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Business Class M2 - Freightliner Trucks

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1. A DEF Warning Lamp illuminated B DEF Lightbar one bar amber Fig 7 11 DEF Level Low Initial Warning DEF Quality or SCR Tampering NOTICE Once contaminated DEF or tampering has been detected in the SCR system the vehicle must be taken to an authorized service center to check the SCR system for damage and to deactivate the warning lights and engine limits If contaminated DEF or tampering is detected the DEF warning light flashes and the MIL illuminates to warn the driver The CHECK engine lamp also illumi nates if the vehicle has a Cummins ISB or ISC L en gine See Fig 7 13 A C 11 08 2010 1611037 A Green bars DEF level indicators C One bar flashing red DEF empty refill DEF B One bar illuminated amber DEF very low refill DEF 1 Diesel Fuel Warning Lamp 2 DEF Warning Lamp Fig 7 10 Fuel DEF Gauge A di Bite A dii des 07 09 2009 1470537 11 08 2010 1470539a NOTE MIL illuminates CHECK engine lamp illuminates if Cummins ISB or ISC L engine Engine power is lim ited A DEF Warning Lamp flashing B DEF Lightbar one bar flashing red Fig 7 12 DEF Empty Warning Detroit Diesel engines Power is limited with a 55 mph 90 km h speed limit If the fault is not cor rected the STOP engine light illuminates and a 5 mph 8 km h speed limit will be applied after the next engine shut down or while parked and idling
2. Fuse Identification Main Fuse Box NS Description Fuse Color Rating F1 VCU MBE900 only Red 10 Amp F2 Blower Motor Green 30 Amp F3 Engine ECU Yellow 20 Amp F4 UL cael Control Giaah 30 Amp F5 Ignition Switch Tan 5 Amp F6 Spare F7 Bulkhead Module Green 30 Amp F8 ICU Red 10 Amp F9 ee Control Yellow 20 Amp F10 Door Locks optional Red 10 Amp F11 Mirrors optional Blue 15 Amp F12 Radio Diagnostics Yellow 20 Amp F13 Chassis Module Green 30 Amp L H Power Windows F14 optional Blue 15 Amp F15 Bulkhead Module Green 30 Amp F16 ABS ECU Blue 15 Amp F17 Chassis Module Green 30 Amp F18 Bulkhead Module Green 30 Amp F19 Chassis Module Green 30 Amp F20 Bulkhead Module Green 30 Amp R H Power Windows F21 optional Blue 15 Amp F22 Bulkhead Module Green 30 Amp F23 Spare F24 Spare F25 Spare F26 Spare M1 Battery Power 125 Amp M2 Battery Power 125 Amp M3 Battery Power 150 Amp Table 2 1 Fuse Identification Main Fuse Box Trailer and Taillight Fuse Boxes The trailer fuse box and the taillight fuse box on ve hicles so equipped are mounted on a bracket with the chassis module on the left hand frame rail aft of the cab or on a crossmember at the end of the frame rail These may be referred to as the chassis fuse box or chassis PDM See Fig 2 13 for trailer fuse and relay information and Fig 2 14
3. dico P Weekly Post Trip Inspections Checks rela Manually drain air reservoirs that are equipped with automatic drain valves Inspect batteries and battery cables Wi 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 Table 11 2 Weekly Post Trip Inspection and Maintenance Checklist dis d Monthly Post Trip Inspections Checks sess 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 Inspect natural gas fuel system leak test if equipped M5 drain the CNG high pressure fuel filter housing if equipped M6 Inspector Date Table 11 3 Monthly Post Trip Inspection and Maintenance Checklist Pretrip and Post Trip 1 1 Open the wet tank valve The drain cock or pull chain drain is located on the for Maintenance Procedures ward end of the supply air reservoir which Daily Pretrip Inspection and Maintenance sor Block the valve open is connected directly to the air compres Whenever equipment requires adjustment replace ment
4. 6 3 GluteliBS qs ek ovale i ee ee ede wee hee Xe ee ox 8 1 Clutch Adjustments 0005 8 2 Glutch Lubrication screens giene rear 8 2 Clutch Operation o o o o oooo ooo o 8 1 Clutch Wear 2 0 0 0 0 eee eee 8 2 Sachs Hydraulic Clutch 0 8 2 Cold Weather Operation 7 13 Cold Weather Starting o o o oooooo 7 10 Cruise Control sses rasido ritenere e nEs 7 11 Dash Mounted Switches 7 11 Shift Knob Controls Optional 7 12 Index Subject Page D Dashboard Care llle 12 1 E Eaton Fuller AutoShift 05 8 12 Automate Mods zuo eee Bawa ek goma 8 13 Manual Mode 220000005 8 13 Push Button Shift Selector 8 12 Selecting Gears o o ooo ooo 8 14 Eaton Fuller Range Shift MANSMISSIONS a 2 524 dee haa i a A 8 9 General Information Range Si a eus home wt Han eae pde 8 9 Operation Deep Reduction Models 2 mz om e dx 8 11 Operation Range Shift 8 10 Eaton Fuller UltraShift 8 15 General Information UltraSt ASW x ez 945 24 we RPM 8 15 General Information UltiaShift DM xs sena rueba Rs eee TR 8 15 Operation UltraShift 8 16 UltraShift Diagnostics 8 20 Eaton Fuller Straight Shift TANSMISSIONS x a e m fm a ER ae 8 8 General Informat
5. llus 9 1 Steering Wheel Adjustment 9 1 T Tire and Rim Labels 0 1 2 TOWINGWHEV siie a a pague Ret ne die i a ka a da 15 3 TOWING eee a ao oe She ee LSE ps 13 5 Front Towing HOOKUP xau 62 25 hone 13 5 Rear Towing Hookup 13 5 V Vehicle Specification Decal 1 1 Velour Upholstery Cleaning 12 2 Chewing Gum or Wax llle 12 3 Grease and Oil Based Stains 12 3 MCW axons dos e p ee GaN Bok e ds 12 3 Sugar and Water Based SIS Saeed wae een dock e bacio E 12 3 Vinyl Upholstery Cleaning less 12 2 Ball Point Ink 22m REI RI ny 12 2 Chewing GUN isse misias e moni mk XR RR RR 12 2 MisCellaneouUs lude Re bed ots 12 2 Nail Polish and Nail Polish REMOVED oua dax mac y al us E ERU a 12 2 Ordinary DIM isse zo more RR 12 2 Paint Shoe Heel Marks 12 2 Shoe Polisi 3 3 233 pe TREE he ew E 12 2 Sulfide StalliS a esr a C Re S Res 12 2 Tars Asphalts and Creosote 12 2 W Warning and Indicator Lights 3 5 Engine Protection System 3 5 MVIDICIOWSS s t caras E RM eet aed Aad Rede a 51 Windshield Washer Reservoir 5 11
6. Fig 8 15 Switches Ultrashift Transmission Drivetrain To change mode at any time move the slide switch in the desired direction This allows the driver to re spond to a wide range of driving conditions such as blind corners tight curves and steep hills IMPORTANT Whatever the mode it is always possible to shift manually by moving the lever up or down as needed When the engine speed is within 75 revolutions per minute rpm of the load based shift point for an automatic shift the UltraShift TCU will advance the shift In either mode the gear indicator displays the cur rent gear See Fig 8 16 10 13 2003 f610680 NOTE The gear indicator displays the current gear In this example it displays first gear Fig 8 16 Current Gear Display At the start of a shift the current gear continues to display until the transmission has been pulled into neutral At this point as the transmission is synchro nizing for the new target gear the gear indicator flashes the number of the new gear When the shift is complete the new gear displays solid without flashing Automatic Mode AUTO In automatic drive mode AUTO upshifts and down shifts are made by the transmission without driver intervention Press in the neutral lock button move the selector switch to drive D and press down on the throttle pedal The transmission will shift auto matically If driving conditions require it is still
7. 10 29 2001 1610598 Fig 4 4 Panel Light Increase Decrease Switch When the panel lights are on both legends are back lit in green Daytime Running Lights Switching on the ignition and releasing the parking brakes automatically activates the daytime running lights if equipped The daytime running lights will operate until the parking brakes are applied or the headlights are turned on NOTE Daytime running lights are standard on all Canadian vehicles The daytime running lights illuminate at about two thirds of normal power Marker Light Interrupt Switch The marker light interrupt MRKR INT paddle switch temporarily flashes the marker lights and taillights Fig 4 5 With the vehicle lights on raise the paddle to briefly turn off the marker lights and taillights With the vehicle lights off raise the paddle to briefly turn on the marker lights and taillights Turning off the vehicle lights automatically turns off the marker lights When the panel lights are on the marker light icon and MRKR INT legend are backlit in green Road Light Switch Optional The road light ROAD LAMP rocker switch operates the optional road lights which are recessed into the front bumper or mounted on the lower edge of a cut out in the center of the front bumper 4 3 Raise the paddle to flash the marker lights Fig 4 5 Marker Light Interrupt Switch The low beam headlights must be turned on before the road lig
8. Cummins engines Power is limited with progres sively harsher engine power limits applied If the fault is not corrected the STOP engine light illuminates and a 5 mph 8 km h speed limit will be applied after the next engine shut down or while parked and idling 7 8 Engines A gt DEF gt 211 i e 11 08 2010 f 470540a NOTE STOP engine light illuminates Engine power limited speed limit of 5 mph 8 km h A DEF Warning Lamp flashing B DEF Lightbar one bar flashing red Fig 7 13 DEF Empty and Ignored Warning Engine Starting For cold weather starting refer to Cold Weather Starting later in this chapter 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 re
9. 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 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 IMPORTANT Use ultralow sulfur diesel ULSD with 15 ppm sulfur content or less based on ASTM D2622 test procedure Fail ure to use ultralow sulfur diesel fuels may void the warranty on emission components 8 6 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 8 7 Before installing the fuel cap clean the area with a rag or if necessary clean the cap with solvent 8 8 f needed prime the fuel system For priming procedures see the applicable engine manufacturer s manual 9 If equipped with a fuel water separator check for water Drain any water found Check the fuel water separator for leaks and contaminants 9 1 Place a suitable container under the fuel water separator 9 2 Check the water level in the sight bowl if equipped and loosen the filter vent at the top of the separator 9 3 Drain the water by looseni
10. Use the third or second range for heavy city traffic and for braking on steeper downgrades 1 First Range Use first range when pulling through mud or deep snow when maneuvering in tight spaces or when driving up or down very steep grades First range provides the vehicle with its maximum driving torque and maximum engine braking effect NOTE To have the transmission select these ranges automatically leave the selector lever in D drive 8 5 Allison MD Series Refer to the Allison website for additional information www allisontransmission com Safety Precautions Do not leave the vehicle unattended with the en gine running If you leave the vehicle and the en gine is running the vehicle can move suddenly which could result in personal injury or property damage On vehicles with MD series transmissions do the following steps if you have to leave the cab with the engine running for example when checking the transmission fluid 1 Bring the vehicle to a complete stop using the service brake Put the transmission in N neutral 3 Ensure that the engine is at low idle 500 to 800 rpm 4 Apply the parking brake and emergency brakes and make sure they are properly engaged 5 Chock the rear tires and take any other steps necessary to keep the vehicle from moving Operating Instructions MD Series The Allison MD transmission is electronically con trolled and comes with a push button shift contr
11. 4h CAUTION Do not attempt to upshift until the vehicle has reached a sufficient speed The clutch absorbs the speed difference by generating heat which causes the clutch to wear out too soon Many drivers upshift into the next gear or even skip shift into a higher gear before the vehicle has reached the correct speed This type of shifting is almost as bad as starting off in a gear that is too high When the engine speed rpm and the vehicle speed mph or km h are too far apart the clutch must absorb the difference in speed by generating heat To downshift in MANUAL press the downshift button down arrow and release The number of the gear will appear on the mode indicator If the requested gear is available the transmission will shift down If any requested gear is not available an audible warning will sound and the digital display will indicate that the gear is not available Selecting Gears R Reverse Reverse R is used to back the vehicle Make sure the vehicle comes to a full stop and the clutch pedal has been pressed before shifting into reverse To select reverse press the clutch pedal to the floor Then press the R button N Neutral Neutral N is used for starting parking or any sta tionary operation No gear is selected The transmis sion must be in neutral to start the engine IMPORTANT If the vehicle starts up in any gear but neutral bring the vehicle to an authorized Freightliner servic
12. 8 Perform a coupling inspection checking that there is no gap between the bottom of the trailer and the fifth wheel and that the kingpin is se curely locked See Fig 10 6 When lockup has occurred the fifth wheel con trol handle moves to the locked position Make sure that the safety latch is down over the lock control handle to hold the control handle in the locked position The safety latch will only rotate down if the operating rod is fully retracted in the locked position See Fig 10 2 for Fontaine fifth wheels See Fig 10 3 for Holland fifth wheels 9 Release the tractor parking brakes Test for king pin lockup slowly inching the tractor forward pull ing on the trailer against the chocks 10 After lockup is completed connect the tractor to trailer air system lines and the electrical cable to the trailer Take care to prevent dirt or foreign material from entering the air system lines 10 3 U Reso A B 09 10 2010 A No gap between trailer and fifth wheel 311126 B Kingpin inside lock Fig 10 6 Coupling Inspection NOTICE Always make sure the connection hanger keeps the trailer air hoses and electrical cables posi tioned so that they do not rub on anything Rub bing may wear through hoses or cables resulting in air leaks or exposed or broken wires poten tially affecting trailer brake or electrical systems 11 Charge the air brake system with air checking t
13. Clean the headlight lenses by hand only using a flannel cloth with mild non caustic soap or detergent and water Ah CAUTION Do not use a power buffer paper towels chemi cal solvents or abrasive cleaners on the head light lens all of which can remove the UV coating from the surface and result in yellowing of the lens Dashboard Care Periodically wipe the dashboard with a water dampened cloth A mild detergent can be used but avoid using strong detergents Ah CAUTION Do not use Armor All Protectant STP Son of a Gun or other equivalent treatments These cleaners contain vinyl plasticizers that can cause Cab Appearance 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 repeated sever
14. 5 Do not shift from high range to low range at high vehicle speeds 6 Use double clutching between all upshifts and downshifts 7 After your shifting ability improves you may want to skip some of the ratios This may be done only when operating conditions such as load grade and road speed permit 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 3 Press the clutch pedal to the floor Shift into low or first gear then engage the clutch with the en gine at or near idle speed to start the vehicle moving Accelerate to 80 percent of engine gov erned speed 4 Shift progressively up from low or 1st gear to the top gear in low range double clutching between shifts and accelerating to 80 percent of engine governed speed 8 11 5 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 As the shift lever passes through neutral the transmission will automati cally shift from low range to high range 6 With the transmission in high range shift pro gressively up through each of the high range gears double clutching between shifts Downshifting 1 With the transmission in high range shift pro gr
15. Close all windows and doors dur ing the fueling process Keeping windows and doors closed allows for easier leak detection inside the cab after fueling WARNING Liquefied natural gas is a cryogenic liquid stored at approximately 259 F 162 C Cryogenic burns can be caused by coming into contact with the pressurized liquid stream or by coming into contact with fuel system components that have been cooled to cryogenic temperatures Always wear gloves and a face shield and cover ex posed skin when fueling 2 Remove the fuel fill fitting dust cap See Fig 16 2 Natural Gas Vehicle 05 29 2009 1 Fuel Fill Fitting 2 Fuel Outlet Line 3 Primary Relief Vent Line 1470534 4 Fill Vent Fitting 5 Shroud Cover 6 Shroud Cover Latches Fig 16 2 LNG Fuel Tank 3 Using compressed air remove any dirt debris or water that may have collected in the fuel fill fit ting and the station dispensing nozzle Contami nants in the fuel system can cause drivability problems Natural gas fuel tanks lines and valves are al ways pressurized Always observe safety precau tions Failure to do so could lead to loss of con trol over a filling hose or to ignition of the natura
16. Engines in this chapter for instructions on preventing au tomatic regen if necessary The exhaust temperature can remain high even after the vehicle has stopped When stopping the vehicle shortly after an automatic regen ensure the exhaust outlets are directed away from struc tures trees vegetation flammable materials and anything else that may be damaged or injured by exposure to high heat Operating at reduced engine load will allow soot to accumulate in the DPF When this occurs the DPF lamp illuminates indicating that a regen must be per formed and the driver must either bring the vehicle up to highway speed to increase the load or park the vehicle and initiate a parked regen See Parked Regen later in this chapter for instructions After the exhaust stream passes through the ATD it flows through another canister housing the SCR de vice A controlled quantity of diesel exhaust fluid DEF is injected into the exhaust stream where heat converts it to ammonia NH gas This mixture flows through the SCR device where the ammonia gas reacts with the NOx in the exhaust to produce harm less nitrogen N and water vapor H20 which then exits out of the tailpipe ATS Warning Lamps The malfunction indicator lamp MIL illuminates to indicate a fault that affects the emissions See Fig 7 3 Warning lamps in the driver s message center alert the driver of situations with the aftertreatment sys tem A decal at
17. See Fig 4 17 On some models cruise control can be activated by a button on the transmission shift knob The On Off Switch this two position rocker switch bears the legend SPD CNTL on the lower half of the switch When cruise control is on an amber light illuminates in the top part of the switch The Set Resume Switch this three position paddle switch bears the legend RES ACC above the paddle and SET CST below the paddle NOTE For more information about cruise con trol operation see Chapter 7 Engine Brake Switch Optional The engine brake switch controls the degree of en gine braking Normally there are two paddle switches a two position On Off Switch to activate the engine brake and a two position HI LO Switch to control the amount of engine braking To turn the two position On Off Switch on raise the paddle When the two position switch is on an amber LED light emitting diode illuminates inside the switch To turn the two position HI LO Switch on high raise the paddle at the HI LO icon To turn the two position HI LO Switch on low lower the paddle at the ENG BRK legend See Fig 4 18 A three position switch is used on MBE900 engines equipped with both the regular engine brake and the constant throttle decompression brake It works the same as the two position HI LO switch except that there is a third off position when the switch is left at its normal position 09 13 2001 1610510 To turn
18. Users of natural gas fueled vehicles should never expect to detect natural gas leaks by scent For natural gas to burn it must first vaporize then mix with air in the proper proportions flammable range is 5 to 15 by volume in air and then be ig nited A typical natural gas fuel system consists of Fuel supply cylinders that store compressed gas at high pressure CNG or a tank that stores liquefied gas at an extremely low tem perature LNG e A vaporizor or heat exchanging device that changes LNG to gaseous form LNG fuel sys tems only e Pressure relief and manual fuel shutoff valves A filling connection with a check valve that pre vents the gas from flowing back out of the fuel filling line High pressure and low pressure fuel filters A pressure control regulator that reduces the high fuel tank or cylinder pressure to the lower pressure needed for the engine A fuel contents gauge that indicates the fuel supply in the tank or cylinders 16 1 Safety Precautions Natural gas is highly flammable Failure to ob serve the following safety precautions could lead to the ignition of the natural gas which could cause serious bodily injury or death Follow these safety precautions when operating or repairing a natural gas vehicle Do not start the engine if a natural gas leak is detected Do not transfer CNG from one vehicle to an other as a buildup of static electricity could cause a sp
19. a spin on fuel filter element If there is an emergency while driving cautiously pull off the road Turn on the hazard warning lights Place the flares and reflector along the side of the road to alert other drivers that an emergency situation exists 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 Emergency Filter Replacement Davco If the filter cover on the Davco fuel water separator is broken it will not be possible to operate the vehicle A standard spin on filter will correct this problem Refer to the Davco web site for additional informa tion www davcotec com To replace the filter on all Davco fuel water separa tors follow these procedures 1 Drain the fuel until it is below the level of the fil ter collar See Fig 13 2 for the model 232 233 fuel water separator and Fig 13 3 for the model 382 fuel water separator 2 Remove the filter vent and vent seal NOTE The filter vent and vent seal are not needed in the emergency replacement They should be retained for later installation at the time when the filter cover is replaced 3 Remove the filter collar using channel lock pliers 4 Remove the filter cover filter cover seal and spring Retain them for later assembly 5 Remove the filter element and dispose of it prop erly 6 Install the standard
20. doing so could change the effectiveness of the system Failure to replace worn or damaged seat belts or making any modifications to the system may re sult in personal injury or death Pretrip and Post Trip Inspections and Maintenance 28 1 Check the web for fraying cuts extreme dirt and dust or for severe fading from exposure to sunlight especially near the buckle latch plate and in the D loop guide area 28 2 Check operation of the buckle latch Kom fort Latch or Sliding Komfort Latch if equipped web retractor and upper seat belt mount on the door pillar Check all visible components for wear or damage 28 3 Check the seat belt and tether belt con nection points and tighten any that are loose 29 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 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 1 1 Access the batteries Be sure the battery hold down is secure If it is loose tighten the hold down bolts if it is
21. downshifting and allows the engine to make better use of its fuel Nevertheless shift gears as needed to avoid excessive exhaust smoke Engine Shutdown 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 After hard operation shutting down the engine without idling may cause damage 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 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 46 C NOTICE Except in an emergency do not shut down the engine when the coolant temperature is above 194 F 90 C To do so could damage the engine 3 Turn off the ignition switch and shut down the engine Engine Braking The engine brake switch controls the degree of en gine braking Normally there are two paddle switches a two position On Off Switch to activate the engine brake and a two position HI LO Switch to control the amount of engine braking T
22. or damage may occur to the ATD 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 Use only certified diesel exhaust fluid DEF in the DEF tank After exhaust gasses leave the engine they flow into the ATS First they flow into a two part ATD com prised of a diesel oxidation catalyst DOC and a diesel particulate filter DPF The DPF traps soot particles then exhaust heat converts the soot to ash in the DPF in a process called regeneration regen The harder an engine works the better it disposes of soot When the engine is running under load and regen occurs without input it is called passive regen If the engine isn t running hot enough the electronic controls may initiate an active regen whereby extra fuel is injected into the exhaust stream before the diesel particulate filter to superheat the soot trapped in the filter and burn it to ash Both types of regen occur without driver input 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 cause a fire heat damage to objects or materials or personal injury to persons near the exhaust outlet See Regen Inhibit Switch later
23. 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 Fire in the Cab The incidence of fire in medium duty trucks is rare according to data from the National Highway Traffic Safety Administration Federal Motor Vehicle Safety Standard 302 limits the flammability of specified materials used inside the cab but despite this most materials will burn The cab of this vehicle contains urethane foam which is of concern in this respect 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 6 Preliminary Checks 14 Headlight Aiming Ghecking Aeadight AIN MD L TU 14 1 Adjusting Headlight AIM usse rex ke er E RR A ew 14 2 Headlight Aiming Preliminary Checks Before che
24. stays illuminated Abnormal Response If the LED blinks for more than 30 seconds the lock mechanism may not be fully engaged disengaged Bring the vehicle to an autho rized Freightliner service facility for testing Interaxle Lock Operation To engage interaxle lock and achieve maximum pull ing power in slippery or hazardous road conditions operate the interaxle lock switch as discussed above while maintaining vehicle speed Let up momentarily on the accelerator until the axle lock engages Pro ceed over poor road conditions with caution Do not wait until traction is lost and the tires are spinning before engaging the interaxle lock A CAUTION Do not turn on the interaxle lock switch when the tires are slipping Do not continuously operate the vehicle with the interaxle lock engaged dur ing good road conditions To do so could result in damage to the axle gearing and excessive tire wear To disengage the interaxle lock after leaving poor road conditions operate the interaxle lock switch as discussed above while maintaining vehicle speed Let up momentarily on the accelerator to allow the axles to fully unlock then resume driving at normal speed Axle Shift Ah CAUTION To prevent transmission and axle damage make sure the automatic transmission is in high range when performing an axle shift with the vehicle moving Axle shift is a function installed on vehicles with two speed axles to allow the use of the low spee
25. temperature shown in Table 3 2 Air pressure falls below approximately 70 psi 483 kPa e Parking brake is set with the vehicle moving at a speed greater than two miles per hour e System voltage falls below 12 0 volts Door is open and the parking brake is off Occupied seat belts are not fastened and the parking brake is off Outside temperature falls below 35 F 1 7 C Minimum Oil Pressure 3 At Idle Speed At Rated RPM Engine Model psi kPa psi kPa Caterpillar 10 20 69 138 30 45 207 310 Cummins 15 103 35 241 3 4 Instruments Minimum Oil Pressure Engine Model At Idle Speed At Rated RPM psi kPa psi kPa Detroit Diesel 14 97 55 350 Mercedes Benz 7 50 36 250 Oil pressures are given with the engine at operating temperature With the engine cold oil pressure may be higher Individual engines may vary from the listed pressures observe and record pressures when the engine is new to create a guide for checking engine condition Table 3 1 Minimum Oil Pressure Maximum Coolant Temperature Engine Make Temperature F C Caterpillar 230 110 Cummins 225 107 Detroit Diesel 215 101 Mercedes Benz 222 105 Table 3 2 Maximum Coolant Temperature Warning and Indicator Lights There can be up to 28 warning and indicator lamps installed in the dash message center See Fig 3 7 for pre EPAO07
26. the entire seat belt must be replaced both retractor and buckle side Any time a vehicle is involved in an accident and the seat belt system was in use the entire vehicle seat belt system must be re placed before operating the vehicle Do not at tempt to modify the seat belt system doing so could change the effectiveness of the system Failure to replace worn or damaged seat belts or making any modifications to the system may re sult in personal injury or death Inspect the seat belts and tether belts if so equipped 1 Check the web for fraying cuts extreme dirt and dust or for severe fading from exposure to sun light especially near the buckle latch plate and in the D loop guide area 2 Check operation of the buckle latch Komfort Latch or Sliding Komfort Latch if equipped web retractor and upper seat belt mount on the door pillar Check all visible components for wear or damage 3 Check the seat belt and tether belt connection points and tighten any that are loose Seat Belt Operation Three Point Seat Belt With Komfort Latch or Sliding Komfort Latch 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 When engaged and
27. there is a prob lem which may or may not be apparent to the driver Bring the vehicle at once to a safe stopping place and call an authorized Freightliner service facility for assistance Clutch Overload If the TRANS TEMP telltale light comes on while driving and the current gear indicator begins to flash between the current gear and CO clutch overload the clutch has begun to overheat The clutch overload may have been caused by im proper driving practices such as frequent and rapid start stop driving or hillholding with the throttle pedal In this case allow the clutch to cool and continue on but cease the improper driving practices If the clutch overload message returns or continues the clutch is worn or damaged Bring the vehicle at once to a safe stopping place and call an authorized Freightliner service facility for assistance Low Hydraulic Fluid Level IMPORTANT The only hydraulic fluid permitted in this system is Pentosin CHF 11S No other fluid can be substituted If the CHECK TRANS telltale light comes on while driving and the current gear indicator begins to flash between the current gear and FL fluid level there has been an unusual loss of hydraulic fluid Bring the vehicle at once to a safe stopping place and call an authorized Freightliner service facility for assistance The hydraulic reservoir holds about 1 05 quarts one liter of Pentosin CHF 11S NOTE After hydraulic fluid loss a speci
28. 0 00000 ae 9 3 Automatic Slack Adjusters 9 3 Emergency Braking System 9 2 Meritor WABCO Antilock Braking System ABS for Air Brakes us be va ewe eee Yee wee eS 9 4 Parking Brakes Tractor and D I lA ee eens che lad ob eo eh dep 9 2 Primary Air Brake System Ls 9 1 Secondary Air Brake System 9 1 Allison MD Series llle 8 5 Operating Instructions MD SENES eus rs de dos 8 5 Safety Precautions o o o ooo oo 8 5 Allison On Highway TransmisslOns ica cc EE ER 8 3 Operating Instructions On Highway Transmissions oo 8 4 Range Inhibit Indicator 2000 and 2400 Series o o oo ooooo o o 8 3 Safety Precautions o o ooo oo 8 3 All Wheel Drive Controls Optional iius oc a de ee See eS 4 11 AWD Operation Switch 0 4 12 AWD Range Switch o o o oooo oo 4 12 B Back of Cab Access llle 2 5 Climbing Down from Back OP uoce daten 26 oe m emo e hae ee we 2 6 Entering Back of Cab 4 2 6 Battery ACCESS ou cane pe m Rr ux Pada 2 6 Battery Compartment 2 2 6 Cab Battery Isolation ol MEE EET 2 7 Braking s i eee eREEGGEUE SerEGS 4 13 Meritor WABCOS Antilock Braking System ABS 4 13 Parking Brake Control Valve 4 13 Trailer Air Supply Valve 4 13 Trailer Brake Lever 0
29. 1 High Pressure Gauge 2 Low Pressure Gauge 3 Manual Fuel Shutoff Valve 4 Fuel Fill Port Fig 11 5 CNG Fuel Panel 10 10 Inspect the LNG vaporizer overpressure regulator if equipped for signs of damage or leaks 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 hangers 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 with a long handled or telescoping window clean ing device and standard cleaning solutions Stand only on the ground on a stepladder or an elevated walkway The cab entry exit steps and handholds are not designed for this purpose The tires fenders engine and other under hood components do not have adequate gripping sur faces and handholds Check the condition of the windshield wiper arms and blades Be sure the windshield wiper blades are ten sioned against the windshield Inspect the wiper blades for damage and deterio rated rubber Replace the wiper arms if the wiper blades are not t
30. 12 Remove the station dispensing nozzle from the vehicle fill port 13 Install the dust cap on the vehicle fuel fill port and close the fuel panel access door 16 3 LNG Vehicle Fueling The LNG fuel tank is designed to be filled from any LNG fuel source that has a 100 micron or finer fuel filter and a fuel delivery pressure between 120 and 225 psi 827 and 1551 kPa The LNG fuel tank is designed to be top filled through a single hose with no vent return As cold LNG is sprayed into the vapor space of the tank the cold liquid condenses the vapor and creates space for itself inside the tank eliminating any need to vent during the filling process The LNG tank is equipped with a small internal ul lage tank for vapor space which allows for fuel ex pansion and increases vehicle standby time When an LNG tank is full fuel can continue to flow into the ullage tank However if the ullage tank is completely filled during fueling standby time will be reduced to zero and the primary relief valve will open almost immediately after fueling allowing excess LNG vapor to escape If fueling is stopped when the ullage tank is empty i e the fuel tank has sufficient vapor space to accommodate fuel expansion due to temperature increase the vehicle will have approximately one week of standby time before venting will occur Use the following steps to fuel an LNG vehicle 1 Shut down the engine and apply the parking brake IMPORTANT
31. Battery Access Door Fig 13 4 Battery Compartment Open C A a F a B D 2 yoy KO O E E Fa gt CN e SE Si es F C A 1 2 10 18 94 1540303a To Ground E To Starter 3rd F 2nd To Frame ground G 1st 4th Booster Battery Discharged Battery Y com Fig 13 5 Jumper Connections 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 4 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 mm 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 On vehicles with Mercedes Benz AGS transmis sions make sure the current gear indicator dis plays N before starting the vehicle If the trans mision starts in gear it could cause an accident resulting in death serious personal injury or property damage 5 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 o Attempt to start the engine of the vehicle with the batteries receiving the charge Do not operate the starter longer than
32. Cater pillar engines or 20 inH O for Mercedes Benz engines See Group 09 of the Business Class M2 Workshop Manual for filter element replacement instructions 09 12 2001 1 Primary Filter Element 2 Secondary or Safety Filter Element 1090363 Fig 11 2 Air Cleaner Filter Elements 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 11 5 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 collapsed 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 of the intake air passes through the air cleaner 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 For n
33. DEF See operator s manual for complete instructions 11 30 2010 1 DPF Warning Lamp 2 HEST Warning Lamp 1080161 3 DEF Warning Lamp Fig 7 6 Warning Lamp Decal Sunvisor 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 IMPORTANT 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 has cooled to normal operating temperature 1 5 5 To stop a parked regen at any time during the process engage the clutch brake or throttle pedal or turn off the engine DPF Maintenance Eventually ash will accumulate in the DPF and the filter will require servicing DPF servicing must be performed by an authorized technician following the engine manufacturer s instructions A record must be maintained for warranty purposes that includes date of cleaning or replacement vehicle mileage particulate filter part number and serial num
34. DEF level reads low the following warnings strongly encourage the driver to refill the DEF tank e One bar of the DEF level indicator illuminates amber DEF very low refill DEF DEF warning lamp illuminates solid amber See Fig 7 11 The DEF tank must be filled to cancel the warning sequence DEF Empty When the DEF level reads empty the following warn ings are activated e One bar of the DEF level indicator flashes red DEF empty refill DEF e DEF warning lamp flashes amber MIL lamp illuminates e CHECK engine lamp illuminates for Cummins ISB and ISC L engines Detroit Diesel engines Power is limited with a 55 mph 90 km h speed limit Cummins engines Power is limited with progres sively harsher engine power limits applied See Fig 7 12 The DEF tank must be filled to cancel the warning sequence DEF Level Empty and Ignored If the empty warning is ignored and the DEF is not refilled the red STOP engine lamp illuminates in ad dition to the DEF warning lamp MIL and CHECK engine lamp if Cummins ISB or ISC L engine See Fig 7 13 If the DEF is not refilled a 5 mph 8 km h speed limit will be applied after the next engine shut down or while parked and idling Engines 1 2 ULTRA LOW SULFUR IESEL FUEL ONLY 1 2 gt ULTRA LOW SULFUR IESEL FUEL ONLY 1 2 ULTRA LOW SULFUR IESEL FUEL ONLY
35. Engaged Light Shutdown Reset Button 611034 10 Buzzer Alarm 12 Green Light 13 Sensor Fig 16 6 AMGaDS III Plus Overhead Console drivers and technicians using it should be trained re garding the red and green lights and the audible warning The control module located on the left side of the overhead console contains the status lights and con trol buttons for the system The areas that the sen sors monitor are defined as Zone 1 cab and Zone 2 engine compartment The control module has lights assigned to each zone that will illuminate if a sensor detects a trace level leak between 20 and 30 LFL a significant level leak above 50 LFL or if a sensor is disconnected or malfunctioning Trace Level If either sensor detects gas fumes at a concentration greater than 2096 to 3096 LFL 196 gas in air by volume the amber light next to the 7race indicator for that zone will flash There is no buzzer alarm for a trace level detection and the large green light on the alarm panel will remain illuminated 16 7 e Significant Level If either sensor detects gas fumes at a concentration greater than 5096 to 60 LFL 2 5 gas in air by volume the small red light next to the S GNIFICANT indi cator for that zone will flash After approxi mately 15 seconds the large green light on the alarm panel will switch off the red light will illu minate and the buzzer will sound All alarm indicators will remain on as
36. High Beams When the high beam headlights are on a blue light illuminates on the instrument cluster between the ta chometer and speedometer For vehicles built to op erate in the United States switching on the high beams will switch off the road lights NOTE The ignition switch must be on for the high beams to work With the headlight low beams on pull the lever back ward towards the steering wheel to flash the high beams turn them on momentarily 4 6 Controls The headlight low beams remain on continuously during high beam operation If the low beam head lights are turned off by use of the headlight switch the high beams turn off also Hazard Warning Flasher The hazard warning light flasher Fig 4 10 is a red rocker switch located on the top of the multifunction switch module When the flashers are activated all of the turn signal lights front side and rear and the two green indicator arrows on the control panel will blink on and off To flash the hazard warning lights press down on the upper part of the rocker towards the dash To stop the hazard warning lights press down on the lower part of the rocker towards the steering wheel Horn Controls NOTE It is possible to have both the electric and the air horn installed on one vehicle Electric Horn A single electric horn is standard Dual electric horns are available as an option The button for the electric horn is located in the cen
37. Lock Switch 4h CAUTION Differential lock should only be engaged when the vehicle is stopped or moving slowly at low throttle This will prevent internal axle damage Normally when differential lock is available on dual drive vehicles one switch activates the lock on both rear drive axles As an option it possible to have two differential lock switches one for the forward rear and one for the rearmost drive axle It is also pos sible for some vehicles to have differential lock on only one of the drive axles A two position guarded rocker switch Fig 8 21 con trols differential lock causing the wheels on each axle governed by the switch to rotate together To lock the wheels together press the upper half of the rocker momentarily at the red LED To unlock the wheels press the upper half of the rocker again IMPORTANT The differential lock rocker switch is guarded to prevent unintentional switch acti vation If the LED in the switch begins to blink during normal operation when the switch has not been activated this indicates an error condi tion Bring the vehicle to an authorized Freight liner service facility as soon as possible When the differential lock switch is pressed three responses are possible a normal response a slow response and an abnormal response Normal Response The LED in the switch blinks until the axle has responded to the request to lock the wheels At this point the LED comes on steady an
38. Mode Floor Mode Selection between Floor Mode and Floor Defrost Mode Floor Defrost Mode Selection between Floor Defrost Mode and Defrost Mode 11 Defrost Mode 30 puoo Pw o Fig 6 4 Air Selection Switch With Air Conditioning through the floor outlets and 25 percent through the defrost outlets Floor Defrost Mode Directs the airflow equally to the floor outlets and the defrost outlets Selection between Floor Defrost Mode and Defrost Mode Directs 75 percent of the airflow through the defrost outlets and 25 percent through the floor outlets Defrost Mode Directs all airflow through the defrost outlets Air Selection Switch With Air Conditioning T Air Conditioning Face Mode Directs all airflow through the face or instrument panel outlets Selection between the Air Conditioning Face Mode and the Air Conditioning Bi Level 6 2 Heater Ventilator and Air Conditioner Mode Directs 75 percent of the airflow to the face outlets and 25 percent to the floor outlets 3 Air Conditioning Bi Level Mode Directs the airflow equally to the face outlets and the floor outlets 4 Selection between the Air Conditioning Bi Level Mode and the Face Mode Directs 25 percent of the airflow to the face outlets and 75 percent to the floor outlets 5 Face Mode Directs all airflow through the face outlets 6 Selection between Face Mode and Floor Mode Directs the airflow equally through the face outlets and
39. Neutral is always available during operation what ever the vehicle speed When in neutral requests to upshift or downshift are ignored If the selector switch is moved from neutral to drive while the vehicle is moving the transmission will shift into a gear within the engine s operating speed range When shifting from neutral always press on the brake pedal If the brake pedal is not pressed the transmission will not shift the current gear display will flash N and an audible alert will sound NOTE To reset the transmission return the se lector switch on the SmartShift lever to N and attempt the shift again this time with the brake pedal pressed Before shutting down the engine return the selector switch to N When the ignition is turned off the transmission will reset to neutral in a few minutes regardless of the position of the shift lever Drive Drive D is directly below N on the four position se lector switch located at the end of the SmartShift control lever To select D press in the neutral lock button and move the selector switch to the position below N When drive is selected the number of the currently selected forward gear 1 through 6 on six speed UltraShift ASW 1 through 10 on ten speed UltraShift DM displays on the gear indicator See Fig 8 16 When in drive requests to upshift or downshift are enabled Either manual or automatic mode can be selected on the slide switch Two starting gears a
40. Parked Regeneration vehicle must be equipped with a dash mounted Regeneration Switch See Engine Operator s Manual for complete Regeneration Instructions 24 01583 000B 1080147 Fig 7 7 Exhaust Aftertreatment Warnings close to odorless It may have a slightly pungent odor similar to ammonia It is nontoxic nonflam mable and biodegradable It is mildly corrosive to aluminum but it will not affect the strength or struc ture of the aluminum A white powder may be notice able around components that the DEF comes in con tact with Around 12 F 11 C DEF freezes to slush but is not damaged or destroyed if frozen and is fully usable when thawed The DEF supply lines are elec trically heated and are purged when the engine is shut down The DEF in the tank is allowed to freeze while the vehicle is non operational At start up nor mal operation of the vehicle is not inhibited if the DEF is frozen an immersion heater with engine cool ant flowing through it will warm the DEF once the engine is running to allow the SCR system to oper ate DEF Tank EPA10 compliant vehicles are equipped with a DEF tank located on the driver s side of the vehicle usu ally behind the battery box or an optional location forward of the fuel tank for day cab configurations See Fig 7 8 and Fig 7 9 The DEF tank has a 19 mm filler neck inlet that prevents the hose from a diesel outlet from being inserted and has a blue cap for easy i
41. Pressing the up arrow continuously causes the range position to continue to rise until the button is released or the highest available position is attained Pressing the up or down arrows does not override the transmission automatic shifting operation If a higher or lower position is selected the transmission continues shifting through the ranges according to the vehicle operating characteristics until the highest or lowest selected position is reached Mode Button The MODE button starts a specialized input or output function that has been previously programmed into the ECU or TCM Pressing the MODE button changes transmission operation for a specific func tion Mode Indicator LED When the MODE button is pressed the mode indica tor LED illuminates A mode identification label lo cated above the MODE button identifies the function associated with a mode change Drivetrain Digital Display The dual digital display shows both the selected range SELECT and actual range attained MONI TOR The single digital display shows the selected range Cil Level Sensor Allison MD Series transmissions have an electronic oil level sensor to read fluid level information The fluid level diagnostic will display whether the oil level is OK too low or too high It will also display a de fault code and indicate if the preconditions of receiv ing the fluid level information are not met IMPORTANT Maintain the the proper flu
42. RE ER ERE Gn ERN QU RES A FERT RE EE EE 9 1 Air Brake Syste so revegones queda pP Even edd Lua d q ENDE ae op edax a 9 1 Hydraulic Brake System eer cere tr EEEE EErEE Ke ERE ESS Sade ewe Reds BESS Ee 9 6 Steering and Brake Systems Steering System Steering Wheel Adjustment Two steering wheels are available a standard 18 inch 450 mm steering wheel and an optional 20 inch 500 mm steering wheel When there is no load on the vehicle and the front tires are pointed straight ahead the standard steer ing wheel spokes should be at the 3 o clock and 9 o clock positions or within 10 degrees of these posi tions See Fig 9 1 10 NN 10 j y Y A A 1 0 o E s 1 0 o 11 14 2001 1461923 NOTE The standard steering wheel is shown 1 9 o Clock 2 3 o Clock Fig 9 1 Steering Wheel Centered On the optional 20 inch 500 mm wheel the steering wheel spokes should be at the 4 o clock and 8 o clock positions or within 10 degrees of these posi tions For steering wheel adjustment procedures see Group 46 of the Business Class M2 Workshop Manual Power Steering System The power steering system consists of a steering gear which includes a manual steering mechanism a hydraulic control valve and a hydraulic power cyl inder hydraulic hoses power steering pump power steering reservoir and other components Some models are also equipped with a separate hydraulic power cylinder on the right side of the front ax
43. WABCO recommends that front and rear tire sizes be within 16 of each other Contact the Meritor WABCO Customer Support Center at 800 535 5560 if you plan a tire size difference greater than 8 Installing different sized tires could result in inaccurate wheel speed signals to the ECU resulting in a reduced braking force which could lead to longer stop ping distances ABS includes signal generating tone rings and sen sors located in the wheel hubs of each sensed axle The sensors transmit vehicle wheel speed informa tion to the ECU which interprets these signals to cal culate wheel speed and a vehicle reference speed If the calculations indicate wheel lockup the appropri ate control circuit signals the brake pressure modula tor to increase or decrease braking pressure Ah CAUTION An accumulation of road salt dirt or debris on the ABS tone wheels and sensors can cause the ABS warning light to come on If the ABS light does come on the tone rings and sensors should be inspected for corrosion and serviced if necessary The service should include cleaning of the tone rings and sensors If any tone ring on a vehicle shows severe corrosion all tone rings on that vehicle should be replaced During winter months in areas where corrosive materials are used on the highways periodically clean the underside of the vehicle including the tone rings and sensors to ensure proper ABS Steering and Brake Systems function and to pr
44. Wheel Drive Controls Optional All wheel drive AWD allows the driver to direct driveline power to all four axles front and rear Two switches are used to control AWD an AWD operation switch used to activate all wheel drive and an AWD range switch used to select the high or low range AWD controls are not multiplexed Controls AWD Operation Switch The AWD operation switch is a two position rocker switch with a light emitting diode LED that illumi nates when AWD is engaged The legend LOCKED is underneath the LED on the upper half of the switch On the lower half is the legend AWD See Fig 4 27 When the panel lights are on the AWD legend is backlit in green LOCKED AWD 08 10 2006 1610807 Fig 4 27 AWD Operation Switch To engage AWD press the upper half of the rocker switch The LED illuminates to indicate that AWD is engaged To turn off AWD press the lower half of the switch The LED goes out to indicate the AWD is no longer engaged When AWD is engaged the LOCKED legend is backlit in red In addition a red indicator with the leg end T CASE ENGAGED displays on the dash mes sage center AWD Range Switch 4h CAUTION To prevent damage to the transfer case and the driveline stop the vehicle and apply the parking brake before using the range switch The AWD range switch is used under similar condi tions to those of the axle shift switch on a two speed rear axle Use the high range when
45. a dry cleaning product follow the instructions carefully and clean only in a well ventilated area Avoid any product that contains carbon tetrachloride or other toxic materials With either method pretest a small area before proceeding Use a professional upholstery cleaning service when extensive cleaning is needed Grease and Oil Based Stains Dampen a small absorbent cloth with dry cleaning solvent or spot remover Apply the cloth carefully to the spot from the outer edge to the center Pat and blot the spot with a clean dry cloth Repeat several times as necessary turning the cloths so that the stain does not redeposit on the fabric Sugar and Water Based Stains Apply water based detergent or cleaner working in circular motions Pat and blot as dry as possible Re peat if necessary before drying thoroughly Chewing Gum or Wax Harden the gum or wax with an ice cube wrapped in a plastic bag then scrape it off with a dull knife 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 13 In an Emerge
46. air gauges do not sweep NOTE If active fault codes are present take the vehicle to an authorized Freightliner service fa cility as soon as possible If the fault is a serious problem that requires immedi ate attention the engine protection system will acti vate In most cases the check engine light will illumi nate also If service miles or service hours has been exceeded either Fig 3 4 or Fig 3 5 will come up before the fault screen if fault codes are present If no fault codes are present and service hours or miles are exceeded either Fig 3 4 or Fig 3 5 will stay dis played until the parking brake is released with the engine running or the mode reset button is pressed 3 3 10 26 2009 HOURS SERVICE 1040805 Fig 3 4 Service Hours Exceeded 10 26 2009 MI SERVICE 1040806 Fig 3 5 Service Miles Exceeded Instruments Odometer The odometer is set to display in either miles or kilo meters depending on the primary scale of the speedometer The legend either MI or KM illumi nates between the odometer and the volts display when the engine is running or the headlights are on The odometer is a 7 digit display with a decimal point until the vehicle has traveled 999 999 9 miles or kilo meters km At one million miles km the odometer rolls over to 1000000 without the decimal point and can continue up to 9 999 999 The odometer only disp
47. 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 intake 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 Inspect hub oil seals and lubrication levels Check automatic transmission fluid level Inspect air brake chambers and pushrods Inspect air brake lines Inspect slack adjusters Check air brake system operation Check Bendix Hydro Max Power Booster if equipped Inspect frame rails missing bolts and crossmembers bent or loose Check mud flaps aren t damaged at least 10 inches above the ground and brackets o are secure Check exhaust system mounted securely connected tightly no signs of leaks such as un soot trails Inspect seat belts and tether belts D28 Remove chocks and test service brakes D29 Inspector Date Table 11 1 Daily Pretrip Inspection and Maintenance Checklist 11 2 Pretrip and Post Trip Inspections and Maintenance
48. appear on the gear indicator when the vehicle is restarted during the reset procedure NOTE If the transmission becomes locked in gear while the vehicle is moving increased braking effort may be required to stop the ve hicle If the current gear indicator displays a dash during power up with the selector switch in neutral do the following steps 1 Make sure the parking brake is set 2 Turn off the ignition and wait at least two min utes Apply the service brakes With the service brakes applied release the parking brake 5 Make sure the selector switch is in neutral and turn on the ignition key Do not attempt to start the engine at this time 6 If necessary to get the transmission to shift into neutral release the pressure on the brake pedal slightly 7 Once the UltraShift TCU reaches neutral a solid N will appear on the current gear indicator and the vehicle will start Make sure the service brakes are applied and the parking brake is set If the gear indicator continues to display a dash con tact an authorized Freightliner or Eaton service facil ity Drivetrain Mercedes Benz Manual Transmissions Ah CAUTION Operating a manual transmission with the fluid level higher or lower than recommended can re sult in transmission damage Mercedes Benz transmissions use a simple 6 speed gear pattern as shown in Fig 8 19 1 3 5 N R 2 4 6 05 03 2001 261098 Fig 8 19 Shift Pa
49. are set and that the trailer is prepared for uncoupling NOTE On Fontaine and Holland fifth wheels if the tractor parking brake is not set the air actuated kingpin release valve will not activate Fifth Wheels and Trailer Couplings 11 02 2010 1311133 A Locked Position C Lockset Position upper rod resting against casting B Unlatched Position safety indicator rotated towards the above slot rear of the fifth wheel D Open Position ready for recoupling 1 Safety Indicator 3 Upper Rod 2 Operating Rod 4 Plate Casting Fig 10 9 Holland Kingpin Locking Mechanism 2 Pull and hold the kingpin release valve until the Jost Fifth Wheels Air Activated Kingpin kingpin lock mechanism opens and locks in Unlock place See Fig 10 10 1 Verify that both the yellow parking brake and red Release the pull valve trailer air supply knobs are out the tractor and Release the tractor parking brake trailer parking brakes are set and that the trailer is prepared for uncoupling 5 Drive out from under the trailer 10 6 Fifth Wheels and Trailer Couplings SET PARKING BRAKE PULL TO UNCOUPLE TRAILER TRAILER WILL S FROM THE TRACTU 10 26 2010 fe11102 Fig 10 10 Air Actuated Kingpin Release Valve NOTE With Jost fifth wheels if the trailer park ing brake is not set the air actuated valve will not activate 2 Release the tractor parking
50. brakes to become inoperative The front brakes will continue to be operated by the sec ondary air system In addition the trailer brakes if equipped will be operated by the secondary air system Secondary Air Brake System Loss of air pressure in the secondary air system causes the front axle brakes to become inoperative The rear service brakes will continue to be operated by the primary air system In addition the trailer brakes if equipped will be operated by the primary air system Steering and Brake Systems Emergency Braking System When air pressure is lost in either the primary or sec ondary air system the air compressor will operate but the air supply in the other system the one that is not leaking will not be replenished There will be enough air in the other system to stop the vehicle safely The dual air brake system thus provides emergency braking capability When the low air pres sure warning light and emergency buzzer first come on stop the vehicle immediately Do not drive the vehicle until the cause of the problem is corrected Parking Brakes Tractor and Trailer The yellow diamond shaped knob parking brake control valve on the auxiliary dash panel applies the parking brakes spring brakes Pulling out the knob applies both the tractor and the trailer parking brakes and automatically causes the red octagonal knob trailer air supply valve to pop out See Fig 9 2 d i N X S EN Y 2 3 a S V
51. 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 fall 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 Use the cab access system grab handles access steps and steering wheel to enter or exit the cab Entering from the Driver s Side To enter the cab from the driver s side do the follow ing steps Fig 2 4 Ls 3 11 02 2001 7 Steering Wheel B Pillar Grab Handle Bottom Step Top Step Inner Door Grab Handle optional 1720399 NPON Fig 2 4 Cab Access System Driver s Side 1 Use the door pull handle to open the driver s door and place anything that you are carrying in the cab 2 Grasp the B pillar grab handle with both hands Reach up as far as is comfortable 3 Place your right foot on the bottom step and pull yourself up 4 Place your left foot on the top step 5 Grasp the steering wheel with your left hand and step up 6 Step into the cab with your right foot first and grasp the steering wheel with your right hand 2 2 Vehicle Access NOTE You can also use the inner door grab handle if available as a support when getting up
52. contact your Freight liner Dealer 3 Check the steering wheel for excessive play Pretrip and Post Trip Inspections and Maintenance 3 1 Start the engine With the front tires straight ahead turn the steering wheel until motion is observed at the front wheels 3 2 Align a reference mark on a ruler then slowly turn the steering wheel in the oppo site direction until motion is again detected at the wheels 3 3 Check the lash free play at the rim of the steering wheel See local federal regula tions for acceptable ranges of lash 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 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 worn 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 Business Class M2 Workshop Manual for lining replacement instructions and cam shaft end play inspection 4 3 Check the brake drums for wear and cracks 4 4 Chec
53. damage to the clutch but also to the entire powertrain Clutches are designed for specific vehicle applica tions and loads These limitations should not be ex ceeded Riding the Clutch Pedal Riding the clutch pedal is destructive to the clutch Partial clutch engagement permits slippage and gen erates excessive heat Riding the clutch pedal will also put a constant thrust load on the release bear ing which can thin out the lubricant Release bearing failures can be attributed to this type of misuse 8 1 Holding the Vehicle on an Incline With a Slipping Clutch A slipping clutch accumulates heat faster than it can be dissipated resulting in early clutch failures Never use the clutch to hold a vehicle on a hill Coasting With the Clutch Released pedal down and the Transmission in Gear 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 If the transmission remains in a low gear and the ve hicle gains speed as may occur on a downgrade the input shaft and clutch driven disc will turn at speeds that are higher than normal This occurs be cause the rear wheels and the driveline become the input for the transmission and a higher than normal speed for a given transmission gear translates to a higher rpm value for the clutch driven disc Clutch drive
54. detects that the parking brake is off and the driver seat belt is not fastened on some vehicles On other vehicles this lamp illuminates for 15 seconds when the ignition is first turned on Table 3 3 Common Warning and Indicator Lamps AIR WASH WAIT i WHEEL LOW CHECK FILTER FLUID TO START E SPIN WATER TRANS OPT 8 OPT 9 L E i uF d lt i BRAKE C 4 BRAKE 4 mii D AIR gt 11 09 2011 f611107a Fig 3 9 EPA10 Dash Message Center Standard Instruments Standard instruments are present on every vehicle They are listed here in alphabetical order to make the information easier to find Air Pressure Gauges A WARNING If air pressure falls below minimum pressure the braking ability of the vehicle will be limited Slow the vehicle down and bring it to a gradual stop Do not attempt to move the vehicle until air pres sure has risen above the minimum level Moving 3 9 a vehicle without adequate braking power could cause an accident resulting in personal injury or death Air pressure gauges as shown in Fig 3 10 register the pressure in the primary and secondary air sys tems The gauges are labeled for the A or B reser voir Normal pressure with the engine running is 100 to 120 psi 689 to 827 kPa in both systems A low air pressure warning light
55. drive wheels still in con tact with the road surface the vehicle axle shafts or driveline must be removed or disconnected See Towing in Chapter 13 16 Natural Gas Vehicle General Infermaltieh 3x ERA ERERE GA roamed A T EX AR d RR ER aA REGERE 16 1 Sab PIBCSUJMOS s octcinese2ed0405 6 esas SOS Madera ERA a rai Pas 16 1 Fuel Tank Filling Procedures Gas Detection System Engine Staing scsi EAR Grad eee A A Sees a wees Shee UR Rx 16 9 Major Repair and Replacement of Parts Natural Gas Vehicle General Information The Business Class M2 can be equipped with a compressed natural gas CNG fuel system or a lig uefied natural gas LNG fuel system CNG is made by compressing natural gas to less than 1 of its volume at standard atmospheric pressure LNG is created by condensing natural gas into a liquid by cooling it to approximately 259 F 162 C When vaporized at ambient temperatures natural gas is less dense than air and it rises and disperses However LNG is intially heavier than air due to its cryogenic temperature When released in large amounts it may drop or pool on the ground before it s temperature rises and the LNG vaporizes Cold atmospheric conditions may prevent natural gas from dispersing quickly when released in large amounts Natural gas is nontoxic but it can cause asphyxiation if present in very large concentrations CNG often contains an odor producing chemical while LNG does not have any odor
56. driving at normal speeds under off road conditions or on non paved surfaces Use the low range when extra traction is needed at lower speeds for example under condi tions of mud snow or ice This switch should be used only when AWD has been engaged In most cases the AWD range switch is a two position rocker switch with the legends LO RANGE at the upper end and HIGH RANGE at the lower end On vehicles with a power take off unit PTO the three position switch has a neutral N TRL posi tion in the middle See Fig 4 28 When the panel lights are on the HIGH RANGE legend is backlit in green 07 21 2006 1610808 1 Two Position Switch 2 Three Position Switch Fig 4 28 AWD Range Switches Two Position Switch no PTO On vehicles without a PTO high range is considered standard operation To activate the low range press the upper half of the switch When the low range is activated the LO RANGE legend is backlit in red In addition a red indicator with the legend T CASE LO RNG displays on the dash message center To switch back to HIGH RANGE press the lower half of the switch Three Position Switch with PTO IMPORTANT Always use the N TRL switch po sition when operating the PTO On vehicles with a PTO neutral is considered stan dard operation switch in the middle position An amber indicator with the legend T CASE NTRL dis plays on the dash message center To activate the high range press th
57. engine spin on filter included in the emergency kit on the threaded stud NOTE Remove the rubber grommet from the stud 7 Install the filter cover filter cover seal and spring as removed 8 Install the filter collar over the filter cover Tighten the filter collar finger tight 9 Start the engine and run it at increased rpm for one minute to purge air from the fuel lines In an Emergency 11 14 2001 1 Filter Vent 5 Filter Cover Seal 2 Filter Vent Seal 6 Spring 3 Filter Collar 7 Filter Element 4 Filter Cover 10 1470416 8 Threaded Stud 9 Fuel Port 10 Drain Fig 13 2 Davco Model 232 and 233 Fuel Water Separator 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 13 2 In an Emergency 2 3 J N 8 4 5 A TEC 10 11 7 11 14 2001 1470417 1 Filter Collar 5 Filter Cover Seal 9 Fuel Port 2 Filter Vent 6 Spring 10 Drain 3 Filter Vent Seal 7 Filter Element 11 Bottom Plat
58. for taillight fuse and relay information 2 8 Vehicle Access These fuse boxes contain mini blade type fuses 12 volt mini relays and 12 volt micro relays STOP LMP x STOP LAMP 30A MARKER LAMP N RELAY 3 5 RELAY 6 if MINI RELAY MRKR LMP wiNT RELAY 30A RT TURN 20A RIGHT TURN LEFT TURN RELAY 2 RELAY 5 MICRO RELAY LT TURN MICRO RELAY 20A 1 i TAIL LMP S Y AIL LAMP 30 RAILER PWR y RELAY 1 m RELAY 4 MINI RELAY TRLR PWR MINI RELAY 30A i FREIGHTLINER A06 47383 000 09 28 2004 1544528 09 25 2001 1543935 Fla 2 13 Traller E aa f ig 2 railer Fuse Box Diagram 1 Bulkhead Module 2 Main Fuse Box g g Fig 2 11 Location of the Main Fuse Box RT TURN RIGHT TURN 20A LEFT TURN RELAY 3 RELAY 6 MICRO RELAY DOA MICRO RELAY RT STOP 20A RIGHT STOP EFT STOP RELAY 2 RELAY 5 MICRO RELAY LT STOP MICRO RELAY 20A BACKUP ie LEFT TAIL RELAY 1 RELAY 4 MICRO RELAY TA MICRO RELAY 20A FREIGHTLINER A06 48216 000 10 25 2001 1543936 10 07 2004 1544541 Fig 2 12 Main Fuse Box Diagram 2 9 Fig 2 14 Taillight Fuse Box Diagram Instruments lnsirumentation Control UNIE cool sara rere iate RUE aa Ebr UR ang i EE 3 1 Warning end Indicator Lei oeste quete cx het 4404846 cistitis A E 3 5 Standard Instruments
59. 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 Make sure the exhaust brake is turned off before shutting down the engine Driving Downhill While approaching a steep grade make sure that the upper half of the exhaust brake switch is pressed in with the amber light illuminated The exhaust 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 guide line 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 Pacbrake9 Exhaust Brake The Pacbrake exhaust brake is intended as a supplement to the service brakes and will not bring the vehicle to a complete stop The Pacbrake will assist in the control or reduction of road speed in conjunction with or independent of the service brakes The amount of retarding or braking force is controlled by the driver 7 17 Pacbrake Operation Caterpillar The Pacbrake is controlled by the exhaust brake switch and the throttle pedal All applications
60. hold for 4 seconds to activate See Fig 7 4 NOTE The regen switch can initiate a parked regen only when the DPF lamp is illuminated because the engine software is signaling for a parked regen The regen inhibit switch provides additional control over the aftertreatment regeneration process A driver may decide to use this feature if they are hauling cargo that should not be exposed to possible high exhaust temperatures from an automatic regen When activated the inhibit switch will stop a regen eration cycle in progress and prevent the start of a regeneration cycle until the switch is no longer ac tive See Fig 7 5 To initiate a parked regeneration perform the follow ing steps 1 Parkthe 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 7 4 Engines DPF Regen Needed IMPORTANT Diesel Particulate Filter DPF regeneration is needed e If flashing regenerate as soon as possible Engine derate possible Hot Exhaust e Hot exhaust can cause fire Keep flammables and people away from exhaust DEF Refill Needed E i l Diesel Exhaust Fluid DEF level is low Engine derate likely e Refill tank with certified
61. 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 DDEC VI system will deactivate the engine brake system when the engine speed falls below 1000 rpm or when the vehicle slows down to a preset speed depending on DDEC programming This prevents stalling the engine Exhaust Braking Systems Exhaust Brake Switch The optional exhaust brake is controlled by a dash mounted rocker switch to help slow the vehicle when the accelerator is released Engines To turn the exhaust brake on press on the upper part of the rocker at the light inside the switch The exhaust brake turns off automatically See Fig 7 18 or Fig 7 19 11 28 2001 1610589 Fig 7 18 Exhaust Brake Switch 3 3 03 31 2009 1610589a Fig 7 19 Exhaust Brake Switch When the exhaust brake switch is on an amber LED illuminates inside the switch When the panel lights are on the EXHST BRK legend is backlit in green Mercedes Benz Exh
62. on sliding rails Before attempting to couple a trailer to a sliding fifth wheel the slide feature must be locked to prevent the top plate from sliding rap idly forward or rearward causing damage to the fifth wheel or kingpin Fontaine and Holland Fifth Wheels Coupling 1 Chock the front and rear of the trailer tires to prevent the trailer from moving 2 Ensure the fifth wheel jaw is fully open and the operating rod is in the unlocked position See Fig 10 2 or Fig 10 3 3 Make sure the fifth wheel top plate is tilted so the ramps are as low as possible Fifth Wheels and Trailer Couplings b 10 26 2010 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 2 Fontaine Locking Mechanism 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 NOTICE Attempting to couple at the wrong height may cause improper coupling which could result in damage to the fifth wheel or kingpin 5 Adjust the trailer height if required For a standard fifth wheel plate the trailer should contact the fifth wheel approximately 4 to 8 inches 10 to 20 cm behind the fifth wheel pivot See Fig 10 4 For a low lube fifth wheel plate the fifth wheel must slide freely under the trailer and the tra
63. overspeed Upshifting To request an upshift with the transmission in drive pull the control lever up towards you If the gear is available the transmission upshifts and the new gear displays on the gear indicator No skip shifts are available while upshifting No upshifts are available in low except to prevent engine overspeed If the transmission does not upshift quickly enough after power up or a load change begin the shift manually The UltraShift TCU will learn the new load based shift conditions after three or four shifts If the gear requested is unavailable a tone will sound An unavailable request to upshift is not stored in memory The upshift must be requested again Downshifting NOTE The driver can manually downshift at any time even when the slide switch is set to AUTO mode To request a downshift with the transmission in drive or low push the control lever down away from you If the gear is available the transmission downshifts and the new gear displays on the gear indicator Skip shifts are available while downshifting For best engine braking select low while moving In low downshifts are performed at higher rpm than in drive IMPORTANT If the engine is approaching over speed the UltraShift TCU will override the cur rent gear setting and upshift to prevent engine damage If the gear requested is unavailable a tone will sound An unavailable request to downshift is not stored in mem
64. retarding power Certain conditions may require that the transmission be downshifted in order to generate adequate rpm for the amount of retarding power required Pacbrake exhaust brakes are designed and approved for safe use at 300 rpm above the engine s maximum gov erned rpm Refer to individual engine manufacturer s specifications The Pacbrake will function best if it is used all of the time However if the vehicle is used inconsistently or seasonally it may be necessary to perform a preven tive maintenance procedure Engines 1 With the engine shut down use any oil free or nonpetroleum based high heat lubricant and spray or coat a sufficient amount on the restricter valve shaft and the attaching locations at each end of the actuation cylinder See Fig 7 20 A Te 03 06 2000 490228 A Lubrication Point Fig 7 20 Pacbrake Exhaust Brake and Air Cylinder 2 With your hands or a pair of pliers motion the valve several times to distribute the lubricant down the shaft and the attaching locations NOTE Starting the engine and idling for short periods of time is not recommended During a cold engine start up enough moisture is devel oped within the engine and the exhaust system to create a corrosion hazard that could affect the future operation of the Pacbrake The brake housing may trap water in the valve shaft bore causing corrosion i
65. shifts are typically not permitted if appreciable output shaft speed is detected When some types of unusual transmission op erating conditions are detected by the TCM the TCM temporarily limits transmission opera tion until the vehicle can be driven to a service location When this type of situation is de tected the TCM will lock the transmission in a safe gear range The TCM will prevent shifts from park or neu tral to range when auxiliary equipment such as a power takeoff unit PTO is in operation Operating Instructions On Highway Transmissions Allison automatic transmissions are electronically controlled The shift selector provides five or six for ward ranges and one reverse range P Park optional on 1000 and 2400 Series Use park when turning the engine on or off to check vehicle accessories to operate the engine in idle for longer than 5 minutes and for stationary operation of the power takeoff if equipped This position places the transmission in neutral and engages the park pawl of the transmission NOTE This does not apply the parking brake PB Auto Apply Parking Brake optional on 2000 Series The auto apply parking brake places the transmis sion in neutral and applies the parking brake R Reverse Reverse is used to back the vehicle When the selec tor is in reverse the reverse warning signal will sound Always bring the vehicle to a complete stop before shifting from a forward range t
66. the pedal is de pressed When starting or stopping on hills and grades use extra care to prevent the vehicle from rolling back A rollback accident could cause death seri ous personal injury or property damage 7 Prevent the vehicle from rolling backwards when stopped on a hill or grade or when the vehicle is starting from a stop on a hill or grade 7 1 To start from a full stop on a hill or grade quickly move your foot from the brake pedal and press firmly on the throttle pedal On steep hills set the parking brake and release it only when there is enough en gine power to prevent rollback 7 2 To stop on a hill or grade press and hold the brake pedal to keep the vehicle from moving On steep hills set the parking brake Never hold a hill with the throttle pedal This will cause the clutch to overheat Power Down 1 Bring the vehicle to a complete stop Set the parking brake Move the selector switch to N Wait until N ap pears on the current gear indicator Always apply the parking brake before shutting down the engine AGS will shift into neutral after shutdown regardless of the position of the shift lever If you do not set the parking brake the ve hicle could roll and cause an accident resulting in death serious personal injury or property damage 4 Turn the ignition switch off and shut down the engine 5 If the current gear indicator flashes PB when the engine is shut down set the parkin
67. the vehicle A 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 leaving the back of cab area Always maintain three point contact with the back of cab access supports while entering and Vehicle Access 09 28 2007 1602336 1 Steps 3 Deck Plate 2 Grab Handle Fig 2 6 Back of Cab Access Supports typical 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 fall 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 Entering Back of Cab When climbing onto the deck plate do the following 1 Grasp the sidewall grab handle with both hands Reach up as far as is comfortable 2 Place one foot on the bottom step and pull your self up 3 Place your other foot on the top step 4 Move your lower hand to a higher position on the grab handle 5 Step onto the deck plate Climbing Down from Back of Cab To climb down from the back of cab area 1 Grasp the sidewall grab handle with both hands 2 Step one foot at a
68. two position slide switch Fig 8 10 is mounted on the body of the control lever just before the paddle widens out The slide switch allows the driver to choose automatic AUTO or manual MAN mode In AUTO mode gears shift automatically without driver interaction Manual gearshifts are accom plished by a momentary pull or push on the control in the plane perpendicular to the steering wheel Pull upward toward you on the control to upshift and push downward away from you to downshift The control is spring loaded and returns to mid position when released after an upshift or downshift For Eaton Fuller UltraShift Fig 8 10 a four position R N D L selector switch is located at the end of the lever For the Mercedes Benz AGS Fig 8 11 a three position R N D selector switch is located at the end of the lever Embedded in the selector switch is a small neutral lock button to prevent accidental shifts into gear from neutral Any time you shift through N press down on the neutral lock button to move the switch from neu tral N to another gear such as drive D low L or reverse R When shifting to N it is not necessary to press the neutral lock button 3 4 lo SHIFT MS MAN AUTO FU R gt Sma ShA SAG N i Fa f lt PUSH j 9 1 a m D i ng 11 12 01 24 2003 1270120 To upshift manually pull the lever up towards you To downshift manually push the lever down away from you 1 SmartShift Control
69. used properly the Komfort Latch Fig 5 16 and the Sliding Komfort Latch Fig 5 17 Cab Features introduce a small amount of slack into the seat belt resulting in a more comfortable ride 03 11 2010 1910620 A Disengaged B Engaged 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 Fasten the three point seat belt by pushing the latch into the buckle Listen for an audible click See Fig 5 18 Fig 5 16 Komfort Latch 7 1910004a Komrort LATCH www clicktugsnug com 11 18 2010 fo10621a Fig 5 17 Sliding Komfort Latch 1 Slowly pull the latch end of the three point seat belt out of the retractor and pull it across your Fig 5 18 Fastening the Three Point Belt 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 Snug the seat belt to your waist Position the shoulder strap diagonally across your chest with the adjustable D loop bracket if equipped If desired engage the Komfort Latch or Sliding Komfort Latch as follows If equipped with a Sliding Komfort Latch make sure that the shoulder strap is snug against your chest Without loosening the shoulder strap push the Sliding Komfort Latch switch to the ON position See Fig 5 17 To act
70. vehicle shows severe corrosion all tone rings on that vehicle should be replaced During winter months in areas where corrosive materials are used on the highways periodically clean the underside of the vehicle including the tone rings and sensors to ensure proper ABS function and to protect the components from cor rosion Clean more frequently when unusually corrosive chemicals are being used During vehicle operation if the safety circuit senses a failure in any part of the ABS system a sensor solenoid control valve wiring connection short cir cuit etc the TRACTOR ABS indicator light comes on and the control circuit where the failure occurred is switched to normal braking action The remaining control circuit will retain the ABS effect Trailer ABS Light The amber TRAILER ABS indicator light operates as follows when a compatible trailer is properly con nected to the tractor When the ignition switch is turned to the on position the trailer ABS light will illuminate mo mentarily then turn off If the light comes on momentarily during ve hicle operation then shuts off a fault was de tected and cleared If the light flickers or comes on and goes off repeatedly it could indicate an intermittent wir ing problem Bring the vehicle to an authorized Freightliner service facility for testing and re pairs If the light comes on and stays on during ve hicle operation there is a fault with the trailer ABS R
71. 01 1820383 Rotate the control dial away from you to turn the wipers on or speed them up Rotate the control dial towards you to slow the wipers down or turn them off Washer Button OFF Position Delay Positions Wipers On Low Speed OP OO Wipers On High Speed Fig 4 12 Wiper Washer Controls Rotating the control dial forward in a counterclock wise direction turns the wipers on If they are al ready on rotating the handle further forward to a faster speed setting increases the speed of the wip ers through the various delay settings and to LO and then HI Rotating the control dial in the opposite direction clockwise causes the wipers to slow down Rotating the control dial clockwise as far as it will go to the OFF setting turns the wipers off The washers are operated by a yellow button at the very end of the turn signal lever To operate the washers press the button in and hold it in until you want the washers to stop Headlight High Beams Push the turn signal lever forward towards the wind shield to turn on the high beam headlights Pull the turn signal lever back to its original position to turn them off See Fig 4 13 10 17 2001 1820385 Move the lever away from you to turn on the high beams Move the lever back to its original position to turn them off Move the lever towards you to flash the high beams momentarily 1 Turn Signal Lever 2 Boot Fig 4 13 Headlight
72. 010 1470558 1 Coolant Inlet Port 9 Fuel Fill Port 2 Coolant Outlet Port 10 Filter Housing 3 Pressure Relief Valve 11 Filter Bowl 4 Pressure Regulator 12 Filter Drain Plug 5 Wiring Harness 13 Solenoid Valve 6 Manifold Bleed Valve 14 Fuel Line To Cylinders 7 Manifold 8 Manual Fuel Shutoff Valve Fig 11 18 CNG Fuel Panel Components IMPORTANT Some pressure may remain in the fuel system between the solenoid valve and the engine Use caution when loosening fittings as a small amount of gas may leak out 6 5 6 6 6 7 11 19 Put a clean receptacle under the filter as sembly Using an 11 16 inch wrench remove the drain plug from the filter bowl When all liquid has drained install and tighten the drain plug on the filter bowl Close the bleed valve on the manifold and open the manual fuel shutoff valve on the fuel panel Open the fuel cylinder shutoff valves 6 8 6 9 Use a methane detector to leak test all fuel system components between the fuel cylinders and the solenoid valve A bubble solution can be used to pinpoint the exact location of leaks Repair or replace any leaking compo nents Using the two capscrews removed in sub step 6 3 install the access cover on the fuel panel 12 Cab Appearance Cab Washing and Polishing ibd Rx RR EE RR ER RR t ranere Ae 12 1 Care o Fiberglass Pans aselasetibne RPe Bo ere rre ei RDeU PES PES 12 1 Care ol Chrome Pans iuosoeeso be re
73. 2 d y 15 o 250 WATER P a 09 10 2009 f610525a NOTE This instrument cluster is shown with the U S speedometer which shows miles per hour mph more prominently than kilometers per hour km h 1 Engine Oil Pressure Gauge 2 Dash Message Center 3 Driver Display Screen 4 Headlight High Beam Indicator 5 Fuel DEF Level Gauge 6 Primary Air Pressure Gauge 7 Mode Reset Button 8 Secondary Air Pressure Gauge 9 Speedometer U S version 10 Tachometer 11 Transmission Temperature Gauge 12 Coolant Temperature Gauge Fig 3 1 Typical Gauge Layout U S EPA10 shown 3 1 Instruments 10 11 2001 1 Left Hand Control Panel 2 ICU3 3 Right Hand Control Panel NOTE Instruments and controls and their locations may vary from those shown 4 Auxiliary Dash Panel 1610578 Climate Control Panel Fig 3 2 Dash Panel Layout typical 7 character LCD that normally shows odometer read ings and below that a smaller 3 character LCD that shows voltmeter readings Warning messages and diagnostic fault codes will also appear in the display screen Information provided by the driver display screen in cludes e odometer readings in miles or kilometers e trip and total engine distance e trip and total engine hours service screens fault code displays warning messages Ignition Sequence When the ignition is turned on the ICUS run
74. 27 Fig 5 21 Overhead Storage Center Storage Console optional On vehicles with individual driver s and passenger s seats a center storage console can be installed be tween the seats The center storage console has a table top that can be lifted up to deploy a writing surface See Fig 5 22 In another version the center storage console has a printer top with a paper slot in it See Fig 5 23 Windshield Washer Reservoir The standard location for the windshield washer res ervoir is on the right hand side of the cab underneath the door just above the trailing edge of the top cab step See Fig 5 24 Cab Features 1 Y 2 A 3 d 4 E Lc 10 08 2001 in m 1680026 1 Table Top 2 Storage Console Cover 3 Storage Area 4 Storage Console Base 1 gt 5 A JA 3 l gt E 10 08 2001 n d 1680025 1 Printer Top 3 Storage Console Base 2 Printer Paper Area Fig 5 22 Center Storage Console with writing surface Fig 5 23 Center Storage Console printer option 1 n 2 WS Y Yi 10 08 2001 WD 1820378a 1 Cab 2 Washer Reservoir Fill Cap 3 Top Step Fig 5 24 Windshield Washer Reservoir 5 12 6 Heater Ventilator and Air Conditioner Glimate Control Panel zc diua Ente ise etra er eins dd EU eee Rd ES ded ea aed RA EUR 6 1 Heater Ventilator and Air Conditioner Climate Control Panel The climate control panel allows you to control the heating vent
75. 30 seconds and wait at least two minutes between starting attempts to allow the starter to cool N 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 8 Disconnect the grounded cable from the frame or other non battery location then disconnect the other end of the cable o Disconnect the remaining cable from the newly charged battery or jump start post if equipped first then disconnect the other end 13 4 In an Emergency 10 Close the battery compartment For detailed in structions see Chapter 2 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 i
76. 590 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 Ot tawa Ontario Canada K1A ON5 For additional road safety information please visit the Road Safety website at www tc gc ca roadsafety STI 455 4 1 12 A24 01238 000 Printed in U S A Foreword 2001 2012 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 comand www FreightlinerTrucks com Chapter OONOOARWN Contents Page Introduction Environmental Concerns and Recommendations Event Data Recorder Customer Assistance Center Reporting Safety Defects enccckcekwete ass A Sead de ee ME Foreword Vehicle G6ntn
77. 6 Press down on the upper part of the rocker to activate the hazard warning flashers Washer Button Wiper Control Dial Turn Signal Lever Hazard Flasher red rocker switch Multifunction Switch Module OTAN Fig 4 10 Multifunction Turn Signal Switch Turn Signal Controls The turn signal lever Fig 4 11 is mounted on the steering column Moving the lever down turns on the left turn signal lights moving it up turns on the right turn signal lights 10 17 2001 1820384 Move the lever down to turn on the left turn signals Move the lever up to turn on the right turn signals Fig 4 11 Turn Signal Controls When one of the turn signal lights is on a green indi cator arrow flashes at the far left or far right of the warning and indicator light panel Controls The lever automatically returns to the neutral position self cancels the switch when the steering wheel returns to the straight ahead position after a turn To cancel the signal manually move the lever to the neutral position Windshield Wiper Washer Controls CAUTION Do not move the wiper arms manually Wiper motor damage will occur if the arms are moved The wipers are operated by a rotary switch in the wiper control dial which is on the end of the turn sig nal lever See Fig 4 12 There are five delay set tings marked on the dial by lines of increasing length and two steady speed settings LO and HI 10 29 20
78. 70096 2 Vent Window Fig 5 2 Operating Vent Window optional 5 1 Mirrors The standard outside mirrors are mounted on the door frame There is a primary rear view mirror and a convex mirror Mirror Heat Switch Optional One or both outside door mirrors can be heated to keep them clear of fog frost and ice To heat the mirrors press the upper part of the mir ror heat switch MIRR HEAT on the dash See Fig 5 3 When the mirror heat switch is on an amber indicator light illuminates inside the switch MIRR HEAT 10 09 2001 fe10524 To heat the mirrors press up press down to turn off the heat Fig 5 3 Mirror Heat Switch The mirror heat switch is a smart switch fully multi plexed Power Mirrors Optional The main outside mirrors if heated can be equipped with an electrical remote control located on the driv er s door See Fig 5 4 To select the mirrors on the left hand side press the left side of the mirror select switch To select the mir rors on the right hand side press the right side of the mirror select switch The keypad has four arrow keys pointing up down left and right To adjust the mirror position press the keypad in the direction you want the mirror to move Down View Mirror Optional A down view mirror can be installed on the top of the passenger door frame to allow the driver a view of Cab Features the area adjacent to the right side of the c
79. DU which cranks the engine very quickly The back up cranking system is the standard 12 volt starter on the engine If the hybrid system is offline or the hybrid batteries are insufficiently charged the vehicle will automatically use the 12 volt cranking System to start the engine Starting 1 Set the parking brake 2 Place the key in the ignition and turn it clock wise to the ON position to initiate power to the hybrid system Wait for the gauges on the instrument panel to complete two sweeps one from left to right and one from right to left and return to their normal ranges 3 Ensure the transmission is in neutral The gear display should display a solid N Never start the engine unless the transmission is in neutral and the brake is applied Accidental movement of the vehicle could result in property damage personal injury or death 4 Turn the key clockwise to the START position The engine will crank after a brief delay As soon as the engine starts release the key allowing it to return to the ON position The engine will con tinue to run with the key in the ON position 5 Apply the service brake then release the parking brake 6 With the service brake applied press the desired mode on the shift control to put the vehicle into gear 7 Slowly release the service brake NOTE The vehicle may be powered by the electric motor or the diesel engine depending on battery charge and the demand for drive
80. 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 Freightliner Trucks reserves the right to discon tinue models and to change specifications or design at any time without notice and without incurring obligation Descriptions and specifica tions contained in this publication provide no warranty expressed or implied and are subject to revisions and editions without notice Environmental Concerns and Recommendations Whenever you see instructions in this manual to 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 equ
81. G When going downhill use a combination of downshifting braking and other retarding de vices to control vehicle speed and the engine s rated governed speed Failure to do so could re duce vehicle braking possibly causing loss of vehicle control and resulting in personal injury or property damage When going downhill downshift to a lower transmis sion range to increase engine braking and to help maintain control The transmission has a feature to prevent automatic upshifting above the lower range selected However during downhill operation if the 8 7 engine governed speed is exceeded in the lower range the transmission may upshift to the next higher range 1 First Range Use the first range when pulling through mud or deep snow when maneuvering in tight spaces or when driving up or down steep grades First range provides the vehicle with its maximum driving torque and maximum engine braking effect Push the down arrow until the first range appears on the display Up and Down Arrows When a lower range is desired after D has been pressed press the down arrow until the desired range is shown on the display Pressing the down arrow continuously causes the range position to con tinue to go down until the button is released or the lowest range is attained When the transmission is in drive and the down arrow has the transmission in a lower range position press the up arrow to shift to a higher selector posi tion
82. ICE A sudden decrease or absence of oil pressure 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 until the cause has been determined and cor rected The engine oil pressure gauge as shown in Fig 3 12 displays the current engine oil pressure If engine oil pressure falls below the minimum levels shown in Table 3 1 the CHECK engine lamp will illu minate If the condition does not improve the STOP engine lamp will also illuminate and an audible warn ing will sound The engine will then derate or shut down depending on the type of engine protection System installed 50 PSI 100 OIL 10 09 2001 1610528 Fig 3 12 Engine Oil Pressure Gauge Fuel Gauge Pre EPA10 Pre EPA10 compliant vehicles have a fuel level gauge indicating the level of diesel in the fuel tank s See Fig 3 13 A single fuel gauge is standard If equipped with an optional second fuel gauge each fuel tank level is indicated on a separate gauge Instruments N 1610566 10 09 2001 Fig 3 13 Fuel Level Gauge Pre EPA10 Fuel Diesel Exhaust Fluid DEF Gauge EPA10 For engines that are EPA10 compliant the fuel and DEF levels are measured in a dual purpose fuel DEF gauge See Fig 3 14 4 DIESEL FUEL ONLY Q Q D Coo DEF lt gt 08 21 2009 1 Diesel Fuel Level Indicator 2 DEF Level Indi
83. Lever Slide Switch forward driving mode switch MAN Mode of slide switch AUTO Mode of slide switch Upshift Direction Reverse Position of selector switch Selector Switch Neutral Lock Button Neutral Position of selector switch 10 Drive Position of selector switch 11 Low Position of selector switch 12 Downshift Direction 0 Og OI Fig 8 10 SmartShift Control with Eaton Fuller UltraShift Eaton Fuller UltraShift The Eaton Fuller UltraShift transmission uses the four position SmartShift control lever on the steering column to change gears combined with a gear indi cator on the right hand control panel as shown in Fig 8 12 All forward shifts can be made either manually or automatically at the driver s choice No clutch pedal is required to operate the vehicle General Information UltraShift ASW UltraShift ASW is a six speed medium duty fully au tomated transmission used on the M106 only Six speed UltraShift ASW uses a wet clutch system in which the drive and driven discs rotate in a bath of transmission fluid Dexron III General Information UltraShift DM UltraShift DM is a ten speed heavy duty fully automated transmission used on the M112 only Ten speed UltraShift DM uses a dry clutch system which Drivetrain 3 e SHIFT AS MAN AUTO POL R gt Sma Shite 27 N ES PUSH 9 1 a D 2 710 a 11 11 11 2002 f270080 To upshift manually pull the
84. N A TRAILER PARKING AIR SUPPLY NOT FOR PARKING BRAKE d B SU EM Sy e Sy PA a x E TO rd NS B y 03 10 99 1610291 1 Trailer Air Supply Valve red knob 2 Parking Brake Control Valve yellow knob Fig 9 2 Brake Valve Control Knobs The red octagonal shaped knob on the auxiliary dash panel 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 448 kPa the red knob must be pushed in and should stay in to charge the trailer air supply system and release the trailer parking brakes Before discon necting a trailer or when operating a vehicle without a trailer the red knob must be pulled out If pressure in both air systems drops to 35 to 45 psi 241 to 310 kPa the red knob automatically pops out exhausting the trailer air supply and applying the trailer parking brakes If the trailer is not equipped with parking brakes pull ing out the yellow knob applies both the tractor park ing brakes and the trailer service brakes When the tractor and trailer parking brakes or trailer service brakes are both applied the trailer brakes can be released by pushing in the red knob leaving the trac tor parking brakes applied The trailer brake lever hand control valve is used for applying the trailer brakes without applying the truck or tractor service brakes It is usually mounted on the right hand control p
85. NG BRK switch to toggle the engine brake ON The engine brake will engage at the rate last set on the brake intensity switch Move the intensity switch to the desired inten sity Depending on engine model LO will pro vide 1 3 or 1 2 of the full braking capacity of the engine HI will provide maximum engine braking 7 15 Use the dash mounted switch set at the LO position when driving on flat open stretches of road If the service brakes are still required to slow down on a grade switch to a higher set ting on the dash switch until there is no need for the service brakes Grade descent speed should be such that the service brakes are used infrequently and that they remain cool thus retaining their effectiveness For maximum retarding maintain the top gov erned speed of the engine through the appro priate selection of gears When shifting gears the engine brake will disengage when the clutch pedal is depressed then engage when the clutch pedal is released To cancel the engine brake application toggle the ENG BRK switch OFF 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 in the DDEC VI system programming the engine brake will come on low when the set road speed increases a few miles per hour kilometers per hour above the cruise set speed The maximum amount
86. P Power Takeoff PTO Governor 7 13 Powertrain Controls llle 4 7 Index Subject After Treatment System ATS Request Inhibit Regen Switch Axle Switches Cruise Control Switches Engine Brake Switch Optional Engine Fan Switch Optional Exhaust Brake Switch Optional Transmission Controls Preliminary Checks llle Pretrip and Post Trip Inspection Checklists Pretrip and Post Trip Maintenance Procedures Daily Pretrip Inspection and Maintenance Monthly Post Trip Inspection and Maintenance Weekly Post Trip Inspection and Maintenance Safety Precautions HEV Safety Precautions Seat Belts and Tether Belts General Information Seat Belt Inspection Seat Belt Operation Seat Controls Bench Seat Adjustment Controls Suspension Seat Adjustment Controls Seats Bench Seats Bostrom Seat General Information National 2000 Series Seat Sears Seat Standard Instruments Air Pressure Gauges Coolant Temperature Gauge Engine Oil Pressure Gauge Fuel Gauge Pre EPA10 Fuel Diesel Exhaust Fluid DEF Gauge EPA10 Speedometer oo Voltmeter Starting After Extended Shutdown or Oil Change Subject Page Starting and Engine Shutdown HEN 262 cent ous pee te bbeenmsd teases 15 2 Engine Shutdown 0000 0 eae 15 2 SIMAO 5 atte eee wees eed ew Ee 15 2 The Cranking System 04 15 2 Steering Systemi 4 sec eon Oh Ge sao Ae ae P 9 1 Power Steering System
87. REEREERE ea ERE 8 8 Eaton Fuller Range Shift Transmissions 0 0 cece 8 9 Eaton Fuller AUIOBINIC 2 ccna edo porras CEP RR ERES eee RSs re AA Vete 8 12 Freightliner SmartShift Shift Control i e ku ves RR RR ERR ExRRRETRER ee Sew es SERGEY ES 8 15 Eaton Fuller ASME esos res o ar A ea 8 15 Mercedes Benz Manual Transmissions oooooooococerrr ees 8 22 Mercedes Benz Automated Transmissions Meritor Drive Axles Drivetrain Clutches Clutch Operation Applying the Clutch Brake The purpose of the clutch brake is to stop the trans mission gears from rotating in order to engage the transmission gears quickly in making an initial start To apply the clutch brake put the transmission in neutral and press the clutch pedal to the floor CAUTION Never apply the clutch brake while the vehicle is moving The clutch pedal should never be pressed down fully before putting the transmis sion in neutral Considerable heat will be gener ated which will be detrimental to the friction discs release bearings and transmission front bearings Applying the clutch brake with the transmission still in gear puts a reverse load on the gear At the same time it will have the effect of trying to stop or decel erate the vehicle with the clutch brake Rapid wear of friction discs will take place necessitating frequent re placement Vehicle Overload or Overloading the Clutch 4h CAUTION Overloading will not only result in
88. TO equipped and APG if equipped The HEV s cooling system is separate from the engine cooling system For coolant use a mixture of 50 percent ethylene glycol and 50 percent water Electric Power Take Off ePTO The Electric Power Take Off ePTO option provides standard hydraulic functions without continuous die sel engine operation The PTO drive power is pro vided by the hybrid motor and hybrid batteries When the hybrid batteries deplete the diesel engine auto matically starts to recharge them and provide PTO drive power Once the batteries are fully charged the engine shuts down automatically Vehicles with the ePTO option are designed with a safety switch to ensure the diesel engine does not start when the hood is open A DC DC converter is required for ePTO applications to convert high voltage DC to 12 volt DC Hybrid Electric Vehicle NOTE To maintain a power supply from the ve hicle s low voltage batteries the alternator charges them when the vehicle is being driven Safety Precautions HEV The HEV has high voltage components including 340 volt DC batteries and a 500 volt AC motor Never cut high voltage cables or connectors Do not paint high voltage cables Avoid direct pressure wash on high voltage connec tions PEC DC DC Converter and the air intake and exhaust on the PEC Starting and Engine Shutdown HEV The Cranking System The primary engine starter is the electric motor in the H
89. There are two new electrical modules a master mod ule located near the frontwall bulkhead module and a slave module located between the frame rails chassis module This new wiring system features intelligent controls that blink to show switch activity and error conditions These controls cannot be distinguished by their ap pearance only by their function For more information about these controls see under the headings Axle Switches and Suspension Dump Switch Lighting Controls The lighting controls mentioned under this heading generally operate through switches located on the dash Two types of dash switches are used Paddle switches with a single paddle located in the center of the switch The paddle can be raised or lowered to perform a function Rocker switches that can be pressed at either the upper or lower end to perform a function Certain rocker switches are guarded to prevent them from being switched on or off acciden tally When the panel lights are on most switch legends are backlit with a colored light usually green This allows the driver to find the switch more easily in the dark When the switch is on the switch icon is nor mally backlit with a colored light usually amber Some switch icons are dead fronted not visible until the switch is turned on When turned on some switches are illuminated from within by a red or amber LED light emitting diode Control Panels The left hand co
90. This could result in loss of vehicle control possibly result ing in severe personal injury or death NOTICE Do not operate the vehicle over uneven ground such as ramps speed bumps curbs etc with the air springs deflated Doing this may lead to air bag separation from the piston preventing the suspension air springs from inflating 10 26 2001 1610597 Fig 10 1 Air Suspension Dump Valve 10 1 Fifth Wheel Lubrication WARNING Keep the fifth wheel plate lubricated to prevent binding between the tractor and trailer A binding fifth wheel could cause erratic steering and loss of vehicle control possibly resulting in personal injury or death The standard fifth wheel plate must be kept well lu bricated with chassis grease to prevent friction and binding between the tractor fifth wheel plate and the trailer For a low lube fifth wheel plate inspect the condition of the low lube pads There should be no damaged or missing pieces Slight puckering at the outside edges is normal For lubrication instructions see Group 31 of the Business Class M2 Maintenance Manual Fifth Wheel Coupling Fifth wheel coupling is activated with the lock control handle located on either the right side or left side of the fifth wheel Coupling has successfully occurred when the kingpin has been forced into the jaws and the lock control handle has moved to the locked position NOTICE Some fifth wheels may be mounted
91. a low lube fifth wheel plate the fifth wheel must slide freely under the trailer and the trailer should contact the fifth wheel at the pivot See Fig 10 5 8 Back the tractor under the trailer On a standard fifth wheel the fifth wheel must lift the trailer On a low lube fifth wheel do not lift the trailer as this may damage the fifth wheel plate 9 After sliding under the trailer STOP to prevent from hitting the kingpin too hard then resume backing slowly until the fifth wheel locks WARNING A visual inspection is required by law Some im proper couplings can pass a pull test Sound is not reliable Get out of the cab and look Incor rect coupling could cause the trailer to discon nect possibly resulting in serious personal injury or death 10 Apply the tractor parking brake then perform a physical check for positive kingpin lockup and that there is no gap between the trailer and the fifth wheel See Fig 10 6 11 Ensure that the release handle is in the locked position adjacent to the casting See Fig 10 8 12 Release the tractor parking brakes and test for kingpin lockup by slowly moving the tractor for ward pulling on the trailer against the chocks Fifth Wheel Uncoupling Manual Uncoupling 1 Apply the tractor and trailer parking brakes 2 Chock the trailer rear wheels 3 Lower the trailer landing gear until the weight is removed from the fifth wheel 4 Disconnect the tractor to trail
92. ab See Fig 5 5 10 05 2001 1610523 To adjust the mirror position press the keypad on the door in the direction you want the mirror to move 1 Mirror Select Switch 2 Keypad Fig 5 4 Power Mirror Switch Pad 10 05 2001 1 Mirror 1720396 Fig 5 5 Down View Mirror optional Seats General Information Keep hands tools and other objects away from the scissor points under the seats Failure to do So could cause personal injury Unless otherwise noted all seat adjustments should be made while seated and before the engine is started Due to the high degree of adjustability found in high back air suspension seats it is possible to set the seat back recline adjustment and the seat slide ad justment in such a combination that the seat back will come into contact with the rear wall of the cab It is the responsibility of the driver to adjust the seat to prevent damage to the seat and the cab interior The following is a description of adjustments that are available on one or more seats Not all seats have all of the adjustments listed below 1 Seat Slide fore and aft When this adjustment is made the entire seat moves forward or back ward on its track Fig 5 6 10 05 2001 A Seat Slide fore and aft Adjustment B Isolator Feature 1910482 Fig 5 6 Seat Slide Adjustment and Isolator Feature 2 Isolator This feature also referred to as back slap isolator or Chugge
93. air compressor has built up a minimum pressure of 95 psi 655 kPa in both the primary and secondary air sys tems 3 While driving the low air pressure warning light and buzzer come on if air pressure drops below 65 to 75 psi 448 to 517 kPa in either system If this happens check the air system pressure gauges to determine which system has low air pressure Steering and Brake Systems Although vehicle speed can be reduced using the service brake either the front or rear service brakes will not be operating causing a longer stopping distance Bring the vehicle to a safe stop and have the air system repaired before continuing 4 During normal brake stops depress the service brake 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 IMPORTANT In the event of a total loss of ser vice brakes use the parking brake control valve yellow knob to bring the vehicle to a complete stop in the safest location possible 5 When the forward speed of the vehicle has de creased almost to the idling speed of the engine press in the clutch pedal on manual transmis sions and shift the transmission to neutral Apply the parking brakes if the vehicle is to be parked 6 Ifthe brakes are wet drive the vehicle in low gear and lightly apply the brakes to heat and dry them CAUTION Do not use the spring parking brakes if the ser v
94. al pro cedure is required to fill the hydraulic reservoir This procedure must be carried out by an autho rized Freightliner service facility Meritor Drive Axles Refer to the Meritor website for additional informa tion www arvinmeritor com 8 26 Drivetrain Drive Axles With Differential Lock The Meritor driver controlled differential lock feature side to side wheel lock traction control or traction equalizer is available on single drive or dual drive rear axles It is available on both axles of a dual drive vehicle or on one only It is only available on drive axles Differential lock must only be used under adverse road conditions where greater traction is needed With differential lock on the turning radius is increased and vehicle handling is affected The differ ential lock switch Fig 8 21 allows the driver to lock the wheels on the same axle together The red differ ential lock warning light illuminates on the dash mes sage center when differential lock is engaged 10 26 2001 f610596 Fig 8 21 Differential Lock Switch Differential lock provides maximum traction under slippery conditions When the differential lock is en gaged the clutch collar completely locks the differen tial case gearing and axle shafts together maximiz ing the traction of both wheels and protecting against spinout Under normal traction conditions do not use the dif ferential lock feature Differential
95. al times as necessary If dirt is deeply imbedded use a soft bristle brush after applying the soap If dirt is extremely difficult to remove wall washing preparations normally found around the home can be used Powdered cleaners such as those used for sinks and tiles are abrasive and must be used with caution as they can scratch the vinyl or give it a 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 Tars asphalts and creosote stain vinyl after pro longed contact They should be wiped off immedi ately 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 cloth to remain on th
96. all drive wheels spin ATC reduces engine torque to provide improved traction ATC turns itself on and off Drivers do not have to select this feature If drive wheels spin during accel eration the WHEEL SPIN indicator comes on indi cating ATC is active It goes out when the drive wheels stop spinning Hydraulic Brake System General Information The hydraulic brake system includes a power booster master cylinder reservoir hydraulic lines a brake rotor on each wheel hub and a brake caliper and pad assembly at each rotor IMPORTANT Make sure that the fluid level in the master cylinder reservoir is up to the ridge that surrounds the reservoir See Fig 9 5 Use only heavy duty brake fluid DOT 3 in the hy draulic brake system 9 6 Steering and Brake Systems 1460513a 10 31 94 A Open caps and check fluid level B Fill to this level Fig 9 5 Hydraulic Brake Reservoir The master cylinder controls braking power to the front and rear brakes The Bendix Hydro Max power booster is attached to the rear of the master cylinder and is connected to the power steering system which provides pressurized power steering fluid An electrically powered backup pump operates if there is inadequate fluid flow from the power steering pump to the power booster The brake system warning light comes on if there is a problem within the system Bring the vehicle to a safe stop and correct the prob lem before continuing
97. an be inserted and removed only in this position The following can be operated in the off position re gardless of whether the key is inserted The low beam headlights taillights brake lights road lights dome lights clearance lights turn signals hazard warning lights horn CB radio power windows ciga rette lighter clock and electric oil pan heater In the ACCESSORY position the key is turned coun terclockwise The radio stereo system mirror heat air dryer backup lights and all of the electrical sys tems that are operable in the off position are oper able in the accessory position In the ON position the key is turned clockwise and all electrical systems are operable The low air pres sure and low oil pressure warning lights or mes sages and buzzer operate until the engine is started and pressure is built up Electrical System The Business Class M2 features a new type of electrical system different from any previous vehicle Multiple electrical signals are carried along a simpli fied set of wires reducing the size of wiring bundles There are significantly fewer wires overall meaning less chance of damage shorts and other problems 4 1 Do not attempt to modify add splice or remove electrical wiring on this vehicle without authoriza tion from Freightliner Engineering Doing so could damage the electrical system and result in a fire that could cause serious personal injury or property damage
98. and audible warning connected to both the primary and secondary sys tems activate when air pressure in either system drops below 64 to 76 psi 441 to 524 kPa Instruments P N 60 90 AC c 30 120 v OK 150 RESVRV PRESS TNT NPSI P 05 14 2001 f610556 Fig 3 10 Air Pressure Gauge reservoir A shown When the engine is started the warning light and audible warning remain on until air pressure in both systems exceeds minimum pressure Coolant Temperature Gauge NOTICE A sudden increase in coolant temperature may indicate engine or cooling system failure Bring the vehicle to a safe stop and investigate the cause to prevent further damage Do not operate the engine until the cause has been determined and corrected During normal engine operation the coolant tem perature gauge as shown in Fig 3 11 should read 175 to 195 F 79 to 91 C If the temperature re mains below 160 F 71 C inspect the cooling sys tem to determine the cause 7150 200 10 09 2001 1610565 Fig 3 11 Coolant Temperature Gauge If coolant temperature rises above the maximum temperature listed in Table 3 2 the CHECK engine lamp will illuminate If the condition does not im prove the STOP engine lamp will also illuminate and an audible warning will sound The engine will then derate or shut down depending on the type of en gine protection system installed Engine Oil Pressure Gauge NOT
99. and or repair see the Business Class M2 Workshop Manual for procedures and specifications Specific references to the manual will be found where appropriate 1 Drain manually drained air reservoirs Water and oil normally enter the air reservoir in the form of vapor because of the heat generated during compression After the water and oil con dense drain the resulting emulsion as follows 11 3 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 and Post Trip Inspections and 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 2 Check the fluid level in the windshield washer reservoir Add washer fluid as needed Unscrew the cap to add fluid Washer fluids may be flammable and poisonous Do not expose washer fluid to an open flame or a
100. and side headlight bucket is shown The left hand side is opposite 1 Inboard Adjusting Knob 2 Outboard Adjusting Knob Fig 14 4 Headlight Adjusting Knobs NOTE Horizontal aim should not be adjusted in the field 2 With the vehicle parked 25 ft 7 6 m from the screen or wall put the headlights on low beams and turn both adjusting knobs the same amount as needed to adjust the lights until the beam pat tern meets the acceptable standard Turn the knobs clockwise to raise the beam and counter clockwise to lower it NOTE Blocking off each light is not necessary but it can help to present a clearer beam pat tern 3 Remove the chocks from the front tires 14 2 15 Hybrid Electric Vehicle Hybrid Electric Vehicle HEV Overview seeeeeeeer III 15 1 Safety Precautions HEV i cuocin se cents PES airea d 6 4 aea QA S PECES Modes pd Pe 15 2 Starting and Engine Shutdown HEV isse ses prr ERR REREFCPEY ERES CRY a 15 2 Hybrid System Fault Lamps HEV iua io eR RO ERREUR OPERE ne bE He EEO EE TR Rd DE 15 2 Ermmerosneles HEV occ Gees vind RORXD CERA REG EA brew GO RR RR RC ws sade ne 15 3 JUMPS CHEV PE 15 3 Towing HEV Hybrid Electric Vehicle Hybrid Electric Vehicle HEV Overview A hybrid electric vehicle HEV has both a diesel en gine and an electric motor Engine torque is aug mented with electrical torque The electric motor is powered by batteries which are charged by regen
101. anel See Fig 9 3 10 17 2001 f610591 Fig 9 3 Trailer Brake Lever The valve can be partially or fully applied but in any partially on position it will be overridden by a full ap plication of the service brake pedal Moving the lever down applies the trailer brakes while moving it up releases the trailer brakes The lever will automati cally return to the up position when it is released On Tractor Trailers If both the primary and secondary air systems be come inoperative on tractor trailers the trailer service brakes or parking brakes will automatically apply when the air pressure drops below 35 to 45 psi 241 to 310 kPa The tractor parking brakes will automatically apply when the air pressure drops below 20 to 30 psi 138 to 207 kPa On Trucks Trucks are equipped with spring brake modulation If an air pressure loss occurs in the primary air system the rear parking brakes will be modulated applied and released in proportion to the service brake ap plication There will only be enough air in the sec ondary system for two to four brake applications at 9 2 Steering and Brake Systems which time the parking brake control valve will pop out and fully apply the brakes On trucks the parking brakes will apply when the air pressure drops below 20 to 30 psi 138 to 207 kPa Do not wait for the brakes to apply automatically Be fore continuing to operate the vehicle correct the cause of the air l
102. ansmission lubricant oper ating temperature Temperatures vary by application but the transmission fluid temperature gauge reading should not exceed 250 F 121 C 200 275 A F 10 L TRANS 10 30 2001 1610600 Fig 3 23 Transmission Fluid Temperature Gauge NOTICE A sudden increase in transmission fluid tempera ture that is not caused by a load increase may indicate mechanical failure Bring the vehicle to a safe stop and investigate the cause to prevent further damage Do not operate the vehicle until the cause has been determined and corrected 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 If the temperature returns to normal when the load de creases there is no problem Turbocharger Boost Pressure Gauge A turbocharger boost pressure gauge shown in Fig 3 24 measures the pressure in the intake mani fold in excess of atmospheric pressure being cre ated by the turbocharger Overhead Instrument Panel The optional overhead instrument panel shown in Fig 3 25 may hold a citizen s band C B radio a microphone clip and any switches that can not be 10 10 2001 1610574 Fig 3 24 Turbo Boost Pressure Gauge accommodated on the driver s or auxiliary dash panels The underside of the overhead console also holds the sun visors and the optional dome reading light assembly For more info
103. anufacturer and NFPA 52 2010 should be maintained as a permanent part of the ve hicle service records Use of alcohol propane and other harsh liquids or gases are not acceptable methods for testing Always test the system and sensors after any com ponent has been replaced or if the vehicle has been involved in an accident or fire Ensure that the gas detection system is wired directly to the battery It is recommended that the highest level of safety validation be utilized if there are multiple validation requirements in the state or locality where the vehicle is operated or domiciled Control Module Functions functioning Item Display Function Action Required Illuminated System is on None required Ensure the batteries are connected and replace any blown areen Power Ndi Unlit Detection STD fuses If the gas detection system is still not functioning replace the System immediately SIGNIFICANT Gas Concentration Lights Red illuminated Dangerous gas concentration detected Suspend vehicle operation immediately and follow alarm procedures Trace Gas Concentration Lights Amber flashing Minor gas concentration detected Use caution and monitor the system a Off Sensor is functioning properly None required SENSE EURO On Sensor has malfunctioned Replace the sensor immediately Press to reset the system only after the gas has cleared the Shutdown Reset Button
104. are ad ditionally affected controlled or governed by engine speed through transmission gear selection The Allli son MD3060 transmission has automatic downshift ing when the exhaust brake is requested See the information on the Allison World Transmission later in this chapter On some applications when the Pacbrake is in use it may be necessary to check that the cruise control is not set and that the throttle is in the idle position On some applications the engine transmission cruise control and the Pacbrake exhaust brake may electronically interact with each other which auto matically operates their functions Following are some examples of the programmed options that may be available with the cruise control in the on position e The coast mode engages the Pacbrake when the service brake is applied and disengages when the service brake is released The latch mode engages the Pacbrake when the service brake is applied and the Pacbrake remains on after the service brake is released The Pacbrake is disengaged when another input depressing the throttle or clutch engine speed drops below 800 rpm or the exhaust brake switch is turned off is supplied The manual mode does not require the cruise control switch to be on and operates the Pacbrake manually at the driver s discretion The amount of braking power the engine will develop is related to the speed rpm of the engine The higher the engine rpm the greater the
105. ark and ignite the fuel Avoid open flames or sparks near a natural gas vehicle Cover eyes and exposed skin when working on a natural gas fuel system or fueling a natural gas vehicle Permit no smoking or other ignition sources within thirty feet of a natural gas vehicle Have CO fire extinguishers ABC minimum located in a highly visible and easily accessible location Always purge the fuel lines before performing maintenance or repairs on a natural gas fuel system To purge the lines close the manual fuel shutoff valve and start the engine Let the vehicle idle until the fuel lines are empty and the engine stops Always use a natural gas detector to test the System for leaks whether an odor is present or not Routinely inspect the fuel filtering and regulating mechanisms and the fuel lines A bubble solution can be used to pinpoint the exact location of leaks Always tighten fasteners and fuel connections to the required torque specification Overtight ening or undertightening could cause leaks Close the fuel shutoff valve s before perform ing maintenance and repairs Do not store a natural gas vehicle indoors for any extended period of time Do not bring a natural gas vehicle inside indoors unless the Natural Gas Vehicle workshop is equipped with a methane detec tion and ventilation system Fuel Tank Filling Procedures CNG Vehicle Fueling CNG is moved from the fuel station storage tanks to the ve
106. as recom mended could result in release bearing damage and damage to the clutch NOTE The Sachs hydraulic clutch does not re quire lubrication of the release bearing Sachs Hydraulic Clutch The Sachs hydraulic clutch is a 14 5 inch 365 mm push type clutch that is used with the Mercedes Benz medium duty transmissions models MBT520 and MBT660 NOTE All Mercedes Benz transmission models require a hydraulic clutch system For more in formation on the Mercedes Benz transmissions see under the heading Mercedes Benz Manual Transmissions The clutch hydraulic system consists of three main components A pedal unit including the pedal master cylin der and fluid reservoir A slave cylinder at the clutch A hydraulic hose that connects the master and slave cylinders Keep the clutch fluid reservoir full to the MAX mark If fluid level falls below the MIN mark have the hy draulic system checked for leaks at an authorized Freightliner service facility Use only DOT 4 brake fluid to fill the reservoir The hydraulic clutch provides smooth quiet and reli able clutch actuation with a minimum of mainte nance Pressure builds up in the master cylinder when the clutch pedal is pressed This pressure is transmitted through the brake fluid in the hose to the slave cylin der where it acts directly on the clutch release fork 8 2 Drivetrain Allison On Highway Transmissions The Allison on highway tran
107. ate the lamp assembly from the trimplate and disconnect the wiring harness Replace the lamp assembly Snap the lamp assembly and trimplate together Connect the lamp assembly to the wiring har ness 6 Insert the tabs on the trimplate into the slots on the overhead console attachment plate 7 Center the lamp assembly in the headliner cutout and install the center tapping screw 8 Install the remaining tapping screws Dome Light Switches In the standard cab there is one dome light switch in the driver s door that turns on the diffuse dome light when the driver s door is opened In one option two switches are installed so that the diffuse dome light turns on when either the driver s or passenger s door is opened Clear Reading Lights Optional Clear reading lights are available as a option They are included only in the light assembly installed in the overhead console located next to the diffuse dome light in the same fixture Fig 4 9 Like the dome lights the reading lights are door activated Multifunction Turn Signal Switch The multifunction turn signal switch is attached to the steering column just below the steering wheel on the left hand side This switch has the following functions e The turn signals e The windshield wipers and washers The headlight high beams The hazard warning flasher See Fig 4 10 for the multifunction switch and its component parts 4 5 11 16 2001 182038
108. atural gas vehicles use only Exxon Bus gard Geo 15W 40 natural gas engine oil Bus gard Geo engine oil with an SAE grade of 15W 40 has multiple benefits in natural gas ve hicles including improved cold weather starting and pumping and reduced oil consumption 1 2 01 13 99 1011525 NOTE The MBE900 dipstick is shown 1 Maximum Fill Level 2 Minimum Fill Level Fig 11 3 Checking Engine Oil Level A 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 and check the fuel level in the fuel tank s Pretrip and Post Trip Inspections and Maintenance 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 For repair and or replacement procedures see Group 47 of the Business Class M2 Workshop Manual or take the vehicle in to an authorized Freightliner dealer 8 4 f equipped 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 loss of engine power and re duced vehicle control 8 5 Check the fuel level in the fuel tank s
109. ature gauge shown in Fig 3 18 displays the in cab or outside temperature depend ing on the settings selected set Cans ALARM 12 14 2011 f611153 Fig 3 18 Ambient Temperature Gauge When the alarm is enabled the ambient temperature gauge will sound an audible alert and the amber lamp will illuminate when the outside or inside tem perature depending on the setting selected reaches the set temperature Turn the alarm on and off using the steps below 1 Press the IN button for in cab temperature or the OUT button for outside temperature Press the SET button Press the ADJ button until the desired tempera ture is displayed 4 Press the ALARM button and AL will appear on the display 5 Press the SET button to return to the current temperature display NOTE To turn the alarm off press the ALARM button again and AL will disappear from the display Ammeter An ammeter shown in Fig 3 19 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 dis charged the needle moves to the minus side A con sistent negative reading when the engine is running indicates a possible problem with the charging system 10 10 2001 1610573 Fig 3 19 Ammeter Digital Clock The digital clock shown in Fig 3 20 displays the current time and has a 24 hour alarm
110. aust Brake 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 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 1100 and 2700 rpm Depressing the accelerator or clutch pedal deacti vates the exhaust brake The ABS system when ac tive 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 upper half of the exhaust brake switch is pressed in with the amber light on the switch illuminated an air cylinder shuts the but terfly valve which restricts the flow of exhaust gases and retards the engine This retarding action is car ried through the engine and drivetrain slowing the vehicle and reducing the need for frequent service brake applications Exhaust brakes are not intended for use as the pri mary braking system during vehicle operation Operating Characteristic
111. be alert to vehicle speed and main tain vehicle control by downshifting and or using the service brakes as needed 8 24 Drivetrain When braking or slowing in MAN downshift as nec essary to prevent lugging the engine when speed is resumed If the vehicle comes to a complete stop the TCU resets the transmission to neutral NOTE A downshift request will be refused if the selected gear would cause engine overspeed Cruise Control Cruise control is fully functional with AGS transmis sion in either AUTO or MAN mode In AUTO the TCU will adjust the gear selections to maintain the speed settings as desired No driver action is necessary In MAN the vehicle speed settings must be within the engine speed range for the gear selected If the engine cannot maintain set speed due to changes in road grade the driver must downshift or upshift as necessary For vehicles equipped with a power take off PTO unit two modes of operation are possible stationary and mobile For PTO operation see Chapter 7 Selecting Gears Reverse Reverse R is at the upper end of the three position selector switch located at the end of the SmartShift control lever To select reverse R press in the neu tral lock button and move the selector switch upward to the position above neutral When reverse is se lected the letter R displays on the gear indicator See Fig 8 17 IMPORTANT The vehicle must come to a com plete stop before sele
112. ber DEF DEF is used in the aftertreatment system to lower NOx in the exhaust stream DEF is colorless and Engines Level 1 Level 2 Filter Regeneration Necessary Filter Regeneration Recommended Indicator Lamp Message s Filter is now reaching maximum capacity Diesel Particulate Filter is reaching Filter Condition capacity Required Action Bring vehicle to highway speeds to allow for an Automatic to highway speeds Regeneration or to allow for an perform a Parked Automatic Regeneration To avoid engine perform a Parked Regeneration as Soon as possible 06 29 2009 Derate Vehicle must be derate bring vehicle parked and a Parked Regeneration must be performed engine will begin Regeneration or derate EXHAUST AFTERTREATMENT SYSTEM INFORMATION INDICATOR LAMP S A WARNING E zE Parked Regeneration Parked Regeneration Required fl HEST High Exhaust Required Engine Engine Shut Down System Temperature Filter has reached maximum capacity Flashing A regeneration is in progress Filter has exceeded maximum capacity Vehicle must be parked and a Parked Regeneration or Service Solid Regeneration must be performed I Exhaust Components Check engine operator s manual and exhaust gas are for details engine will shut down at high temperature When stationary keep away from people and flammable materials or vapors For a driver performed
113. brake 3 Pull and hold the kingpin release valve then drive forward slowly 4 After the trailer has slid down the fifth wheel and pick up ramps release the pull valve Fifth Wheel Slide 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 On sliding fifth wheel assemblies the fifth wheel plate is attached to rails that allow forward and rear ward movement of the fifth wheel to optimally distrib ute the load across the axles Slots are evenly spaced along the slide rails and retractable wedges are positioned through the slots to hold the fifth wheel in the desired position The amount of load distribution on the front steering axle and rear drive axle s will have a direct effect on the steering control of the vehicle Determine the front and rear axle weights by weighing the vehicle on scales designed for this purpose 10 7 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 we
114. brake pedal and press firmly on the throttle pedal On steep hills set the parking brake and release it only when there is enough en gine power to prevent rollback 7 2 To stop on a hill or grade press and hold the brake pedal to keep the vehicle from moving On steep hills set the parking brake When parking chock the tires front and or rear Never hold a hill with the throttle pedal This will cause the clutch to over heat Power Down 1 Apply the service brake 2 Select neutral N by moving the selector switch to the N position When the N on the gear indi cator is solid rather than flashing the UltraShift TCU is ready to power down See Fig 8 13 3 With the transmission in neutral set the parking brake 4 Turn off the ignition key and shut down the en gine Automatic and Manual Modes The SmartShift control has a slide switch located on the body of the control lever just before the paddle widens out See Fig 8 15 The slide switch controls the forward driving mode automatic or manual E CY AIR AR gem TR Nee TN e 400 N ad H PSI Y pH ERREUR 450 V d J 1 smt Ww AN J a 1 CEU VA N LO woo VOR Lal lt A ge 3 pa q KY BOWN Lon uu NR a i 1 Slide Switch controls forward driving mode 2 Selector Switch controls gear selection 3 Neutral Lock Button prevents accidental shift into 01 21 2004 f270079c gear
115. broken replace it 1 2 Ifthe battery is equipped with a built in hydrometer examine the hydrometer If a green dot shows in the sight glass the battery is sufficiently charged If the sight glass is dark the charge is low and the battery must be recharged If the sight glass is clear the battery has a low level of electrolyte and must be re placed 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 Business Class M2 Maintenance Manual for recom mended lubricants IMPORTANT Before removing the fill plug al ways clean the hub cap and plug 3 Examine the steering components See Fig 11 15 If repairs are needed see Group 46 of the Business Class M2 Workshop Manual for instructions or take the vehicle to an authorized Freightliner dealer 1461916 10 11 2001 1 Steering Gear Mounting Bolt 2 Pitman Arm Pinch Bolt Nut 3 Drag Link Nut Fig 11 15 Steering Gear Fasteners 3 4 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 11 16 Pretrip and Post Trip Inspections and Maintenance 4 Check the condition of the serpent
116. cator 3 Low DEF Warning Lamp amber below 10 DEF Fig 3 14 Fuel DEF Gauge EPA10 1611045 4 Low Fuel Warning Lamp amber at 1 8 tank of fuel The diesel fuel level is indicated at the top of the gauge with a low fuel warning lamp that illuminates when the diesel fuel level registers 1 8th of capacity The DEF level is indicated in the lightbar on the lower portion of the gauge There is a low DEF level warning lamp that illuminates when the DEF level reaches 1096 of capacity See Chapter 7for details of the DEF gauge functions 20 25S a5 9 BBXN 30 55 so 9 65V 10 x 110 15 J 75 130 e 5 5 910 85 UN RPM e kmn AY X100 ND MPH 10 09 2001 1 Tachometer f610527 2 Speedometer Fig 3 15 Speedometer and Tachometer U S version Speedometer Three speedometer options see Fig 3 15 are avail able The U S version of the speedometer registers speed in both miles per hour mph and kilometers per hour km h with mph in larger numbers The metric version of the speedometer face reverses this arrangement with km h in larger numbers The metric only version shows km h exclusively Voltmeter The voltmeter is a digital readout located on the bot tom line of the dash message center whenever the ignition switch is turned on The voltmeter indicates the vehicle charging system voltage when the engine is running and the battery voltage when the engine is off By monitoring th
117. cesar decree REIR See hed awed oral RIGGquRRPICsq rd 3 9 Optional ThelrttBBlllS 264220 0scteo s0o0 te eet tO 055i tReet hi ies souk AHORA DS RC lt 3 12 Overhead Instrument Panel Instruments Instrumentation Control Unit The ICU3 instrument cluster is a single unit that pro vides the driver with engine and vehicle information It is comprised of gauges warning and indicator lamps an audible warning and a liquid crystal dis play LCD screen IMPORTANT Vehicles that are domiciled out side of the U S and Canada may not have EPAO7 or EPA10 compliant engines with an emission aftertreatment system ATS depend ing upon local jurisdictional emissions guide lines Figure 3 1 shows a typical ICU3 instrument cluster installed in EPAO7 and EPA10 compliant vehicles Vehicles that are not EPA10 compliant do not have a fuel diesel exhaust fluid DEF gauge There can be up to eight gauges on the driver s in strument panel six electronic and two mechanical The air gauges operate mechanically The ICU3 also has the capability to drive up to six independent stand alone gauges such as those in stalled on the auxiliary dash panel Figure 3 2 shows a typical dash panel layout Dash Message Center The dash message center houses all of the standard and optional warning and indicator lamps as well as the driver display screen The display screen has a 2 A Re 1
118. cking or adjusting the headlight aim do the following Remove large amounts of mud or ice from the underside of the fenders Check the springs for sagging or broken leaves Check the suspension for proper functioning of the leveling mechanism On cabs with air sus pensions make sure that the height is properly adjusted Check for damage to the hood and hinge as sembly Repair as necessary With the vehicle unloaded check that the tires are inflated to the recommended air pressure Clean the headlight lenses Clean by hand only using a flannel cloth with mild non caustic soap or detergent and water CAUTION Do not use a power buffer paper towels chemi cal solvents or abrasive cleaners on the head light lens all of which can remove the UV coating from the surface and result in yellowing of the lens Checking Headlight Aim 1 Park the vehicle on a level surface 25 ft 7 6 m from a screen or wall that can be used for aiming the headlights Shut down the engine apply the parking brake and chock the front tires See Fig 14 1 NOTE The low beam headlight is the top bulb in the dual beam assembly 2 On each headlight find the bulb center See Fig 14 2 3 Measure the distance from the ground to the center of each low beam bulb Note those dis tances 6 ft 1 8 m i 01 20 2003 1 Vertical Centerline of Right Headlight 2 Distance Between Headlights 3 Vertical Centerline of Le
119. commended maximum speed of the engine For specifics for any engine refer to the engine manufacturer s operation manual Prolonged idling of engines is not recommended and is illegal in some states The belief that idling a die sel engine causes no engine damage is wrong ldling produces sulfuric acid that is absorbed by the lubri cating oil and eats into bearings rings valve stems and engine surfaces 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 If the engine is programmed with the idle shutdown timer ninety seconds before the preset shutdown time the CHECK ENGINE light will begin to flash at a rapid rate If the position of the clutch pedal or ser vice brake changes during this final ninety seconds CHECK ENGINE lamp flashing the idle shutdown timer will be disabled until reset 7 11 Cruise Control 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 Dash Mounted Switches NOTICE Do not attempt to shift gears without
120. control unit 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 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 speeding or following too close on slippery road surfaces The main circuit of the control unit interprets the speed sensor signals and calculates wheel speed wheel retardation and a vehicle reference speed If the calculations indicate wheel lockup the main cir cuit signals the appropriate solenoid control valve to reduce braking pressure The electronic control unit also has a safety circuit that constantly monitors the wheel sensors solenoid control valves and the electrical circuitry During emergency braking the solenoid control valve alter nately reduces increases or maintains th
121. cruise control on press the upper half of the On Off rocker switch To turn cruise control off press the lower half of the On Off rocker switch 1 Cruise Control On Off rocker Switch 2 Cruise Control Set Resume paddle Switch Fig 4 17 Cruise Control Switches Dash Mounted 10 17 2001 1 On Off Switch 1610588 2 HI LO Switch Fig 4 18 Engine Brake Switches The engine brake turns off automatically or when the clutch pedal is pressed On vehicles without a clutch pedal the brake pedal can be used to deactivate the engine brake For more information about engine brake operation see Chapter 7 When the panel lights are on the HI LO icon is back lit in amber on the HI LO switch On both switches 4 8 Controls the ENG BRK legend is backlit in green when the panel lights are on Exhaust Brake Switch Optional The optional exhaust brake is controlled by a dash mounted rocker switch to help slow the vehicle when the accelerator is released See Chapter 7 under the heading Exhaust Braking System Optional for addi tional information To turn the exhaust brake on press on the upper part of the rocker at the light inside the switch The exhaust brake turns off automatically See Fig 4 19 or Fig 4 20 11 28 2001 1610589 Fig 4 19 Exhaust Brake Switch 03 31 2009 1610589a Fig 4 20 Exhaust Brake Switch When the exhaust brake switch is on an amb
122. cting reverse If reverse is selected with the vehicle moving forward an audible alert will sound and continue sounding at three second intervals until the selector switch is returned to N or D Once the vehicle has come to a complete stop re verse can be engaged Neutral Neutral N is in the center of the three position se lector switch located at the end of the SmartShift control lever Always start the engine in neutral To select neutral move the selector switch to the center position When neutral is selected the letter N dis plays on the gear indicator See Fig 8 18 Do not coast in neutral Coasting in neutral can cause an accident possibly resulting in severe personal injury or death Neutral is always available during operation what ever the vehicle speed When in neutral requests to upshift or downshift are ignored If the selector switch is moved from neutral to drive while the vehicle is moving the transmission will shift into a gear within the operating torque range of the engine A WARNING Always apply the parking brake before shutting down the engine AGS will shift into neutral after shutdown regardless of the position of the shift lever If you do not set the parking brake the ve hicle could roll and cause an accident resulting in death serious personal injury or property damage Before shutting down the engine return the selector switch to N When the ignition is turned off the transmi
123. d stays illuminated In normal operation the wheels may lock so quickly that the blinking of the switch is barely noticeable If operation of the switch is not possible for any rea son ignition is turned off vehicle is moving faster than 25 mph etc the LED will stop blinking and turn off Slow Response If operation of the switch is slowed for any reason vehicle moving too fast low air pres sure etc the switch will continue to blink until the wheels are able to lock As in the normal response the LED comes on steady and stays illuminated once the wheels have locked NOTE If the vehicle is moving too fast let up slightly on the accelerator As the vehicle slows the wheels will lock Abnormal Response If the LED blinks for more than 30 seconds the lock mechanism may not be fully engaged disengaged Bring the vehicle to an autho rized Freightliner service facility for testing Drivetrain Differential Lock Operation Locking the wheels when the vehicle is traveling down steep grades or when the wheels are slip ping could damage the differential and or lead to loss of vehicle control causing personal injury and property damage Lock the wheels only when the vehicle is standing still or moving at very low speed less than 5 mph 8 km h Never lock the wheels when the vehicle is traveling down steep grades or when the wheels are slipping NOTE On some vehicles the differential lock system is connected th
124. d it there to slide the seat forward or backward to the desired position Move the lever back to its origi nal position to lock the seat in place 11 14 2000 1910445 Backrest Tilt Knob Lumbar Support Switch Height Adjustment Switch Seat Slide Lever Front Cushion Height Adjustment Handle Isolator Handle Rear Cushion Adjustment Knob nNOOROIN Fig 5 12 National 2000 Series Seat Isolator To use the isolator feature turn the isolator handle to the horizontal position Turn the isolator handle down to lock out the isolator 5 5 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 Backrest Tilt To tilt the backrest turn the backrest tilt knob until the desired position is reached Seat Cushion Adjustment To adjust the height of the front of the seat cushion lift the front cushion height adjustment handle and pull forward or push back to the desired setting To adjust the height of the rear of the seat cushion remove your weight from the seat and turn the rear cushion adjustment knob to one of three positions Ride Height Adjustment To raise or lower the height of the seat use the height adjustment switch on the side of the seat Sears Seat Seat Slide Adjustment Push the seat slide fore and aft adjustment lever Fig 5 13 all the way to the left and slide the seat forward or backward as
125. d position Isolator To engage the isolator put the seat slide and isolator lever in the center position Lock out the isolator by moving the lever to the right 10 10 96 1910131 Backrest Tilt Lever Air Lumbar Support Control Valve optional Damper Adjustment Switch Height Adjustment Switch Seat Cushion Tilt Knob Seat Slide and Isolator Lever Lumbar Support Knob standard NOORON Fig 5 11 Bostrom Seat Lumbar Support To increase lumbar support rotate the lumbar sup port knob forward To decrease lumbar support ro tate the knob rearward On seats equipped with air lumbar support press the control valve upward to increase lumbar support Press the control valve downward to decrease lum bar support Seat Cushion Tilt Rotate the seat cushion tilt knob to increase or de crease seat cushion tilt Backrest Tilt To tilt the backrest lean forward slightly to remove pressure from the cushion and hold the backrest tilt lever rearward Lean backward slowly to the desired position and release the lever to lock the backrest in place 5 4 Cab Features Ride Height and Damper Adjustment To raise the seat press the upper portion of the height adjustment switch To lower the seat press the lower portion of the switch Press the damper adjustment switch to adjust the damper National 2000 Series Seat Seat Slide Adjustment Move the seat slide lever Fig 5 12 to the left and hol
126. d range when greater traction and maximum pulling power is needed at low engine speed rpm Under normal operating conditions the vehicle is op erated using the high speed gear ratios of the axle Under extreme weather or off road conditions at low speed and rpm and or to pull heavy loads the ve hicle must be operated using the low speed or re duction gear ratios of the axle Drivetrain Axle Shift Switch The axle shift switch is a two position guarded rocker switch Fig 8 24 installed on vehicles with two speed axles 10 26 2001 1610594 Fig 8 24 Axle Shift Switch To shift the axle from low speed to high speed press the upper half of the rocker momentarily at the LED To turn the axle shift off switch from high speed back to low speed press the upper half of the rocker again When the axle has shifted speed the LED turns off When the panel lights are on the AXLE SHIFT leg end is backlit in green IMPORTANT The axle shift rocker switch is guarded to prevent unintentional switch activa tion If the LED in the switch begins to blink dur ing normal operation when the switch has not been activated this indicates an error condition Bring the vehicle to an authorized Freightliner service facility as soon as possible When the axle shift switch is pressed three re sponses are possible a normal response a slow re sponse and an abnormal response Normal Response The LED in t
127. d to replace stan dard safety practices that should be conducted around flammable gases IMPORTANT To function properly the gas de tection system must be powered at all times The gas detection system is directly powered by the batteries and can only be powered off by disconnecting the batteries When servicing a natural gas fueled vehicle disconnect the bat teries only when necessary and do not leave the batteries disconnected for extended periods of time The lower flammability limit LFL is the smallest amount of the gas that supports a flame when mixed with oxygen and ignited Zero percent 096 LFL indi cates a gas free atmosphere One hundred percent 10096 LFL indicates that gas concentration has reached its lower flammability limit 5 gas in air by volume The red warning light and audible alarm located in the overhead console activate when a sen 16 5 sor detects gas fumes in concentrations above 50 LFL and should allow ample time to utilize safety procedures However individuals with special needs should review the system with a professional safety engineer Alarm Procedure Before operating the vehicle the driver must be fa miliar with the procedures as shown on the interior sticker on the overhead panel Fig 16 4 and the exterior sticker on the door Fig 16 5 4 WARNING Buzzer and Red Light indicate significant Fuel Leak Explosion and asphyxiation can occur Exit vehicle Close
128. de if needed 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 2 1 To remove the key turn it coun terclockwise to its original position Pull out on the door pull handle to open the door 10 22 2001 1 Key 2 Lock 1720397 3 Door Pull Handle Fig 2 1 Exterior Door Handle To unlock the passenger s door from outside the cab insert the key in the lockset and turn it one quarter turn counterclockwise Turn the key clockwise to the original position to remove it NOTE The cab door locks can be operated when the doors are open To lock a door from outside the cab do either one of the following Insert the key in the lockset and turn it in the direction opposite to the unlocking direction counterclockwise for the driver s door clock wise for the passenger s door Close the door if it is open Push down the inside lock button Fig 2 2 Close the door 2 1 2 Poi ye A y A Soy j uf AC K d S S A SE y 4 EN Fw Y NON 4 P he KU 4 ee E 2 SN OX 10 25 2001 1720398 To open the door from the inside lift up on the door lever arrow Lock Button Armrest Handle Door Lever Window Crank Inner Door Grab Handle optional UE QI Fig 2 2 Door Interior To open the door from the inside lift up on the door lever This will unlatch the door whether or not it is loc
129. dentification DEF consumption will vary depending on ambient conditions and vehicle application 07 24 2009 1 Batteries 1470542 2 DEF Tank Fig 7 8 DEF Tank Located Behind the Battery Box 7 6 Engines 1470541 07 24 2009 1 DEF Tank 2 Fuel Tank Fig 7 9 DEF Tank Located Forward of the Fuel Tank Fuel DEF Gauge The diesel fuel and DEF levels are measured in a dual purpose gauge See Fig 7 10 The diesel fuel level is indicated at the top of the gauge Below the fuel level a diesel fuel warning lamp illuminates amber when the diesel fuel level drops below 1 8th of the capacity The lower portion of the gauge has a DEF warning lamp that illuminates amber when the DEF tank is near empty and a lightbar that indicates the level of DEF in the tank The DEF light bar illuminates as follows Four bars illuminated green Between 7596 and 100 full Three bars illuminated green Between 5096 and 75 full Two bars illuminated green Between 25 and 50 full One bar illuminated green Between approxi mately 10 and 25 full One bar illuminated amber DEF very low re fill DEF One bar flashing red DEF empty refill DEF LL DEF Warnings and Engine Derates IMPORTANT Ignoring the DEF warning lights will result in limited engine power with a speed limit of 5 mph 8 km h eventually being applied DEF Level Low lnitial Warning When the
130. desired Release the lever to lock the seat in the desired position 4 10 08 2001 1910487 Seat Slide Lever Seat Cushion Tilt Adjustment Ride Height Knob Lumbar Support Lever NAON Backrest Lever Fig 5 13 Sears Low Profile Seat Cab Features Isolator To engage the isolator if installed move the seat slide and isolator lever Fig 5 14 all the way to the right To lock out the isolator move the isolator lever to the center position 10 09 2001 NOTE Armrests are optional Lumbar Support Lever Backrest Lever Ride Height Knob Shock Absorber Bracket ride firmness Pin ride firmness Snap Ring ride firmness Seat Slide and Isolator Lever Seat Cushion Adjustment f910486 Oo 0 012 tc NS Fig 5 14 Sears Fleetmaster Seat with isolator Lumbar Support Move the three position lumbar support lever upward to increase lumbar support firmer Move the lever downward to decrease lumbar support less firm NOTE This three position lever see inset does not rotate a full 360 degrees For seats with air support use the aft rocker switch on the control panel on the left hand side of the seat Fig 5 15 Press up to make the seat firmer press down to make the seat less firm 10 08 2001 1 2 1910488 1 Ride Height Switch 2 Air Lumbar Support Switch Fig 5 15 Air Controls Sears Seat Seat Cushion Tilt To raise the seat cushion lift upward on
131. door with both hands 2 3 10 23 2001 1720400 Bottom Step Top Step B Pillar Grab Handle Sidewall Grab Handle optional A Pillar Cover Grab Handle OE Di Fig 2 5 Cab Access System Passenger s Side and Back of Cab 3 Place your left foot on the bottom step and step up to the upper step with your right foot 4 Move your right hand to the A pillar cover grab handle 5 Place your left foot on the top step and step up 6 Move your left hand to the A pillar cover grab handle 7 Step into the cab with your left foot first NOTE You can also use the inner door grab handle if available as a support when getting up or down from the bottom step Exiting from the Passenger s Side To exit the cab from the passenger s side do the fol lowing steps Fig 2 5 IMPORTANT Do not attempt to exit the cab while carrying any items in your hands 1 If you wish to take any items with you after you exit the cab place them in an accessible location Vehicle Access on the seat or cab floor Make sure they will not get in your way as you exit WARNING Always face in when exiting the cab Do not at tempt to exit with your back to the cab as you would going down a flight of stairs It is easier to slip or lose your balance If you slip when exiting in this way there is a greater likelihood of per sonal injury 2 Grasp the A pillar cover grab handle with both hands then place your right
132. double clutching between gears 4 Do not downshift into LO LO from LO unless op erating conditions make it necessary If it is nec essary make sure that the shift lever is in the LO gear position and the auxiliary section is in the low range Then move the DEEP REDUCTION lever on the dashboard to the IN position mme diately release the accelerator depress the clutch pedal once to break torque engage the clutch and accelerate The auxiliary section will automatically shift from LO to LO LO when the gears reach the same speed 4h CAUTION Never use the clutch brake when downshifting or as a brake to slow the vehicle This will cause premature clutch brake wear Eaton Fuller AutoShift Refer to the Eaton website for additional information www roadranger com IMPORTANT Before starting the vehicle always do the following Be seated in the driver s seat Place the transmission in neutral Set the parking brakes Press the clutch pedal if equipped down to the floor The AutoShift ASW is an automated 6 speed Eaton Fuller transmission No clutch is necessary to oper ate the vehicle The AutoShift AS2 is a partially automated 10 speed Eaton Fuller transmission The driver must use the clutch and put the transmission in neutral to start and stop the vehicle A push button shift selector Fig 8 9 is used with AutoShift AS2 and ASW transmissions IMPORTANT If you have to leave the cab with the engin
133. dus i Syste Mallar an aan buzzer has turned off and the alarm panel light has returned to green Relay is engaged and test or Relay Engaged Light On alarm is being cleared Press the Shutdown Reset button Off Normal condition None required Test Button Tests the overhead console operation and circuitry Press and hold for one minute to to activate a test of all overhead console components Silence Button Silences the alarm buzzer Press to silence the alarm buzzer 16 8 Natural Gas Vehicle Control Module Functions item Display Action Required Suspend vehicle operation Indicates the buzzer is active but Silence Engaged Light silenced immediately and follow alarm procedures Normal condition None required Table 16 2 Control Module Functions Overhead Console Test Press and hold the Push To Test button for one minute The system will proceed with a self diagnostic test that will include illumination of the Trace and SIGNIFICANT gas concentration lights and the sensor fault lights Verify the large red light and buzzer activate and that all lights illuminate or flash to ensure that all bulbs are operational Sensor Test The gas detection system sensors must be tested using certified test gas which can be purchased as part of a test kit Testing with alcohol or heavy gases such as butane or propane does not satisfy CCR 935 2 or NFPA 52 regulati
134. e voltmeter the driver can stay aware of potential bat tery charging problems and have them fixed before the batteries discharge enough to create starting diffi culties The voltmeter will normally show approximately 13 7 to 14 1 volts when the engine is running The voltage of a fully charged battery is 12 7 to 12 8 volts when the engine is off Battery voltage under 12 0 volts is considered a low battery and a completely dis charged battery will produce only about 11 0 volts The voltmeter will indicate lower voltage as the ve hicle is being started or when electrical devices in the vehicle are being used Instruments If the voltmeter shows an undercharged or over charged condition for an extended period have the charging system and batteries checked at an autho rized Freightliner service facility On a vehicle equipped with a battery isolator system the voltmeter measures the average voltage of all the batteries when the engine is running When the en gine is off the voltmeter shows only the isolated bat tery voltage and does not indicate the voltage of the engine starting batteries Optional Instruments Optional instruments typically located on the auxil iary dash panel or right hand control panel are not found on every vehicle They are listed here in alpha betical order to make the information easier to find Air Restriction Gauge The air intake restriction gauge measures the vacuum on the engine side
135. e 15 1 High Voltage Safety Features void bx aep den wap dert 15 1 Regenerative Braking 15 1 Hybrid System Fault Lamps HEV Lino ems poems sey tame pex eee 15 2 Hydraulic Brake System oo 9 6 General Information len 9 6 Meritor WABCO Antilock Braking System ABS for Hydraulic Brakes e ee cirese scaire e 240804 9 7 Operation saa oe as a We pe e 9 7 Ignition Switch and Key less 4 1 Instrumentation Control Unit 3 1 Audible Warnings lt lt lt lt 3 4 Dash Message Center o o o o oooo oo 3 1 Ignition Sequence o o o ooooooooo 3 2 Mode Reset Button lt lt 3 4 OdOMBIS ca du ca di 3 4 J Jumpstarting HEV llle 15 3 L Lighting Controls sss rr RI 4 1 Control Panels o o o o o oo ooo oo 4 1 Exterior Light Controls o o o 4 2 Interior Lights and Light Controls ss pes repe sex cede acce erue means 4 4 Major Repair and Replacement Ol PAMS cita ares a Be pace eee Se E 16 10 Mercedes Benz Automated Transmissions 0 00 eee ee eee 8 22 Subject Page AGS Diagnostics i c 8 26 General Information AGS 8 22 Operation AGS ce tae ese ee dees wa ds 8 23 Mercedes Benz Manual Transmissions 0 00 eee ee ee eee 8 22 Meritor Drive Axles leen 8 26 Axle Shift 2 za psani rc is 8 29 Drive Axles W
136. e Collar 4 Filter Cover 8 Threaded Stud Fig 13 3 Davco Model 382 Fuel Water Separator 1 Apply the parking brakes and turn off the lights A CAUTION and all other electrical devices Make sure both starting systems have the same voltage outputs and avoid making sparks Other wise the vehicle charging systems could be se verely damaged Also do not attempt to charge 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 13 3 2 To gain access to the batteries open the battery compartment See Fig 13 4 For detailed instruc tions see Chapter 2 CAUTION Always connect the battery jumper cables and charger correctly positive to positive and negative to negative Connecting a charging de vice backwards positive to negative will blow fuses that power the bulkhead module BHM and In an Emergency chassis module CHM and the devices they con trol will not work 3 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 5 3 4 1 iia 10 24 2001 Sl 1543933 1 Top Step 3 Cab 2 Battery 4
137. e facility as soon as possible To select neutral press the clutch pedal to the floor Then press the N button Set the parking brakes and slowly release the clutch pedal NOTE Neutral is always available during ve hicle operation When in neutral requests to upshift or to downshift are ignored D Drive Drive D is used for normal highway driving In drive the transmission shifts into the proper gear for start ing and then automatically selects additional gears as needed in a range between the starting gear and the highest gear To select drive press the clutch pedal to the floor Then press the D button Slowly release the clutch pedal and drive the vehicle To start up in a gear other than the normal starting gear push the upshift arrow with D selected and while the vehicle is stopped IMPORTANT AutoShift will not start up in any gear higher than third gear The number of the gear selected will flash on the auxiliary display until the driver presses the clutch pedal This gear will be stored in memory as the de fault starting gear until a different starting gear is se lected by the driver or until the engine is shut down NOTE The transmission may be programmed so that it is not possible to select a starting gear other than the preprogrammed starting gear L Low LOW is used to hold the transmission in low gear when descending steep hills If LOW is selected when the vehicle is stopped the transmissi
138. e lower half of the Switch No indicator displays on the dash message center with the high range activated Press the upper half to return to N TRL To activate the low range press the upper half of the Switch A red indicator with the legend T CASE LO RNG displays on the dash message center On the switch the LO N TRL legend is backlit in red Press 4 12 Controls the lower half to return to N TRL and then press the lower half again to select HIGH RANGE Braking Parking Brake Control Valve The yellow diamond shaped knob Fig 4 29 on the auxiliary dash panel operates the parking brake con trol valve park brake switch Pulling the yellow knob applies the tractor parking brakes spring brakes Pushing in the knob releases the tractor parking brakes Before the parking brakes can be released the air pressure in either air brake system must be at least 65 psi 448 kPa 1 J d TO WO S N 2 dn EE PARKING ren ina p 03 10 99 1610291 1 Trailer Air Supply Valve red knob 2 Parking Brake Control Valve yellow knob Fig 4 29 Brake Valve Control Knobs See Chapter 9 under the heading Dual Air Brake System for further information about the parking brake control valve Trailer Air Supply Valve The red octagonal shaped knob Fig 4 29 on the auxiliary dash panel operates the trailer air supply valve After the vehicle and its air hoses are con nected to a trailer and the pressure in the ai
139. e more effective Rec ommended engine braking speed is above 1800 rpm and below the rated speed The engine brake must be disengaged when shifting gears using the clutch pedal 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 NOTICE Do not allow the engine to exceed 2500 rpm Se rious engine damage could result Control speed is the speed at which the engine brake performs 100 percent of the required downhill braking resulting in a constant speed of descent The control speed varies depending on vehicle weight and the downhill grade For faster descent select a higher gear than that used for control speed Service brakes must then be used intermittently to prevent engine overspeed and to maintain desired vehicle speed A driver may descend slower than control speed by selecting a lower gear being careful not to over speed the engine Occasional deactivation of the en gine brake may be necessary to maintain the desig nated road speed under these conditions Below a set engine temperature when the engine is cold the brake may be disabled depending on the brake type To activate the engine brake after the engine is warmed up and the vehicle is in motion e Remove your feet from both the clutch and throttle pedals Press the dash mounted E
140. e running Place the transmission in neutral e Set the parking brakes e Chock the tires Push Button Shift Selector Gear information is presented to the driver on the push button shift selector usually mounted on the 8 12 Drivetrain 10 i 1 DN R N EIE D ES N 7 M SHIFT Y 6 LOW EATON FULLER TRANSMISSIONS MANUAL E T N 11 14 2001 1261145 1 Not Used 7 Upshift Downshift 2 R reverse Arrows 3 N neutral 8 SERVICE Light 4 D drive 9 Mode Indicator 5 MANUAL Mode 10 Mode Button 6 Low Gear Hold Fig 8 9 Eaton Push Button Shift Selector right hand control panel On this display the informa tion is presented as follows To select neutral press the N button When neutral is engaged the telltale LED will light up next to the N button To select reverse press the R button When reverse is engaged the telltale LED will light up next to the R button To select drive press the D button When drive is engaged the telltale LED will light up next to the D button To select low gear press the LOW button When low is engaged the telltale LED will light up next to the LOW button To change gears manually press the MANUAL button When the manual mode is engaged the telltale LED will light up next to the MANUAL button Use the shift buttons upshift downshift to change the current starting gear selection in R D and LOW In MANUAL the shift b
141. e 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 12 2 Cab Appearance or the foam from a mild detergent When using a sol vent or
142. e supply of air pressure in the brake chamber thereby prevent ing front and or rear wheel lockup 9 5 Even if the ABS system is partially or completely in operative normal braking ability is usually main tained IMPORTANT If a solenoid control valve or combination solenoid control valve is damaged and inoperative normal braking may be im paired ABS Indicator Lights IMPORTANT If any of the ABS indicator lights do not work as described below or come on while driving repair the ABS system immedi ately to ensure full antilock braking capability Tractor ABS Light If equipped only with the tractor ABS system the amber TRACTOR ABS indicator light see Fig 9 4 comes on after the ignition switch is turning on The indicator light goes out only if all of the tractor ABS components are working 8888888 188 VOLTS 10 12 2000 1 Tractor ABS Indicator 2 Wheel Spin Indicator optional 610454 3 Trailer ABS Indicator Fig 9 4 ABS Indicator Lights Ah CAUTION An accumulation of road salt dirt or debris on the ABS tone wheels and sensors can cause the ABS warning light to come on If the ABS light does come on the tone rings and sensors should be inspected for corrosion and serviced if necessary The service should include cleaning Steering and Brake Systems of the tone rings and sensors If any tone ring on a
143. e the Komfort Latch by giv ing the shoulder belt a quick tug If you lean for ward against the shoulder belt the Komfort Latch will automatically release and will need to be reset NOTE Neither the Komfort Latch nor the Sliding Komfort Latch need to be manually released in an emergency situation Each will release by itself under rough road or other abnormal condi tions Make sure the three point seat belt is completely retracted when it is not in use Air Bag Optional Your vehicle may or may not be equipped with a driver s air bag supplemental restraint system The air bag when used with seat belts provides ad ditional protection to the driver in severe frontal colli 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 WARNING 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 positi
144. eave the cab with the engine running for example when checking the transmission fluid Without Auto Apply Parking Brake Follow the instructions for vehicles with 1000 series transmissions under the heading Without Park Posi tion With Auto Apply Parking Brake 1 Bring the vehicle to a complete stop using the service brake 2 Ensure that the engine is at low idle rpm Put the transmission in PB auto apply parking brake 4 Apply the parking brake if equipped and make sure it is properly engaged 5 Chock the rear tires and take any other steps necessary to keep the vehicle from moving 2400 Series On vehicles with 2400 series transmissions follow the instructions for vehicles with 1000 series trans missions Range Inhibit Indicator 2000 and 2400 Series A RANGE INHIBIT indicator is a standard feature of the 2000 series and 2400 series transmissions The RANGE INHIBIT indicator comes on to alert the driver that transmission operation is being inhibited and that the range shifts being requested by the driver may not occur When certain operating condi tions are detected by the TCM transmission control module the controls will lock the transmission in the current operating range Shift inhibits occur under the following conditions e Shifts from neutral to reverse or from neutral to a forward range when the engine is above idle greater than 900 rpm Drivetrain e Forward reverse directional
145. ed badly worn bent rusty or 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 Use the tightening pattern in Fig 11 10 for 10 hole wheels and the tightening pattern in Fig 11 11 for 8 hole wheels See Group 40 of the Business Class M2 Workshop Manual for more information NOTICE 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 22 Inspect the outboard side of all wheel hubs and the hub oil seal area on the inboard side of each wheel for signs of oil leakage If any oil is found on wheel and tire or brake components remove the vehicle from service until the leak has been repaired If needed fill the hubs to the level indicated on the hub cap See Group 35 of the Business Class M2 Maintenance Manual for recom mended lubricants NOTE Vehicles operating under severe or ad verse conditions should be checked more fre quently 23 Inspect the air brake chamber and the air brake chamber pushrods WARNING Do not operate the vehicle with the front brakes backed off o
146. ed to the 1 Date of Manufacture by month and year driver s side sunvisor another copy is inside the rear 2 Gross Vehicle Weight Rating developed by taking cover of the Owner s Warranty Information for North the sum of all the vehicle s gross axle ratings America booklet An illustration of the decal is shown 3 Gross Axle Weight Ratings developed by in Fig 1 1 considering each component in an axle system including suspension axle wheels and tires and using the lowest component capacity as the value COMPONENT INFORMATION for the system MANUFACTURED BY USE VEHICLE ID NO Fig 1 2 Certification Statement U S WHEN ORDERING PARTS MODEL VEHICLE ID NO im DATE OF MFR REND ENGINE MODEL TRANS NO J E TRANS MODEL MAIN FRT AXLE NO J FRONT AXLE MODEL REAR AXLE NO REAR AXLE MODEL REAR AXLE NO RATIO IMRON PAINT CAB PAINT MFR CAB COLOR A WHITE 4775 FOR COMPLETE PAINT INFORMATION PAINT NO CAB COLOR B BROWN 3295 SEE VEHICLE SPECIFICATION SHEET CAB COLOR C BROWN 29607 CAB COLOR D DARK BROWN 7444 11 21 96 f080021 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 N apply to your vehicle 11 13 2001 HE 1080117 1 Tire and Rim I
147. ee Fig 6 4 4 3 5 2 v 6 jdn f We 7 vod ad P 8 9 06 17 2003 831455 1 Face Mode 2 Selection Between Face Mode and Bi Level Mode 3 Bi Level Mode 4 Selection Between Bi Level Mode and Floor Mode 5 Floor Mode 6 Selection Between Floor Mode and Floor Defrost Mode 7 Floor Defrost Mode 8 Selection Between Floor Defrost Mode and Defrost Mode 9 Defrost Mode Fig 6 3 Air Selection Switch Without Air Conditioning Air Selection Switch Without Air Conditioning T Face Mode Directs all airflow through the face or instrument panel outlets Selection between Face Mode and Bi Level Mode Directs 75 percent of the airflow through the face outlets and 25 percent through the floor outlets Bi Level Mode Directs the airflow equally to the face outlets and the floor outlets Selection between Bi Level Mode and Floor Mode Directs 25 percent of the airflow through the face outlets and 75 percent through the floor outlets Floor Mode Directs all airflow through the floor outlets Selection between Floor Mode and Floor Defrost Mode Directs 75 percent of the airflow 6 5 7 4 BD wd s 3 e e 2 Bw 06 8 2000 1831462 A Air Conditioning Modes 1 Air Conditioning Face Mode 2 Selection Between Air Conditioning Face Mode and Air Conditioning Bi Level Mode Air Conditioning Bi Level Mode Selection Between Air Conditioning Bi Level Mode and Face Mode Face Mode Selection Between Face Mode and Floor
148. ee the Business Class M2 Workshop Manuaftor procedures and specifications and see the Business Class M2 Maintenance Manu alfor lubricant recommendations specifications and maintenance intervals 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 and Post Trip Inspections and Maintenance Procedure Performed Procedure Daily Pretrip Inspections Checks check off Reference Drain manually drained air reservoirs not equipped with automatic drain valves D1 Check windshield washer reservoir fluid D2 Check surge tank coolant and if equipped coolant for hybrid cooling system D3 Inspect radiator and charge air cooler D4 Check engine for fuel oil or coolant leaks Inspect engine and chassis wiring D5 Inspect air intake system D6 Check intake air restriction indicator mounted on air intake Check engine oil level Check power steering fluid level Inspect fuel tank s fuel lines connections and fuel level Check fuel water separator Inspect natural gas fuel system if equipped Inspect front
149. engines Fig 3 8 for EPAO7 engines or Fig 3 9 for EPA10 engines The lamps or telltales in the top row are optional The lamps on the other three rows are installed at fixed positions that do not vary If an optional lamp is not requested the position is blank See Table 3 3 for a list of standard and commonly used warning and indicator lamps Engine Protection System If a critical engine condition exists for example low engine oil pressure low coolant level high coolant temperature high diesel particulate filter soot level or uncontrolled regeneration the CHECK engine lamp will illuminate to alert the driver to correct the condition as soon as possible If the condition wors ens the STOP engine lamp will illuminate NOTE If the CHECK engine lamp illuminates during vehicle operation take the vehicle di rectly to an authorized Freightliner service facil ity 3 5 When the red STOP engine lamp illuminates most engines are programmed to shut down au tomatically within 30 seconds The driver must immediately move the vehicle to a safe location at the side of the road to prevent causing a haz ardous situation that could cause bodily injury property damage or severe damage to the en gine The STOP engine lamp illuminates when the engine protection system is activated The engine protection System typically works as follows depending on the engine type Some vehicles may have a shutdown override switch wh
150. ensioned against the windshield Replace damaged or deteriorated wiper blades 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 After starting the engine make sure the oil and air pressure warning systems are operating and that the buzzer stops sounding when the preset minimum is reached If the warning systems do not come on when the ignition is turned on have the systems repaired The air pressure in both the primary and second ary 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 pressure is 130 psi 896 kPa NOTE If the air pressure in both systems is above the preset minimum when the engine is started test the low air pressure warning sys tem by lowering the pressure to below this range or until the warning system comes on 14 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 Chapt
151. entering the cab The recirculation mode can also be used to decrease the time required to cool or heat the cab interior dur ing extreme outside temperature conditions When the recirculation mode is on the recirculation indica tor will be on See Fig 6 2 The recirculation mode is not available when the air selection switch is in one of the following modes floor defrost mode selection between floor defrost mode and de frost mode e defrost mode When the recirculation mode is turned on it will stay on for 20 minutes or until the recirculation button is pressed again or the air selection switch is turned to a defrost mode IMPORTANT On vehicles built before May 2 2003 the recirculation mode turns off after twenty minutes and can be turned back on when the recirculation button is pressed again On vehicles built from May 2 2003 the system enters a partial recirculation mode for five min utes after being in full recirculation mode for 20 minutes This cycle repeats as long as the sys tem is in recirculation mode NOTE To prevent the buildup of fumes or odors inside the cab on a vehicle built before May 2 2003 do not use the recirculation mode for more than 20 minutes It is recommended that the recirculation mode remains off for five min utes before it is turned back on Defrosting Before using any of the defrost modes clear the screen at the base of the windshield if snow or ice is present Heater V
152. entilator and Air Conditioner Air Conditioning Optional There are four air conditioning modes on the air se lection switch The air conditioning settings on the air selection switch are blue in addition to the selection between the air conditioning bi level mode and the face mode IMPORTANT Operate the air conditioner at least five minutes each month even during cool weather This helps prevent drying and cracking of the refrigerant compressor seals and reduces the chance of refrigerant leaks in the system NOTE The heating and air conditioning system has a brushless blower motor with a protection or shutdown mode to prevent damage due to overheating and overcurrent conditions If the brushless blower motor goes into a protection mode the motor will operate at a slower speed If the overheating or overcurrent condition con tinues the motor will shut down and stop com pletely The motor will resume proper operation after the motor has cooled or the overcurrent condition has been resolved It will be necessary to cycle the fan switch off and then on to reset the motor If the problem appears repeatedly take the vehicle to an Freightliner dealer or autho rized service outlet for repairs 6 4 Aftertreatment System ATS cess ri A A di Y E 7 1 EROGO AMINO 32e RS EC EPIS Laus R4 GERE PATE SO I AA RES Rus qd A dus ee 7 9 Cold Woather Staring ieclreskeew kx RR none innir EE EAE RARE RIA EERRPGG AE Eres 7 10 Starting Aft
153. epair the trailer ABS system immedi ately to ensure full antilock braking capability The Trailer ABS light will not illuminate unless a com patible trailer is connected to the tractor IMPORTANT If a compatible trailer is con nected and the light is not illuminating for three seconds when the ignition switch is turned to the ON position it is possible that the light is burnt out Wheel Spin Light If equipped with Automatic Traction Control ATC the amber WHEEL SPIN indicator light illuminates if one of the drive wheels spins during acceleration When the light illuminates partially release the throttle pedal until the light goes out The light goes out when the wheel stops spinning If slippery road conditions continue turn on the differ ential lock switch on dual drive vehicles turn on the interaxle lock switch See Chapter 8 for axle switch instructions A CAUTION Do not turn the differential lock switch on while the WHEEL SPIN indicator light is on To do so could damage the rear axle Automatic Traction Control Optional Automatic Traction Control is an option available on ABS equipped vehicles with air brake systems It im proves traction when vehicles are on slippery sur faces by reducing drive wheel overspin ATC works automatically in two ways e f a drive wheel starts to spin ATC applies air pressure to brake the wheel This transfers en gine torque to the wheels with better traction e If
154. equired 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 Check the air pressure reserve as follows 11 14 Pretrip and Post Trip Inspections and 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 26 4 11 15 Fig 11 14 Haldex Automatic Slack Adjuster 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 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 1 minute and note the air pressure gauge reading Observe the air pressure drop in psi kPa per minute Charge the air system until cut out pres sure of 120 psi 827 kPa i
155. er 2 for detailed operating instructions for the ICU Pretrip and Post Trip Inspections and Maintenance 06 29 2009 2 Coolant Inlet Line Vaporizer 1 Pressure Relief Device 2 Fuel Inlet Line 3 Check Valve 4 CNG Quick Connect Port OND Fuel Shutoff Solenoid Valve 11 Pressure Relief Valve Coolant Outlet Line 1470536 9 Pressure Gauge 10 Overpressure Regulator 12 Fuel Outlet Line Fig 11 6 LNG Vaporizer Assembly 15 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 16 During cold weather make sure the heater de froster and optional mirror heat controls are op erating properly If so equipped turn on the mir ror heat switch and make sure the system is working 11 9 17 Check the operation of all the panel lights and 18 interior lights Turn on the headlights dash lights and four way flashers and leave them on If any of the gauge bulbs the dome light bulbs or the right and left turn indicator bulbs are not working replace them Make sure all the exterior lights are working properly C
156. er Extended Shutdown or Oil Change 0 00 2 eee eese 7 10 Engine Break lf isvsessteshierkxe a RR RE AAA A A an dine 7 10 Engine Operation ausa qued 392 9939 184 593 chose ERROR S EUER rate 7 10 Cruise Control cies eres dies Ses se Onde eee d Y AAA EA AAA 7 11 Power Takeoff PTO GOVerMOT e 463 2 4s none teed nonce TENETE EREE Ce ERROR e 7 13 Cold Weather Operation ananasen RR ER rare 7 13 High Altitude Operatiom cadeau pubs PER PEE RUE eres eee ae 7 13 Engine SHUIC WA sese d e e EROR CHEE GS E E EK ER RU ERR KER EEE EERE RPS SEX 7 14 Engine Braking sss srera bended ee ee we He ES bh ee be DONALL DEAE EE eh eke doe ade 7 14 Exhaust Braking Systems Engines Aftertreatment System ATS IMPORTANT EPAO7 and EPA10 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 EPAO7 or EPA10 compliant engines with an emission af tertreatment system depending upon local statutory emissions guidelines EPAO07 Aftertreatment System ATS On road diesel engines built after December 31 2006 are required to meet EPAO7 guidelines for re duced exhaust emissions of particulate matter and nitrogen oxides NOx NOx is limited to just over 1 gram per brake horsepower hour g bhp hr and par ticulate matter cannot exceed 0 01 g bhp hr EPAO7 compliant engines require ultralow sulfur die sel ULSD
157. er LED illuminates inside the switch When the panel lights are on the EXHST BRK legend is backlit in green 4 9 Engine Fan Switch Optional The engine cooling fan can be turned on by the en gine fan switch ENG FAN legend The fan will con tinue to operate for a set amount of time and then turn off unless the coolant temperature is high enough to continue the fan operation To turn the engine fan on press on the upper part of the rocker at the fan icon See Fig 4 21 When the engine fan is running the fan blade icon is backlit in amber When the panel lights are on the ENG FAN legend is backlit in green 01 04 2011 610590 Fig 4 21 Engine Fan Switch 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 Chapier 8 for complete transmission operating instructions On vehicles with standard Allison On Highway Series automatic transmission the shift selector is lever activated The display mounted on the steering col umn provides four forward ranges and one reverse range See Fig 4 22 When the transmission is in D drive the vehicle will operate in the overdrive 5th gear To shift down into the direct drive 4th gear use the overdrive lockout switch O D legend See Fig 4 23 The transmission will shift into 4th gear and remain in that gear u
158. er air system lines and electrical cable Plug the air lines to prevent dirt or foreign material from entering the lines 5 Verify that both the yellow parking brake and red trailer air supply knobs are out the tractor and trailer parking brakes are set and that the trailer is prepared for uncoupling 6 Release the kingpin locking mechanism following the instructions for each manufacturer below 6 1 Fontaine Lift the safety latch and pull the lock control handle to the unlocked posi tion 6 2 Holland In the locked position the safety indicator swings freely over the operating rod See Fig 10 9 View A To unlock the mechanism manually rotate the safety indicator toward the rear of the fifth wheel See Fig 10 9 View B Pull the operating rod out When the upper operating rod shoulder is outside the slot raise the handle and place the shoulder of the upper rod against the plate casting above the slot See Fig 10 9 View C 10 4 Fifth Wheels and Trailer Couplings 09 10 2010 f311127 Fig 10 8 Jost Release Handle Locked The fifth wheel is now in the lockset posi tion and is ready for uncoupling As the tractor pulls away from the trailer the king pin forces the jaw to rotate contacting the lock Continued rotation of the jaw forces the lock to move outward and drops the upper rod back into the slot See Fig 10 9 View D The wheel is now ready for coupling 6 3 Jo
159. erative braking and on vehicles equipped with the ePTO option the diesel engine The batteries cannot move the vehicle for long dis tances at highway speeds In the event of a diesel engine failure drive the vehicle to a safe location as quickly as possible Eaton Corporation developed and supplies the hybrid electric system for Freightliner Trucks The primary system components are the hybrid drive unit or HDU which includes the electric generator motor and automated transmission power electronics car rier PEC and the motor inverter controller Electric power take off ePTO and auxiliary power generator APG components are optional on the HEV system Freightliner Trucks designed the stand alone liquid cooling system required to support the operation of Eaton s HEV system Its primary system components are the electric water pump reservoir expansion tank radiator electric radiator fan and coolant plumbing Body builders will develop the components for the PTO the PTO plumbing and a safety switch to pre vent the diesel engine from starting when the hood is open Regenerative Braking Regenerative braking reduces vehicle speed by con verting some of the vehicle s kinetic energy into elec tric energy to charge the hybrid system s batteries When the accelerator pedal is at idle while coasting or the service brake is depressed to slow the vehicle the hybrid system charges the batteries The regeneration
160. eservoir is below 70 psi 483 kPa llluminates when starting the engine during cold conditions Wait until the lamp goes out before turning the ignition key to START Indicates the engine oil pressure is below the minimum allowable pressure listed in Table 3 1 Indicates the fuel may contain water Drain any water collected in the fuel water separator Fuel Filter Restriction Indicates the fuel filter is clogged and requires service Low Battery Voltage Indicates that battery voltage is 11 9 volts or less Check Transmission Indicates an undesirable transmission condition ee Transmission Overheat Indicates high transmission temperature NO CHARGE No Charge Indicates an alternator charge output failure Engine Brake Indicates the engine brake is engaged IDLE MGMT Optimized Idle Indicates optimized idle is enabled Left Turn Signal Flashing indicates the outside left turn signal lights are activated Right Turn Signal Flashing indicates the outside right turn signal lights are activated s High Beam Headlights Indicates the high beam headlights are on 3 8 Instruments Common Warning and Indicator Lamps BRAKE Parking Emergency Brake Cruise Control Unfastened Seat Belt 3 Indicates the parking brake is engaged Indicates the cruise control is enabled Activates with an audible alert when the system
161. ess the lower half of the On Off rocker Switch on the instrument panel 3 To resume a preselected cruise speed do these steps 3 1 If the On Off rocker switch on the instru ment panel is off turn it on 3 2 Momentarily raise the paddle of the Set Resume switch to RES ACC Cruise will return to the last speed selected NOTE If the ignition is shut off the speed memory will be lost 4 To adjust cruise speed up raise the paddle of the Set Resume switch to RES ACC and hold it there until the vehicle accelerates to the new speed as desired 5 To adjust cruise speed down lower the paddle of the Set Resume switch to SET CST and hold it there until the vehicle decelerates to the new speed as desired Shift Knob Controls Optional Cruise control can also be activated by the optional PAUSE RESUME and SET buttons on the transmis sion shift knob Fig 7 16 05 23 95 1260316 Fig 7 16 Cruise Control Buttons on the Transmission Shift Knob 1 To cruise at a particular speed do these steps 1 1 Hold the accelerator pedal down until the speedometer reaches the desired speed 1 2 Push the SET button on the transmission shift knob 2 To disengage the cruise control do these steps 2 1 Press down the brake pedal on automatic and manual transmission or Press down the clutch pedal on manual transmission only 2 2 Push the PAUSE button on the transmis sion shift knob 3 To resume a p
162. essively down to the bottom gear in high range double clutching between shifts 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 Operation Deep Reduction Models Upshifting 1 Position the gear shift lever in neutral See Fig 8 8 for the shift pattern Start the engine and bring the air system pressure up to 95 to 125 psi 655 to 862 kPa 2 Position the range preselection lever down into low range NOTE If conditions are difficult start out in LO LO Move the DEEP REDUCTION lever on the dashboard to the IN position Otherwise start out in LO with the DEEP REDUCTION lever in the OUT position Drivetrain 3 Depress the clutch pedal to the floor Shift into LO gear then engage the clutch with the en gine at or near idle rpm to start the vehicle mov ing The vehicle will start in LO or LO LO de pending on the DEEP REDUCTION lever position 4 To upshift if in LO LO move the DEEP REDUC TION lever to the OUT position and immed
163. f 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 3 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 bearings and axle lubricant A 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 13 5 to the vehicle frame Use protection to keep the chains from damaging the frame 5 Remove the bumper end caps and chrome bumper if equipped 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 6 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 6 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 7 Lift the vehicle and secure the safety chains If extra towing clearance is needed re
164. 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 Do not cut drill braze solder weld strike or probe any part of the air bag system 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 af
165. foot on the top step while standing up from the seat facing inward Place your left foot on the top step Move your left hand to the B pillar grab handle Move your left foot to the bottom step Move your right hand to the B pillar grab handle Step to the ground with your right foot first 2 NOAA w Retrieve from the cab any items that you wish to take with you NOTE You can also use the inner door grab handle if available as a support when getting up or down from the bottom step Cab Entry and Exit Vehicles With One Step 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 fall 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 Use the cab access system grab handles access steps and steering wheel to enter or exit the cab Entering from the Driver s Side To enter the cab f
166. for cracks in the batteries for corrosion of the terminals and for tightness of the cable clamps at the terminals Charge the batteries to full capacity Replace any battery that is damaged If so equipped turn off the load disconnect switch after the engine is shut down to prevent battery discharge Have the alternator output checked at an au thorized service provider Check the condition and tension of the drive belts Refer to the engine manufacturer s engine op eration manual for recommended heaters low viscosity lubricating oils wintergrade fuels and approved coolants A winterfront may be used to improve cab heating while idling If a winterfront is used at least 25 of the grille opening should remain open in sectioned stripes that run perpendicular to the charge air cooler tube flow dirrection This assures even cooling across each tube and reduces header to tube stress and possible failure Winterfronts should only be used when the ambient temperature remains below 10 F 12 C 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 Engines each 1000 feet 300 m altitude above sea level for a naturally aspirated engine All engines used on M2 vehicles are altitude compensated by the use of a turbocharger This re duces smoky exhaust at high altitudes requires less
167. front section is used only as a starting gear The other four ratios are used once in LOW RANGE and once in HIGH RANGE giving eight highway ratios LO LO is se lected by the DEEP REDUCTION lever on the dash board See Fig 8 8 for the shift pattern Bie 5 7 R 1 3 P LO 6 8 LO LO 2 jJ 4 03 12 96 f260123a Fig 8 8 Shift Pattern Deep Reduction Operation Range Shift 1 When operating off highway or under adverse conditions always use low gear when starting to move the vehicle 8 10 Drivetrain When operating on highway with no load or under ideal conditions use first gear when start ing to move the vehicle For all conditions use the highest gear that is still low enough to start the vehicle moving with the engine idling and without excessively slipping the clutch 2 Use the clutch brake to stop gear rotation when shifting into low or first or reverse when the ve hicle is stationary The clutch brake is applied by 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 Do not make range shifts with the vehicle moving in reverse gear 4 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
168. ft Headlight 9 a 25 P 1544233 4 Projected Vehicle Centerline 5 Screen or Wall 6 Height of Lamp Centers Fig 14 1 Headlight Aiming Screen or Wall 14 1 Headlight Aiming P 11 06 2002 1544236 Measure beam height from the ground to the small dot roughly in the center of the headlight lens Fig 14 2 Headlight Beam Height Adjusting Dot 4 On the screen or wall 25 ft 7 6 m away make the appropriate markings directly across from each headlight and at the same height as mea sured for the headlight 5 Turn on the headlights to the low beam setting See Fig 14 3 for the ideal and acceptable pat terns for both headlights 01 11 2011 1544153 NOTE The top view shows the ideal beam pattern the bottom view shows an acceptable standard A Vertical Centerline 1 Bright Area B Horizontal Centerline Fig 14 3 Headlight Beam Pattern f either or both headlights do not aim into the inner edges of the centerline follow the adjusting procedure below e f both headlights come close to the inside of each headlight centerline as shown no further work is needed Turn off the head lights and remove the chocks from the front tires Adjusting Headlight Aim 1 Lift the flap over the rear end of the headlight bucket to expose the two plastic adjusting knobs on each headlight See Fig 14 4 N 11 05 2002 1544235 NOTE The right h
169. fuel and they should never be run on fuel with sulfur content higher than 15 ppm In addi tion they require low ash engine oil The following guidelines must be followed or the warranty may be compromised Use ultralow sulfur diesel ULSD with 15 ppm sulfur content or less based on ASTM D2622 test procedure 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 meeting the API CJ 4 index specifications IMPORTANT Using non specification fuels or oils can lead to shortened diesel particulate filter DPF cleaning or exchange intervals For ex ample using Cl 4 oil with 1 3 sulfated ash 3096 more ash content may result in the need for DPF cleaning or exchange 20 to 30 sooner than would normally be required The exhaust system in EPA07 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 ment system has a device that outwardly resembles a muffler called the aftertreatment device ATD GA IMPORTANT See your engine operation manual for complete details and operation of the after treatment system Inside the ATD on Mercedes Benz Detroit Diesel and Cummins engines the exhaust first passes over the diesel oxidation catalyst DOC then it passes through the DPF which traps soot particles If ex haust tempe
170. fuel valve on tank e Evacuate area e Do not open hood 04 28 2009 1080157 Fig 16 4 Interior Warning Sticker IMPORTANT If an audible alarm activates do not operate any electrical switch including lights Avoid causing sparks and stay away from arcing switches and equipment Do not use a telephone including cellular phones or any types of portable communication or electronic devices that have a battery If the vehicle is in motion when the audible alarm activates bring it to a safe stop shut down the en gine and exit the vehicle Do not open the hood If outside the vehicle when the audible alarm acti vates do not open the cab door or hood In the event of an audible alarm immediately follow these procedures as allowed by conditions 1 Immediately shut off all engines Extinguish any cigarettes pilot lights flames or other sources of ignition in the area and adjacent areas Natural Gas Vehicle A WARNING Buzzer and Red Light indicate significant Fuel Leak Explosion and asphyxiation can occur Do not open cab door or hood Close fuel valve on tank Evacuate area 24 01652 001 04 28 2009 1080158 Fig 16 5 Exterior Warning Sticker 2 Manually close all fuel shutoff valves including those on the LNG tank or CNG cylinders 3 If the vehicle is indoors as in a service shop immediately open windows and doors to provide extra venti
171. g 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 A CAUTION 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 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 Inspect each tire f
172. g brake and move the selector switch to N Drivetrain Automatic and Manual Modes The SmartShift control has a slide switch located on the body of the lever just before the paddle widens out See Fig 8 20 The slide switch controls the for ward driving mode automatic or manual eX ZR Y S AE 100 Ur oe D o 150 AIR _ 01 19 2004 1 Slide Switch controls forward driving mode 2 Selector Switch controls gear selection 3 Neutral Lock Button prevents accidental shift into gear f270079b Fig 8 20 Switches AGS Transmissions To change mode at any time move the slide switch in the desired direction This allows the driver to re spond to a wide range of driving conditions such as blind corners tight curves and steep hills IMPORTANT Whatever the mode it is always possible to shift manually by moving the lever up or down as needed In either mode the gear indicator displays the cur rent gear See Fig 8 16 Automatic Mode AUTO Automatic drive mode AUTO is recommended for most driving conditions For the best fuel economy always use AUTO mode In AUTO mode upshifts and downshifts are made by the transmission without driver intervention Press in the neutral lock button move the selector switch to drive D and press down on the throttle pedal The transmission will shift automatically through the for ward gears If driving conditions requi
173. gnal Indicator 13 High Exhaust System 7 Trailer ABS Indicator as applies Temperature HEST Warning Fig 3 8 EPAO7 Dash Message Center 3 6 Instruments o Common Warning and Indicator Lamps CHECK Engine Indicates a critical engine condition low oil pressure low coolant level high coolant temperature high DPF soot level or uncontrolled DPF regeneration Correct the condition as Soon as possible If the condition worsens the STOP engine lamp will illuminate STOP Engine Indicates a serious fault which requires engine shutdown immediately The engine protection system will reduce the maximum engine torque and speed and if the condition does not improve will shut down the engine within 30 to 60 seconds 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 in a hazardous location restart the engine after turning the key to the OFF position for a few seconds Move the vehicle to a safer location er E High Exhaust System Temperature HEST Slow 10 secona flashing indicates a regeneration regen is in progress Solid illumination indicates high exhaust temperatures at the outlet of the tail pipe when speed is below 5 mph 8 km h It does not signify the need for service it only alerts the vehicle operator to high exhaust temperatures when a regen is in p
174. h both hands Place your left foot on the step and stand on the threshold facing into the cab Move your right hand to the B pillar grab handle Move your left hand to the B pillar grab handle Move your right foot onto the step Step to the ground with your left foot first SECO UD de 09 Retrieve from the cab any items that you wish to take with you NOTE You can also use the inner door grab handle if available as a support when getting up or down from the bottom step Entering from the Passenger s Side To enter the cab from the passenger s side do the following steps Fig 2 5 1 Open the passengers door and place anything that you are carrying in the cab Grasp the B pillar grab handle with both hands Place your left foot on the step and step up to the cab with your right foot 4 Move your right hand to the A pillar cover grab handle 5 Move your left hand to the A pillar cover grab handle 6 Step into the cab with your left foot NOTE You can also use the inner door grab handle if available as a support when getting up or down from the bottom step Exiting from the Passenger s Side To exit the cab from the passenger s side do the fol lowing steps Fig 2 5 IMPORTANT Do not attempt to exit the cab while carrying any items in your hands 1 If you wish to take any items with you after you exit the cab place them in an accessible location on the seat or cab floor Make sure they will
175. h is not possible for any rea son vehicle is moving faster than 5 mph ignition is turned off etc the LED will stop blinking and turn off Slow Response If operation of the switch is slowed for any reason by cold weather low air pressure etc the switch will continue to blink until the sus pension completes a dump or fill As in the normal response the LED comes on steady and stays illumi nated when the suspension if fully deflated Abnormal Response If the LED blinks for more than 10 seconds the suspension dump mechanism may not be operating properly Bring the vehicle to an au thorized Freightliner service facility for testing If the ignition is turned off while the vehicle is in dump mode the power to the dump solenoid is cut off to prevent battery drain and the suspension sys tem will autofill the rear air springs The suspension 4 15 will also autofill if the vehicle is operated with the suspension dumped and the speed is over 5 mph e g driver forgot to inflate the bags or there was a system failure Suspension Autofill Override Valve The suspension autofill override option is a dash air valve that keeps the suspension deflated when the ignition is turned off To operate it turn off the ignition then push the override valve knob See Fig 4 34 When the ignition is turned on the override valve will release automatically and the suspension will autofill The suspension dump switch will then opera
176. hat the air connections do not leak 4h WARNING Incorrect fifth wheel lock adjustment could cause the trailer to disconnect possibly resulting in se rious personal injury or death 12 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 If slack is present uncouple the trailer and have the fifth wheel inspected and adjusted by a certified technician Jost Fifth Wheel Coupling 1 Tilt the ramp down Open the kingpin locks See Fig 10 7 Back the vehicle close to the trailer centering the kingpin on the fifth wheel 4 Chock the trailer wheels 5 Connect the air lines and electrical cable 6 Ensure that the red trailer air supply valve trailer brake is pulled out and that the trailer parking Fifth Wheels and Trailer Couplings 09 10 2010 f311128 A Lock held open by catch mechanism Fig 10 7 Jost Release Handle Unlocked brakes are set See Chapter 5 in this manual for operation of the dash mounted brake controls NOTICE Attempting to couple at the wrong height may cause improper coupling which could result in damage to the fifth wheel or kingpin 7 Adjust the trailer height if required For a standard fifth wheel plate the trailer should contact the fifth wheel approximately 4 to 8 inches 10 to 20 cm behind the pivot See Fig 10 4 For
177. he front air brake chambers This inspection requires two people one in the driver seat Pretrip and Post Trip Inspections and Maintenance 25 26 and another to inspect the brake line con nections at the wheels 24 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 24 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 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 experi ence higher than normal rotor corrosion Tone rings should be routinely inspected for corrosion 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 immediately Inspect the slack adjusters 25 1 Meritor Slack Adjusters Check the boot for cuts tears or other damage Have it replaced if necessary 25 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 boo
178. he 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 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 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
179. he cab floor at the left of the driver s seat or inside the battery box The battery isolation switch reduces the power to the cab and engine power wiring Use it whenever the vehicle is to be put out of service for extended periods IMPORTANT The battery disconnect switch does not completely isolate the batteries from the electrical system For service operations that require that the batteries be disconnected al ways shut down the engine and remove the negative battery cables 2 7 NOTE Whenever battery power is discon nected clocks and electronically tuned radios must be reset X 01 18 95 f600150a Fig 2 9 Cab Battery Isolation Switch Hood Opening and Closing The hood can be raised to a full open position A tor sion bar helps you to raise the hood and to lower it to the operating position Hood restraint cables pre vent the hood from overtravel A hood damper limits the closing speed In the operating position the hood is secured to the cab mounted half fenders by a hold down latch on each side of the hood To Open the Hood 1 Apply the parking brakes 2 Release both hood hold down latches by pulling the ends outward See Fig 2 10 CAUTION Do not let the hood free fall to the full open posi tion To do so could cause damage to the hood or hood straps 3 Standing in front of the hood raise the rear of the hood upward until it reaches the over center position 45 degrees fro
180. he switch blinks until the axle shifts speed At this point the LED comes on steady and stays illuminated In normal operation the axle may shift so quickly that the blinking of the switch is barely noticeable If operation of the switch is not possible for any rea son interaxle lock is on ignition is turned off etc the LED will stop blinking and turn off Slow Response If operation of the switch is slowed for any reason by cold weather low air pressure etc the switch will continue to blink until the axle shifts As in the normal response the LED comes on steady and stays illuminated Abnormal Response If the LED blinks for more than 30 seconds the axle shift function mechanism may not be operating correctly Bring the vehicle to an authorized Freightliner service facility for testing Axle Switch Interlock NOTE On vehicles with tandem drive axles there is an interlock that prevents an axle from shifting speed whenever the interaxle lock is on If the axle shift switch is pressed when the interaxle lock is on the axle shift will not be completed The LED does the following e f the LED is off the LED comes on briefly and turns off again e f the LED is on it stays on To complete the axle shift turn off the interaxle lock and press the axle shift switch again If still needed the interaxle lock can then be reactivated 8 30 9 Steering and Brake Systems Sicenmng SYSTEM eerie tiae URGE a
181. he vehicle secure all loose items in the cab so that they will not fly forward during a full brake application Make sure all occupants are wear ing seat belts Parking Brake Interlock CAUTION Do not continually press down on the parking brake control valve yellow knob without press ing down on the service brake pedal This will damage the safety interlock The service brakes and parking brakes have a safety interlock that prevents the unintentional release of the parking brake If the yellow knob is pressed in it will pop back out unless the service brake pedal is being pressed down A decal on the dash alerts you to press down on the service brake pedal before releasing the parking brake If you do not the yellow knob will not allow itself to be pressed in but will return to its old posi tion Operating the Brakes To ensure safe operation and minimum brake wear do the following steps when operating the brakes 1 Monitor the air pressure system by observing the low air pressure warning light the emergency buzzer and both the primary and secondary air pressure gauges When the ignition switch is turned on the low air pressure warning light pressure circle icon illu minates and the emergency buzzer sounds The warning light and buzzer shut off when air pressure in both systems reaches 65 to 75 psi 448 to 517 kPa 2 Before driving your vehicle continue to monitor the air pressure system until the
182. heck that all the lights and reflectors are clean See Fig 11 7 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 Pretrip and Post Trip Inspections and Maintenance NS OS SS A 205 8 7 6 10 81 2000 8 1543920 NOTE The parking lights front clearance lights and taillights all function as turn signals 1 Utility Light 5 Headlight Low Beam 2 Identification Light 6 Headlight High Beam 3 Marker Lights 7 Parking Light 4 Front Clearance Light 8 Road Light Fig 11 7 Exterior Lights 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 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 pressures 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 addin
183. hen starting the engine make sure that the ser vice brakes are applied Failure to apply the ser vice brakes may result in unexpected vehicle movement which could cause severe personal injury or death Failure to apply the vehicle park ing brakes when the transmission is in neutral may allow the vehicle to move unexpectedly pos sibly causing property damage or personal injury Press the N button to select neutral The digital dis play will display N when neutral is selected It is not necessary to press neutral before starting the ve hicle The ECU electronic control unit or TCM transmission control module automatically places the transmission in neutral at start up Failure to apply the vehicle parking brakes when the transmission is in neutral may allow the ve hicle to move unexpectedly possibly causing property damage or personal injury When neutral is selected the vehicle service brakes parking brake or emergency brake must be applied Selecting neutral does not apply vehicle brakes un less an auxiliary system to apply the parking brake is installed A WARNING Do not coast in neutral Coasting in neutral can cause an accident possibly resulting in severe personal injury or death Do not let the vehicle coast in neutral If the vehicle is allowed to coast in neutral the engine brake will not work and you could lose control of the vehicle Always select neutral before turning off the engine Neutral is also
184. here are two options for performing an emergency shutdown The preferred method is to turn off the ignition key The other option is to disconnect the low voltage 12 volt vehicle batteries In either case the engine will shut down dash lights will shut down the hybrid electrical system will shut down and the high voltage batteries in the Power Electronics Car rier PEC will remain live but isolated in the PEC NOTE If the service switch on the PEC is ac cessible it may be pushed in to shut down the hybrid electrical system and isolate the live HEV batteries in the PEC In Case of an Accident or Fire If the HEV becomes involved in an accident or fire be aware of the following Use CC2 or dry chemical extinguishers The batteries in the PEC are lithium ion Do not cut into high voltage cables The high voltage wiring is covered in orange insulation or convoluted tubing Do not cut into or open the PEC 15 3 Do not cut into or open the DC DC converter Do not cut into or open the inverter If it is necessary to remove occupants using cutting equipment avoid high voltage cables and the PEC Jumpstarting HEV Jumpstarting vehicles equipped with the Eaton Hy brid System is identical to Non Hybrid vehicles which use the vehicle 12 volt battery system Towing HEV When towing the vehicle the output shaft of the transmission must not be allowed to spin or turn If the vehicle is towed with the
185. hicle cylinders through a metered dispenser During fueling as pressure inside of the vehicle cyl inders increases so does the temperature The dis penser shuts off when it determines the CNG cylin ders are full CNG fuel cylinders cannot be filled to their full capac ity of 3600 psi 24 800 kPa in cooler weather Since temperature change causes gas to expand and con tract less pressure in the cylinders on a cold day is equal to the same amount of gas at a higher pres sure on a warm day The fuel station dispenser has a temperature pressure compensating device which accounts for ambient temperature during fueling See Table 16 1 for approximate full cylinder pressures at various temperatures IMPORTANT Close all windows and doors dur ing the fueling process Keeping windows and doors closed allows for easier leak detection inside the cab after fueling A WARNING Natural gas fuel tanks lines and valves are al ways pressurized Always observe safety precau tions Failure to do so could lead to loss of con trol over a filling hose or to ignition of the natural gas which could cause serious bodily injury death or severe property damage 2 Ensure all fuel cylinder shutoff valves are open See Fig 16 1 Table 16 1 CNG Temperature Pressure Compensation Values Use the follo
186. hts can be turned on The road lights will not illuminate if the high beam headlights are already on and switching from low beams to high beams will switch off the road lights To turn the road lights on press on the upper part of the rocker at the road light icon See Fig 4 6 To turn the road lights off press on the lower part of the rocker at the ROAD LAMP legend 10 15 2001 1610582 Fig 4 6 Road Light Switch When the road lights are on the road light icon is backlit in amber When the panel lights are on the ROAD LAMP legend is backlit in green Utility Light Switch Optional The utility light switch operates one of the following lights or sets of lights e A single round utility light swivel mounted in the center of the cab roof Controls Two round utility lights mounted in fixed posi tions on each side of the cab roof e Two flush mounted utility lights mounted on the back of the cab one on each side To turn the utility light s on press in on the upper part of the utility light UTLY LAMP rocker switch Fig 4 7 To turn the utility light s off press on the lower part of the rocker at the UTLY LAMP legend 10 15 2001 1610583 Fig 4 7 Utility Light Switch When the utility lights are on the diagonal light beam icon is backlit in red When the panel lights are on the UTLY LAMP legend is backlit in green Spotlight Optional The spotlight switch is located
187. iately release the accelerator depress the clutch pedal once to break torque and reengage the clutch The auxiliary section will shift from LO LO to LO when the gears reach the same speed 5 Shift progressively upward from LO through 1st 2nd 3rd and 4th gears while the range prese lection lever is in LO Always double clutch be tween gears 6 When in 4th gear and ready for the next upshift pull up the range preselection lever and move the shift lever double clutching to the 5th gear position As the shift lever passes through neu tral the auxiliary section will automatically shift from low to high range A CAUTION Never move the shift lever into the LO gear posi tion after high range preselection or anytime the auxiliary section is in high range Transmission damage could result 7 Continue upshifting from 5th gear through 8th gear always double clutching between gears Downshifting 1 While in high range move the gear shift lever from 8th gear through 5th gear as conditions re quire always double clutching between gears 2 When in 5th gear and ready for the next down shift push down the range preselection lever and move the shift lever to the 4th gear position being sure to double clutch As the shift lever passes through neutral the auxiliary section will automatically shift from high to low range 3 While in the low range continue downshifting from 4th through LO as conditions require al ways
188. icationl acit daca Ce aC QR Gale eva nA CE Rr aw Rad Rd 1 1 Vehicle Access 2 0 0 e rrr 2 1 INSUMOS centen order da rada alo as acere ay rater ae Dra ea 3 1 c at ete O a a a E a a e E a e A e a 4 1 0 A ee kee eee ee a a AE aT a a a E a E E i 5 1 Heater Ventilator and Air Conditioner cese 6 1 0 PT 7 1 DlVeltalli ac ia de tct cen tan on a b E a UR ea Re cR RR Re n eic 8 1 Steering and Brake Systems cuiereioekRem E RE ERETF dra 9 1 Fifth Wheels and Trailer Couplings 000 0 eee eee eee eee 10 1 Pretrip and Post Trip Inspections and Maintenance 0000e cece 11 1 Cab Appearance nc cwctie au suns drid ri ais aria agen 12 1 in an EImergeliby cris ada a ta eee tia 13 1 scele e error A AAA a 14 1 Hybrid Electric Vehicle coo rr A 15 1 Nat rali Gas Vehicle 12e ada na RA rr AAA AAA 16 1 E O o EET 1 1 Vehicle Identification Federal Motor Vehicle Safety Standard FMVSS Labels Canadian Motor Vehicle Safety Standard CMVSS Labels 00 00 cee eee eee eee 1 2 Tire and Rim Labels EPA Emission Control Vehicle Identification Vehicle Specification Decal 1 3 The vehicle specification decal lists the vehicle model identification number and major component E models It also recaps the major assemblies and in stallations shown on the chassis specification sheet 11 14 2001 2 1080118 One copy of the specification decal 18 attach
189. icator 20 Not Used 3 Intake Heater On Indicator 13 Tractor ABS Indicator 21 Air Restriction Indicator 4 Water In Fuel Indicator 14 Transmission Temperature 22 Left Turn Signal 5 Wheel Spin Indicator Indicator 23 Low Battery Voltage Warning 6 Low Coolant Warning 15 Trailer ABS Indicator as applies 24 Driver Display Screen 7 Check Transmission Indicator 16 Low Oil Pressure Warning 25 High Beam Headlights Indicator 8 Engine Fan On Indicator 17 High Coolant Temperature 26 Low Air Pressure Warning 9 Low Fuel Warning Warning 27 Right Turn Signal 10 Check Engine Indicator 18 Fasten Seat Belts Warning Fig 3 7 Pre EPA07 Dash Message Center 12 3 4 5 6 7 f j OPT opt OPT OPT OPT OPT OPT OPT OPT ee Kes ggggggg O 3320 E er MI OO eii 2800 3 188 VOLTS y ES D 1 1 13 14 16 17 18 19 10 18 2006 1610850 Typical installation shown Location of legends installed in the top row may vary and other legends may be specified 1 Optional Indicator 8 Low Oil Pressure Warning 14 Left Turn Signal 2 Check Engine Indicator 9 High Coolant Temperature 15 Low Battery Voltage Warning 3 Stop Engine Indicator Warning 16 Driver Display Screen 4 Malfunction Indicator Light MIL 10 Fasten Seat Belt Warning 17 High Beam Headlights Indicator 5 Tractor ABS Indicator 11 Parking Brake On Warning 18 Low Air Pressure Warning 6 Transmission Temperature 12 DPF Status Lamp 19 Right Turn Si
190. ice 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 brakes if hot or cause them to freeze during cold weather If the brakes are wet drive the vehicle in low gear and lightly apply the brakes to heat and dry them Allow hot brakes to cool before using the spring parking brakes Always chock the tires 7 Allow hot brakes to cool before using the parking brakes Always chock the tires Parking the Vehicle A WARNING Do not use the trailer service brakes for parking they are not designed for this purpose If air bleeds out of the trailer air tank during parking the vehicle could roll causing serious personal injury or property damage IMPORTANT Air pressure in the primary or sec ondary reservoir must be at least 65 psi 448 kPa before the tractor parking brakes and the trailer service brakes or parking brakes can be released On trailers without parking brakes do the following to park safely To park just the trailer chock the trailer tires before disconnecting the tractor To park a tractor with a trailer apply the tractor parking brakes Caging the Parking Brakes A WARNING Do not drive the vehicle with the parking brakes caged If the vehicle is driven with the parking brakes caged there would be no means of stop ping the vehicle if a complete loss of air pressu
191. ich may be used to momentarily override the shutdown sequence See Chapter 7 for more information On some engines the engine protection sys tem will derate the engine allowing it to run at lower rpm and slower vehicle speed drive the vehicle to a safe location or to a service facility On other engines the engine protection sys tem will shut down the engine It will first der ate the engine then shut it down completely 30 to 60 seconds after the indicator illuminates depending on the critical fault type if the con dition does not improve Bring the vehicle to a stop on the side of the road before the engine shuts down Do not at tempt to restart the engine while the vehicle is moving To restart the engine turn the ignition switch to OFF leave it there a few seconds then turn the switch to START The engine will run for a short period and shut down again if the condition does not improve Instruments 1 2 3 4 5 6 7 8 10 11 12 18 14 15 8888888 L M BRAKE 388 VOLTS 4 16 17 18 A 19 20 21 03 05 2002 22 23 24 25 26 27 1610593a Typical installation shown Location of legends installed in the top row may vary and other legends may be specified Wheel Lock Warning 11 Engine Protection Warning 19 Parking Brake On Indicator 2 Low Washer Fluid Indicator 12 No Charge Ind
192. icone based chemicals and cleaners will per manently disable the sensors When cleaning the vehicle cover the sensors with a plastic cover ing Keep the sensors covered until the area has been cleared of any cleaning fumes Harsh chemicals and extremely high tempera tures may damage the sensor Puncture of or damage to the seal located inside the sensor housing will significantly shorten the sensor life Frequent exposure to high concentrations of gas will accelerate sensor deterioration Overhead Console The overhead console consists of an alarm panel on the right side and the control module on the left side The alarm panel has a green light a red light a buzzer and a sensor See Fig 16 6 It is located within view from outside of the vehicle The large green light is continuously illuminated during normal operating conditions Before entering the vehicle always verify that the green light is illuminated If the green light is not illu minated do not enter the vehicle Complete the alarm procedure previously outlined The alarm panel meets the California Highway Patrol Title 13 2008 and NFPA 52 2010 requirements All 16 6 Natural Gas Vehicle Silence Engaged Relay Engaged 6 re 8 9 04 28 2009 Test Button Sensor Fault Indicator Lights Zone 1 Leak Indicator Lights Power Indicator Light Zone 2 Leak Indicator Lights On cour c Silence Button Silenced Engaged Light 11 RedLight Relay
193. id level at all times If the fluid level is too low the con verter and clutch do not receive an adequate supply of fluid If the level is too high the trans mission may shift erratically or overheat To access the oil level display mode park the vehicle on a level surface shift to N Neutral apply the parking brake and idle the engine Then simulta neously press both the up and down arrows once The oil level will display at the end of a two minute countdown Diagnostic Codes Diagnostic codes are numerical indications relating to a malfunction in transmission operation These codes are logged in the TCM ECU memory The most se vere or most recent code is listed first A maximum of five codes numbered d1 d5 may be listed in memory at one time If the mode indicator LED is illuminated the displayed code is active If it is not illuminated the displayed code is not active NOTE During normal operation an illuminated mode indicator LED signifies the specialized mode operation is in use To enter diagnostics mode first park the vehicle and apply the parking brake Then simultaneously press both the up and down arrows twice Eaton Fuller Straight Shift Transmissions Refer to the Eaton website for additional information www roadranger com General Information Straight Shift Eaton Fuller 5 speed FS models are fully synchro nized They have five forward speeds and one re verse See Fig 8 3 for the shift patte
194. ield VEHICLE NOISE EMISSION CONTROL oe FREIGHTLINER CORPORATION TE OF MANUFACTURE 01 96 THIS VEHICLE CONFORMS TO U S EPA REGULATIONS FOR NOISE EMISSION APPLICABLE TO MEDIUM AND HEAVY TRUCKS THE FOLLOWING ACTS OR THE CAUSING THEREOF BY ANY PERSON ARE PROHIBITED BY THE NOISE CONTROL ACT OF 1 A THE REMOVAL OR RENDERING SNOPERATIVE OTHER THAN FOR PURPOSES OF MAINTENANCE REPAIR OR REPLACE ANY NOISE CONTROL DEVIC ELEMENT OF DESIGN LISTED IN THE OWNERS MANUAL INCORPORATED INTO Tuis 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 1080026 Fig 1 7 Vehicle Noise Emission Control Label 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 EPAO7 and EPA10 Emission Control To meet EPAO7 and EPA10 emissions regulations for vehicles domiciled in the USA or Canada engines manufactured after December 31 2006 EPAO07 or December 31 2009 EPA10 are equipped with an emission aftertreatment system Vehicles domiciled outside of the USA and Canada may not have after treatment equip
195. ight rating given on the FMVSS or CMVSS label Manual Slide Operation The manual slide feature is operated from the fifth wheel plate with a manual release handle using the following procedure See Fig 10 11 1 Lr qug qox d i 494 Ly 19 494 x Ww du OFA Fa EE ad dT pu Fat Jo fart Ffal M o o o o o Oo o o o 2 07 25 95 1 Locking Wedge 2 Slide Release Pull Handle f310190 Fig 10 11 Manual Release Sliding Fifth Wheel Fontaine shown 1 Stop the tractor and trailer in a straight line on level ground Pull the red trailer air supply knob to apply the trailer parking brakes 2 Apply the tractor parking brake then release the sliding mechanism using the appropriate method for the fifth wheel manufacturer 2 1 Fontaine Lift the slide release pull handle to disengage it from the guide plate Then pull out the handle until it is in the un locked position and can be positioned against the guide plate to hold it out The Fifth Wheels and Trailer Couplings handle will stay in the unlocked position until it is manually disengaged from the guide plate See Fig 10 12 10 26 2010 1310050 Fig 10 12 Releasing the Sliding Fifth Wheel Fontaine 2 2 Holland Pull the operating rod out Make sure both side plungers have released See Fig 10 13 10 26 2010 1310445 1 Baseplate 5 Slider Sadd
196. ilating defrosting and air conditioning functions The climate control panel without air condi tioning is shown in Fig 6 1 The climate control panel with air conditioning is shown in Fig 6 2 Fan Switch The fan switch controls the fan speed and forces fresh or recirculated air through the air outlets The fan switch has eight fan speeds and an off position To increase airflow turn the fan switch to the right or to a higher number To decrease the airflow turn the switch to the left or to a lower number Air Selection Switch The air selection switch allows you to control the flow of air through the face outlets the floor outlets the defrost windshield outlets or a combination of these outlets to give you nine air selection modes on a system without air conditioning See Fig 6 3 A system with air conditioning has 11 air selection 1 2 3 1 e 2 e ws wv pita g NN ANN N e de Pe Mad 0 4 06 17 2003 1831452a 1 Fan Switch 2 Air Selection Switch 3 Temperature Control Switch Fig 6 1 Climate Control Panel Without Air Conditioning 1 2 3 2 gt i du v 104 7 i s j ej ws 0 4 T d d SW 06 18 2003 5 4 1831453a 1 Fan Switch 3 Temperature Control Switch 5 Recirculation Indicator 2 Air Selection Switch 4 Recirculation Button Fig 6 2 Climate Control Panel With Air Conditioning 6 1 Heater Ventilator and Air Conditioner modes four of which are air conditioning modes S
197. iler should contact the fifth wheel at the pivot See Fig 10 5 6 With the fifth wheel lock opening aligned with the trailer kingpin back the tractor slowly toward the trailer After sliding under the trailer STOP to up Q S Tay 11 02 2010 d A 1310447 1 Safety Latch 2 Operating Rod locked 3 Operating Rod unlocked Fig 10 3 Holland Simplex SE Locking Mechanism npe OOM 10 28 2010 311124 A Fifth wheel must lift C Ramps tilted down trailer D 4to 8 inches B Adjust trailer height ae 9 Fig 10 4 Trailer Connection Point Standard Fifth Wheel prevent from hitting the kingpin too hard then resume backing slowly until the fifth wheel locks On a standard fifth wheel the fifth wheel must lift the trailer On a low lube fifth wheel do not lift the trailer as this may damage the fifth wheel plate 10 2 Fifth Wheels and Trailer Couplings a Ay OOT LA 09 10 2010 A Adjust trailer height 311125 B Ramps tilted down Fig 10 5 Trailer Connection Point Low Lube Fifth Wheel 7 Apply the tractor parking brakes WARNING A visual inspection is required by law Some im proper couplings can pass a pull test Sound is not reliable Get out of the cab and look Incor rect coupling could cause the trailer to discon nect possibly resulting in serious personal injury or death
198. ine 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 Business Class M2 Work shop Manual NOTICE Do not drive with a serpentine belt that is visibly worn or damaged If it fails the lack of coolant flow could rapidly cause damage to engine com ponents 5 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 16 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 Business Class M2 Workshop Manual for instructions or take the vehicle to an authorized Freightliner dealer 10 31 94 1200036a A Deflection B Belt Free Span Fig 11 16 Checking Belt Tension Monthly Post Trip Inspection and Maintenance 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 11 17 1 Clean the batteries 1 1 Remove any corrosion from the hold down and the top of the battery NOTICE Take care to keep the vent plugs tight so that t
199. instructions on preventing au tomatic regen if necessary The exhaust temperature can remain high even after the vehicle has stopped When stopping the vehicle shortly after an automatic regen ensure the exhaust outlets are directed away from struc tures trees vegetation flammable materials and anything else that may be damaged or injured by exposure to high heat A steady yellow DPF lamp indicates that a parked regen is required soon and should be scheduled for the earliest convenient time See Fig 7 2 A blinking 09 25 2006 f610815a Fig 7 2 Diesel Particulate Filter DPF Status Lamp yellow DPF lamp indicates that a parked regen is required immediately or an engine derate may occur A solid yellow malfunction indicator lamp MIL indi cates an engine fault that affects the emissions See Fig 7 3 Diesel particulate filter servicing must be performed by an authorized service facility and a record must be maintained for warranty purposes The record must include date of cleaning or replacement vehicle mileage e particulate filter part number and serial number f610814a 09 25 2006 Fig 7 3 Malfunction Indicator Lamp MIL The request regen switch is located on the dash See Fig 7 4 The function of the switch varies by the engine make and model in the vehicle See the engine operation manual for switch operation details NOTE The regen switch can start an active regen only
200. ion Straight Shift sss canice 2 0420 rx 8 8 Operation Straight Shift 8 8 Electrical System nea 4 1 Emergencies HEV o o o ooooooo 15 3 Emergency Shutdown iss 15 3 In Case of an Accident or ISl o caida ase RAS Sea as BAe Aa Pa 15 3 Emergency Filter Replacement aU A uM iras eevee Md CE eee Le Rs 13 1 Emergency Kit Optional 13 1 Emergency Starting With Jumpet Gables across 13 2 Engine Braking 3 dm Ee beua 7 14 Engine Break In 2 000 ee eee ee eee 7 10 Engine Operation llle 7 10 Engine Shutdown 002002 ee i 7 14 Engine Startltigi 25 ea Eee ee ears E 16 9 Pie Stal 52 2 c I e RR VA S 7 9 Starting Precautions All Enges o 45 eens oY vad ae we es 7 10 EPA Emission Control o o o ooo 1 2 EPAO07 and EPA10 Emission CORTOS m 1 2 Vehicle Noise Emission Control babel usd ile RR R 1 2 Exhaust Braking Systems 7 15 Subject Exhaust Brake Switch Mercedes Benz Exhaust BIake cuicos eaa aes a Pacbrake Exhaust Brake F Federal Motor Vehicle Safety Standard FMVSS Labels Fifth Wheel Coupling Fontaine and Holland Fifth Wheels Coupling Jost Fifth Wheel Coupling Fifth Wheel Slide Air Slide Operation Manual Slide Operation Fifth Wheel Uncoupling Air Actuated U
201. ion The five forward gears selected in LO range are used again in HI range to provide the 10 progressive forward gears See Fig 8 7 for the shift patterns See Table 8 1 for the shift progressions HN 7N 9 wo 2 47 i N i B 6 8 10 1 13 15 12 15 1999 1261053 A HI Range B LO Range Fig 8 7 Shift Pattern 10 Speed Models Once the highest shift lever position fifth gear is reached in LO range the driver preselects the range shift lever for HI range The range shift occurs auto matically as the shift lever is moved from fifth gear position to the sixth gear position Eaton Fuller Shift Progressions LO Range Model 7 HI Range Off Highway On Highway g 5 7 R R R 9 Speed Kd VS JU 37 y are Direct or t AAA Me do Overdrive 10W 274 AA E 1260322 1260323 1260324 VUA TS R R R 10 Speed 2 gt 4 E 2 E 4 4 Direct or LAS ALN GAL 67 85 A0 Overdrive Vos VS E 1260329 1260329 1260330 Table 8 1 Eaton Fuller Shift Progressions When downshifting the driver preselects the range lever for LO range and the range shift occurs auto matically during the shift lever movement to the next gear position Eaton Fuller Deep Reduction Models Eaton Fuller deep reduction models are not synchro nized They have a five speed front section and a two speed auxiliary section which has an extra deep reduction gear The LO gear in the
202. ion Switch Fig 4 32 Adjustable Steering Column NOTICE Never exhaust air from the suspension while driving When the air is exhausted the suspen sion will not absorb road shocks and compo nents may be damaged The suspension dump switch is a two position guarded rocker switch Fig 4 33 It allows the air in the vehicle air suspension to be quickly exhausted lowering the rear of the vehicle This makes it easier to connect to or disconnect from a trailer To lower the rear of the vehicle quickly press the upper half of the rocker momentarily at the LED To 4 14 Controls 10 26 2001 1610597 Fig 4 33 Suspension Dump Switch raise the suspension to its normal height press the upper half of the rocker again When the panel lights are on the tractor icon is backlit in green IMPORTANT The suspension dump switch is guarded to prevent unintentional switch activa tion This switch does not have a diagnostic blink function when inactive When the suspension dump switch is pressed three responses are possible a normal response a slow response and an abnormal response Normal Response The LED in the switch blinks while the suspension is deflating or filling When it is completely deflated the LED comes on steady and stays illuminated In normal operation the suspen sion may dump or fill so quickly that the blinking of the switch is barely noticeable If operation of the switc
203. ior Light Controls Headlight Parking Light Switch The headlight parking light switch Fig 4 3 is a paddle switch located on the left hand control panel above the cruise control switches When the paddle is lowered the parking lights illuminate the front turn signals the cab marker and identification lights and the taillights When the paddle is raised the low beam headlights illuminate along with all the parking lights To turn off all lights return the paddle to the center position 10 15 2001 1610580 Raise the paddle to illuminate the headlights low beam Lower the paddle to illuminate the parking lights Fig 4 3 Headlight Parking Light Switch NOTE The front turn signal is the amber lens in each headlight unit The low beam headlight is the top clear lens in each headlight unit When the headlights or parking lights are on the panel lights also illuminate An amber light in the Switch backlights either the top icon for headlights and parking lights or the bottom icon for parking lights only Panel Light Increase Decrease Switch When the panel lights are on they can be either brightened or dimmed by using the INCR DECR rocker switch just below the headlight switch Fig 4 4 To brighten the panel lights press on the upper part of the rocker at the INCR legend To dim 4 2 Controls the panel lights press on the lower part of the rocker at the DECR legend 05 09 2002 1610581
204. ipped 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 DC 20
205. ission damage do not move the vehicle from a standing start unless this can be accomplished safely taking into account the gear that is engaged and the load on the vehicle Mercedes Benz Automated Transmissions General Information AGS The AGS Automated Gear Shift is a fully automated 6 speed medium duty transmission The clutch is ac tivated by a hydraulic system that is integral to the transmission No clutch pedal is needed to operate the vehicle AGS transmissions use the SmartShift control lever on the steering column to select gears A manual shift is possible at any time by moving the SmartShift lever up or down as needed The transmission control unit TCU can direct all forward shifts in response to driving conditions and the driver s pressure on the brake and throttle ped als To know which gear the transmission is in look at the round current gear indicator on the right hand control panel as shown in Fig 8 12 The TCU always selects first gear to start the vehicle in motion It is possible in manual mode to start an unloaded or lightly loaded vehicle in second gear In most cases second gear is acceptable for downhill starts In other situations for best results always start moving in first gear Loaded vehicles or vehicles on substantial grades must start moving only in first gear 8 22 Drivetrain CAUTION At the first sign of a transmission malfunction take the vehicle out of service immedia
206. ith Differential LOG ss far esr encase ata EROR I eoa d ena Rei 8 27 Tandem Drive Axles With Interaxle LOCK ius us asked 8 28 MINOIS Jiu Eure mea d d Ra RC Y 3 ps 5 1 Down View Mirror Optional 5 1 Mirror Heat Switch Optional 5 1 Power Mirrors Optional 5 1 Multifunction Turn Signal Switch 4 5 Hazard Warning Flasher 4 7 Headlight High Beams sn 4 6 Turn Signal Controls o oo 4 5 Windshield Wiper Washer Controls 2 eee ca da a ds 4 6 O Optional Instruments noaa aaa 3 12 Air Restriction Gauge o ooo oooooo o 3 12 Ambient Temperature Gauge 3 13 Amtmelel 3 4 6 36 6 obs aub bx ow ed ae he sd 3 13 Digital CloGK iuam Saale ae haa ER epe 3 13 Drive Axle Oil Temperature Qauges ecca cees ol r erei EEk xA 3 14 Engine Oil Temperature Gauge ende cur a Bib Be wa es 3 14 Tachometer llle 3 14 Transmission Fluid Temperature Gauge 0 05 3 15 Turbocharger Boost Pressure Gauge lille enn 3 15 Other Dash Mounted Controls 4 14 CB Radio Connections LL 4 14 Cigarette Lighter o o oo o oooo 4 14 Suspension Autofill Override NAIVE sos eos a eae OES RAE Ca n 4 15 Suspension Dump Switch 4 14 Windshield Fan Switches Opina s cuna and emm em SR aes ERA 4 14 Overhead Instrument Panel 3 15
207. ivate the latch lean forward until you hear a click This will allow for approximately 1 inch 2 5 cm of slack between your chest and the shoulder harness Once engaged the latch will allow you to lean forward about 5 inches 13 cm without having to reset the latch Leaning forward more than 5 inches 13 cm will disengage the Sliding Kom fort Latch requiring it to be reset 5 8 Cab Features If equipped with a Komfort Latch pull on the shoulder strap to lessen the pressure of the strap on your shoulder and chest Allow no more than 1 inch 2 5 cm of slack between your chest and the shoulder harness More slack can signifi cantly reduce the seat belt effectiveness in an accident or a sudden stop While holding the belt slack press the Komfort Latch lever up clamp ing the seat belt webbing Fig 5 19 and Fig 5 20 01 06 95 f910048a A 1 Inch 2 5 cm Maximum Fig 5 19 Adjusting Shoulder Harness Clearance Komfort Latch 4 11 02 95 d N 1910144 Fig 5 20 Locking the Komfort Latch 6 Unbuckle the three point seat belt and release the Komfort Latch or the Sliding Komfort Latch as follows If equipped with a Sliding Komfort Latch un buckle the seat belt then tug on the shoulder 5 9 belt to release the Sliding Komfort Latch or press the Sliding Komfort latch to the OFF po sition then unbuckle the seat belt If equipped with a Komfort Latch unbuckle the seat belt then releas
208. k that the inspection plugs in the dust shields or backing plates if so equipped are installed Leak test the natural gas fuel system if equipped Use a methane detector to test all fuel system components joints and fittings for leaks A bubble solution can be used to pinpoint the exact location of leaks Replace any leaking or damaged fuel tanks and fuel lines repair or replace leaking or damaged fittings Drain the CNG high pressure fuel filter housing if equipped 6 1 Purge the CNG fuel lines by closing the CNG fuel cylinder shutoff valves Start the engine and let it idle until the fuel lines are empty and the engine stops Gauges on the fuel panel should now read at or near 0 psi 0 kPa 6 2 Close the manual fuel shutoff valve on the fuel panel 6 3 Remove the two capscrews that secure the access cover to the fuel panel then remove the access cover See Fig 11 17 Save the capscrews for installation 05 04 2010 1470557 1 Fuel Panel Access 5 Coolant Outlet Line Cover 6 Coolant Inlet Line 2 Capscrews qty 2 7 Fuel Inlet Line to fuel 3 Wiring Harness cylinders 4 Pressure Relief Valve 8 Fuel Outlet Line to and Cap engine Fig 11 17 CNG Fuel Panel Assembly 11 18 Pretrip and Post Trip Inspections and Maintenance Slowly open the bleed valve on the mani fold to relieve remaining fuel pressure within the system See Fig 11 18 ee oe 05 04 2
209. ke 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 speeding or following too close on slippery road surfaces 9 8 10 Fifth Wheels and Trailer Couplings Fifth Wheels General Information v vC 10 1 FI ISS Eee MM m 10 1 Em Wheel DncouilinBl cc ics carrer detested is 10 4 Fifth Wheel Slide Fifth Wheels and Trailer Couplings Fifth Wheels General Information A WARNING Do not use any fifth wheel that fails to operate properly Doing so may cause loss of vehicle control possibly resulting in severe personal in jury or death Air Suspension Dump Valve The air suspension dump valve may be used to ad just the tractor height to aid with coupling to or un coupling from a trailer See Fig 10 1 When the switch is set to LOWER the air suspension dump valve deflates the air springs to lower the rear of the vehicle In the AUTO position the automatic ride control valves operate for normal driving Never exhaust air from the suspension while driving The suspension will not absorb road shocks possibly damaging components and ve hicle handling may be compromised
210. ked If it is open close the door by pulling the inner door grab handle To lock either door from inside the cab slide the lock button downwards Fig 2 3 To unlock the door without unlatching it push the lock button upwards A red dot will show below the lock button when it is unlocked Grab Handles and Access Steps For ease of entry and exit there are three grab handles one on the A pillar one on the inner B pillar and an optional one on the inside of the door In ad dition the steering wheel may be used to provide secure handholds There are one or two access steps to provide secure footholds Vehicle Access 10 24 2001 1720401 Move the button down to lock and up to unlock arrows The door is unlocked when the red dot shows 1 Door 3 Red Dot 2 Lock Button Fig 2 3 Door Lock Button NOTE The A pillar grab handle is not installed on the driver s side The grab handles access steps and steering wheel are all part of the cab access system Use these helping hands when getting into or out of the cab They will increase your security and comfort Cab Entry and Exit Vehicles With Two Steps 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
211. l gas which could cause serious bodily injury death or severe property damage 4 Connect the station fueling nozzle to the tank fuel fill fitting 5 Connect an electrical ground clamp and cable to the fuel tank IMPORTANT An LNG tank which is first in stalled or is on a vehicle that has not been op erated in approximately ten days is considered to be a hot tank When fueling a hot tank LNG entering the tank will immediately vaporize causing tank pressure to spike above 250 psi 1724 kPa and automatically shutting down the station fuel pump To prevent the pump from shutting down connect a vent line to the fill vent fitting on the LNG tank to capture escaping vapor then open the shroud cover and open the vapor shutoff valve Fig 16 3 Item 2 6 Open the station s fill valve if equipped and start fueling Monitor the flow or line pressure as filling progresses When filling begins line pres sure will spike quickly until the vehicle tank cools down The flow and pressure will then remain stable during the remainder of the filling procedure 05 05 2010 1470533 1 Pressure Control 7 Primary Relief Valve Regulator 8 Tank Pressure Gauge 2 Vapor Shutoff Valve 9 Fill Vent Fitting 3 Fuel Fill Hose 10 Excess Flow Valve 4 Secondary Relief 11 Fuel Shu
212. lation to the area Do not start the en gine or any other type of equipment until the gas leak is corrected and the area cleared of natural gas Evacuate the area Check the fuel lines LNG tank CNG cylinders and fittings to locate the leak After the area is cleared of natural gas and the alarm is no longer active have the vehicle inspected by a qualified technician IMPORTANT Do not consider the area clear until all alarm indicators are off and the alarm panel light returns to green Sensors Gas detection sensors are located on the cab over head console and in the engine compartment on the frontwall The sensors are located in high areas where rising gas vapors will pass by or accumulate If the system detects that one of the sensors has been disconnected or has malfunctioned the sensor fault light for that zone will illuminate A failed sensor may trigger and lock on an alarm If a fault condition or locked alarm continues after the sensor s connec tion and wiring integrity has been verified replace the sensor The sensors are sensitive to all hydrocarbon vapors An alarm may be triggered by the use of chemicals such as cleaners paint polish lacquer gasoline silicone silicone spray or other harsh chemicals The sensors will also detect hydrogen fumes from an overcharged battery If a sensor sends an alarm but no gas fumes are present check for recent use of chemicals or a battery charger NOTICE Sil
213. lays significant figures no leading zeros Mode Reset Button The mode reset button Fig 3 6 is located on the right side of the instrument cluster The mode reset button is used to scroll through the displays on the driver display screen and to reset the trip distance and trip hours values to zero PUSH MODE HOLD RESET 09 25 99 1610340 Fig 3 6 Mode Reset Button Functions When the parking brake is off pressing the mode reset button will scroll through the following screens i Trip distance i Trip hours il Outside temperature iv Back to odometer When the parking brake is set pressing the mode reset button will scroll through the following screens i Trip distance i Trip hours iii Outside temperature iv Select screen v Temperature alert screen vi Diagnostic screen vii Clear screen with less than 254 miles vii Engine miles ix Engine hours X Setup screen xi Back to odometer Trip Miles To reset trip miles and or trip hours to zero press the mode reset button for one second or longer Miles or Kilometers To toggle between MI miles or KM kilometers press the mode reset button while in the Select Screen Audible Warnings An audible warning sounds during the ignition se quence and whenever one of the following conditions exist Engine oil pressure falls below the minimum level shown in Table 3 1 Coolant temperature rises above the maximum
214. le The power steering pump driven by the engine pro vides the power assist for the steering system If the engine is not running there is no power assist 9 1 If the power assist feature does not work due to hy draulic fluid loss steering pump damage or some other cause bring the vehicle to a safe stop Do not drive the vehicle until the cause of the problem is 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 use the power available with a power steering system carefully If the front tires become lodged in a deep chuckhole or rut drive the vehicle out instead of using the steering system to lift the tires from the hole Avoid turning the tires when they are against a curb as this places a heavy load on steering components and could damage them Air Brake System A dual air brake system consists of two independent air brake systems that use a single set of brake con trols Each system has its own reservoir plumbing and brake chambers The primary air system oper ates the service brakes on the rear axle the second ary air system operates the service brakes on the front axle Service brake signals from both systems are sent to the trailer Primary Air Brake System Loss of air pressure in the primary air system causes the rear service
215. le Plate 2 Bolted Stop 6 Safety Latch 3 Baseplate Rail 7 Operating Rod 4 Fifth Wheel Mount 8 Operating Lever Fig 10 13 Sliding Fifth Wheel Manual Release Holland Simplex 3 Lower the trailer landing gear just enough to re move the weight from the tractor 4 Chock the front and rear of the trailer tires to prevent the trailer from moving 5 Release the tractor parking brakes then slowly move the tractor forward or backward until the fifth wheel is in the desired location NOTICE When 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 Check that the locking wedges have seated in the slots Failure to achieve complete lockup may allow disengagement of the tractor from the trailer possibly resulting in serious personal in jury or death 6 Apply the tractor parking brakes then lock the sliding member in position using one of the fol lowing methods 6 1 Fontaine Disengage the slide release pull handle from the guide plate The slide release pull handle is spring loaded in the locked position and will seek the locked position when disengaged from the guide plate After the slide release pull handle returns to the fully locked position
216. lease 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 7 9 Ring gear and starter pinion damage caused by improper starting procedures is not warrantable Pre Start NOTE These pre start steps apply to all en gines 1 Perform the engine pretrip inspection and daily maintenance checks in Chapter 11 2 Setthe parking brake 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 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 4 Turn the ignition switch to the ON position Fig 7 14 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 FF fr IN 1 START ACC N A A 09 12 2001 1610509 Fig 7 14 Ignition S
217. lever up towards you To downshift manually push the lever down away from you 1 SmartShift Control Lever Slide Switch MAN Position of slide switch AUTO Position of slide switch Upshift Direction Reverse Position of selector switch Selector Switch Neutral Lock Button Neutral Position of selector switch 10 Drive Position of selector switch 11 Downshift Direction o 0 Og POI is offered only on this automated transmission sys tem Operation UltraShift Power Up NOTE These operating instructions apply equally to six speed UltraShift ASW and ten speed UltraShift DM with the exceptions ex plained below 1 With the parking brake set select neutral N by moving the selector switch to the N position 2 With the transmission in neutral turn on the igni tion switch The CHECK TRANS and TRANS TEMP telltale lights come on and go out again bulb check See Fig 8 13 Fig 8 11 SmartShift Control with Mercedes Benz AGS 10 13 2003 1270079 To know what gear the transmission is in look at the current gear indicator 1 Gear Indicator 2 SmartShift Control 1 2 CHECK J TRANS TRANS TEMP J 1 pa ME BRAKE O a M 10 27 2003 1610677 1 CHECK TRANS Light 2 TRANS TEMP Light Fig 8 12 Shift Controls and Indicators UltraShift Transmissions Fig 8 13 Telltale Lights UltraShift Transmission 3 After the ignition is tu
218. line torque If the electric motor alone is powering the driveline the diesel engine will stay at idle Engine Shutdown 1 Place the transmission in neutral by selecting N on the shift control IMPORTANT The transmission must be in neu tral for proper shutdown 2 Setthe parking brake 3 Turn the key counterclockwise to the OFF posi tion NOTE Intermittent noises such as clicking and transmission shifting may be audible from the transmission while it completes a self test and shutdown Hybrid System Fault Lamps HEV There are two lamps on the dashboard that indicate a hybrid system fault is active the red STOP HY BRID lamp and the amber CHECK HYBRID lamp See Fig 15 1 When the red STOP HYBRID lamp is illuminated do not drive the vehicle have it towed to a Freightliner dealer or an authorized service center for repairs When the amber CHECK HYBRID lamp is illuminated the vehicle can still be driven though it may operate without the assistance of the hybrid electrical system 15 2 Hybrid Electric Vehicle CHECK HYBRID STOP HYBRID 07 09 2008 f611013 Fig 15 1 Hybrid System Fault Lamps Emergencies HEV Emergency Shutdown A WARNING After disabling the vehicle power is maintained in the high voltage electrical system for up to five minutes Unprotected contact with any live high voltage components can cause serious injury or even death T
219. lines NOTICE It is extremely important that the following points be followed for vehicles with EPA07 or EPA10 compliant engines or damage may occur to the aftertreatment device and the warranty may be compromised 7 10 Engines 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 Adequate maintenance of the engine and the diesel particulate filter are the responsibility of the owner operator and are essential to keep the emission levels low Good operating prac tices regular maintenance and correct adjust ments are factors that will help to stay within the regulations The driver should be familiar with the vehicle warning System in order to bring the vehicle to a safe stop if the engine malfunctions If the driver doesn t under stand how the warning system works an engine shutdown could occur causing a safety hazard See Chapter 3 for information All engines have an operating range specific to that engine in which the engine performs most efficiently The operating range extends from maximum torque rpm at the low end to engine rated speed at the high end Most engines deliver best fuel economy when operated in the low and mid speed segments of the efficiency range and produce maximum horsepower at rated speed which is also the re
220. lled de pending on the make and model of the seat Fig 5 9 9 Damper When you sit on the seat a leveling valve places you in the center of the ride zone When the damper is adjusted properly under nor 5 3 10 05 2001 1910485 A Ride Height Fig 5 9 Ride Height Adjustment mal driving conditions the seat should not top or bottom against the limits of the vertical travel 10 Ride Firmness A firmer ride gives a better feel for the road but less protection against uneven ness in the road surface A softer ride smooths out the bumps Cab Features Bench Seats The three person full bench seat is standard See Fig 5 10 10 05 2001 Y 1910481 1 Three Person Seat 2 Seat Slide Lever Fig 5 10 Full Bench Seat The full bench seat has a seat slide adjustment to allow more or less leg room for the driver and pas sengers Release the seat slide lever and push back wards or forwards to move the seat along its track High back air suspension seats are optional for both driver s and passenger s seats Also available are a non suspended passenger s seat and a two person bench seat with a safe or tool box located under the seat No adjustments are possible on the two person bench seat or the non suspended passenger seat Bostrom Seat Seat Slide Adjustment Move the seat slide and isolator lever Fig 5 11 to the left and hold it there to slide the seat forward or backward to the desire
221. long as fumes are detected Sensor Fault If the system detects that either of the sensors has been disconnected or has malfunctioned an amber light next to the Sen sor Fault indicator for that zone will illuminate The control module also has buttons used to test or reset the the control module after an alarm Red lights next to each button indicate when they are en gaged Natural Gas Vehicle e Shutdown Reset If an alarm has been acti vated and the Relay Engaged light is illumi nated the Shutdown Reset button will reset the internal relay Press the Shutdown Reset button only after the gas has cleared the buzzer has turned off and the alarm panel light has returned to green Push To Silence If an alarm has been acti vated the Push To Silence button will silence the buzzer See Table 16 2 for the functions of all lights and but tons on the overhead console Testing Daimler Trucks North America strongly recommends that all operators follow California Code of Regula tions CCR inspection requirements regardless of where the vehicle is operated Per Title 13 CCR 935 2 gas detection systems should be tested three times per calendar year at equal intervals The testing procedure should simulate the same operat ing environment in which the vehicle is used with the same gaseous fuel Test results validating the performance of the gas detection system within the parameters established by the component m
222. ls Eaton Fuller 9 speed range shift models are not syn chronized They have nine forward speeds and two reverse speeds The shift lever controls five forward gears and one reverse gear in the transmission front section and the range lever controls a LO and HI range in the two speed auxiliary section The first position in the front section is used only as a starting gear The other four ratios are used once in LO range and once again in HI range See Fig 8 6 for the shift patterns After shifting out of the first gear position use the Roadranger repeat H shift pattern Select both LO range and HI range with the range lever range knob It is used once during the upshift sequence and once during the downshift sequence Always preselect the range shift After preselection the transmission will automatically make the synchro nizer range shift as the shift lever passes through neutral Eaton Fuller 10 Speed Models Eaton Fuller 10 speed range shift models are not synchronized They have ten forward speeds and Drivetrain ANO BY FN wr 1 3 f N i Y 6 8 B LO 2 4 11 23 99 261047 Move the range lever up for HI range down for LO range A HI Range B LO Range Fig 8 6 Shift Pattern 9 Speed Models two reverse speeds The shift lever controls five for ward gears and one reverse gear in the transmission front section and the range lever controls a LO and HI range in the two speed auxiliary sect
223. lways 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 times 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 5 7 Seat Belt Inspection WARNING Inspect and maintain seat belts When any part of a seat belt system needs replacement
224. m vertical Then slowly bring it to a stop To Close the Hood 1 Push the hood over center Vehicle Access 3 2 E AN lt NS NN SEN 4 1 10 24 2001 880555 1 Fender 3 Latch Handle 2 Latch Hook 4 Half Fender Fig 2 10 Hood Hold Down Latch 2 As the hood goes over center the damper auto matically slows its rate of descent If needed you can also slow its rate of descent with your hand 3 Make sure the hood is flush with the cowl then secure the hood by engaging both hood hold down latches IMPORTANT Make sure that both hold down latches are fully engaged before operating the vehicle Fuse Identification Main Fuse Box PDM The main fuse box also known as the power distri bution module or PDM is located under the hood on the left front fender just forward of the bulkhead mod ule See Fig 2 11 To open the fuse box pull down on the wire clips holding the lid on the fuse box A sticker inside the lid of the fuse box shows the lo cations of the fuses and describes the circuit s that each fuse protects see Fig 2 12 See Table 2 1 for descriptions of a typical set of fuses The fuses in the main fuse box are mini blade type fuses Battery power fuses located near the batteries are bolt in megafuses Because the electrical system is multiplexed no re lays are needed The multiplexing module performs the functions normally provided by relays
225. makes it ERARI EEES RI KE RUE A P KR 12 1 Gate Or Extenor vr APR rra bn a be reee 12 1 Dashboard CAG si 66ers ee raw ors ee Piscine RATE RARE A AA 12 1 Vinyl Upholstery Cleaning 2c c2 s0obbeterGeeear circa tie ERRARE P REA EXTUS RE 12 2 Velour Upholstery Cleaning iuceseskxec ERES ESTRERIREKRRRRFEREYaTPEFF EEEXATERESLRREXaREEE 12 2 Cab Appearance Cab Washing and Polishing 4h CAUTION When pressure washing the vehicle or leaving the hood open when parked outdoors and sub ject to rain cover the air cleaner inlet with a plas tic bag to prevent water from entering the air in take system and possibly damaging the engine To protect the 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 During the first 30 days do not use anything abrasive on your vehicle Brushes chemicals and cleaners may scratch the finish During the first 120 days do not wax your vehicle To extend the life of your vehicle s finish follow these guidelines Avoid washing your vehicle in the hot sun Al ways 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 reg
226. ment depending upon local statutory emissions guidelines There is a warning label placement will vary for important new warning indi cators in the driver s message display that pertain to the aftertreatment system Vehicle Identification It is a violation of US federal law to alter exhaust plumbing or aftertreatment in any way that would bring the engine out of compliance with certification requirements Ref 42 U S C S7522 a 3 It is the owner s responsibility to maintain the vehicle so that it conforms to EPA regulations Vehicle Access Gab Door Locks and Handles iui xax rtrt tinnu AORERE RTE EEEE EE ROR RC I CR EUR 2 1 Grab Handles and ACCESS Steps iis pesbRERASERRRRARRASPEREEQIG ERNO EEE SE EET Rapi g CES 2 1 Cab Entry and Exit Vehicles With Two Steps 0 c cece eee ee eee es 2 2 Gab Entry and Exit Vehicles With Cine Step LexxesessekiakrebeXeet ku erskteterr eTk5e Ck bows 2 4 Back o CaD ACCESS cxososa xam ee E KR REAGAN SURREY RUE A RR Y RR PR RR ERR RE 2 5 Battery ACCESS evodirgrtster dde OR RR pde CERES Um 18 59 CERRAR ERO AU RAT Eua de e 2 6 Hood Opening and Closing suco E EROR E oS ROO eH OY WR ROC RE RACE WE RR A IHR tens 2 7 FUSE GENINGAHOM Suet Seek ob US MEE pe ek Re ERR REPRE CRI REI e er e S 2 8 Vehicle Access Cab Door Locks and Handles One key operates the ignition switch and all of the door locks IMPORTANT Each key is numbered Record the number so a duplicate key can be ma
227. move the front wheels 8 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 9 Chock the tires on the disabled vehicle and con nect the towing vehicle s air brake system to the vehicle being towed Then release the spring parking brakes and remove the chocks Rear Towing Hookup 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 In an Emergency 01 11 2006 IMPORTANT Do not reeve when towing 1 Tow Hook LU gt E GED ER 2 Chain ERY UMET T 1880694 Fig 13 6 Reeving Ah CAUTION Failure to protect the frame rails from the chains could cause damage leading to eventual frame failure 3 On dual drive axles using protection 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
228. mper e End of frame crossmember LNG fuel tank fill port maximum psi if equipped Check for the presence of all necessary vent caps on pressure relief valves and devices CNG Fuel System Check for the pres ence of blue caps on all pressure relief devices Each fuel cylinder is equipped with two caps one on each end which are visible on the back of the CNG fuel cylinder storage box One cap is located on the pressure relief valve on the inboard side of the CNG fuel box next to the fuel outlet line If any blue caps are missing remove the vehicle from service and have the fuel system inspected by a qualified technician LNG Fuel System Check for the presence of a red cap on the secondary relief valve If the red vinyl cap is missing from the secondary relief valve Fig 11 4 Item 4 remove the vehicle from service and have the fuel system inspected by a qualified technician Inspect all plumbing components includ ing the fuel shutoff valve s primary and secondary relief valves and the LNG vapor shutoff and excess flow valves if equipped for signs of damage or leaks See Fig 11 4 or Fig 11 5 Inspect the fuel fill fitting for signs of dam age or leaks Inspect all lines for signs of leaks or dam age and check all threaded connections Inspect all fuel gauge components for signs of leaks or damage Inspect the LNG fuel level sender cable and wiring if equipped 05 05 2010 1 Pressure C
229. n an improperly functioning or nonfunctioning brake If it is necessary to pe riodically start the engine it is recommended that normal operating temperatures be attained before shutting down the engine Allison World Transmission Pacbrake exhaust brakes on engines that are used with the Allison World Transmission MD series are interfaced with the transmission electronic control module ECM An exhaust brake enabled transmis sion ECM will usually provide converter lockup in gears two through six Effective exhaust braking be gins when the transmission automatically downshifts into fifth gear 62 mph or less Once on the Pacbrake exhaust brake will control road speed and or slow the vehicle sufficiently that the transmis sion will automatically downshift if necessary to Alli son s preselect mode The preselect mode is normally assigned to second gear however the transmission can be repro grammed by an Allison Transmission Distributor to third or fourth gear should the operator desire If ad ditional retarding power is required before the auto matic downshifting occurs you can select a lower transmission gear on the Allison shift selector 7 18 Drivetrain rolg RR 8 1 Allison OnHighway Transmissions secos hestesuiecobe treeteees4FeSRejesERPRERRERISPSR RE 8 3 AlliS n MD Series iesosk su ied ER Skee ee sak EIE Ue e RRCRER AY RIEEE Ex PG ew S 8 5 Eaton Fuller Straight Shift Transmissions vexirrs oc ERR ERRERRRE
230. n discs are designed to allow for some amount of excess rotational speed but the facing has a limited burst strength If the clutch driven disc rpm increases too much the clutch facing can be thrown off the disc s Engaging the Clutch While Coasting 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 Report Erratic Clutch Operation Promptly Reporting erratic clutch operation as soon as pos sible will give maintenance personnel a chance to inspect the clutch components CAUTION Operating the vehicle with incorrect clutch pedal free travel could result in clutch damage See Group 25 of the Business Class M2 Workshop Manual for free pedal adjustment procedures and specifications Drivetrain On mechanical clutch linkages free pedal travel should be included and commented on daily in the driver s report since clutch free pedal travel is the best guide to the condition of the clutch and the re lease mechanism Clutch Wear 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 temperatures developed in typical op eration will not break down the clutch friction sur faces However if a clutch is slipped excessively or required to do the job of a fluid coupling high tem peratures develop quickly and destroy the clu
231. nal Safety Mark 1 2 11 14 2001 f080119 1 Gross Weight Rating By Component in Axle System 2 Gross Vehicle Weight Rating By Component in Vehicle As a Whole Fig 1 6 Tire and Rim Information 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 completion 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 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 windsh
232. nce is recommended if the hose is located above the heat source 24 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 24 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 24 4 Check for hose damage caused by abra sion If abraded have the hose replaced Check for the cause of abrasion such as loose or damaged hose clamps Have the clamps repaired or replaced as needed 24 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 24 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 24 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 t
233. ncoupling Manual Uncoupling Fifth Wheels General INFORMATION ass bed bd eee hee Air Suspension Dump Valve Fifth Wheel Lubrication Fire Extinguisher Fire in the Cab In Case ofa Cab Fire Freightliner SmartShift Shift Control aci o cc di General Information SMANSA x cux Wee a ewe Fuel Tank Filling Procedures CNG Vehicle Fueling LNG Vehicle Fueling Fuse Identification Main Fuse Box PDM Trailer and Taillight Fuse BOXES c xau dob ate UR ace ee Gas Detection System Alarm Procedure Overhead Console SOfiSOlS imus End ere ee TESTO 2a ei em gem kd oye General Information Grab Handles and Access Steps o scria ore x RS Hazard Warning Lights Index Subject Page Heater Air Conditioner Control Panel 125 coi eere Bl edes d teur dedu doro 4 15 High Altitude Operation lille 7 13 Hood Opening and Closing 2 7 To Close the Hood 0000 ee eee 2 7 To Open the Hood 22 05 0 54 2666 eR 2 7 Horn Controls xaxa RE bag ER Beas Sees 4 7 Air Horn Optional s ses 42 4 2 weeds mnis 4 7 Electric Hor uiis rug xe go keys 4 7 Hybrid Electric Vehicle HEV OVetVIeW srera taea eK ERSTE Sus 15 1 Cooling Syste s soc sha Pewee es 15 1 Electric Power Take Off ePTO wack eda ee ee Geb we oe eee
234. ncy Hazard Warning Lights EET 13 1 Fre EXUIBOUISFIBI crocen dhe dorede lanes dre Inpede RU prece ge deus P6 rd 13 1 Emergency Kit Optional scegoxa cua RR RREFRERERERR ER ERA rRREerigd 4k REREk GR eR E E 13 1 Emergency Filter Replacement DavOO 116a ccs rer RakRE E Kroken A ERS e 13 1 Emergency Starting With Jumper Cables 0 0 0 eren 13 2 A rekedt Eei E ERRERA e aE E e a E ERE e E a E E E E E a 13 5 Fire in the Cab In an Emergency Hazard Warning Lights The hazard warning light flasher Fig 13 1 is part of the multifunction turn signal switch It is a red rocker switch located on the top of the multifunction switch module 11 16 2001 1820386 Press down on the upper part of the rocker to activate the flashers Washer Button Wiper Control Dial Turn Signal Lever Hazard Flasher red Q RON Multifunction Switch Module Fig 13 1 Hazard Warning Flashers To flash the hazard warning lights press down on the upper part of the rocker towards the dash To stop the hazard warning lights press down on the lower part of the rocker towards the steering wheel Fire Extinguisher A fire extinguisher is located in the cab by the driv er s door Emergency Kit Optional An optional emergency kit is located in the cab The kit includes one or more of the following a first aid kit a reflective vest a triangular reflector a flare kit and on vehicles with a Davco fuel water separator
235. nformation 2 Certification Statement Tractors with or without fifth wheels purchased in the U S are certified by means of a certification state ment Fig 1 2 and the tire and rim information com Fig 1 3 Label Location bined into one label This label is 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 an incomplete certification label Fig 1 4 attached to the left rear door post In addition after completion of the vehicle a certifica 11 14 2001 1080120 tion label similar to that shown in Fig 1 2 must be attached by the final stage manufacturer This label Fig 1 4 Incomplete Vehicle Certification Label U S will be located on the left rear door post and certifies 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 information Fig 1 6 is also included in the label attached to the left rear door post EG oNNAD CMVSs o o IyAsN 963 o o AOS 10 10 2006 1080024 Fig 1 5 Canadian Natio
236. ng the valve at the bottom and allowing the water to run out Close and tighten the valve finger tight 9 4 Close and tighten the filter vent at the top of the separator 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 10 Inspect all natural gas fuel system components if equipped for damage or leaks Replace com ponents as necessary 10 1 Inspect fuel tanks for dents scratches gouges or other signs of damage Inspect the fuel lines and connections for leaks 10 2 Check that the fuel tanks are securely mounted Look for signs of abrasion be tween components CNG Fuel System Ensure that the CNG fuel cylinder storage box is secured to the frame Inspect for any signs of looseness LNG Fuel System Ensure that the LNG fuel tank is secured to the mounting brackets and that the mounting brackets are secured to the frame Inspect for any 11 6 Pretrip and Post Trip Inspections and Maintenance 10 3 10 4 10 5 10 6 signs of looseness Ensure all rubber iso lator straps are secure around the LNG fuel tank Check for the presence of all required de cals Natural gas decals should be present in the following locations Left front bu
237. nless a range inhibitor is active such as engine overspeed See Chapter 8 for more information about range inhibitors To shift to fourth gear press on the upper part of the rocker at the LED The LED will come on and stay Controls 2 3 01 22 2003 1270119 1 All Series Standard without park 2 1000 2400 Series Optional with park 3 2000 Series Optional with auto apply parking brake Fig 4 22 Steering Column Mounted Shift Controls OFF O D 01 22 2003 1610638 Fig 4 23 Overdrive Lockout Switch illuminated until the bottom part of the rocker switch is pressed On vehicles with Allison MD Series automatic trans mission or Eaton Autoshift automated transmission a push button shift selector provides four five or six forward ranges and one reverse range See Chap ter 8 for more information about the push button shift selector Axle Switches All axle switches contain a red LED light emitting diode that illuminates the switch from within when the switch is turned on the upper part of the rocker is pressed The legend under the LED if any is not visible until the switch is turned on IMPORTANT A guard is positioned around all axle switches to prevent unintentional activation NOTE For more information on axle switch function see Chapter 8 Differential Lock Switch CAUTION Differential lock should only be engaged when the vehicle is stopped or moving slo
238. not get in your way as you exit 2 5 Always face in when exiting the cab Do not at tempt to exit with your back to the cab as you would going down a flight of stairs It is easier to slip or lose your balance If you slip when exiting in this way there is a greater likelihood of per sonal injury 2 Grasp the A pillar cover grab handle with both hands then place your right foot on the step while standing up from the seat facing inward Place your left foot on the step Move your left hand to the B pillar grab handle Move your right hand to the B pillar grab handle Step to the ground with your right foot first NH gv 2 Retrieve from the cab any items that you wish to take with you NOTE You can also use the inner door grab handle if available as a support when getting up or down from the bottom step Back of Cab Access When trailer air and electrical connections cannot be reached conveniently from the ground Federal Motor Carrier Safety Regulations require commercial carri ers to provide back of cab access Optional grab handles are mounted on each cab sidewall or on the left sidewall only See Fig 2 6 Steps are mounted either on the fuel tank s or on metal brackets When a deck plate is necessary it is mounted across the top of the frame rails IMPORTANT Climb onto and down from back of cab access facing in toward the vehicle as you would on a ladder Do not climb up or down facing out away from
239. nsmission will ig nore the request 5 To end the mobile mode bring the vehicle to a stop The clutch will open and shut off power to the PTO 6 To resume stationary mode shift to neutral The PTO will engage 7 To end stationary mode press the dash switch When the light in the switch goes out power to the PTO is shut off Shut down the engine Cold Weather Operation 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 temperature the greater the amount of modification required For service products approved for use in 7 13 cold weather for your engine see the engine manu facturer s engine operation manual supplied in the vehicle documentation package If satisfactory engine temperature is not maintained maintenance costs will increase due to greater en gine wear If the engine coolant temperature be comes too low raw fuel will wash the lubricating oil off the cylinder walls and dilute the crankcase oil causing all moving parts of the engine to suffer from poor lubrication If the engine is in good mechanical condition and the precautions necessary for cold weather operation are taken ordinary cold weather will not cause difficulty in starting or loss of efficiency The following points are important to observe when operating in cold weather e Check
240. ntrol panel Fig 4 2 contains a lou vered window outlet for the face vents of the heating Controls ventilation and air conditioning system HVAC and four switches arranged in a vertical line usually the headlight panel light increase decrease and the cruise control On Off and Set Resume switches AU 10 15 2001 1610579a Left Hand Control Panel Instrumentation Control Unit Right Hand Control Panel Radio Panel NAPN Auxiliary Dash Panel Fig 4 2 Switch and Gauge Panels The instrument cluster ICU3 M2 is located right be hind the steering wheel No controls are installed on the standard instrument cluster The right hand control panel Fig 4 2 usually con tains the transmission push button shift selector on vehicles with automatic or automated transmission and the trailer brake lever hand control valve On vehicles with manual transmission a variety of switches are installed here If there is a dash mounted air restriction indicator it is often mounted here The radio panel contains two louvered dash outlets for the face vents of the HVAC one on either side of the radio if installed The auxiliary dash panel Fig 4 2 below the radio panel contains the marker interrupt switch the air brake valve knobs the cigarette lighter and a variety of switch options The HVAC climate control panel is on a separate panel below the auxiliary dash panel between the two cupholders Exter
241. ny burning material such as a cigarette Always comply with the washer fluid manufacturer s rec ommended safety precautions 3 Check the engine coolant levels in the radiator surge tank and if equipped the reservoir for the hybrid cooling system See Fig 11 1 If the coolant is low add a 50 50 mixture of water and the type of antifreeze speci fied for your vehicle Fill the surge tank with cool ant to the MAX line when the tank is cool If the surge tank was empty start the engine after re filling and check the level again when the engine is at operating temperature For natural gas vehicles use only Fleetguard ES Compleat EG Premix 50 50 engine coolant For vehicles equipped with a hybrid cooling sys tem the coolant should be approximately 1 5 inches 4 cm below the top of the reservoir for this system If the coolant is low add a 50 50 mixture of water and the type of antifreeze speci fied for your vehicle 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 11 02 2001 Sail 1820382 Add coolant here arrow Fig 11 1 Coolant Level Checking 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 radia
242. o o 4 13 Subject Page C Cab Amenities llle 5 10 Cab Storage iul Eve EE Sees 5 10 Cup Holders sc su mex xk 5 10 Cab Door Locks and Handles 2 1 Cab Entry and Exit Vehicles With One Step x ous suem Fons baka Rex 2 4 Entering from the Driver s jo MENO ae cats ain ss Mi eed ae 2 4 Entering from the Passengers Side ooo 2 5 Exiting from the Drivers Side 2 4 Exiting from the Passenger s Se 2 as eia te ote ene aM ee UR SR 2 5 Cab Entry and Exit Vehicles With Two Steps is 686566 o RR 2 2 Entering from the Driver s c MEM ts yd tek hide hd ee es 2 2 Entering from the Passengers Side o o oo ooooo ooo 2 3 Exiting from the Drivers Side 2 3 Exiting from the Passenger s SIGS dere s a ver eec PEERS 2 3 Cab Washing and Polishing 12 1 Canadian Motor Vehicle Safety Standard CMVSS Labels 1 2 Gare of Chrome Pans sss b EEG 12 1 Care of Exterior Lights 12 1 Care of Fiberglass Parts liess 12 1 Checking Headlight Aim 14 1 Climate Control Panel o o 6 1 Air Conditioning Optional 6 4 Air Selection Switch liess 6 1 DDefroslig xus eor Ee Po RE NUR e 6 3 Fam SWIG ocaso ne ties ed BAS Ge eek Ee 6 1 Fresh Air Mode copia cal 6 3 Recirculation Mode 055 6 3 Temperature Control Switch
243. o reverse or from reverse to a forward range Ah CAUTION Extended idling in reverse may cause transmis sion overheating and damage Do not idle in reverse for more than 5 minutes Se lect P park PB auto apply parking brake or N neutral when time at idle exceeds 5 minutes NOTE The shift into reverse may not succeed if a range inhibitor is active Check for illumination of the RANGE INHIBIT indicator N Neutral The neutral position places the transmission in neu tral This position is used when starting the engine and for stationary operation A WARNING Failure to apply the vehicle parking brakes when the transmission is in neutral may allow the ve hicle to move unexpectedly possibly causing property damage or personal injury When neutral is selected the vehicle service brakes parking brake or emergency brake must be applied Selecting neutral does not apply vehicle brakes un less an auxiliary system to apply the parking brake is installed Do not coast in neutral Coasting in neutral can cause an accident possibly resulting in severe personal injury or death Do not let the vehicle coast in neutral If the vehicle is allowed to coast in neutral the engine brake will not work and you could lose control of the vehicle CAUTION Coasting in neutral can cause severe transmis sion damage D Drive A WARNING When going downhill use a combination of downshifting braking and other reta
244. o turn the two position On Off Switch on raise the paddle When the two position switch is on an amber LED light emitting diode illuminates inside the switch To turn the two position HI LO Switch on high raise the paddle at the HI LO legend To turn the two position HI LO Switch on low lower the paddle at the ENG BRK legend See Fig 7 17 10 17 2001 1 On Off Switch 1610588 2 Hi Lo Switch Fig 7 17 Engine Brake Switches When the panel lights are on the Hi Lo legend is backlit in amber on the three position switch On both the three position switch and the two position switch the ENG BRK legend is backlit in green when the panel lights are on Whenever vehicle braking is required on good road conditions the engine brake may be used in con junction with the service brakes There is no time limit for operation of the engine brake However an engine brake does not provide the precise control available from the service brakes and is not a sub stitute for a service braking system Usage of the engine brake as the primary braking System can cause unpredictable stopping dis tances that could result in personal injury or property damage Service brakes are the primary vehicle braking system 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 7 14 Engines speed makes the engine brak
245. of the air cleaner On standard installations it is mounted on the air intake duct in the engine compartment As an option for easier viewing the air intake restric tion indicator see Fig 3 16 can be mounted on the dash usually on the right hand control panel NOTE Rain or snow can wet the filter and cause a higher than normal reading temporarily Air intake restriction vacuum is measured in inches of water inH O For vehicles equipped with a graduated indicator or a restriction gauge on the dash check the gauge with the engine off If the yel low signal stays locked in the red zone once the en gine is shut down or is at or above the values shown in Table 3 4 the air cleaner element needs to be replaced Vehicles may be equipped with a go no go restriction indicator without graduations see Fig 3 17 instead of a graduated indicator 10 10 2001 1610568 Fig 3 16 Air Intake Restriction Indicator 04 08 2005 1090431 Fig 3 17 Manual Reset Air Restriction Indicator Go No Go Air Intake Maximum Restriction Values Engine Make Pre EPA07 EPAO7 EPA10 Engines inH O Engines inH20 Caterpillar 25 Cummins 25 25 Detroit Diesel 20 22 Mercedes Benz 22 22 Turbocharged engines must be checked at full gine speed oad and governed en Table 3 4 Air Intake Maximum Restriction Values Instruments Ambient Temperature Gauge The ambient temper
246. of the clutch These are some conditions which lead to clutch abuse Using the throttle to hold the vehicle on a grade e Starting the vehicle in too high a gear Overloading the vehicle e Using high idle with the vehicle in gear The UltraShift TCU is programmed to prevent clutch abuse When the clutch overheats the following alerts take place The TRANS TEMP light comes on The gear indicator displays CA e A warning tone sounds at one second intervals The alerts continue until the clutch cools the throttle is released or the clutch is fully engaged System Problem In the event of a problem do the following steps 1 Note the driving conditions at the time the prob lem occurred 2 Record the status of the transmission at the time of the problem AUTO or MAN mode gear set ting R N D or L current gear engine speed etc 3 Reset the system using the procedure below Reset Procedure Transmission operation can sometimes be restored by doing the following reset procedure 1 Stop the vehicle when it is safe to do so 2 Place the selector switch in neutral and turn off the ignition 3 Check all harness connectors as described in Chapter 11 4 Wait at least two minutes with the engine shut down 5 Restart the engine If the problem continues contact an authorized Freightliner or Eaton service facility Locked In Gear If the transmission becomes locked in gear a dash gt will
247. off interaxle lock press the upper half of the rocker again When the panel lights are on the double axle icon is backlit in green IMPORTANT The interaxle lock rocker switch is guarded to prevent unintentional switch activa tion This switch does not have a diagnostic blink function when inactive Axle Shift Switch A CAUTION To prevent transmission and axle damage make sure the automatic transmission is in high range when performing an axle shift with the vehicle moving 4 11 The axle shift switch is a two position guarded rocker switch installed on vehicles with two speed axles See Fig 4 26 10 26 2001 1610594 Fig 4 26 Axle Shift Switch To shift the axle from low speed to high speed press the upper half of the rocker momentarily at the LED To turn the axle shift off switch from high speed back to low speed press the upper half of the rocker again NOTE On vehicles with tandem drive axles there is an interlock that prevents a 2 speed axle from shifting whenever the interaxle lock is on When the panel lights are on the AXLE SHIFT leg end is backlit in green IMPORTANT The axle shift switch is guarded to prevent unintentional switch activation If the LED in the switch begins to blink during normal operation when the switch has not been acti vated this indicates an error condition Bring the vehicle to an authorized Freightliner service fa cility as soon as possible All
248. ol that provides five or six forward ranges and one re verse range The push button shift selector has an R reverse an N neutral a D drive an up arrow a down arrow a mode button and a digital display New shift controls known as fourth generation were introduced in mid 2006 They replaced the pre vious units that are commonly referred to as WTEC Ill See Fig 8 1 and Fig 8 2 R Reverse Press the R button to select reverse The digital dis play will show R when reverse is selected Always bring the vehicle to a complete stop and let the en gine return to idle before shifting from a forward range to reverse or from reverse to a forward range Drivetrain A 3 4 07 27 2006 270113 1 Digital Display 3 Mode Indicator LED 2 Mode Identification 4 Mode Button Label Fig 8 1 WTEC III Push Button Shift Selector Transmission 07 27 2006 1610804 3 Mode Indicator LED 4 Mode Button 1 Digital Display 2 Mode Identification Label Fig 8 2 Fourth Generation Push Button Shift Selector Ah CAUTION Extended idling in reverse may cause transmis sion overheating and damage Do not idle in reverse for more than 5 minutes Se lect neutral when time at idle exceeds 5 minutes NOTE The shift into reverse may not succeed if a range inhibitor is active When reverse is se lected always be sure that R is not flashing N Neutral W
249. on re mains in low gear until drive is selected If LOW is selected while the vehicle is moving the transmis sion downshifts at a higher engine speed than nor mal in order to maximize the engine braking effect To select LOW press the clutch pedal to the floor Then press the LOW button Slowly release the clutch pedal and drive the vehicle IMPORTANT Before parking the vehicle always do the following Place the transmission in neutral Set the parking brakes Chock the tires if parking on an incline 8 14 Drivetrain Freightliner SmartShift Shift Control General Information SmartShift The SmartShift transmission control is an electronic transmission control device It is installed with the following transmissions e Eaton Fuller UltraShift Mercedes Benz Automated Gear Shift AGS It replaces the typical floor mounted shift lever or dash mounted push button control SmartShift accepts driver requests for transmission functions and transmits them through hard wiring to the transmission control unit TCU SmartShift is a true shift by wire system SmartShift offers two main advantages over conven tional transmission control devices Without a floor mounted shift control usable cab space is increased The SmartShift control mounts to the right hand side of the steering column and is operated by the fingers of the driver s right hand allowing both hands to re main on the steering wheel A
250. on the pivoting handle of the spotlight There may be a single spotlight as sembly mounted on the driver s door or one on each door Interior Lights and Light Controls The interior lights include dome lights red map lights and clear reading lights Dome Lights Diffuse dome lights are installed on all cabs The standard dome light has a clear lens and is installed on the back of the cab above the rear window See Fig 4 8 for the rear dome light On cabs with an overhead console there is an op tional overhead dome light assembly containing a diffuse dome and a clear reading light See Fig 4 9 for the optional dome reading lights on the overhead console 10 16 2001 1543926 To remove the lens press in at the mounting tabs arrows Fig 4 8 Rear Dome Light 10 17 2001 1 Overhead Console 2 Trimplate 1610587 3 Light Assembly Fig 4 9 Overhead Console Dome Lights Light Replacement Rear Dome Light To replace the rear dome light Fig 4 8 do the fol lowing steps 1 Press in on the lens at the four mounting tabs arrows 2 Replace the bullet type bulb and install the lens on the lamp base with the button at the bottom Overhead Console Dome Reading Lights To replace the overhead console dome reading lights Fig 4 9 do the following steps 4 4 Controls 1 Remove the tapping screws that attach the lamp assembly and trimplate to the overhead console 2 Separ
251. oned 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 Cab Features steering wheel Any objects may cause harm dur ing an accident 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 components WARNING 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
252. ons Expose each sensor to certified test gas for at least thirty seconds The system will proceed through the alarm procedure consistent with a significant leak and the buzzer will sound after approximately fifteen seconds If a sensor fails to respond after exposure to the test gas replace the sensor Engine Starting NOTE Before starting the engine read Chap ter 3 for detailed information on how to read the instruments and Chapter 4 for detailed informa tion on how to operate the controls Read the operating instructions in the engine manufactur er s operation manual before starting the en gine 1 Before engine start up complete the engine pre trip and post trip inspections and maintenance procedures in Chapter 11 Ensure the fuel shutoff valve is open Set the parking brake 16 9 4 Ensure that the transmission shift control is in Neutral N Park P or the Park Brake PB po sition 5 Without starting the engine turn the ignition switch to the ON position Fig 16 7 The elec tronic gauges on the instrumentation control unit ICU will complete a full sweep of their dials the warning and indicator lights will illuminate and the buzzer will sound for three seconds oom ON MS 1 N START ACC A 09 12 2001 f610509 Fig 16 7 Ignition Switch Positions 6 Turn the ignition switch to the START position Press down on the clutch pedal if equipped but do not press down on the accelerat
253. ontrol Regulator 1470533 7 Primary Relief Valve 8 Tank Pressure Gauge 9 Fill Vent Fitting 1 1 2 Vapor Shutoff Valve 3 Fuel Fill Hose 0 Excess Flow Valve 4 Secondary Relief 1 Fuel Shutoff Valve Valve red cap liquid 5 Fuel Fill Fitting 12 Fill Check Valve 6 Fuel Level Sender Box Fig 11 4 LNG Tank Plumbing Components 10 7 Inspect all coolant hoses for signs of chaf ing kinks or leaks The LNG fuel system utilizes coolant hoses between the engine and the vaporizer while the CNG fuel sys tem utilizes coolant hoses between the engine and the pressure regulator inside the fuel panel 10 8 If equipped with an LNG fuel system check the LNG fuel tank pressure gauge to ensure that pressure is within the nor mal range of 120 to 150 psi 827 to 1034 kPa In the unlikely event that tank pres sure exceeds 230 psi 1586 kPa and the pressure relief valve does not open auto matically vent the tank immediately 10 9 Inspect the LNG vaporizer if equipped for signs of damage or leaks See Fig 11 6 Inspect the vaporizer mounting brackets for signs of looseness Pretrip and Post Trip Inspections and Maintenance G i me OPEN VALVE SLOWLY 04 30 2010 1470556
254. open and free of debris See Group 42 of the Business Class M2 Workshop Manual to replace any damaged parts 11 12 Pretrip and Post Trip Inspections and Maintenance 24 Inspect the air brake lines A DANGER 24 1 Check the clearance between the hoses 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 Business Class M2 Workshop Manual 23 5 On all parking brake installations make sure the end cover cap or dust plug is se curely snapped into place See Fig 11 12 02 22 2000 1421352 A Do not remove this clamp ring 1 MGM TF T TR Series Brake Chamber shown Fig 11 12 Parking Brake Chamber Clamp 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 23 6 Check for rusted connections missing snap rings and damaged camshaft grease seals Have damaged or missing parts repaired or replaced 11 13 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 150 mm of clearance More cleara
255. operation of the vehicle See Group 42 of the Business Class M2 Workshop Manual for hydraulic brake system troubleshooting and adjustment procedures 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 that all occupants are wearing seat belts Check that the brake system warning light is off after releasing the parking brake If the warning light does not go off correct the prob lem before continuing operation of the vehicle 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 When the forward speed of the vehicle has de creased to almost the idling speed of the engine 9 7 push the clutch pedal in and shift the transmission into Neutral Apply the parking brake if the vehicle is to be parked Meritor WABCO Antilock Braking System ABS for Hydraulic Brakes The Meritor WABCO Antilock Braking System ABS is an electronic wheel speed monitoring and control system that works with the hydraulic brake system ABS passively monitors vehicle wheel speed at all times but controls wheel speed during an emer gency or reduced traction stop In normal braking applications the standard hydraulic brake system is in effect IMPORTANT For proper hydraulic ABS opera tion Meritor
256. or bulges cracks cuts and penetrations 11 10 Pretrip and Post Trip Inspections and 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 8 and Fig 11 9 E NS 7 P 02 09 95 gt 1400058 Fig 11 8 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 Business Class M2 Workshop Manual tor service procedures on the studs and hubs and see Group 40 in the same manual for wheel and tire servicing or take the ve hicle to an authorized Freightliner dealer Ah WARNING 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 11 11 occur possibly resulting in serious personal in jury or death 21 8 Have broken crack
257. or down from the bottom step Exiting from the Driver s Side To exit the cab from the driver s side do the follow ing steps Fig 2 4 IMPORTANT Do not attempt to exit the cab while carrying any items in your hands 1 If you wish to take any items with you after you exit the cab place them in an accessible location on the seat or cab floor Make sure they will not get in your way as you exit A WARNING Always face in when exiting the cab Do not at tempt to exit with your back to the cab as you would going down a flight of stairs It is easier to slip or lose your balance If you slip when exiting in this way there is a greater likelihood of per sonal injury 2 Grasp the steering wheel with both hands Place your left foot on the top step and stand on the threshold facing into the cab Move your right hand to the B pillar grab handle Move your right foot to the bottom step Move your left hand to the B pillar grab handle Step to the ground with your left foot first NO node 60 Retrieve from the cab any items that you wish to take with you NOTE You can also use the inner door grab handle if available as a support when getting up or down from the bottom step Entering from the Passenger s Side To enter the cab from the passenger s side do the following steps Fig 2 5 1 Open the passenger s door and place anything that you are carrying in the cab 2 Grasp the B pillar grab handle on the
258. or pedal Release the key the moment the engine starts 7 Bring the engine up to operating speed gradually as it warms up and develops stable oil pressure If the vehicle has not been operated previously in a 24 hour period allow the vehicle to idle for five minutes NOTICE Do not rev the engine if the oil pressure gauge indicates no oil pressure Shut down the engine Natural Gas Vehicle within approximately ten seconds to avoid engine damage 8 Check the oil pressure gauge for any drop in lu bricating oil pressure or mechanical malfunction in the lubricating oil system Major Repair and Replacement of Parts If a natural gas fueled vehicle is involved in an acci dent remove the fuel tank or cylinders from service and have them inspected by a qualified technician Replace any leaking or damaged fuel tanks cylinders and fuel lines repair or replace leaking or damaged fittings Install parts and components in accordance with the manufacturer s instructions 16 10 Index Subject Page A Adjustable Steering Column 4 13 Adjusting Headlight Aim 14 2 Aftertreatment System ATS 055 7 1 EPA07 Aftertreatment System ATS ule ku gn Reed 7 1 EPA10 Aftertreatment System ATS csc se Rex 7 3 Air Bag Optional vos mier de ic a 5 9 Air Bag Safety Guidelines 5 10 Air Brake Systemi cocoa pra cogo Renan es 9 1 Air Brake Operation
259. ory The downshift must be requested again When coasting to a stop the UltraShift TCU may not finish the downshift until the driver presses down on the throttle pedal again IMPORTANT A downshift request can never result in a shift into neutral even if the vehicle is in the drive position in the lowest possible gear Before starting down a hill slow down Downshift to a speed that you can control without hard pressure on the service brakes Before entering a curve slow down to a safe speed Downshift if necessary This lets you use some power through the curve to help the vehicle be more stable on the turn It also allows you to regain speed faster as you come out of the curve UltraShift Diagnostics Clutch Calibration NOTE Clutch calibration only occurs on six speed UltraShift ASW The UltraShift TCU automatically adjusts for clutch wear The calibration takes place whenever the fol lowing conditions are met The engine is at normal operating temperature The vehicle is stopped The engine is at idle speed The selector switch on the control lever is in neutral 8 20 Drivetrain Calibration may take up to two minutes to complete The engine may slow and return to normal idle sev eral times during calibration To stop calibration at any time select one of the drive positions on the selector switch R D or L Clutch Protection Fault Excessive clutch slippage creates heat and reduces the life
260. oss 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 installation or in an emergency situation When the brake pushrod stroke exceeds the legal brake adjustment limit on a vehicle there likely is 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 A WARNING 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 Air Brake Operation A WARNING 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 Before driving t
261. otect the components from cor rosion Clean more frequently when unusually corrosive chemicals are being used The ECU also has a safety circuit that constantly monitors the wheel sensors brake pressure modula tor and the electrical circuitry The ABS indicator lamp comes on after the ignition is switched on and will go out within three seconds if the system is func tioning correctly If the ABS indicator lamp does not come on or does not go out after three seconds have the vehicle serviced before operation If during vehicle operation the safety circuit senses a failure in any part of the ABS system a sensor brake pressure modulator wiring connection short circuit etc the warning lamp comes on and the control circuit where the failure occurred is switched to normal braking action Even if the ABS system is partially or completely inoperative normal braking ability is maintained An exception would be if the brake pressure modulator or a hydraulic fluid line is damaged Since these components are an integral part of the hydraulic 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 bra
262. ounters poor traction conditions however it also increases drivetrain and tire wear and should be used only when improved traction is required Interaxle Lock Switch A two position guarded rocker switch Fig 8 23 con trols interaxle lock causing both axle shafts to rotate together To lock the axles together press the upper half of the rocker momentarily at the red LED To turn off interaxle lock press the lower half of the rocker at the double axle icon IMPORTANT The interaxle lock rocker switch is guarded to prevent unintentional switch activa tion This switch does not have a diagnostic blink function when inactive When the interaxle lock switch is pressed three re sponses are possible a normal response a slow re sponse and an abnormal response Normal Response The LED in the switch blinks until the interaxle lock is engaged At this point the LED comes on steady and stays illuminated In normal operation the interaxle may lock so quickly that the blinking of the switch is barely noticeable If operation of the switch is not possible for any rea son ignition is turned off vehicle is moving too fast etc the LED will stop blinking and turn off Slow Response If operation of the switch is slowed for any reason by cold weather low air pressure etc the switch will continue to blink until the axles lock together or for a maximum of 10 seconds As in the normal response the LED comes on steady and
263. possible to re quest a manual shift The transmission will make the shift if the engine speed is within 75 rpm of the load based shift point for that gear If the driver presses down on the throttle pedal after a manual downshift in automatic mode the transmis sion will upshift again if the UltraShift TCU requires it Manual Mode MAN In manual drive mode MAN upshifts and down shifts are made by the driver To shift up pull the lever up towards you To shift down push the lever down away from you The system will hold the current gear until the driver requests a shift In downhill situations in particular the driver must be alert to vehicle speed by down shifting and or using the service brake A shift request will still be refused if the selected gear would cause engine overspeed or excessive lugging Selecting Gears Reverse Reverse R is at the upper end of the four position selector switch located at the end of the SmartShift control lever To select R press in the neutral lock button and move the selector switch upward to the position above neutral Six speed UltraShift ASW has one reverse gear When reverse is selected the letter R displays on the gear indicator See Fig 8 17 10 14 2003 7 1610681 Fig 8 17 Reverse Gear Display 8 18 Drivetrain Ten speed UltraShift DM has two reverse gears re verse low and reverse high To shift manually be tween them
264. pped causing premature clutch brake wear 3 To upshift do the following steps 3 1 Accelerate to engine governed speed 3 2 On synchronized models disengage the clutch and move the shift lever to second gear On unsynchronized models disengage the clutch and move the shift lever to neutral Engage the clutch again With the shift lever in neutral disengage the clutch and move the shift lever to second gear 3 3 Engage the clutch and note the drop in engine rpm before accelerating up to en gine governed speed again 3 4 Continue upshifting using the same se quence described in the previous step Follow the pattern on the shift lever 4 To downshift do the following steps 4 1 Wait until the engine speed drops to the rpm noted immediately after the upshift 8 9 4 2 On synchronized models disengage the clutch and move the shift lever to the next lower gear On unsynchronized models disengage the clutch and move the shift lever to neutral Engage the clutch again With the shift lever in neutral disengage the clutch and move the shift lever to the next lowest gear 4 3 Engage the clutch smoothly 4 4 Use the sequence described above to shift progressively down through each successive lower gear as driving condi tions require Eaton Fuller Range Shift Transmissions Refer to the Eaton website for additional information www roadranger com General Information Range Shift Eaton Fuller 9 Speed Mode
265. r 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 Whenever the isolator is not desired it can be locked out Fig 5 6 Lumbar Support Lumbar support changes the shape of the seat back to give more or less sup port to the occupant s lumbar lower back area 5 2 Cab Features This adjustment is either mechanical or air con trolled depending on make and model of the seat Fig 5 7 10 05 2001 1910483 A Lumbar Support B Headrest Adjustment 10 05 2001 f910484 A Backrest Tilt B Seat Cushion Tilt Fig 5 8 Cushion Tilt Adjustments Fig 5 7 Lumbar Support and Headrest Adjustment 4 Headrest When this adjustment is made the upper part of the backrest back cushion changes angle to provide head and upper back support Fig 5 7 5 Backrest Tilt This adjustment pivots the backrest forward or backward Fig 5 8 6 Seat Cushion Tilt This adjustment raises or low ers the front and or back of the seat bottom cushion This adjustment is easier to perform when all weight is removed from the seat Fig 5 8 7 Seat Tilt When this adjustment is made the seat assembly both backrest and seat cushion tilts forward or backward Fig 5 8 8 Ride Height Adjustment The entire seat moves up or down when adjusting the ride height The adjustment is either manual or air contro
266. r disconnected Backing off or dis connecting the front brakes will not improve ve hicle handling and may lead to loss of vehicle Pretrip and Post Trip Inspections and Maintenance 02 09 95 1400001 08 23 93 f400081a Fig 11 10 Tightening Pattern 10 Hole Wheels A 08 20 93 f400052a Fig 11 11 Tightening Pattern 8 Hole Wheels Fig 11 9 Worn Stud Holes control resulting in property damage or personal injury 23 1 Check that the air brake chamber is mounted securely on its mounting bracket and that there are no loose or missing bolts 23 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 23 3 Seeifthe 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 Business Class M2 Workshop Manual 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 4 Inspect the exterior surfaces of the cham ber for damage Make sure that breather holes in the non pressure section s are
267. r system is at least 65 psi 448 kPa the red knob must be pushed in and should stay in to charge the trailer air supply system and release the trailer spring park ing brakes Before disconnecting a trailer or when operating a vehicle without a trailer the red knob must be pulled out See Chapter 9 under the heading Dual Air Brake System for further information about the trailer air supply valve 4 13 Trailer Brake Lever The trailer brake lever hand control valve is used for applying the trailer brakes without applying the truck or tractor brakes It is usually mounted on the right hand control panel See Fig 4 30 See Chap ter 9 under the heading Dual Air Brake System for operating instructions 10 17 2001 f610591 Fig 4 30 Trailer Brake Lever Meritor WABCO Antilock Braking System ABS The Meritor WABCO Antilock Braking System ABS has an amber tractor indicator light TRACTOR ABS legend and if equipped with automatic traction con trol ATC an amber wheel spin indicator light WHEEL SPIN legend See Fig 4 31 On vehicles equipped with a compatible trailer there is also an amber trailer indicator light TRAILER ABS legend See the brake system operating instructions in Chap ter 9 for more information about ABS Adjustable Steering Column To tilt the steering column press down on the foot pedal located below the steering column Tilt the steering column up or down to the desi
268. rature is high enough the trapped soot is reduced to ash in a process called passive regen eration 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 EPAO07 engine works the better it disposes of soot as the exhaust heat alone is enough to burn the soot to ash Over the course of a workday however pas sive regeneration cannot always keep the ATD filter clean so the filter must undergo active regenera tion In active regeneration extra fuel is injected into the exhaust stream to superheat the soot trapped in the DPF and turn it to ash Active regeneration happens only when the vehicle is moving above a certain speed determined by the engine manufacturer Con sult manufacturers documentation for details Both active and passive regeneration happen automati cally without driver input If conditions do not provide for at speed active re generation the vehicle will need a driver activated parked regeneration The vehicle must be standing still and the driver must initiate parked regen Com pleting a parked regen takes 20 minutes to an hour depending on ambient conditions During parked regeneration 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 outlet
269. rding de vices to control vehicle speed and the engine s rated governed speed Failure to do so could re duce vehicle braking possibly causing loss of vehicle control and resulting in personal injury or property damage Drivetrain In the drive position the transmission will initially go into first range when drive is selected As vehicle speed increases the transmission will upshift auto matically through each available range up to fourth range or fifth range As the vehicle slows the trans mission will downshift automatically When going downhill downshift to a lower transmis sion range to increase engine braking and to help maintain control The transmission has a feature to prevent automatic upshifting above the lower range selected However during downhill operation the transmission may upshift to the next higher range if the engine is exceeding its governed speed in the lower range CAUTION Do not idle in drive for more than 5 minutes Ex tended idling in drive may cause transmission overheating and damage Always select PB auto apply parking brake or P park if time at idle is longer than 5 minutes NOTE The shift into drive may not succeed if a range inhibitor is active Check for illumination of the RANGE INHIBIT indicator 4 and 3 Fourth and Third Ranges optional Use the fourth or third range for city traffic and for braking on steep downgrades 3 and 2 Third and Second Ranges standard
270. re it is still possible to re quest a manual shift The transmission will make the shift unless the selected gear would cause engine overspeed If the driver presses down on the throttle pedal after a manual downshift in automatic mode the transmis sion will upshift again if the TCU requires it On downgrades the transmission holds the current gear until the driver requests a shift or presses the throttle pedal While driving off road or with locked differential in AUTO mode use extra caution Shifts of the AGS could interrupt power to the drive wheels causing a rollback accident while climbing steep grades at low speeds A rollback accident could cause death serious personal injury or property damage Manual Mode MAN Manual mode may be required under certain condi tions such as n difficult or slippery conditions On hills steep grades or other situations where driveline torque interruption is not desir able During off road driving or driving with a locked differential n downhill driving where control of engine braking is needed e f necessary to hold a specific gear on a down grade In manual drive mode MAN upshifts and down shifts are made by the driver To shift up pull the lever up towards you To shift down push the lever down away from you The system will hold the current gear until the driver requests a shift In downhill situations in particular the driver must
271. re occurred This could result in serious personal injury or vehicle damage To move a vehicle with insufficient system air pres sure it is necessary to release the parking brake springs There are two ways to do this Apply an external air source at the gladhands Cage manually release the parking brakes IMPORTANT Before caging the parking brakes make the connection to a towing vehicle or chock the tires After correcting the brake system problem uncage the parking brakes before resuming normal vehicle operation Meritor WABCO Antilock Braking System ABS for Air Brakes ABS is an electronic wheel speed monitoring and control system that works with the air brake system It passively monitors vehicle wheel speed at all times but controls wheel speed during an emer gency or reduced traction stop In normal braking 9 4 Steering and Brake Systems applications the standard air brake system is in ef fect ABS Operation The Meritor WABCO ABS is a four sensor system It combines one front axle control channel with one rear axle control channel to form one control circuit Example The sensor and solenoid control valve at the left front wheel form a control circuit with the sen sor and solenoid valve at the right rear wheel ABS includes signal generating tone wheels and sen sors located in the wheel hubs of each sensed axle The sensors transmit vehicle wheel speed informa tion to an electronic
272. re available first and second The default starting gear is second but first can be selected by the driver if desired To change the start ing gear press the brake pedal and select D with the vehicle stopped The current gear indicator will dis play the starting gear Move the shift lever up or down until the desired starting gear is displayed The UltraShift TCU adapts to the working conditions of each vehicle and its driver After power up or a load change it needs to learn the new conditions Drivetrain While learning it may hold a gear too long before upshifting Start the upshift manually It may take three or four shifts before UltraShift succeeds in learning the new load based shift points but after that it will handle the shifting automatically Low Low L is located at the lower end of the four position selector switch located at the end of the SmartShift control lever To select L press in the neutral lock button and move the selector switch to the position below D When in low the current gear is maintained Re quests to upshift are not enabled IMPORTANT If the engine is approaching over speed the UltraShift TCU will override the cur rent gear setting and upshift to prevent engine damage To enhance engine braking downshifts are per formed at higher rpm than normal If L is selected from neutral while stopped the ve hicle starts up in first gear and stays there until the engine approaches
273. red position Release the foot pedal to lock the steering column in place See Fig 4 32 To telescope the steering column press down on the foot pedal located below the steering column Pull the steering wheel closer to you or push the steering Controls esesese L bel 2 M Yn 18 8 VOLTS 10 12 2000 1 Tractor ABS Indicator 2 Wheel Spin Indicator optional 610454 3 Trailer ABS Indicator Fig 4 31 ABS Indicator Lights wheel farther away from you Release the foot pedal to lock the steering column in place Other Dash Mounted Controls Windshield Fan Switches Optional Ceiling mounted defogger fans are operated by LOW OFF HIGH toggle switches located in the base of the fan Cigarette Lighter Push in the lighter to heat the element The lighter will stay in and 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 Suspension Dump Switch NOTICE Do not operate the vehicle over uneven ground such as ramps speed bumps curbs etc with the air springs deflated Doing this may lead to air bag separation from the piston preventing the suspension air springs from reinflating 07 19 2006 1610799 4 Adjustable Steering Column foot Pedal 5 Steering Wheel 1 Multifunction Turn Signal Switch 2 Headlight Switch 3 Ignit
274. reselected cruise speed push the RESUME button on the transmission shift knob Cruise will return to the last speed selected NOTE If the ignition is shut off the speed memory will be lost 4 To adjust cruise speed up push the SET button and hold it in until the vehicle accelerates to the new speed as desired 7 12 Engines 5 To adjust cruise speed down push the RESUME button and hold it in until the vehicle decelerates to the new speed as desired Power Takeoff PTO Governor Front Engine Power Take Offs PTO are devices used to tap into engine power to run auxiliary de vices Common uses are vehicles with hydraulic pumps which power additional equipment The fol lowing instructions are general guidelines for operat ing a PTO 1 Set the parking brake Shift the transmission to neutral 2 Press the dash PTO switch Release the switch when the light begins to blink When the light comes on steadily the PTO is engaged and ready to operate In stationary mode the vehicle must remain in neutral with the parking brake set 3 To activate the mobile mode shift from neutral to reverse 1st or 2nd gear The clutch will open and the PTO will disengage for a moment 4 Touch the throttle pedal to close the clutch and engage the PTO in mobile mode The PTO may be operated with the transmission in the follow ing gears only R N 1 2 NOTE Do not attempt to change gears while the vehicle is moving The tra
275. rmation on the dome reading light assembly see Chapter 4 Instruments 04 19 2002 1 Storage Area with Netting 2 C B Radio 1680028 3 Microphone Clip 4 Dome Reading Light Assembly Fig 3 25 Overhead Instrument Panel 3 16 Controls laden Switch and Key sovioccra ERR ERE e e P ERU GC EST E E 4 1 ElCIICA SYSTEM sexescaranon ade aho v8 brea bed VIE doi e Bea a 4 1 Lighting Conttale 22 2052 uer RE E ER UE REN E T RRRE NACER EU RE KR RE EE 4 1 Multifunction Turn Signal SWIEDIT 4 s ox pax eo Edd RERO Yelp ECRIRE RERO REIR ORG 4 5 COMICIOS orca cent eie tes otc atten o a A f en iL cem 4 7 Powertrain GontolS Jue ii PERDERE a Gow woah Ede REGE a EE wee re 4 7 All Wheel Drive Controls Optional o oooocooococoor hr 4 11 Braking Ree ee ee ee epen we ee ee ee ee PDT 4 13 Adjustable Steering Column isses he bes RR WHE OG OSs HELGE ES EDEN HES oe ELE EX RE 4 13 Other Dash Mounted Controls ecos cea Ree open xx hos dee p Pek RI Res dar 4 14 Heater Air Conditioner Control Panel 0 0 eee eens 4 15 Seal SH OIS crore inc orders ce he sa been Ee et da 4 15 Controls Ignition Switch and Key The ignition switch Fig 4 1 has four positions AC CESSORY OFF ON and START In addition the same key locks and unlocks the cab doors Mii NOS f ACC 1 START 09 12 2001 1610509 Fig 4 1 Ignition Switch Positions In the OFF position the key slot is vertical the key c
276. rn 05 21 2008 f261049 Fig 8 3 Shift Pattern 5 Speed FS Models Eaton Fuller 6 speed FS and FSO models are fully synchronized They have six forward speeds and one reverse See Fig 8 4 for the shift pattern 05 21 2008 1261048 Fig 8 4 Shift Pattern 6 Speed FS and FSO Models Eaton Fuller 7 speed T models are not synchronized They have seven forward speeds and one reverse See Fig 8 5 for the shift pattern These transmissions are designed for use with on highway fuel economy engines where a minimum of shifting is desired and less gear reduction is accept able Operation Straight Shift 1 Always use first gear when starting to move the vehicle forward IMPORTANT Do not rest your foot on the clutch pedal while driving This causes partial clutch 8 8 Drivetrain 05 21 2008 f261051 Fig 8 5 Shift Pattern 7 Speed T Models disengagement which could cause premature clutch wear 2 On synchronized models press the clutch pedal to the floor when shifting gears Double clutching is unnecessary On unsynchronized models press the clutch pedal to the floor to contact the clutch brake only when engaging the first or reverse gears NOTE If the vehicle is moving when shifting press the clutch pedal just far enough to disen gage the clutch Pressing it to the floor will en gage the clutch brake if so equi
277. rned on the current gear indicator shows the dot display arranged in a square pattern All dots in the pattern should light up without gaps or spaces See Fig 8 14 4 Wait for the current gear indicator to show a solid N When the N is solid rather than flashing the UltraShift transmission control unit TCU is powered up Apply the service brake and start the engine 5 Select drive D by pressing in the neutral lock button and moving the selector switch downward to the position below neutral Release the park ing brake The gear is displayed on the current gear indicator 8 16 Drivetrain 10 13 2003 1610678 Fig 8 14 Power Up Dot Display NOTE When D is selected the transmission controller starts up in second gear On both six speed Ultrashift ASW and ten speed Ultrashift DM the driver can select to start up in first No other start gear is available 6 Ona level grade release the service brake and press down on the throttle pedal to allow the ve hicle to move forward When starting or stopping on hills and grades use extra care to prevent the vehicle from rolling back A rollback accident could cause death seri ous personal injury or property damage 7 Prevent the vehicle from rolling backward when stopped on a hill or grade or when the vehicle is starting from a stop on a hill or grade 7 1 To start from a full stop on a hill or grade quickly move your foot from the
278. rogress DPF Status Solid illumination indicates a regen is required Change to a more challenging duty cycle such as highway driving to raise exhaust temperatures for at least twenty minutes or perform a parked regen Blinking indicates that a parked regen is required immediately An engine derate and shutdown will occur Malfunction Indicator Lamp MIL Indicates an emissions related fault See the engine operation manual for details Vehicle ABS Indicates the vehicle ABS is engaged When ABS is not engaged illumination indicates a problem with the vehicle ABS Repair the ABS immediately to ensure full braking capability Trailer ABS Indicates the trailer ABS is engaged When ABS is not engaged illumination indicates a problem with the vehicle ABS Repair the ABS immediately to ensure full braking capability Wheel Spin Indicates the Automatic Traction Control ATC is engaged Solid illumination indicates a problem with the ATC system Repair the ATC system immediately to ensure full braking capability High Coolant Temperature Indicates the coolant temperature is above the maximum allowable temperature listed in Table 3 2 3 7 Instruments BRAKE AUR WAIT TO START q ea a a Common Warning and Indicator Lamps Low Air Pressure Wait To Start Low Engine Oil Pressure Water In Fuel Indicates air pressure in the primary or secondary r
279. rom the driver s side do the follow ing steps Fig 2 4 1 Use the door pull handle to open the driver s door and place anything that you are carrying in the cab Use the door armrest handle and if available the inner door grab handle as a sup port if needed 2 Grasp the B pillar grab handle with both hands Reach up as far as is comfortable 3 Place your right foot on the step and pull your self up 4 Step into the cab with your left foot 5 Grasp the steering wheel with your left hand 6 Step into the cab with your right foot and grasp the steering wheel with your right hand NOTE You can also use the inner door grab handle if available as a support when getting up or down from the bottom step Exiting from the Driver s Side To exit the cab from the driver s side do the follow ing steps Fig 2 4 IMPORTANT Do not attempt to exit the cab while carrying any items in your hands 1 If you wish to take any items with you after you exit the cab place them in an accessible location on the seat or cab floor Make sure they will not get in your way as you exit A WARNING Always face in when exiting the cab Do not at tempt to exit with your back to the cab as you would going down a flight of stairs It is easier to slip or lose your balance If you slip when exiting in this way there is a greater likelihood of per sonal injury 2 4 Vehicle Access 2 Grasp the steering wheel wit
280. rough the low speed range of the transmission If this system is used the transmission must be in the low speed range for the wheels to fully lock WARNING A vehicle with locked wheels can still slip side ways causing possible loss of vehicle control personal injury and property damage Be especially careful when driving under slippery conditions with the wheels locked Though forward traction is improved the vehicle can still slip side Ways If the vehicle is moving maintain a constant vehicle speed when the differential lock is turned on Briefly let up on the accelerator to relieve torque on the gearing allowing the wheels to lock completely When the wheels are fully locked the turning radius will increase because the vehicle understeers See Fig 8 22 Drive cautiously and do not exceed 25 mph 40 km h To disengage differential lock after leaving poor road conditions operate the differential lock switch as dis cussed above while maintaining vehicle speed Let up momentarily on the accelerator to allow the wheels to fully unlock then resume driving at normal speed NOTE If the differential lock system is con nected with the transmission in its low speed range shifting out of the low speed range will also disengage the differential lock function The Pa 02 09 96 f350079a A Turning Radius When the Differential Lock is Engaged understeer condition B Turning Radius When the Differential Lock i
281. rt period are not unusual If the temperature returns to normal when the load de creases there is no problem Engine Oil Temperature Gauge 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 During normal operation the optional engine oil tem perature gauge Fig 3 22 should read in the follow ing temperature ranges e 160 to 195 71 to 91 C for Caterpillar en gines e 200 to 260 93 to 126 C for Detroit Diesel and Cummins engines e 177 to 203 81 to 95 C for Mercedes Benz engines 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 If the temperature returns to normal when the load de creases there is no problem 10 10 2001 1610569 Fig 3 22 Engine Oil Temperature Gauge Tachometer The tachometer shown in Fig 3 9 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 Instruments Transmission Fluid Temperature Gauge The transmission fluid temperature gauge shown in Fig 3 23 measures the tr
282. s 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 Before starting the engine make sure that the lower half of the exhaust brake switch is pressed in and the amber light is not illuminated Do not turn the ex haust brake on until the engine has reached normal operating temperatures When you remove your feet from both the accelera tor and clutch pedals and the upper half of the ex haust brake switch is pressed in with the amber light illuminated the exhaust brake is applied The follow ing 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 e 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 7 16 Engines 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
283. s Disengaged Fig 8 22 Turning Radii switch will blink until the wheels unlock and then go out Tandem Drive Axles With Interaxle Lock CAUTION The interaxle lock should not be engaged on a vehicle with obviously spinning wheels Engage ment at high speed or power can damage the axle s Meritor has an interaxle lock axle lock interaxle dif ferential lockout feature that is standard on all dual drive tandem drive vehicles Interaxle lock is recom mended for use under adverse road conditions where greater traction is needed See the axle manu facturer s manual provided with the vehicle for more information The interaxle lock switch Fig 8 23 allows the driver to lock both rear axles together The red interaxle warning light illuminates on the dash message center when interaxle lock is engaged When the interaxle lock is not engaged there is dif ferential action between the two axles The differen tial compensates for different wheel speeds and variations in tire size Keep the interaxle lock disen gaged when driving on roads where traction is good When the interaxle lock is engaged the differential action between the two axles is locked Both drive axles now share the power Both axles and both 8 28 Drivetrain 10 26 2001 1610595 Fig 8 23 Interaxle Lock Switch sets of wheels turn together at the same speed The interaxle lock should be used when the vehicle en c
284. s through the ignition sequence See Fig 3 3 First the ICUS performs a self test looking for active fault codes and displays them if any one after the other until the engine is started or the ignition switch is turned off If there are no active fault codes the driver display screen displays the odometer When the ignition is first turned on all the electronic gauges complete a full sweep of their dials the warning and indicator lamps illuminate and the au dible warning sounds for three seconds On EPA10 compliant vehicles the DEF level indicator illumi nates all segments green then turns them off one at a time before turning the left most segment amber then red 3 2 Instruments HEADLIGHTS ON POWER ON IGNITION OFF IGNITION ON 123456 7 MI ICU PERFORMS SELFTEST ODOMETER ELECTRONIC GAUGE NEEDLES SCREEN SWEEP WARNING INDICATOR LIGHTS COME ON BUZZER SOUNDS IF NO FAULTS IF FAULT DETECTED WERE DETECTED ABS 11 kk 123456 7 MI FAULT CODE 12 3 VOLTS SCREEN PARK BRAKE RELEASED MOVING 123456 7 RELEASE PARK BRAKE MI lt 12 3 VOLTS 10 26 2009 HOURS SERVICE or MI SERVICE may display If the key was cycled off wile displaying Trip Miles Trip Hours or Ambient Air Temperature that screen will be dis played instead of odometer miles when the key is cycled ON without any fault codes 1040804 Fig 3 3 Ignition Sequence NOTE The
285. s are directed away from structures trees vegetation flammable materi als and anything else that may be damaged or injured by prolonged exposure to high heat There are three warning lamps in the driver message center that alert the driver of the need to perform a parked regen clean the filter or of an engine fault that affects the emissions Engines A slow 10 second flash of the high exhaust system temperature HEST lamp indicates a regeneration is in progress and the driver is not controlling the en gine idle speed A solid illuminated high exhaust system temperature HEST lamp alerts the operator of high exhaust temperature during the regeneration process when the speed is below 5 mph 8 km h See Fig 7 1 The HEST lamp does not indicate the need for any kind of vehicle or engine service it only alerts the vehicle operator of high exhaust temperatures The driver must be careful that the exhaust pipe outlet is not directed at any person or at any object or mate rial that can be damaged or ignited by the heat 09 25 2006 f610816a Fig 7 1 High Exhaust System Temperature HEST Lamp 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 cause a fire heat damage to objects or materials or personal injury to persons near the exhaust outlet See Regen Inhibit Switch later in this chapter for
286. s been dislodged or is miss ing the station dispensing nozzle will not con nect securely to the fill port 6 Turn the selector knob on the service pump to the VENT position if equipped 7 Connect the quick coupling on the dispensing nozzle securely to the vehicle fuel fill port 8 Turn the selector knob on the service pump to the FILL position if equipped IMPORTANT If at any time the service pump or vehicle begins to vent CNG uncontrollably notify a station attendant or activate the service sta tion emergency shut off switch to cease the flow of CNG 9 Switch on the service pump A slight hissing noise may be heard as the fuel cylinders fill 10 Watch the pressure gauge on the service pump When the gauge reads approximately 3600 psi 24 800 kPa or when the fill pressure stops climbing the CNG oylinders are full The service pump will shut itself down automatically See Table 16 1 for pressure compensation values based on ambient temperatures 11 Move the selector knob on the service pump to the VENT position if equipped A short hiss will be heard as a small amount of natural gas is vented into the hose Do not attempt to remove the fill station nozzle from the tank fill fitting until venting of pressure is noted If no venting occurs ask for assistance from the station attendant Removing an un vented coupling could result in an uncontrolled hose which could lead to property damage or personal injury
287. s reached With the parking brakes released and the ser vice brake applied shut down the engine wait 1 minute and note the air pressure gauge reading Observe the air pressure drop in psi kPa per minute If leakage exceeds the limits shown in Table 11 4 repair all areas of leakage be fore driving the vehicle Maximum Allowable Service Brake Air Leakage Air Leakage in psi Description kPa Per Minute 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 27 Check the operation of the Bendix Hydro Max brake booster if equipped as follows 27 1 With the engine off depress the brake pedal the warning light and buzzer should come on and the electric motor should run 27 2 Start the engine and allow the gauges to sweep Depress the brake pedal no warn ing lights buzzer or electric motor should come on 28 Inspect the seat belts and tether belts WARNING Inspect and maintain seat belts When any part of a seat belt system needs replacement the entire seat belt must be replaced both retractor and buckle side Any time a vehicle is involved in an accident and the seat belt system was in use the entire vehicle seat belt system must be re placed before operating the vehicle Do not at tempt to modify the seat belt system
288. smissions are fully auto matic and include the 1000 Series 2000 Series and 2400 Series Refer to the Allison website for additional information www allisontransmission com Safety Precautions Do not leave the vehicle unattended with the en gine running If you leave the vehicle and the en gine is running the vehicle can move suddenly which could result in personal injury or property damage 1000 Series On vehicles with Allison 1000 series transmissions do the following steps if you have to leave the cab with the engine running for example when checking the transmission fluid Without Park Position 1 Bring the vehicle to a complete stop using the service brake Ensure that the engine is at low idle rpm Put the transmission in neutral Apply the parking brake and make sure it is properly engaged 5 Chock the rear tires and take any other steps necessary to keep the vehicle from moving With Park Position 1 Bring the vehicle to a complete stop using the service brake Ensure that the engine is at low idle rpm Put the transmission in P park Apply the parking brake if equipped and make sure it is properly engaged 5 Engage the park range by slowly releasing the service brake 8 3 6 Chock the rear tires and take any other steps necessary to keep the vehicle from moving 2000 Series On vehicles with Allison 2000 series transmissions do the following steps if you have to l
289. ssion will reset to neutral during power down Drive IMPORTANT The vehicle must come to a com plete stop before selecting drive If drive is se lected with the vehicle moving in reverse an audible alert will sound and continue sounding at three second intervals until the selector switch is returned to N or R Drive D is at the lower end of the three position se lector switch located at the end of the SmartShift control lever To select drive press in the neutral lock button and move the selector switch to the position below neutral When drive is selected the number of the currently selected forward gear 1 2 3 4 5 or 6 displays on the gear indicator Upshifting NOTE The driver can manually upshift at any time even when the slide switch is set to AUTO mode To request an upshift with the transmission in drive pull the control lever up towards you If the gear is Drivetrain available the transmission upshifts and the new gear displays on the gear indicator As in a manual transmission upshifting too early causes engine lugging and uneven operation To achieve smooth operation in MAN mode upshift when the engine speed reaches approximately 2000 revolutions per minute rpm Heavy loads or steep grades require higher rpm lighter loads require lower rpm An unavailable request to upshift is not stored in memory The upshift must be requested again Downshifting NOTE The driver can manually do
290. st Pull the retractable handle out then secure it in the open position with the catch 7 Release the tractor parking brake then drive out slowly allowing the trailer to slide down the fifth wheel and pick up ramps Air Actuated Uncoupling An air actuated kingpin release valve is optional with all fifth wheels See Fig 10 10 NOTE In the event of an air system failure air actuated kingpins can be manually released fol lowing the instructions for manual unlocking A WARNING Once the kingpin release valve has been pulled the kingpin lock is released The vehicle MUST NOT be driven with the trailer until the trailer has 10 5 been uncoupled and coupled again Failure to do so may result in separation of the trailer from the tractor possibly causing serious personal injury or death Preparing the Trailer for Uncoupling Before using the air valve to unlock a fifth wheel kingpin prepare the trailer as follows 1 Apply the tractor and trailer parking brakes 2 Chock the trailer rear wheels 3 Lower the trailer landing gear until the weight is removed from the fifth wheel 4 Disconnect the tractor to trailer air lines and elec trical cable Plug the air lines to prevent dirt or foreign material from entering the lines Fontaine and Holland Fifth Wheels Air Activated Kingpin Unlock 1 Verify that both the yellow parking brake and red trailer air supply knobs are out the tractor and trailer parking brakes
291. t is damaged have it re placed See Fig 11 13 Haldex Slack Adjusters Inspect each slack adjuster and anchor strap for dam age See Fig 11 14 Have any damaged components replaced 25 3 Check the air brake system for proper operation 26 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 psi 827 kPa With the engine idling apply the brake pedal sev 06 17 2003 Ts O9 ON 7 16 inch Adjusting Nut Grease Fitting Boot Link Brake Chamber Piston Rod 1421398 Clevis 1 2 inch Clevis Pin 1 4 inch Clevis Pin Grease Relief Opening 10 Slack Adjuster Spline fo CON o Fig 26 2 26 3 11 13 Gunite Automatic Slack Adjuster 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 be adjusted to these specifications If the air governor cannot be adjusted or re paired replace it before operating the ve hicle 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 r
292. tached to the driver s sun visor ex plains the aftertreatment system DPF HEST and DEF warning lamps See Fig 7 6 e An illuminated DPF lamp indicates a regen is needed A slow 10 second flashing of the HEST lamp alerts the driver that a parked regen is in progress but the exhaust temperatures are still relatively cool It also indicates that the high idle speed is being controlled by the engine software not the driver A steadily illuminated HEST lamp alerts the operator of high exhaust temperatures when vehicle speed is below 5 mph 8 km h while it is performing an automatic regen and during a parked regen e An illuminated DEF warning lamp in the gauge indicates that the DEF tank should be refilled at the next opportunity Parked Regen During parked regeneration 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 structures trees vegetation flammable materi als and anything else that may be damaged or injured by prolonged exposure to high heat See Fig 7 7 for an explanation the ATS warnings and actions required to avoid further engine protec tion sequences The regen switch located on the dash is used to initiate a parked regen of the aftertreatment device It is a momentary switch that you press and
293. tch Temperatures generated between the flywheel driven discs and pressure plates can be high enough to cause the metal to flow and the friction facing material to char and burn CAUTION 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 Slipping and excessive heat are practically nonexist ent when a clutch is fully engaged But during the moment of engagement when the clutch is picking up the load it generates considerable heat An incor rectly 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 recognizing clutch malfunctions and knowing when to adjust a clutch Clutch Adjustments Some clutches have an internal adjustment See the applicable section in Group 25 of the Business Class M2 Workshop Manual for clutch adjustment procedures and specifications A CAUTION Operating the vehicle with the clutch incorrectly adjusted could result in clutch or clutch brake failure Clutch Lubrication The release bearing should be lubricated at frequent intervals See Group 25 of the Business Class M2 Maintenance Manual for intervals and procedures Ah CAUTION Failure to lubricate the release bearing
294. te nor mally as described previously TURN IGNITION O amp PUSH KNOB 09 11 2007 321102 Fig 4 34 Suspension Autofill Override Valve Heater Air Conditioner Control Panel Standard controls Fig 4 35 for the heating ventila tion and air conditioning system HVAC consist of an eight speed fan switch an air selection switch and a temperature control switch On vehicles with air conditioning the panel also contains a telltale LED and an air recirculation button See Chapier 6 for detailed operating instructions for the HVAC Seat Controls Bench Seat Adjustment Controls The standard bench seat has one control the seat slide lever See Fig 4 36 The two person bench Controls 1 2 3 22 ANRE p d DN 7 Y 10 03 2001 1831452 1 Fan Switch 2 Air Selection Switch 3 Temperature Control Switch Fig 4 35 HVAC Climate Control Panel Standard seat and the non suspended passenger seat have no controls 10 05 2001 4 v 4 1910481 1 Three Person Seat 2 Seat Slide Lever Fig 4 36 Full Bench Seat Suspension Seat Adjustment Controls All controls for adjusting air suspension seats are located within easy reach of the occupant 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
295. tely De pending on the type of problem further shifting may not be possible and driveline torque may be interrupted Operation AGS Power Up 1 With the parking brake set and or the brake pedal pressed down select neutral N by mov ing the selector switch to the center position 2 With the transmission in neutral turn on the igni tion switch The CHECK TRANS and TRANS TEMP telltale lights come on and go out again bulb check See Fig 8 13 3 On power up the current gear indicator shows the dot display arranged in a square pattern All dots in the pattern should light up without gaps or spaces See Fig 8 14 4 When the current gear indicator shows N start the engine NOTE No matter what the circumstances do not start the engine unless the current gear indi cator shows N See Chapter 13 for jump start ing information 5 Select drive D by pressing in the neutral lock button and moving the selector switch downward to the position below neutral Release the park ing brake and or service brake pedal The gear is displayed on the current gear indicator NOTE When D is selected the transmission starts up in first gear To start up in second gear downhill start vehicle unloaded or lightly loaded pull up on the SmartShift lever when the current gear indicator displays 1 6 Ona level grade press down on the throttle pedal to allow the vehicle to move forward The vehicle will not move until
296. ter 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 Cab Amenities Cup Holders There are two cup holders molded into the lower part of the auxiliary dash panel one on either side of the HVAC control head Cab Storage There are storage bins in the dash and the overhead console On vehicles with optional individual driver s and passenger seats there is a center storage con sole between the seats There is a dash storage bin located under the cup holders on the center panel The bin has a hinged 5 10 Cab Features cover and can be used to store sunglasses There is also a small storage pocket above the radio Overhead Storage Vehicles without an overhead console have two stor age bins located above the windshield On vehicles equipped with an overhead console most vehicles have a storage bin located in the over head console See Fig 5 21 The overhead storage bin is often removed and replaced with a CB radio Two map holders with netted openings are located overhead one on either side of the overhead console 10 08 2001 1 Overhead Storage Bin 2 Overhead Console 3 Map Holder Netting 16800
297. ter of the steering wheel To sound the horn press down on the button See Fig 4 14 10 17 2001 f461918 To sound the electric horn press down on the horn button 1 Horn Button The air horn is controlled by a wire lanyard hanging down just inboard on the driver s door See Fig 4 15 Pull downward on the lanyard to sound the air horn N y ry LL 10 17 2001 1610592 To sound the air horn pull down on the lanyard arrow Fig 4 15 Air Horn Control Powertrain Controls After Treatment System ATS Request Inhibit Regen Switch A parked regen of the ATS can be initiated with the request inhibit regen switch It may also be used to inhibit the vehicle from performing an automatic regen See Fig 4 16 The style and function of switch will vary with the en gine make and model See the engine operation manual for operation details 10 02 2006 1610848 Fig 4 14 Electric Horn Control Air Horn Optional Single and dual air horns are available as options 4 7 Fig 4 16 Request Inhibit Regen Switch Controls Cruise Control Switches Ah CAUTION Do not attempt to shift gears without using the clutch pedal when the cruise control is engaged Failure to follow this precaution will result in a temporarily uncontrolled increase in engine speed transmission damage and gear stripping could result On standard models cruise control is activated by two dash switches
298. the floor outlets 7 Floor Mode Directs all airflow through the floor outlets 8 Selection between Floor Mode and Floor Defrost Mode Directs 75 percent of the airflow through the floor outlets and 25 percent through the defrost outlets 9 Floor Defrost Mode Directs the airflow equally to the floor outlets and the defrost outlets The recirculation button will not work in this mode 10 Selection between Floor Defrost Mode and Defrost Mode Directs 75 percent of the airflow through the defrost outlets and 25 percent through the floor outlets The recirculation button will not work in this mode 11 Defrost Mode Directs all airflow through the defrost outlets The recirculation button will not work in this mode Temperature Control Switch The temperature control switch is used to select the desired temperature Turn the switch to the left counterclockwise for cool air or to the right clock wise for hot air There are 21 positions on the tem perature control switch ranging from full cool air to full hot air Fresh Air Mode Fresh air or outside air is circulated through the heating and air conditioning system unless the recir culation mode if equipped is turned on 6 3 Recirculation Mode The recirculation mode is only available on vehicles with air conditioning The recirculation mode limits the amount of outside air entering the cab Press the recirculation button to prevent dusty or smoky air from
299. the front of the seat cushion and then push it rearwards To lower the seat cushion pull forward on the front of the seat cushion and then push downwards Backrest Adjustment To adjust the backrest push downwards on the back rest lever just below the bottom of the backrest cush ion With the lever down lean forward or backward to the desired position Release the lever to lock the backrest in place Ride Height Adjustment Push the ride height knob inwards to inflate the air cylinder raising the height of the seat Pull the ride height knob outwards to deflate the air cylinder low ering the height of the seat For seats with air support use the forward rocker switch on the control panel on the left hand side of the seat Fig 5 15 Press up to raise the seat press down to lower the seat Ride Firmness Adjustment For a softer ride remove the snap ring and pin from the shock absorber bracket see inset Relocate the pin in the other set of holes in the bracket and se cure it with the snap ring 5 6 Cab Features 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 gers regardless of age or physical condition use seat belts when riding in the vehicle A
300. the responsibility of the driver to adjust the seat to prevent damage to the seat and the cab inte rior All adjustment controls for a suspension seat are lo cated on the seat base See Chapter 5 for complete instructions 4 16 Cab Features NINOS Lost ended ELA a Mee e s eee MEE Ee 5 1 A aah ee Qed TIPP 5 1 SOS cubus nA m M ee LE 5 2 Seat Belts and Tether Belts liliis ee eee RR RR rers 5 7 Air Bag Optional sexi ood Rows eb pee Ses eS enews ER RR EK oes AR A RETE 5 9 CAP piapa e aeaa e eaa e e aee EE aeaea Di 5 10 Windshield Washer Reservoir Cab Features Windows Standard windows operate mechanically using a hand crank Power windows are optional and can be installed on one side or both sides One power window switch window icon will be installed on the dash for each window See Fig 5 1 If your vehicle is equipped with power windows press up to raise the window press down to lower the window Releasing the switch causes the window to stop E v 10 09 2001 1610522 Press up to raise the window press down to lower the window Releasing the switch causes the window to stop Fig 5 1 Power Window Switch Standard vent wing windows do not open Operat ing vent windows are optional To open the operating vent window turn the latch on the window and push the window open See Fig 5 2 ao A YA f 10 05 2001 1 Latch 16
301. time onto the top step 3 Move your upper hand to a lower position on the grab handle 4 Move one foot to the bottom step 5 Move your upper hand to a lower position on the grab handle 6 Step to the ground with your upper foot first Battery Access Battery Compartment The battery compartment is located in the lower part of the cab beneath and to the rear of the driver s door It is fastened by a quarter turn fastener To open the battery access door turn the quarter turn fastener with a small screwdriver See Fig 2 7 10 25 2001 7 1543934 Open the battery access door by turning the quarter turn fastener arrow with a small screwdriver Fig 2 7 Battery Compartment Closed 2 6 Vehicle Access With the battery access door open Fig 2 8 it is easy to get access to the battery terminals for clean ing charging or emergency jump starting 3 4 4 LES 10 24 2001 eS C 1543933 1 Top Step 2 Battery 3 Cab 4 Battery Access Door Fig 2 8 Battery Compartment Open To close the battery access door do the following steps 1 Swing the battery access door to line up the quarter turn fastener with the hole in the cab door frame 2 Close the battery access door and check to be sure the quarter turn fastener is engaged with the hole 3 Turn the fastener one quarter turn Cab Battery Isolation Switch The cab isolation switch see Fig 2 9 is located on t
302. toff Valve Valve red cap liquid 5 Fuel Fill Fitting 12 Fill Check Valve 6 Fuel Level Sender Box Fig 16 3 LNG Fuel Tank Plumbing Components IMPORTANT When fueling a hot tank initially put 5 to 10 gallons 19 to 37 liters of LNG in the tank and manually stop the fueling process Drive the vehicle for 15 to 20 minutes to cool 16 4 Natural Gas Vehicle the tank and reduce tank pressure then con tinue fueling the tank to full 7 When the tank is full the line pressure will rap idly spike and the flow rate will fall When a pres sure rise or flow rate drop is observed close the station s fill valve if equipped NOTE Do not over fill an LNG tank If the ul lage tank is completely filled during fueling tank standby time will be reduced to zero and the primary relief valve will open almost immediately after fueling 8 Disconnect the station hose from the tank fuel fill fitting 9 Disconnect the electrical ground clamp and cable from the fuel tank 10 Install the dust cap on the tank fuel fill fitting Gas Detection System A gas detection system is used in all Daimler Trucks natural gas fueled vehicles This system has a sen sor in the engine compartment and one in the cab both situated in high areas to detect natural gas buildup as a result of leaks The AMGaDS III Plus is a natural gas detection sys tem This device is meant to serve as a supplemen tal warning only It is not intende
303. tor 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 4 4 Check the radiator for leaks If leaks are found have the radiator repaired or re placed See Group 20 of the Business Class M2 Workshop Manual for instruc tions or take the vehicle to an authorized 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 Pretrip and Post Trip Inspections and Maintenance 4h CAUTION Failure to maintain a sealed air intake system could allow the entry of dirt and contaminants into the engine This could adversely affect en gine performance and result in engine damage 6 1 Check the intake air restriction indicator if mounted in the air intake system 6 2 Replace the primary filter element in the air cleaner see Fig 11 2 if the yellow signal stays locked at 25 inH5O for
304. tractor forward or backward until the fifth wheel is in the desired location NOTICE Ensure the trailer landing gear does not come in contact with the tractor frame or other compo nents and that the front of the trailer will not come in contact with the rear of the cab or other components if they extend beyond the rear of the cab 5 Apply the tractor parking brakes WARNING Check that the locking wedges have seated in the slots Failure to achieve complete lockup may allow disengagement of the tractor from the Fifth Wheels and Trailer Couplings trailer possibly resulting in serious personal in jury or death 6 Set the air slide switch to LOCK Visually inspect the locking wedges or plungers to make sure that they are fully inserted in the slide rail slots Verify that the plungers have engaged by tugging the tractor forward while the trailer brakes are locked and the wheels are chocked NOTE The fifth wheel may need to be moved slightly to enable the locking wedges to fully lock 10 10 11 Pretrip and Post Trip Inspections and Maintenance Pretrip and Post Trip In es E ted ids m 11 1 Pretrip and Post Trip M s np m Rm 11 3 Pretrip and Post Trip Inspections and 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
305. ttern M B Transmissions Always use first gear when starting to move the ve hicle forward IMPORTANT Do not rest your foot on the clutch pedal while driving This causes partial clutch disengagement which could cause premature clutch wear While traveling check the tachometer regularly to be sure the engine speed is within the most economical range 1400 to 2000 rpm On level roads drive in the highest usable gear keeping engine speed down CAUTION Do not rest your hand on the gear shift lever while driving This can cause synchronizer dam age When approaching an uphill grade shift down ahead of time to prevent loss of engine rom When ap proaching a downhill grade shift down ahead of time to prevent runaway speed For information about shift points and progressive shifting see Chap ter 7 Change gears only when absolutely necessary Skip gears if needed When shifting always press the clutch pedal all the way down Do not force the gear lever Before shifting into reverse be sure the engine is idling and the vehicle is not moving CAUTION If the transmission locks up while driving mak ing further shifting impossible continue driving in the gear already selected to reach service as sistance as circumstances allow Or safely park the vehicle off the roadway and contact your nearest Freightliner dealer or other qualified ser vice provider for roadside assistance To prevent further transm
306. u larly If the finish has become dull before wax ing remove oxidized paint using a cleaner spe cifically designed for this purpose Remove all road tar and tree sap before waxing Freight liner 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 off with water To prevent corrosion have any nicks or other damage on the finish touched up as soon as possible Park your vehicle in a sheltered area whenever possible 12 1 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 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 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 Care of Exterior Lights
307. use the shift lever as described for MAN mode There is no AUTO mode for reverse When reverse low is selected the letter R displays on the current gear indicator When reverse high is selected the letter H displays on the current gear indicator IMPORTANT Under normal conditions do not select reverse with the vehicle moving forward The vehicle must be moving at less than two miles per hour 3 km h before selecting reverse If reverse is selected when the vehicle is moving faster an au dible alert will sound and continue sounding at three second intervals until the control lever is returned to the D position When the vehicle is moving at the proper speed reverse can be engaged On ten speed UltraShift DM only if necessary to rock the vehicle use the selector switch to shift back and forth at low speed between reverse and drive Neutral IMPORTANT Always start the engine with the transmission in neutral the parking brake set and the service brakes applied Neutral N is directly below R on the four position selector switch located at the end of the SmartShift control lever To select N move the selector switch to the position below R When neutral is selected the letter N displays on the gear indicator See Fig 8 18 10 13 2003 1610679 Fig 8 18 Neutral Display Do not coast in neutral Coasting in neutral can cause an accident possibly resulting in severe personal injury or death
308. used during stationary operation of the power takeoff if your vehicle is equipped with a PTO Drivetrain D Drive When the D button is pushed the highest forward range will appear in the display The transmission will normally go into first range when drive is selected except for those units programmed to start in sec ond range As vehicle speed increases the trans mission will upshift automatically through each range As the vehicle slows the transmission will downshift automatically 4h CAUTION Do not idle in drive for more than 5 minutes Ex tended idling in drive may cause transmission overheating and damage Always select neutral if time at idle is longer than 5 minutes NOTE The shift into drive may not succeed if a range inhibitor is active When drive is selected always be sure that D is not flashing 5 4 3 and 2 Fifth Fourth Third and Second Ranges Occasionally road conditions load or traffic condi tions will make it desirable to restrict automatic shift ing to a lower range Lower ranges provide greater braking for going down grades The lower the range the greater the braking effect Push the up or down arrows on the push button shift selector to select individual forward ranges The digi tal display will display your choice of range When a lower range is selected the transmission may not downshift until the vehicle speed or engine RPM en gine governed speed is reduced A WARNIN
309. 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 On standard models cruise control is activated by two dash switches Fig 7 15 The On Off Switch this two position rocker switch bears the legend SPD CNTL on the lower half of the switch When cruise control is on an amber light illuminates in the top part of the switch The Set Resume Switch this three position paddle switch bears the legend RES ACC above the paddle and SET CST below the paddle 1 To cruise at a particular speed do these steps 1 1 Press the upper half of the On Off rocker switch on the instrument panel 1 2 Hold the accelerator pedal down until the speedometer reaches the desired speed 1 3 Momentarily lower the paddle of the Set Resume switch to SET CST 2 To disengage the cruise control do these steps 2 1 Press down the brake pedal on automatic or manual transmission or Press down the clutch pedal on manual transmission only Engines 09 13 2001 1610510 To turn cruise control on press the upper half of the On Off rocker switch To turn cruise control off press the lower half of the On Off rocker switch 1 Cruise Control On Off rocker Switch 2 Cruise Control Set Resume paddle Switch Fig 7 15 Cruise Control Switches Dash Mounted 2 2 Pr
310. uttons can be used to select gears In automatic mode the number of the forward gear currently engaged appears continually on the mode indicator when in drive In MANUAL the last gear selected appears on the mode indicator If the SERVICE indicator illuminates take the vehicle as soon as possible to an authorized Freightliner service facility The mode button is reserved for future use IMPORTANT To prevent engine overspeed the transmission software will override both MANUAL and LOW if necessary The system will not respond to gear selection requests that will either overspeed or excessively lug the engine Automatic Mode The AutoShift AS2 transmission is normally operated in an automatic mode To select MANUAL mode press the MANUAL button on the push button shift selector When the transmission is in automatic mode the transmission automatically selects and engages the gears although the transmission will respond to up shift and downshift requests as though in manual mode See the instructions for shifting under heading Manual Mode below Manual Mode When the transmission is in manual mode the driver must select the appropriate gear using the shift but tons on the push button shift selector Drivetrain To upshift in MANUAL press the upshift button up arrow and release The number of the gear will ap pear on the mode indicator If the requested gear is available the transmission will shift up
311. vehicle before placing it into service for the day Commercial vehicles may be subject to inspection by authorized inspectors and an unsafe vehicle can be put out of service until the driver or owner repairs it 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 instructions for specific inspection and maintenance instructions 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 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 s
312. visually and physically check the locking wedges to make sure they are fully inserted into the slots in the slide rails Make sure the handle is locked in position against the guide plate 6 2 Holland Raise the operating rod so that it is free to move inward Make sure that the lock pins have seated in the base plate rail holes and the operating rod moves into the locked position NOTE The fifth wheel may need to be moved slightly to enable the locking wedges to enter the fully locked position 10 8 Fifth Wheels and Trailer Couplings Air Slide Operation The slide feature may be operated with an air switch mounted in the dash that operates an air cylinder that locks and unlocks the slide See Fig 10 14 02 22 2011 f611114 Fig 10 14 Air Slide Switch 1 Set the air slide switch to UNLOCK See Fig 10 14 Ensure the locking plungers have released See Fig 10 15 For Jost fifth wheels the mechanism activates as shown in Fig 10 16 2 Lower the trailer landing gear just enough to re move the weight from the tractor 09 10 2010 1311131 A Unlocked B Locked 07 25 95 1310189 1 Locking Wedge 2 Air Oylinder Fig 10 15 Air Operated Sliding Fifth Wheel Fontaine shown 10 9 Fig 10 16 Jost Sliding Fifth Wheel 3 Pull the red trailer air supply knob to set the trailer parking brakes 4 Slowly move the
313. water cannot provide adequate bearing protection at start up For this reason change the engine oil and filters after extended storage NOTICE Failure to eliminate water diluted lubricating oil may lead to serious engine damage at startup Before engine start up complete the engine pretrip and post trip inspections and maintenance proce dures in Chapter 11 Engine Break In Every engine is tested on a dynamometer before shipment 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 Engine Operation 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 injury or death All Freightliner diesel engines comply with the re quirements of the Federal U S Clean Air Act Once an engine is placed in service the responsibility for meeting both state and local regulations is with the owner operator IMPORTANT EPAO7 and EPA10 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 EPAO7 or EPA10 compliant engines with an emission af tertreatment system depending upon local statutory emissions guide
314. when the DPF light is illuminated 7 2 Engines because the engine software calls for a manual regen The regen inhibit switch provides additional control over the aftertreatment regeneration process A driver may decide to use this feature if they are hauling cargo that should not be exposed to possible high exhaust temperatures from an automatic regen When activated the inhibit switch will stop a regen eration cycle in progress and prevent the start of a regeneration cycle until the switch is no longer ac tive See Fig 7 5 10 02 2006 1610848 Fig 7 4 Request Regen Switch 07 30 2009 1610944 Fig 7 5 Regen Inhibit Switch EPA10 Aftertreatment System ATS The EPA mandates that all engines built after De cember 31 2009 must reduce the level of emissions exhausted by the engine to the following levels Nitrogen Oxides NOx 0 2 g bhp hr Particulate Matter PM 01 g bhp hr 7 3 To meet EPA guidelines diesel engines installed in Daimler Trucks North America DTNA chassis for domicile in Canada and the USA use an aftertreat ment system ATS with an aftertreatment device ATD and Selective Catalytic Reduction SCR tech nology to reduce NOx downstream of the engine NOTICE Using non specification fluids can result in seri ous damage to the ATS It is extremely important that the following guidelines be followed for ve hicles with EPA10 compliant engines
315. will feel as if the brake is being lightly applied when you remove your foot from the accelerator pedal The full power of the service brake is always available to the driver and regenerative braking is automatically shut off during an ABS an tilock brake event The Eaton Hybrid Control Unit will automatically shut off regenerative braking when the batteries are fully charged 15 1 High Voltage Safety Features The HEV has high voltage cables and a service switch on the PEC High voltage cables are covered in orange insulation and conduit Each high voltage component is tagged with a warning or danger label IMPORTANT The service switch on the PEC should only be used for an emergency shut down or when the service manual or trouble shooting guide calls for work on the high voltage system The service manual and troubleshooting guide for the hybrid electric system are available from www roadranger com The red service switch is located next to the high voltage cable connections at one end of the PEC Pushing in the red service switch will shut down the engine The hybrid system will be disabled and the high voltage batteries in the PEC though still live are isolated in the PEC NOTE The PEC may be mounted in an area with limited access For information on emergency shutdowns see Emergencies in this chapter Cooling System The HEV requires a liquid cooling system for the HDU inverter DC DC Converter if eP
316. wing steps to fuel a CNG vehicle 1 Shut down the engine and apply the parking brake CNG Temperature Pressure Compensation Values Teniperat ie Fill Station Pressure Set Point F C 3000 psi 20 684 3600 psi 24 821 kPa Set Point kPa Set Point 100 37 8 3415 23 546 4086 28 172 90 32 2 3276 22 587 3909 26 952 80 26 7 3138 21 636 3754 25 883 70 21 1 3000 20 684 3600 24 821 60 15 6 2861 19 726 3445 23 752 50 10 2723 18 774 3288 22 670 AO 4 4 2584 17 816 3131 21 587 30 1 1 2446 16 865 2973 20 498 20 6 7 2307 15 906 2814 19 402 10 12 2 2169 14 955 2655 18 306 0 17 8 2031 14 003 2495 17 202 10 23 3 1893 13 052 2336 16 106 20 28 9 1755 12 100 2180 15 031 04 22 2010 1470554 30 34 4 1616 11 142 2024 13 955 1 Fuel Oylinder Storage Fuel Fill Port 40 40 1477 10 184 1868 12 879 Box Dust Cap ooo 2 Fuel Oylinder Shutoff Manual Shutoff Valve Valves aty 5 Fuel Panel Access 3 High Pressure Gauge Door 4 Low Pressure Gauge Fig 16 1 CNG Fuel Cylinder Storage Box 5 cylinder system shown 16 2 Natural Gas Vehicle 3 Ensure the vehicle fuel system main shutoff valve is open 4 Open the CNG fuel panel access door and re move the dust cap from the vehicle fuel fill port 5 Ensure the O ring is present inside the fuel fill port If the O ring ha
317. witch Positions Engines Starting Precautions All Engines 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 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 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 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 See the engine manufacturer s operation manual for starting aids that are approved for specific engines 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 through normal condensation of moisture on the internal surfaces of the engine Oil diluted by
318. with a 3 minute snooze feature ser Snooze ALARM 12 14 2011 1611154 Fig 3 20 Digital Clock Set the clock by pressing the SET button then se lecting the desired time by pressing the HRS and MIN buttons When the clock is set to PM hours a PM indicator will appear on the display When the PM indicator is not displayed the clock is set to an AM hour Instruments To set the alarm press the SET button then press the ALARM button Select the desired alarm time by pressing the HRS and MIN buttons then press the SET button once again To turn the alarm on and off press the ALARM but ton when the current time is displayed When the alarm sounds pressing the SNOOZE button will delay the sounding of the alarm for three minutes Drive Axle Oil Temperature Gauges 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 vehicle until the cause has been determined and corrected During normal operation forward rear and rear rear axle oil temperature gauges see Fig 3 21 should read between 160 and 220 F 71 and 104 C 10 10 2001 1610571 Fig 3 21 Axle Oil Temperature Gauge Under heavy loads such as when climbing steep grades temperatures that exceed the normal oil tem perature range for a sho
319. wly at low throttle This will prevent internal axle damage The differential lock switch is a two position guarded rocker switch See Fig 4 24 It causes the wheels on each axle governed by the switch to rotate together It is also known as side to side wheel lock 10 26 2001 f610596 Fig 4 24 Differential Lock Switch To lock the wheels together press the upper half of the rocker momentarily at the LED To turn off dif ferential lock press the upper half of the rocker again When the panel lights are on the double axle icon is backlit in green IMPORTANT The differential lock switch is guarded to prevent unintentional switch activa tion If the LED in the switch begins to blink dur ing normal operation when the switch has not been activated this indicates an error condition 4 10 Controls Bring the vehicle to an authorized Freightliner service facility as soon as possible Interaxle Lock Switch CAUTION The interaxle lock should not be engaged on a vehicle with obviously spinning wheels Engage ment at high speed or power can damage the axle s The interaxle lock switch is a two position guarded rocker switch installed on vehicles with dual drive axles See Fig 4 25 It causes both axle shafts to rotate together 10 26 2001 1610595 Fig 4 25 Interaxle Lock Switch To lock the axles together press the upper half of the rocker momentarily at the LED To turn
320. wnshift at any time even when the slide switch is set to AUTO mode To request a downshift with the transmission in drive push the control lever down away from you If the gear is available the transmission downshifts and the new gear displays on the gear indicator Downshifts are not available if the engine speed after the shift would exceed 2700 rpm If the gear re quested is unavailable an audible alert will sound An unavailable request to downshift is not stored in memory The downshift must be requested again To achieve smooth operation in MAN mode down shift when the engine speed reaches approximately 1200 rpm Before starting down a hill slow down Downshift to a speed that you can control without hard pressure on the service brakes Before entering a curve slow down to a safe speed Downshift if necessary This lets you use some power through the curve to help the vehicle be more stable when turning It also allows you to regain speed faster as you come out of the curve AGS Diagnostics A CAUTION At the first sign of a transmission malfunction take the vehicle out of service immediately De pending on the type of problem further shifting may not be possible and driveline torque may be interrupted System Malfunction If the CHECK TRANS telltale light comes on while driving the audible alert sounds and the current gear indicator begins to flash between the current gear and SM system malfunction

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