner needs to be serviced The indicator then needs to be reset by pressing the yellow button Intake Air Restriction Engine Type Initial Service inH O inH5O Cummins 12 25 Detroit Diesel 12 20 Caterpillar 15 25 Mercedes Benz 10 22
381. ting gear by pulling upward on the control while the vehicle is stopped and in forward before disengaging the clutch to engage the selected gear NOTE Each pull upward on the control in creases the starting gear by one gear but no higher than fourth gear The number of the se lected starting gear is displayed for one second and then the signal to disengage the clutch CL is displayed Disengaging the clutch will engage the selected starting gear which will now be stored in memory as the default starting gear However when the transmission controller is reinitialized at the beginning of another power cycle the starting gear will default to the origi nally preprogrammed starting gear The trans mission may also be programmed so that it is not possible to select a starting gear other than the preprogrammed default starting gear Upshifting With the transmission in forward F request an up shift by pulling upward on the control If the re quested gear is available the transmission will up shift NOTE If a requested gear is not available an audible warning will sound and a message will appear on the message display screen advising that the gear is not available An unavailable requested upshift is not stored in memory The upshift must be requested again All shift re quests with the clutch disengaged while the vehicle is in motion will be ignored Skip shifting is not available with the Meritor version of SmartShift
382. tion exhaust tempera tures are very high and could cause a fire heat damage to objects or materials or personal in jury to persons near the exhaust outlet Before initiating a parked regeneration make cer tain the exhaust outlets are directed away from Engines and Clutches structures trees vegetation flammable materi als and anything else that may be damaged or injured by prolonged exposure to high heat To initiate a parked regen perform the following steps 1 Park the vehicle away from all combustible and flammable materials Chock the tires Start and warm the engine until the coolant temperature is at least 150 F 66 C 2 Setthe parking brake If the parking brake was already set you must release it then set it again For manual transmissions fully depress the clutch pedal put the transmission in neutral then release the pedal If the vehicle has a two pedal automated trans mission shift it into gear then back to neutral NOTICE The driver must remain with the vehicle during the entire regen cycle 3 Press and hold the regen switch for 4 seconds The engine will increase rpm and initiate the regen process 4 After the parked regen has run for 20 to 40 min utes the regen cycle is completed The engine idle speed will drop to normal and the vehicle may be driven normally The HEST lamp may be illuminated but will go out when the vehicle speed exceeds 5 mph 8 km h or the system
383. tion inside every gear that is skipped the body of the shift handle Then release the switch See Fig 8 16 This will break Reverse torque 1 Press the system switch on the shift handle so 1 4 Immediately move the shift lever to the that it is in the ON position and the ESS system neutral position is activated 1 5 Allow engine rpm to slow down enough to 2 Push the clutch pedal to the bottom of its travel synchronize with road speed so that the clutch brake stops the transmission 1 6 Move the shift lever to the next higher pet SPI fori rotang gear 3 Move the shift lever and engage reverse 2 To upshift through the rest of the gears repeat 4 Slowly release the clutch pedal and move the the substeps above Before each upshift push vehicle in the reverse direction the top of the shift intent switch into the shift handle body to break torque The range shift is NOTE If a HI reverse range is required follow automatic the steps below 3 To skip a gear press the shift intent switch into 5 Press the system switch on the shift handle so the shift handle body while in neutral one time that it is in the OFF position and the ESS system for every gear that is skipped is deactivated 6 Press the top portion of the shift intent switch to Downshifting engage the HI range 1 To downshift into the next lower gear 7 Push the clutch pedal to the bottom of its travel 1 1 Press the bottom portion of the shift intent so that the clu
384. tion switch on both lights come on for a few seconds then if there is no problem with the 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 features may not work but the vehicle can still be driven If the do not shift light comes on while driving accompanied by eight short beeps from the shift se lector operating limits will be placed on the trans mission such as restricting upshifts and downshifts However the vehicle can still be driven to reach ser vice assistance In either situation have the problem repaired as soon as possible See the Allison Trans mission Service Manual for troubleshooting proce dures See Chapter 8 for complete transmission operating instructions Suspension Seat Adjustment Controls All adjustment controls for a suspension seat are lo cated on the seat base See Chapter 5 for complete instructions Dome Light Switches Diffuse dome lights are installed on all cabs See Fig 2 15 and Fig 2 16 The dome lights are located either on the overhead console or on the cab roof if no overhead console is installed Both dome lights turn on when either the driver s or passenger s door is opened The dome lights can also be turned on by pressing in on the light lens 07 11 97 1541715 Fig 2 15 Dome Tray Red
385. tional control over the aftertreatment regeneration process When activated the inhibit switch will stop a regeneration cycle in progress and prevent the start of a regeneration cycle until the switch is no longer active See Fig 2 5 07 30 2009 f610944 Fig 2 5 Regen Request Inhibit Switch Low Voltage Disconnect The Sure Power Low Voltage Disconnect LVD sys tem monitors battery power when accessories are being used when the engine is shut down The sys tem automatically turns off cab and sleeper accesso ries when voltage drops to 12 3 volts to ensure that there is enough battery power to start the vehicle An alarm sounds for one minute before accessories are turned off If no action is taken within that minute the LVD module will shut off power to predetermined cab and sleeper circuits and illuminate an LED indicator on the LVD module located inside the right hand door frame behind the seat These circuits will re main off until the LVD measures 13 0 volts applied to the system which can be done by starting the en gine After the engine is started the system will reset All vehicles equipped with LVD should have a sticker on the dash indicating the presence of the system Another sticker is located inside the right hand door frame behind the seat along with the LVD module Battery Isolator System A battery isolator system has two or three regular batteries to turn the starter motor and one or t
386. tone and the message HEADWAY EVENT DATA WAS SAVED The data stored will be cleared by the system after 30 days In the event that the first segment is frozen the EVT will continue to record current data in a second seg ment as long as there is power to the system If the first segment of data has already been frozen and the user attempts to freeze another segment the EVT will not allow the user to freeze the segment Instead an audible tone will be heard and the ICU will display the message HDWY EVENT DATA NOT SAVED MEMORY FULL Side Sensor Display The ambient light sensor senses lighting conditions and automatically adjusts the intensity of indicator and alert lights The yellow indicator light illuminates continuously when no vehicle is detected by the side sensor s If the side sensor detects an object the red alert light will illuminate and if the right turn signal is activated the speaker will sound a high frequency double tone Instruments and Controls Identification This tone is sounded only once per activation of the turn signal The red light will also illuminate and stay on if a failure of the side sensor is detected If ob jects are temporarily unable to be detected during very heavy rain storms both the red and yellow lights will illuminate Special Road Situations Certain special road situations may affect the sys tem s ability to detect objects These situations in clude the effects of
387. topped apply the parking brakes Reduce the engine speed to low idle 2 Place the transmission shift lever in neutral NOTE If the engine has been operating at low loads run it at low idle for 30 seconds before stopping If the engine has been operating at highway speed or at high loads run it at low idle for three minutes to reduce and stabilize internal engine temperatures before stopping 3 Turn off the ignition switch and shut down the engine 4 After engine shutdown fill the fuel tank 5 Check the crankcase oil level Maintain the oil level between the add and full marks on the dip Stick 6 If equipped with an idle shutdown timer it can be set to shut the engine down after a preset amount of time Ninety seconds before the pre set shutdown time the CHECK ENGINE light will begin to flash at a rapid rate If the clutch pedal or service brake indicate a position change dur ing this final ninety seconds the idle shutdown timer will be disabled until reset 7 ffreezing temperatures are expected allow the engine jacket water expansion tank to cool then check the coolant for proper antifreeze protec tion The cooling system must be protected against freezing to the lowest expected outside temperature Add permanent type antifreeze if required Engines and Clutches 8 Repair any leaks perform minor adjustments tighten loose bolts etc Observe the vehicle mile age or the service meter reading if so eq
388. tor light panel comes on For vehicles built to operate in the United States switching from low beams to high beams will switch off the road lights NOTE The ignition switch must be on for the high beams to work Trailer Brake Hand Control Valve Lever The trailer brake hand control valve lever Fig 2 13 is used for applying the trailer brakes without apply ing the truck or tractor brakes and is mounted on the 2 10 Instruments and Controls Identification steering column See Chapter 6 under the heading Brake System for operating instructions Transmission Controls If so equipped the transmission range control valve and splitter valve are attached to the gearshift knob Transmission shift pattern labels are located inside the cab See Chapter 8 for complete transmission operating instructions Allison Automatic Transmission Controls Allison HD series automatic transmission models are controlled by an electronic control unit ECU The ECU processes information from sensors pressure switches and the shift selector Fig 2 14 to auto matically control the transmission according to pro grammed specifications 10 28 94 1 Indicator Panel 1600368a 2 Mode ID Fig 2 14 Allison Push Button Shift Selector 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 selector With the igni
389. trailer kingpin consists of a rotating jaw that grips the trailer kingpin and a spring actuated lock The jaw rotates on a jaw pin during coupling and uncoupling operations King pin lockup occurs when the kingpin is forced into the jaw and the operating rod handle moves to the locked position The kingpin is released either by ac tivating a manual operating rod or if equipped with Touchloc by a dash mounted release knob which activates an air cylinder underneath the top plate The air cylinder activates the operating rod The op erating rod is located on the left side of the fifth wheel for Castloc Il and Simplex II fifth wheels and on the right side for the Simplex fifth wheel assem bly 11 28 95 f310353b 3 Operating Rod 4 Mounting Bracket 1 Lubricant Grooves 2 Safety Latch Fig 10 8 Simplex Stationary Fifth Wheel 04 08 96 1310445 Slider Saddle Plate Safety Latch Operating Rod Operating Lever 1 Baseplate 2 Bolted Stop 3 Baseplate Rail 4 Fifth Wheel Mount con oxm Fig 10 9 Taperloc Slide Manually Operated Release On sliding fifth wheels the top plate is mounted on a sliding saddle plate which slides along the baseplate attached to the tractor frame The baseplate rails allow forward and rear movement of the slide assem bly for optimum weight distribution over the tractor axles Tapered slots in the baseplate rails aligned in 4 inch 102 mm increments provide f
390. ts Consider undeployed air bags to be dangerous and capable of deploying at any time Do not at tempt to service the air bag system unless trained to do so Damaged air bag systems should be examined by qualified personnel be fore any attempt is made to remove or to deploy the air bag All intentional deployments and test ing of the system should be performed by trained personnel Unintentional or improper air bag de ployment could cause severe bodily injury or death Do not attempt to disassemble the air bag inflator unit or breach the integrity of the sealed metallic inflator case Doing so could cause severe bodily injury or death Do not allow system chemicals to contact other liquids combustibles and flammable materials Doing so could cause chemical burns or per sonal injury The surface of the deployed air bag may contain small amounts of sodium hydroxide which is a by product of the gas generant combustion and metallic sodium Sodium hydroxide may be irri tating to the skin and eyes Always wear rubber gloves and safety glasses when handling a de ployed air bag Immediately wash your hands and exposed skin areas with a mild soap and water Flush your eyes immediately if exposed to so dium hydroxide Review and comply with the following list of warnings Failure to do so could result in severe injury or death Keep all liquids acids halogens heavy metals and heavy salts away from the air bag system
391. ually inspect the lock pins to make sure they have seated in the base plate rail holes For manually operated models Raise the operat ing rod so that it is free to move inward Make sure that the lockpins have seated in the base plate rail holes and the operating rod moves into the locked position Also the safety latch must drop downward so that it holds the operating rod in the locked position 9 The amount of load distribution on the front steering axle and rear drive axle s will have a direct effect on the steering control of the vehicle Determine the front and rear axle weights by weighing the vehicle on scales designed for this purpose 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 rat ing given on the FMVSS or CMVSS label A WARNING Adjust the fifth wheel slide correctly and do not overload any tractor axle by incorrectly loading the trailer Incorrect slide adjustment or improper axle loading could cause erratic steering and loss of vehicle control possibly resulting in seri ous personal injury or death 10 10 Fifth Wheels and Trailer Couplings Fifth Wheel Lubrication A WARNING
392. uipped Perform periodic maintenance as instructed in the Maintenance Interval Schedule in the Cater pillar Operation and Maintenance Manual Cummins NOTICE When safe to do shut down the engine at the first sign of malfunction Almost all malfunctions give some warning to the operator before signifi cant damage occurs Many engines are saved because alert operators heed warning signs sud den drop in oil pressure unusual noises etc and immediately shut down the engine Failure to do so could damage the engine 1 With the vehicle stopped apply the parking brakes and place the transmission in neutral IMPORTANT Bearings and seals in the turbo charger are subjected to the high heat of com bustion exhaust gases While the engine is run ning this heat is carried away by oil circulation but if the engine is stopped suddenly the turbo charger temperature may rise as much as 100 F 56 C The extreme heat may cause bearings to seize or oil seals to leak 2 Idle the engine three to five minutes before shut ting it down This allows the lubricating oil and the water to carry heat away from the combus tion chamber bearings shafts etc This is espe cially important with turbocharged engines NOTE 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
393. ult your engine manufacturers documentation for details Both active and passive regen happen auto matically without driver input When operating conditions do not allow at speed ac tive or passive regen the vehicle may require a driver activated parked regeneration parked regen with the vehicle stationary Completing a parked regen takes 20 minutes to an hour depend ing on ambient conditions The ATS warning lamps in the driver message center alert the driver of a regen in progress high exhaust temperatures or the need to initiate a regen See Fig 7 1 and Fig 7 2 The engine warning lamps work alongside the ATS warning lamps to indicate the severity of the warning a steadily illuminated yellow malfunction indicator lamp MIL indicates an engine fault that affects the emissions a check engine lamp indicates that an engine derate may occur a stop engine lamp indi cates that an engine shutdown will occur See Fig 7 3 A reference card is included with the driver s docu mentation package initially in the glove box that ex plains the ATS warnings and the actions required to Engines and Clutches d 09 25 2006 f610816a Fig 7 1 High Exhaust System Temperature HEST Lamp 09 25 2006 f610815a Fig 7 2 Diesel Particulate Filter DPF Status Lamp c e e 07 09 2009 1611036 1 Malfunction Indicator Lamp MIL 2 Check Engine Warning Lamp 3 Stop Engine Lamp Fig
394. umber of idle gallons is on the left and the odometer miles are on the right with a space in be tween See Fig 2 47 7 15 132 5 GAL 0007475 MI 07 29 97 601411 Fig 2 47 Idle Hours Idle Gallons Odometer Screen Once the parking brake is released whether the ve hicle is moving or not the regular message screen display is the MPG Graph Target MPG Odometer screen The MPG graph is a dynamic display graph demonstrating how the actions of the driver affect fuel economy The graph moves to the right as fuel economy improves See Fig 2 42 NOTE Press the left arrow key to lower the tar get MPG and the right arrow key to raise it For more information on how to set the target MPG see Setup Information later in this chapter ICU2M Roll Call Each time the ignition switch is turned on the ICU2M roll call function requests data from each ECU on the datalink If the ECU does respond to this request the datalink is communicating with that ECU and no fault code is displayed NOTE Each ICU is configured to receive re sponses from a list of selected ECUs as in stalled on that particular vehicle If the ECU does not respond to this request the ICU2M displays an active fault code that indicates the datalink is not communicating with that ECU For a sample fault code and message of this type see Fig 2 48 For a list of roll call faults see Section 54 03 of the Century Class Trucks Workshop Ma
395. ument control panel down to SET CST or push the SET button on the trans mission shift knob 2 To disengage the PTO 2 1 Depress the brake pedal or clutch pedal Or 2 2 Press the lower half of the SPD CNTL rocker switch on the instrument control panel or press the PAUSE button on the shift knob 3 To resume a previously selected engine speed 3 1 If the SPD CNTL switch on the instrument control panel is turned off turn it on 3 2 Momentarily flip the paddle switch on the instrument control panel up to RSM ACC or press the RESUME button on the trans mission shift knob 4 To adjust engine speed up or down hold the RSM ACC SET CST paddle switch up to accel erate or down to decelerate until the desired speed is reached or press the SET button on the transmission shift knob to accelerate or the RE SUME button to decelerate until the desired speed is reached NOTE The resume engine speed memory is not maintained if the ignition is shut off Engine Braking Systems The engine brake is enabled by an ON OFF switch with a separate intensity switch to select low me dium or high braking power A WARNING To avoid injury from loss of vehicle control do not activate the engine brake system under the following conditions on wet or slippery pavement when driving without a trailer bobtailing or pulling an empty trailer if the tractor drive wheels begin to lock or there is fishtail motion after the engine
396. unicating to the ECM the driver s intention of changing gears Transmissions NOTE If the system switch is OFF use the shift intent switch to select between ranges Push the top of the switch Fig 8 16 to select the HI range on upshifts and the bottom of the switch Fig 8 17 to select the LO range on downshifts NON EUN SAAR A B 02 17 98 1270059 A Press the top portion engage the first position of the shift intent switch to begin an upshift B Press the top portion again engage the second position to break torque Fig 8 16 ESS Upshifting Using the Shift Intent Switch SN X A B 02 17 98 1270060 A Press the bottom portion engage the first position of the shift intent switch to begin a downshift B Press the bottom portion again engage the second position to break torque Fig 8 17 ESS Downshifting Using the Shift Intent Switch Make sure that the transmission is in neutral N when you start the vehicle If the vehicle is started in gear it will suddenly move forward or backward which could result in personal injury and damage to property and the transmission Starting the Vehicle 1 Ensure that the shift lever is in the neutral N position 2 Push the clutch pedal to the bottom of its travel to engage the clutch brake B Start the engine Slowly release the clutch pedal 5 Allow the system air to build up to the range specified on the gauge 6
397. unk Catches sse uke dupe 8 LER DEAL Ib ROV dC S RR 6 AER EERO Rd o CPP e ka 3 13 Baggage Compartment DOOIS Lcucieee esu hr RRRRREREREERRR RR IR ERE ERA ERA EXTA 3 13 Back of Cab Grab Handles Steps and Deck Plate 0 0c cece eee lees 3 13 Battery BOX GOVOl ccc er imien erium KRRERRREYRATRNORERA RE REFXZSQEZEREREERGY RE dese HRS 3 14 Hydraulic Cab S VIDI s oun tend Gene IPod dog Pet bed ra ROS RECETTE CE 3 15 Keyless Security System optional sseeseseeseeseeeeeeee Ie 3 18 Gab ABE sos ced pea e cR S ArT EEE TERI 8564080400464 SAQRUR ERAS S P EA BS 3 21 Windshield Washer Reservoir l llelleleeeseeeee e teens 3 21 Cab Front Access Panel sues IER IE IE uiu be ee ee be ee oe ee eee 3 21 Vehicle Access Ignition and Lock Key One key operates the ignition switch and all of the door locks IMPORTANT Each key is numbered Record the number so if needed a duplicate key can be made Cab Door Locks and Handles To unlock the driver s door from outside the cab in sert the key in the lockset and turn it one quarter turn clockwise Fig 3 1 Turn the key counterclockwise to the original position to remove it Pull out on the paddle handle to open the door Fig 3 1 9 07 95 f600906 1 Lockset 2 Paddle Handle Fig 3 1 Exterior Door Handle To unlock the passenger s door from outside the cab insert the key in the lockset and turn it one quarter turn counterclockwise Turn the key to
398. unusual loss of power turn the engine off as soon as possible and deter mine the cause of the problem Frequently engine damage may be avoided by a quick response to early indications of problems 1 Use the tachometer to determine when to shift Follow the pattern on the shift lever when moving through the gears 2 Depending on the vehicle gearing the posted speed limit can sometimes allow operation in ei ther of the top two gears however for improved operating efficiency fuel economy and engine life operate in the top gear at reduced rpm rather than in the next lower gear at the maxi mum rpm 3 Cruise at partial throttle whenever road condi tions and speed requirements permit This driv ing technique permits operating within the most economical power range of the engine 4 Use lower gears in steep downhill driving Nor mally the gear used to descend a hill is the same gear used to climb a hill of the same grade 5 Never allow the engine to exceed the rated speed Use the exhaust brake and the optional constant throttle brake if installed to lower en gine rpm below the rated speed 6 Never allow the engine to idle for more than 30 minutes Excessive idling can cause oil to leak from the turbocharger NOTICE Stop the engine at the first sign of malfunction Almost all malfunctions give some warning to the operator before significant damage occurs Many engines are saved because alert operators heed t
399. ure may indicate mechanical failure Bring the vehicle to a safe stop and investigate the cause to pre vent further damage Do not operate the engine 2 54 Instruments and Controls Identification until the cause has been determined and cor rected Coolant Temperature Gauge During normal engine operation the coolant tem perature gauge Fig 2 65 should read 175 to 195 F 79 to 91 C If the temperature remains below 160 F 71 C or exceeds the maximum temperature shown in Table 2 5 inspect the cooling system to determine the cause See Group 20 of the Century Class Trucks Workshop Manual for troubleshooting and repair procedures Maximum Coolant Temperature Engine Model F C Caterpillar 215 101 Cummins 225 107 Mercedes Benz Detroit Diesel 221 105 215 101 Table 2 5 Maximum Coolant Temperature Engine Oil Temperature Gauge During normal operation the engine oil temperature gauge should read from 200 to 260 F 93 to 126 C Under heavy loads such as when climbing steep grades temperatures that exceed the normal oil tem perature range for a short period are not unusual NOTICE A sudden increase in oil temperature that is not caused by a load increase may indicate mechani cal failure Bring the vehicle to a safe stop and investigate the cause to prevent further damage Do not operate the engine until the cause has been determined and corrected Voltmeter
400. ure the safety chains If extra towing clearance is needed remove the front wheels A WARNING Failure to lower the vehicle could result in the air fairing striking an overhead obstruction such as a bridge or overpass and causing vehicle dam age or personal injury 10 On vehicles equipped with an air fairing repeat the measurement taken in step 8 The difference between the two measurements must not exceed 14 inches 36 cm If necessary lower the ve hicle 11 Connect the clearance lights taillights and sig nal lights Connect any special towing lights re quired by local regulations Failure to chock the tires or connect the tow truck s air brake system before releasing the spring parking brakes could allow the disabled vehicle to suddenly roll This could cause prop erty damage or personal injury 12 Chock the disabled vehicle s tires and connect the towing vehicle s air brake system to the ve hicle being towed Then release the spring park ing brakes and remove the chocks Rear Towing Hookup CAUTION Using a rear towing hookup on a vehicle equipped with a roof fairing could cause damage to the cab structure 1 Place the front tires straight forward and secure the steering wheel in this position 2 Disconnect the battery ground cables A CAUTION Failure to protect the frame rails from the chains could cause damage leading to eventual frame failure 3 On dual drive axles using protecti
401. ures if needed 19 3 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 Dur ing tire inflation compressed air reservoirs and lines must be kept dry Use well maintained inline moisture traps and ser vice them regularly Do not operate the vehicle with underinflated or overinflated tires Incorrect inflation can stress the tires and make the tires and rims more sus ceptible to damage possibly leading to rim or tire failure and loss of vehicle control resulting in serious personal injury or death 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 inflation Some rims and wheels are stamped with a maximum load and maximum cold inflation rat ing If they are not stamped consult the rim or wheel manufacturer for the correct tire inflation pressure for the vehicle load If the load ex ceeds the maximum rim or wheel capacity the load must be adjusted or reduced 20 Inspect each tire for wear bulges cracks cuts penetrations and oil contamination 20 1 Check the tire tread depth If tread is less than 4 32 inch 3 mm on any front tire or less than 2 32 inch 1 5 mm on any rear tire replace the tire 20 2 In
402. used to reset the counters for trip and fuel information and to reset fault code screens after the faults have been cleared See Fig 2 29 for information on how to use the set reset key With the parking brake released only the odometer and alert screens can be displayed Park the vehicle and set the parking brake to display additional screen functions Trip Information Trip information allows you to view trip mileage and time time spent idling average miles per hour leg mileage and time and roll count if the vehicle has roll stability See Fig 2 30 When the odometer is displayed press the right arrow key to display the trip information screen Press the right arrow key again to display trip miles average miles per hour and leg miles in that order This sequence completes the trip information Screens From here press the right arrow key again to return to the trip information screen From any trip informa tion screen press the left arrow key to return to the previous screen in the sequence Press the down arrow key to go on to fuel information Fuel Information Fuel information allows you to view total fuel usage since the last reset fuel mileage and fuel consumed while idling or running the PTO See Fig 2 31 From the trip information screen press the down arrow key to display the fuel information screen Press the right arrow key to display fuel used and average miles per gallon and again to display idle
403. utton is pushed the fob sends a radio frequency signal to the ECM The signal con tains a unique vehicle access code that identifies the individual fob plus codes that indicate which button has been pushed The ECM detects the signal sent by the fob ampli fies it and converts it to a digital sequence If the LOCK button is pressed the ECM arms the system It locks the two cab doors begins to monitor all the entry points the two cab doors the sleeper cab access door and the two baggage doors as in stalled and instructs the relay module to start flash ing the system LED at the slow rate If any entry points are open the ECM sounds the horn and flashes the cab marker lights twice If the ignition key switch is turned off the ECM interrupts ignition power to the engine The driver may be inside or outside the vehicle However if the engine is running at the time the LOCK button is pressed the system still enters the armed state except that the engine is not immobi lized This improves security for the occupant as well as comfort while sleeping or resting because the System is armed and the heating or air conditioning is operating without draining any batteries Once the system is armed the alarm functions acti vate whenever one of the entry points is opened In the alarmed state the ECM does the following Immobilizes the vehicle by cutting off power between the ignition key switch and the engine electronic contr
404. ve hicle control possibly causing personal injury and property damage A Jacobs engine brake is a hydraulic electric engine attachment that converts a diesel engine into an air compressor This is done by changing engine ex haust valve operation An engine brake is not a sub stitute for a service braking system except in emer gencies because it does not provide the precise control available from the service brakes To engage the engine brake the dash switch must be in the LO or HI position and both the clutch and throttle pedals must be fully released To disengage the engine brake depress the throttle or clutch pedal or move the dash switch to OFF Use the LO position when driving on flat open stretches of road If you need to use the service brakes to slow down 7 23 switch to a higher position until there is no need for the service brakes WARNING The engine brake must be disengaged when shifting gears The clutch must be used if the dash switch is in the LO or HI position If the en gine brake is engaged when the transmission is in neutral the braking power of the engine brake can stall the engine which could result in loss of vehicle control possibly causing personal injury and property damage Since the engine brake is most effective at rated en gine speed gear selection is very important Gearing down the vehicle within the limits of the rated engine speed makes the engine brake more effective Rec om
405. vely 2 Use the clutch brake to stop gear rotation when shifting into low or 1st or reverse when the ve hicle is stationary The clutch brake is actuated by depressing the clutch pedal all the way to the floor For normal upshifts and downshifts only a partial disengagement of the clutch is necessary to break engine torque 8 6 Transmissions A AN TO EE U 3 D N i Y s 6 8 E LOW n 4 03 13 96 A All RT and RTX B Transmissions B All RTO Transmissions C All RTX R Transmissions B C Hi 5 8 Bic 6 8 WT 4 wy j i 4 N N AS 6 B 7 IW Xo xg 1 3 1260027a D High Range E Low Range Fig 8 5 Fuller 9 Speed RT RTO and RTX Model Transmissions Shift Patterns A B HIN TNCS Hi 7 70 HUC 27X4 Pos i N N 1 6 8 10 D 65 85 9 WBS 173 4 03 13 96 f260043a A All RT and RTX Transmissions B All RTO Transmissions C High Range D Low Range Fig 8 6 Fuller 10 Speed RT RTO and RTX Model Transmissions Shift Patterns Do not make range shifts with the vehicle moving in reverse gear Never attempt to move the range preselection lever with the gear shift lever in neutral while the vehicle is moving Preselection with the range preselection lever must be made prior to moving the shift lever out of gear into neutral Do not shift from high range to low range at high vehicle speeds Use double clutching between all upshifts and downshifts After your shiftin
406. ver 200 0000 ee eee 3 14 Brake System c wis dae eae a e ee aa eed 6 1 Automatic Slack Adjusters 6 5 Brake System Operation 6 2 General Information l l 6 1 Meritor WABCOS Antilock Braking System ABS 6 4 C Cab ACCESS ss gl RE IE 3 1 Cab Access Stairs Optional 3 2 Exterior Cab Grab Handles and Fixed Access Steps 3 10 Cab Amenities llle 3 21 Ash Tray and Cigar Lighter 3 21 Courtesy LighlS erai pede RR IRR ERR 3 21 Cup Holders 22s leres ITI 3 21 GIOVE BOX 2 wei soe wd RR SR EROR 3 21 Map Holder 2 2 prm 3 21 Overhead Lights 0004 3 21 Cab Door Locks and Handles 3 1 Cab Front Access Panel 3 21 Cab Washing and Polishing 12 1 Cab to Sleeper Access 0 220055 3 12 Canadian Motor Vehicle Safety Standard CMVSS Labels 1 2 Subject Page Care of Chrome Parts 0 000 ues 12 1 Care of Fiberglass Parts 005 12 1 Circuit Breaker Relay Panel 3 12 Cl teligS 1 es ceia paoe e weed we nw BPS a 7 27 Clutch Operation llle 7 28 General Information 7 27 Lubrication iius ono ey yy Rs 7 29 Collision Warning System CWS Eaton VORAD EVT 300 Stand Alone leeren 2 42 Driver Display Unit DDU
407. w range downshift through the low range gears as conditions re quire Never fully depress the clutch pedal to use the clutch brake when downshifting or as a brake to slow the vehicle Allison Automatic Models General Information HD series automatic transmissions have six forward speeds and one reverse speed See Fig 8 14 These transmissions have electronic shift controls that can be programmed to allow the use of different numbers of geared speeds For instance the trans mission can be programmed to operate as a 4 speed 5 speed or 6 speed unit in the primary shift mode If needed a secondary shift mode can be programmed to provide another shift configuration to optimize vehicle use under different operating con ditions To activate a secondary shift mode or other special function programmed into the electronic con trol unit ECU depress the Mode button Mode On is displayed in the indicator panel just above the push buttons A label just above the Mode button identifies the special function NOTE Each time a push button is depressed on the shift selector a short beep will be heard This indicates that the ECU has received input to change operation The HD series transmission system is designed to warn the driver of transmission malfunctions The driver of a vehicle equipped with these transmissions Transmissions SELECT MONITOR MODE ON 1 2 R vos Alli 10 31 94 600369a 1 Indicator Panel 2 Mode
408. water spray at the side sensor may cause the red light on the side sensor display to illuminate Under these conditions the system is temporarily unable to provide adequate warnings Failure to drive safely and use the system prop erly could result in personal injury and or death and severe property damage NOTE A continuous fixed object on the right side of the vehicle such as a guard rail wall tunnel or bridge may cause the side sensor alert light to stay on Maintenance and Diagnostics 1 Keep the antenna assembly and side sensor s free of a buildup of mud dirt ice or other debris that might reduce the system s range 2 The system tests itself continuously and evalu ates the results every 15 seconds If a problem is detected with the front radar system the HDWY FAIL light on the ICU illuminates continu ously as long as the failure is active The corre sponding fault message is displayed on the ICU 3 Both active and inactive faults can be indicated by the ICU when the system is placed in failure display mode Inactive faults are those that have occurred and have cleared Active faults are still present Faults provide the driver the ability to record the system faults during a trip and to no tify his maintenance department or Eaton VORAD In this mode specific fault messages are displayed on the ICU 4 Additional failure messages display at intervals of approximately 8 seconds Lane Guidance System The L
409. way from the cab Do not engage in horseplay Do not enter the cab with dirty or greasy hands or feet Disregarding this careful step by step procedure can result in your falling from the cab and pos sible personal injury or death 1 Open the driver s door and place anything that you are carrying in the cab 2 Grasp the aft grab handle Fig 3 3 with your right hand and grab the forward grab handle with your left hand Reach up as far as you re com fortable 3 Very carefully place your right foot on the bottom step and pull yourself up 4 Place your left foot on the next step and carefully pull yourself up 3 4 Vehicle Access 5 Place your right foot on the top step and care fully move your right hand to the forward grab handle and your left hand to the steering wheel Hold on very tightly and maintain three point con tact with the cab at all times 6 Then slowly move your left foot to the deck at the top of the stairs 7 Holding tightly to the steering wheel with your left hand move your right hand to the steering wheel 8 With both of your hands gripping the steering wheel tightly step into the cab with your right foot 9 With your right foot securely in the cab and both hands gripping the steering wheel move your left foot into the cab Exiting the Driver s Side Using the Cab Access Stairs Fig 3 3 If the optional cab access stairs do not move into position or if there is not enough room
410. which includes a manual steering mechanism a hydraulic control valve and a hydrau lic power cylinder hydraulic hoses power steering pump reservoir and other components Some models are also equipped with a separate hydraulic power cylinder on the right side of the front axle The power steering pump driven by the engine provides the power assist for the steering system If the en gine is not running there is no power assist If the power assist feature does not work due to hydraulic fluid loss steering pump damage or some other 6 1 cause bring the vehicle to a safe stop Do not drive the vehicle until the cause of the problem has been corrected Driving the vehicle without the power assist fea ture 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 carefully use the power available with a power steering system 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 Brake System General Information A dual air brake system consists of two independent air brake systems which use a single set of brake controls Each system has its own reservoirs plumb ing and brake chambers T
411. witch on the dash controls the engine braking system Like the engine brake the constant throttles are deactivated when the accelerator or clutch pedal is depressed The ABS system when active also deactivates constant throttle braking Exhaust Braking System CAT Cummins DDE S60 M B An exhaust brake is an optional auxiliary braking sys tem that assists but does not replace the service brake system The exhaust brake can be used alone or together with the constant throttle valves for steep or long grades The exhaust brake switch located on the control panel in combination with the accelerator and clutch pedals allows the driver to make maxi mum use of the exhaust brake in off highway and mountain driving as well as in traffic or high speed highway driving 7 24 Engines and Clutches When only the exhaust brake is installed a two position switch on the dash controls the engine brak ing system The exhaust brake is only active when the engine speed is between 900 and 2700 rpm De pressing the accelerator or clutch pedal deactivates the exhaust brake The ABS system when active also deactivates the exhaust brake The exhaust brake is a butterfly valve mounted in the exhaust pipe When the driver s foot is not on the accelerator pedal and the exhaust brake switch is in the on position an air cylinder shuts the butterfly valve which restricts the flow of exhaust gases and retards the engine This retarding action is
412. with a fuel water separator check for water Drain any water found Check the fuel water separator for leaks and contaminants For Racor models see Fig 11 4 Check the water level in the sight bowl To drain the water loosen the valve at the bottom of the bowl two full turns and allow the water to run out Close and tighten the valve finger tight Check the filter element and replace if clogged For ConMet models see Fig 11 5 Place a suit able container under the fuel water separator Check the water level in the sight bowl if so equipped To drain the water loosen the valve at the bottom and allow the water to run out Close and tighten the valve finger tight 11 30 95 1470166 Fig 11 4 Racor Fuel Water Separator 11 30 95 1470167 Fig 11 5 ConMet Fuel Water Separator 11 6 Pretrip Inspection and Daily Maintenance IMPORTANT When draining fluid from a fuel water separator drain the fluid into an appropri ate container and dispose of it properly Many states now issue fines for draining fuel water separators onto the ground On all types of separators stop draining fluid when you see fuel come out of the separator drain valve 11 Inspect the front and rear suspension compo nents including springs spring hangers shocks and suspension brackets 11 1 Check for broken spring leaves loose U bolts cracks in the suspension brackets and loose fasteners in the spring han
413. wo gel cell batteries to provide power for cab and sleeper accessories when the engine is off The system uses an isolator relay which is normally open The relay isolates the engine starting batteries while the engine is not running so the engine can still be started even if the gel cell has been used to the point of complete discharge The isolator relay is closed only while the engine is running With the engine running all four batteries are connected in parallel allowing the alternator to charge them all in addition to supplying power for all vehicle loads When the engine is not running the gel cell provides all of the vehicle s electrical needs except for turning the starter motor The gel cell is longer lived and cheaper to use than a standard wet cell but it can take a charge only within an extremely narrow range 13 8 to 14 1 volts At 14 volts a gel cell has a very high charge accep tance rate Because a truck charging system oper ates at approximately 14 volts under normal condi tions a gel cell will never need to be recharged with an external charger NOTICE Do not attempt to charge a gel cell with a stan dard battery charger All standard battery charg ers supply at least 16 volts to the battery This will damage the gel cell However the single gel cell has limited current supply capability and will drain down faster than a standard multiple battery installation that has no bat tery isolator system
414. would normally be required EPAO07 ATS Operation The exhaust system in EPAO7 compliant vehicles is called the aftertreatment system ATS The ATS var ies according to engine manufacturer and vehicle configuration but instead of a muffler an aftertreat GA ment system has a device that outwardly resembles a muffler called the aftertreatment device ATD IMPORTANT See your engine operation manual for complete details and operation of the after treatment system Inside the aftertreatment system the exhaust first passes over the diesel oxidation catalyst DOC then through the diesel particulate filter DPF which traps soot particles If the exhaust temperature is high enough the trapped soot is reduced to ash in a pro cess called passive regeneration passive regen Passive regeneration occurs as the vehicle is driven normally under load the driver is not even aware that it is happening The harder an EPAO7 en gine works the better it disposes of soot because the exhaust heat gets high enough to burn the soot to ash Over the course of a workday however pas sive regen cannot always keep the ATD filter clean so the filter must undergo active regeneration ac tive regen In active regen extra fuel is injected into the exhaust stream to superheat the soot trapped in the DPF and turn it to ash Active regen happens only when the vehicle is moving above a certain speed determined by the engine manufacturer Con s
415. ws 1 Facing the center of the deck plate grasp the grab handle with both hands Reach up as far as is comfortable 2 Place one foot on the bottom step and pull your self up 3 Place your other foot on the top step 4 Move your lower hand to a higher position on the grab handle 5 Step onto the deck plate Exiting the Back of Cab Area When climbing down from the deck plate use the grab handle and access steps as follows 1 Facing the center of the deck plate grasp the grab handle with both hands 2 Step one foot at a time to the top step 3 Move your upper hand to a lower position on the grab handle 4 Move one foot to the bottom step 5 Move your upper hand to a lower position on the grab handle 6 Step to the ground with your upper foot first Battery Box Cover NOTE On vehicles with vertical mounted muf flers you must tilt the cab slightly in order to open the battery box To remove the cover from the battery box release the latch and lift the cover See Fig 3 20 Vehicle Access A P 2 p E La NONO NS US y 2 53 b A NONO P r 4 LS 4 ag 24 W t ra X a Y AL 04 13 98 1 Battery Disconnect Switch 2 Battery Box Latch 1542519 Fig 3 20 Battery Box Hydraulic Cab Tilt System The hydraulic tilt system used to raise and lower the cab consists of four major parts 1 Ahydraulic pump which consists of pump body reservoir and
416. ximize vehicle fuel economy and perfor mance Cummins diesel engines have been built by Cum mins to comply with the requirements of the Federal U S Clean Air Act Once the engine is placed in service the responsibility for meeting both state and local regulations is with the owner operator Good operating practices regular maintenance and proper adjustments are factors which will help to stay within the regulations Proper maintenance of the engine which is the responsibility of the owner operator is essential to keep the emission levels low Cummins diesel engines produce high horsepower and peak torque characteristics at lower 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 toward peak torque more practical Depending on the vehicle gearing the posted speed limit can sometimes allow operation in either of the top two gears however for improved operating effi ciency fuel economy and engine life operate in the top gear at reduced rpm rather than in the next lower gear at the maximum rpm Cruise at partial throttle whenever road conditions and speed requirements permit This driving tech nique permits operating within the most economical power range of the engine When approaching a hill open the throttle smoothly to start the upgrade at full power then sh
417. y See Fig 2 52 After vehicle information pressing the DOWN ARROW takes you back to trip information and so on Instrumentation Control Unit ICU2L The instrumentation control unit ICU2L is a basic electronic dashboard It can accept information from the various sensors installed on the vehicle and feed it to electronic gauges Only air gauges operate mechanically 2 38 Instruments and Controls Identification See q applicable a Figure SETUP INFORMATION A TYY a VEHICLE INFORMATION ml PUSH SET KEY TO CHANGE TARGET MPG Y Y PUSH SET KEY TO CHANGE BRIGHTNESS ry PUSH SET KEY TO CHANGE LANGUAGE ry PUSH SET KEY TO CHANGE UNITS DATA LINK ACTIVE 11111 tt Y To trip information 01 29 98 See applicable Figure S S IS FLASHING LANGUAGE ENGLISH S W FRENCH SPANISH S CURRENT UNITS IS FLASHING UNITS S W ENGLISH METRIC TARGET MPG 7 0 lt LESS MORE gt DISPLAY BRIGHTNESS LIGHT DARK gt CURRENT LANGUAGE DATA LINK STATUS DASH st AO6 XXXXX XXX USAGE 40 ERROR 6 SW 7 3 9 R RESET PUSH RESET SET KEY TWICE S SET PUSH RESET SET KEY ONCE f040326a Fig 2 52 Setup Information and Vehicle Information There can be up to 14 removable gauges on the driver s instrument panel 11 electronic one electro mechanical and two mechanical The ICU2L cannot drive gauges lo

Drivers Manual - TransChicago Truck Group

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