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FLD Conventional Driver`s Manual

1. TOWING zzi pee me REPRE Front Towing Hookup Rear Towing Hookup Upper Bunk Access 70 Inch Raised Roof SleeperCab Accessing the Upper Bunk Using the Driver s Side Cabinets ues ce RRS aed Accessing the Upper Bunk Using the Passenger s Side Cabinets Vehicle Specification Decal Velour Upholstery Cleaning Chewing Gum or Wax Grease and Oil Based Stains Mildew 000000 Sugar and Water Based Stas cuu Rer ur esk pea Index Subject Page Vinyl Upholstery Cleaning less 12 1 Ball Point MK s 2 me bb Sara 12 2 Ghewing GUM esum mh Rn 12 2 Miscellaneous lessen 12 2 Nail Polish and Nail Polish Remover sarsie eai debug ua a ate a a AVE digo 12 2 Ordinary Dirt e er cuc baea gy x 12 1 Paint Shoe Heel Marks 12 2 Shoe Polish 5 2v s o RR 12 2 Sulfide Stains 2000200 02 12 2 Tars Asphalts and Creosote 12 2 W Warning and Indicator Lights 2 13 Bendix Antilock Braking System ABS 0 000202 e eee 2 15 Kysor Vehicle Instrumentation and Protection VIP System Optional o lu Ste we ade white Oa ar ceed ey 2 19 Meritor WABCO Antilock Braking System ABS lus 2 14 Parking Brake Indicator Light 2 13 VIGIL I Warning System 0000 2 16 VIGIL II Warning System Optional 25 ertum ie uo URS
2. During the first 30 days rinse your vehicle fre quently with water If the vehicle is dirty use a mild liquid soap Do not use detergent e During the first 30 days do not use anything abrasive on your vehicle Brushes chemicals and cleaners may scratch the finish During the first 120 days do not wax your vehicle To extend the life of your vehicle s finish follow these guidelines Avoid washing your vehicle in the hot sun e Always use water After the cab is completely washed dry it with a towel or chamois Do not dust painted surfaces with a dry cloth as this will scratch the paint Do not remove ice or snow from a painted sur face with a scraper of any sort To prevent damage to the finish wax it regu larly Before waxing if the finish has become dull remove oxidized paint using a cleaner specifically designed for this purpose Remove all road tar and tree sap before waxing Freightliner recommends that a quality brand of cleaner or cleaner polish and polishing wax be used Do not let diesel fuel or antifreeze stand on a painted surface If either should occur rinse the surface off with water To prevent rust have any nicks or other dam age on the finish touched up as soon as pos sible Park your vehicle in a sheltered area whenever possible Care of Fiberglass Parts Wash unpainted fiberglass air fairings and shields monthly with a mild detergent such as dishwashing liquid Avoi
3. The system features a speed governor for maximum vehicle speed control The governor can be set anywhere between 45 and 85 mph 70 and 140 km h and controls vehicle speed by cutting fuel delivery pressure when the pre determined speed is reached If this system is malfunctioning the lightbar overspeed light Fig 2 23 will flash on for ten seconds each time that the engine is started 2 18 Instruments and Controls Identification While driving the overspeed light will flash on if the driver exceeds a second predetermined speed set by the customer The system also controls several functions such as headlight high beam indicator Fig 2 23 low air pressure warning light and alarm and control for four optional features The optional features can be any combination of the following or any four that are spe cially ordered transmission temperature axle temperature engine heater alternator no charge fifth wheel lock parking brake sand antilock mirror heater utility lights axle lock sludge ejector Additional Features When the ignition is turned on all the LEDs in the lightbar will light and the low air and low oil pressure alarms will sound The lights and alarms will activate for two one second periods separated by a half second pause This is a self test to indicate whether or not the lightbar is working After the test the LEDs not in use will turn off The low air and oil pressure w
4. 2 y fa 6 7 Models bY 2 LW a 260327 260328 R Roj 4 RO 10 Speed ff 1 K 1 r Y peu ll EAR Standard d TI 57 8 10 f260329 260330 Eu T TS A 10 Speed 222 3 ub RMO rd m LA Vu Models 1 1 X37 X4 8 C839 1260331 260332 Table 8 3 Meritor Shift Progressions To upshift into high range with the transmission still in the highest low range gear move the range selector lever up to put the transmission into high range then partially depress the clutch pedal and move the shift lever into neutral As the shift lever passes through neutral the trans mission will automatically shift from low range to high range 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 IMPORTANT Never use the clutch brake when downshifting or as a brake to slow the vehicle Meritor Splitter and Range Shift Models Refer to the Meritor website for additional informa tion www arvinmeritor com General Information Meritor Splitter and Range Shift Combination splitter and range shift transmissions allow the choice of two splitter ratios in each lever position as well as the additional ratios provided in each lever position after shifting to the other range IMPORTANT Not all lever positions are used in each range and the shift patterns vary bet
5. Fig 8 7 Eaton Fuller 15 Speed RT RTO and RTX Model Transmissions Shift Patterns 8 8 Transmissions vehicle is moving Preselection with the range preselection lever must be made prior to moving the shift lever out of gear into neutral After your shifting ability improves you may want to skip some of the ratios This may be done only when operating conditions permit depend ing on the load grade and road speed Upshifting There are several patterns of upshifting depending on the vehicle load and the road conditions See Table 8 2 for suggested shifting sequences Deep reduction gears are best suited for heavy loads and steep inclines Low gear in 10 speed transmissions is best suited for off highway use The following instructions are recommended for start ing a loaded vehicle moving under adverse condi tions 1 Position the gear shift lever in neutral Start the engine and bring the vehicle air system pressure up to 100 to 120 psi 689 to 827 kPa Position the range preselection lever down into low range Move the deep reduction button to the forward position to engage the deep reduction gears Depress the clutch pedal to the floor Shift into low low gear 10 speed transmissions or 1st gear of deep reduction 15 speed transmissions then engage the clutch with the engine at or near idle speed to start the vehicle moving Ac celerate to 80 percent of engine governed speed For
6. The jaw and wedge each have a pin permanently attached The pin on the jaw and the pin on the wedge fit into elongated notches in the lock control handle The notches in the handle control the limit of movement for both the jaw and wedge The notches are arranged so that the wedge is actuated first dur ing release of the kingpin During lockup the jaw is moved first with the spring loaded wedge being allowed to slip in place against the jaw A timing bracket ensures that the wedge and jaw are moved at the proper time Placing the lock control handle in the unlocked posi tion moves the wedge away from the jaw This action unlocks the jaw so that it can be moved by the trailer kingpin When the tractor is moved out from under the trailer the kingpin moves the jaw until the kingpin is out of the mechanism With the jaw in the un locked position the lock control handle will remain in the unlocked position until manually moved by the operator During coupling Fig 10 18 the motion of the king pin entering the jaw will actuate the jaw and wedge The jaw will move behind the kingpin followed by the wedge The purpose of the wedge is to reinforce the jaw and take up slack around the pin Any wear on the jaw is immediately taken up by the wedge so there is no slack in the connection Fifth Wheel Locking Operation Locking the Fifth Wheel Lock Mechanism A CAUTION Before attempting to lock or unlock the fifth wheel lock mechanis
7. Fore and Aft Seat Adjustment Move the lever to the left and slide the seat forward or rearward to the desired position The slide range is 6 inches 15 cm Isolator Isolation is provided when the lever in the center po sition Move the lever to the right to lock out isola tion Seat Cushion Adjustment Move the lever downward to decrease or upward to increase seat cushion tilt There are five adjustment positions available Bostrom Talladega 900 Seat Fig 5 4 NOTE Two different sets of controls are used on Bostrom Talladega seats On some models the height adjustment lumbar support and damper adjustment are controlled by switches mounted to the bottom cushion On other models these controls are mounted to the seat frame Back Cushion Tilt To tilt the back cushion lean forward slightly to re move pressure from the cushion and hold the lever rearward Lean backward slowly to the desired posi tion and release the lever to lock the cushion in place Height Adjustment To raise the seat push the top portion of the switch To lower the seat push the lower portion of the switch Isolator To engage the isolator put the lever in the center position Lock out the isolator by moving the lever to the right 5 3 7 4 p Y M BE 2 4 N du 5 S 11 06 98 iid f910148a Back Cushion Tilt Lever Lumbar Support Control Switch Damper Adjustment Knob Height Adjustment Switch Bottom Cushion Tilt Adjustm
8. 10 12 Fifth Wheel Slide Operation 10 11 General Information 10 7 Back of Cab Grab Handles Steps and Deck Plate 3 5 Accessing Back of Cab Area 3 5 Exiting the Back of Cab Area 3 6 Baggage Compartment Doors 3 5 Battery Box Cover llle 3 6 Bendix Cruise Control System Optional s sses a riar arra y aS 7 20 Cruise Control Operation 7 20 General Information 7 20 Stationary Throttle Control Operation 4 slo club RR Rd e deg 7 20 Brake System l llle 6 1 Automatic Slack Adjusters 6 6 Brake System Operation LL 6 2 General Information LL 6 1 Meritor WABCO Antilock Braking System ABS 005 6 4 Bunk Maftiess 2nd ko ha ete Re IR 5 12 Cab Door and Sleeper Compartment Vents llle 3 3 Cab Door Locks and Handles 3 1 Cab Washing and Polishing lle 12 1 Cab to Sleeper Access llli 3 3 Canadian Motor Vehicle Safety Standard CMVSS Labels 1 2 Care of Chrome Parts 0 000 12 1 Care of Fiberglass Parts 12 1 Circuit Breaker Relay Panel 04 3 3 Gl tclies Ld ei a dom vac n rpm ae eR de 1s 7 22 Clutch Operation use irm Rs 7 22 General Information ls 7 22 Lubrication
9. 3 Make sure the fifth wheel top plate is tilted so the ramps are as low as possible If equipped with an air suspension make sure the air bags are completely inflated 4 Position the tractor so that the center of the fifth wheel is in line with the trailer kingpin The king pin should be in a position to enter the throat of the locking mechanism See Fig 10 12 Adjust the trailer landing gear so that the lower front trailer edge contacts the top surface of the tilted fifth wheel plate approximately 8 inches 20 cm before the fifth wheel center 5 With the fifth wheel lock opening aligned with the trailer kingpin back the tractor slowly toward the trailer making sure that the kingpin enters the 10 9 throat of the locking mechanism Continue back ward motion until positive lockup occurs 6 Apply the tractor parking brakes 7 Make a visual check even if equipped with the Touchloc air operated system for positive king pin lockup The trailer bed plate must be flush on the fifth wheel plate surface When positive lockup has occurred the fifth wheel operating rod will have moved inward to the locked posi tion and the safety latch will swing freely over the operating rod See Fig 10 14 NOTE Only when the operating rod is fully re tracted in the locked position will the safety latch be freely rotated down 8 Release the tractor parking brakes Test for king pin lockup by pulling on the trailer against the cho
10. hicles is a system that automatically stops and re starts the engine to accomplish the following Keep the engine oil temperature between 60 to 104 F 16 to 40 C Keep the battery charged Keep the cab or sleeper at a constant desired temperature if equipped with a thermostat The benefits of the system include reduced engine idle time fuel savings reduction of exhaust emis sions and noise increased starter and engine life and less chance of dead batteries due to electrical loads Optimized Idle operates in two modes They are the engine mode or the thermostat mode The engine mode keeps the battery charged and the engine oil temperature within factory set limits The thermostat mode is the same as the engine mode but also keeps the cab and sleeper at a constant preset tem perature The engine mode is always activated when the sys tem is operated The thermostat mode is activated when the thermostat is turned on The thermostat mode controls the set point which is the desired temperature of the cab and sleeper and the comfort zone which is the number of degrees from the set point before the engine needs to heat or 7 16 Engines and Clutches cool the cab There are three comfort zones 4 F 2 C 7 F 4 C or 10 F 6 C Vehicles equipped with Optimized Idle have a label and light on the dashboard The dash light is the bot tom one on the vertical array of lights in the center dash panel
11. its can be programmed by authorized personnel into the ECM personality module CT j x us CX K 1 2 x N NV x NC 20A Wann N QE A l aN 72 N E M d d NAN d 03 30 94 1600705 A If equipped with Jacobs engine brake controls the cruise switches may be installed here The location may vary depending on other vehicle options Fig 7 5 Cruise Control Switches Standard Location A WARNING Do not use the cruise control system when driv ing conditions do not permit maintaining a con stant speed such as in heavy traffic or on roads that are winding icy snow covered slippery or roads with a loose driving surface Failure to fol low this precaution could cause a collision or Engines and Clutches 05 23 95 1260316 Fig 7 6 Transmission Shift Knob Buttons loss of vehicle control possibly resulting in per sonal injury or property damage 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 1 To cruise at a particular speed 1 1 Flip the ON OFF switch on the instrument control panel to ON 1 2 Hold the throttle pedal until the speedom eter indicates the desired speed 13 Momentarily move the SET RESUME Switch on the instrument cont
12. locking the pintle hook open 10 17 3 Models 260 and 460 Back up the vehicle until the drawbar eye is over the pintle hook then lower the trailer Model 690 Back up the vehicle until the drawbar eye enters the open jaw contacts the back of the pintle hook and closes the coupling 4 Close the coupling Models 260 and 460 Push in on the pawl wedges and lift the pawl assembly The latch will drop into the closed position Lock the latch by lowering the pawl assembly Model 690 The pintle hook will automatically close and lock from the pressure of the drawbar eye against it Install the linchpin NOTICE Always make sure the connect hanger support keeps the trailer air hoses and electrical cables positioned so that they do not rub on anything Rubbing may wear through hoses or cables re sulting in air leaks or exposed or broken wires potentially affecting trailer brake or electrical sys tems 5 Hook up the trailer s electrical and air lines 6 Remove the chocks from the trailer s tires Trailer Release 1 Apply the truck and trailer parking brakes Do not use the trailer air supply for parking trail ers not equipped with spring parking brakes This applies the trailer service brakes only As air bleeds from the trailer brake system brake appli cation is lost This could allow the unattended vehicle to roll away possibly resulting in serious personal injury or death 2 Chock the front and rear tires
13. 3 7 and Fig 3 8 is located behind the dash skirt on the front wall of the cab To gain access to the relay panel turn the three access panel fasteners one quarter turn then remove the access panel Cab to Sleeper Access Place rigid or heavy objects in storage areas on the floor or under the bunk Sudden stops or swerves could cause personal injury if items fall from overhead storage shelves To open the sleeper access on vehicles with vinyl sleeper curtains unzip the sleeper curtains If de sired unsnap the curtains all the way around the sides and top and remove the curtains Vehicle Access 01 04 96 1540041a Fig 3 7 Circuit Breaker Relay Panel 02 26 99 e O 1542803 Trailer Marker Lights 9 Trailer Tail Lights 1 2 Left Headlight DRLs 10 Right Headlight 3 Turn Signal Flasher 11 HVAC 4 Voltmeter 12 Tractor Marker Lights 5 Ignition Switch Tail Lights 6 Horn Cigarette Lighter 13 A C Clutch 7 Brake Lights 14 Panel Lights 8 Dome Lights Fig 3 8 Circuit Breaker Layout detail To open the sleeper access on vehicles with velour sleeper curtains unfasten the snaps at one side then push the curtain to the opposite side Upper Bunk Access 70 Inch Raised Roof SleeperCab Grab handles are designed into the upper cabinets on each side of the 70 inch raised roof SleeperCab See Fig 3 9 There is a step built into the front of the passenger s side lower cabinet
14. Failure to fol low this precaution could cause a collision or loss of vehicle control possibly resulting in per sonal injury or property damage A 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 1 To cruise at a particular speed 1 1 Flip the ON OFF switch on the instrument control panel to ON 1 2 Hold the throttle pedal until the speedom eter indicates the desired speed 13 Momentarily move the SET RESUME switch on the instrument control panel to SET or push the SET button on the trans mission shift knob 2 To disengage the cruise control 2 1 Depress the brake pedal or clutch pedal or 2 2 Flip the ON OFF switch on the instrument control panel to OFF or push the PAUSE button on the transmission shift knob To resume a preselected cruise speed 3 1 If the ON OFF switch on the instrument control panel is in the OFF position flip it to ON 3 2 Momentarily move the SET RESUME Switch on the instrument control panel to RESUME or push the RESUME button on the transmission shift knob Cruise will return to the last speed selected To adjust cruise speed up or down hold the SET RESUME switch on the instru ment control panel at SET to accelerate or at RESUME to decelerate until the desired speed i
15. It then goes back to displaying the MPG If the engine sends more than one fault code the display blinks each fault code on and off three times and keeps repeating them for 60 seconds It then goes back to reading MPG To find out the engine problem look up the displayed num ber in your engine fault code list If you need to review the fault codes received simply press and release the Reset toggle switch to dis play the fault code history file The display shows h plus each fault code starting with the most recent for example h13 h27 h17 Each code blinks three times before showing the next code After showing all of the codes the display shows and then goes back to displaying MPG If there are no fault codes in the history file the display blinks four times and goes back to showing MPG The history file may be viewed at any time If there are multiple active fault codes they are sent sequentially by the engine databus The sequence repeats as long as the faults are not corrected Any code appears in the history file only once even though the sequence of codes is repeating If you view the history file several times in a short period of time the order of the codes may change depending on which code of the repeating sequence was sent most recently Engine Hour Meter Optional An engine hour meter records continuous operating hours of the engine and is mounted in the control panel In cases where actual mile
16. RPM match 5 Partially depress the clutch pedal and move the shift lever into 1st gear 6 Double clutch to continue upshifting until in fourth gear See Table 8 3 7 To upshift into high range with the transmission still in 4th gear push the range selection lever up to put the transmission into high range then partially depress the clutch pedal and move the shift lever into neutral As the shift lever passes through neutral the transmission will automati cally shift from low range to high range 8 Release the clutch pedal and let the engine slow until the road speed and engine RPM match 9 Partially disengage the clutch and move the shift lever into 5th gear Transmissions 10 To upshift from 5th gear into 5th overdrive flip the splitter control button up to the overdrive po sition then immediately release the accelerator and press and release the clutch pedal It is not necessary to move the shift lever when shifting from direct to overdrive the transmission will shift when synchronization with the engine s speed is reached Accelerate the engine only after the transmission has shifted 11 To shift from 5th overdrive to 6th direct partially disengage the clutch shift into 6th but before engaging the clutch flip the splitter control but ton down into the direct drive position then en gage the clutch and accelerate the engine Do not move the control button while the shift lever is in neutra
17. The high gear in the front section of the R ratio transmissions is used only as the top gear The remaining gear positions of the above transmissions are used once in the low range and once in the high range See Fig 8 16 for the shift patterns 8 16 Transmissions A AN F WE 3 1 A N Y 2 a a row 2 VE 03 13 96 A All Standard A and B Ratios Ratios 1 Up for High Range LOW B RMO Models with A and B B C 5 8 cs 6 8 4 Lo 4 N N 6 a m 5 gt 7 9 2 ALD 3 1260156a C All R Ratios 2 Down for Low Range Fig 8 16 Meritor 9 Speed Transmission Shift Patterns NOTE The 3rd 7th and 4th 8th shift positions in the standard A and B ratio transmissions both direct drive and overdrive are opposite of the RMO model overdrive only transmissions The R ratio transmissions have the 1st Sth shift po sitions where low is in the A and B ratio transmis sions The top gear in the R ratio transmissions is called 9th gear 10 Speed Models Meritor 10 speed transmissions have ten evenly spaced forward ratios Each transmission consists of a 5 speed front section and a 2 speed auxiliary sec tion The ten forward speeds are obtained by twice using a 5 speed shift pattern the first time in low range the second time in high range See Fig 8 17 for the shift patterns A B Hi 7 9 ni 1 10 Ko 2 4 bo 2 57 A N o N D 65 8 10 6 8 9
18. and RSX Models Meritor 9 Speed and 10 Speed M MO RS and RSX Model transmissions do not require use of the clutch except to start and stop the vehicle NOTE Meritor M and MO series ESS transmis sions are available only on vehicles equipped with either Caterpillar or Cummins electronic engines Meritor RS and RSX series ESS trans missions are only available on vehicles equipped with Detroit Diesel electronic engines The ESS system works with the engine fuel control system to automatically synchronize en gine rpm to road speed during gear changes Use the clutch only to start and stop the vehicle and to shift into Forward or Reverse The HI and LO ranges are automated so the driver does not have to select ranges A break torque feature allows the driver to move the shift lever and take the transmission out of gear without changing throttle position Throttle position can be maintained while braking and downshifting through the gears when stopping the vehicle as well as on steep grades The major components of the ESS system are the system switch shift intent switch input and output shaft speed sensors a Neutral position sensor and an electro pneumatic solenoid Operation ESS The ESS system collects and relays information per taining to the positions of the shift intent and system switches Fig 8 19 transmission input and output shaft speeds and shift lever position The informa tion is received by the engin
19. dard battery charger All standard battery charg ers supply at least 16 volts to the battery This will damage the gel cell IMPORTANT To recharge a gel cell see an au thorized Freightliner dealer or the instructions in 2 6 Instruments and Controls Identification Group 54 of the Heavy Duty Trucks Service Manual However the single gel cell like any other single bat tery has limited current supply capability and will drain down faster than a standard multiple battery installation that has no battery isolator system Avoid ultra deep discharging Repeated ultra deep dis charging of a gel cell will reduce its life significantly To protect against ultra deep discharging a low volt age warning alarm and indicator light activate when the battery voltage falls to 12 0 volts or less To si lence the alarm turn off all cab electrical loads or start the engine Fuel Tach Switch Optional The FloScan Fuel Tach is an electronic monitoring system that records fuel consumption and displays average miles per gallon The Fuel Tach gauge pro vides you with immediate feedback showing a per centage difference between the current fuel con sumption rate and the total trip miles per gallon average The system is controlled by a toggle switch See Fig 2 8 NG x ad J NN Z NC amp x 01 18 95 f600070b Fig 2 8 Fuel Tach Switch Optional With nonelectronically controlled engines the On position all
20. engaged and the only resistance to clutch pedal movement is the force of the return spring If clutch free pedal is 3 4 inch 20 mm or less measured at the pedal have the clutch adjusted A BA 02 09 95 1250148b A Free Pedal Fig 7 11 Clutch Free Pedal Free pedal should be included and commented on daily in the driver s report since clutch free pedal is the maintenance department s guide to the condition of the clutch and the release mechanism See Group 25 of the Heavy Duty Trucks Service Manual for clutch adjustment procedures and specifi cations A CAUTION Operating the vehicle with incorrect free pedal could result in clutch damage Clutch brake squeeze is an increased resistance greater than the force of the clutch spring felt as the clutch pedal approaches the end of its stroke If the gears grind when shifting into first or reverse gear with the clutch pedal fully depressed the clutch is out of adjustment or the clutch brake is worn and needs to be replaced Clutch Adjustments Clutches have an internal adjustment and external linkage adjustment See Group 25 of the Heavy Duty Trucks Service Manual for clutch adjustment proce dures and specifications CAUTION Operating the vehicle with the clutch improperly adjusted could result in clutch or clutch brake failure Lubrication The release bearing and linkage should be lubricated at frequent intervals See Group 25 of the Heavy
21. 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 96 currently referred to as CJ 4 oil The exhaust system in EPAO7 compliant vehicles is called the aftertreatment system ATS The ATS var ies according to engine manufacturer and vehicle configuration but instead of a muffler an aftertreat ment system has a device that outwardly resembles a muffler called the aftertreatment device ATD IMPORTANT See your engine operation manual for complete details and operation of the after treatment system Inside the ATD on Mercedes Benz Detroit Diesel and Cummins engines the exhaust first passes over the diesel oxidation catalyst DOC then it passes through the diesel particulate filter DPF which traps Soot particles If exhaust temperature is high enough the trapped soot is reduced to ash in a process called passive regeneration regen Passive regen eration occurs as the vehicle is driven normally under load the driver is not even aware that it is happening The harder an EPAO7 engine works the better it disposes of soot as the exhaust heat alone is enough to b
22. 10 Speed RTO Model Transmissions Shift Patterns Transmissions 15 Speed RT RTO and RTX Models Eaton Fuller 15 speed RT RTO and RTX model transmissions have a 5 speed front section and a 2 speed rear range section They also have five ad ditional deep reduction ratios The 5 speed front sec tion and the low and high range sections provide ten evenly and progressively spaced forward speeds The five deep reduction ratios are also evenly and progressively spaced however they do overlap the low range ratios and should be used only when op erating under adverse conditions See Fig 8 7 for the shift patterns noting that the 4th 9th and the 5th 10th shift positions in the RT direct ratio and RTX overdrive ratio transmissions are directly opposite in the RTO overdrive ratio transmissions Operation Deep Reduction IMPORTANT The shifter knob has an interlock feature that prevents the deep reduction button from being moved forward when the range pre selection lever is up in high range When in low range and the deep reduction button is in the forward position the range preselection lever cannot be moved up 1 For all driving conditions use the highest gear that is still low enough to start the vehicle moving with the engine idling and without slipping the clutch excessively Use the clutch brake to stop gear rotation when shifting into low low low 1st whichever is used as a starting ratio or reverse wh
23. 10 speed transmissions When ready for the next upshift move the deep reduction button rearward then break the torque on the gears by momentarily releasing the accel erator or depressing the clutch pedal Do not move the shift lever For 15 speed transmissions Shift upward from 1st gear of deep reduction to 5th gear of deep reduction double clutching be tween shifts and accelerating to 80 percent of engine governed speed See Table 8 2 When ready for the next upshift move the deep reduction button from the forward position to the rearward position then double clutch through neutral and move the shift lever to the 4th gear position in the low range Shift upward from low gear 10 speed transmis sions or 4th gear 15 speed transmissions to the top gear in low range Table 8 2 double clutching between shifts and accelerating to 80 percent of engine governed speed While in the top gear of the low range shift pat tern and ready for the next upshift flip the range preselection lever up into high range Double clutch through neutral and shift into the bottom gear in high range Table 8 2 As the shift lever passes through neutral the transmission will au tomatically shift from low range to high range Eaton Fuller Shift Progressions DEEP REDUCTION LOW RANGE HIGH RANGE TRANSMISSION zm F Adverse Conditions Off Highway and On Highway and Ideal MODEL A LA All Conditions Only Adverse Condition
24. 1270059 A Press the top portion engage the first position of the shift intent switch to begin an upshift B Press the top portion again engage the second position to break torque Fig 8 20 ESS Upshifting Using the Shift Intent Switch MSS SS NN NX A B 02 17 98 1270060 A Press the bottom portion engage the first position of the shift intent switch to begin a downshift B Press the bottom portion again engage the second position to break torque Fig 8 21 ESS Downshifting Using the Shift Intent Switch Starting the Vehicle 1 Ensure that the shift lever is in the neutral N position 2 Push the clutch pedal to the bottom of its travel to engage the clutch brake Start the engine Slowly release the clutch pedal 5 Allow the system air to build up to the range specified on the gauge 6 Release the parking brake Transmissions Shifting Into a Starting Gear CAUTION 2 Always use the proper starting gear Do not shift into neutral and coast as this will result in dam age to the transmission 1 Press the system switch down into the ON posi 3 tion to activate the ESS system 2 Press the top portion of the shift intent switch 1 6 Move the shift lever to the next higher gear To upshift through the rest of the gears repeat the substeps above Before each upshift push the top of the shift intent switch into the shift handle body to break to
25. 15 degree vertical by 15 degree horizontal beam pattern The radar beam of the CWS will detect near range cut ins of approximately 30 feet 9 meters or less depending on the angle of en trance into the lane in front of your vehicle A WARNING Heavy rain or water spray at the side sensor may temporarily prevent the system from providing adequate warnings Failure to drive safely and use the system prop erly could result in personal injury and or death and severe property damage NOTE A continuous fixed object on the right side of the vehicle such as a guard rail wall tunnel or bridge may cause the side sensor alert light to stay on In Case of Accident The optional vehicle accident reconstruction capabil ity provides two segments of system data one of which can be stored in system memory Push and hold the DDU range knob for at least 5 seconds to store the first segment Within 6 seconds the green SC indicator light will blink rapidly 8 times confirming that the data has been saved If the range knob is pushed again a fail tone will sound After the first segment is saved the second segment runs continu ously but only contains the last 10 minutes approxi mately of system data The system will cease re cording data 30 seconds after the vehicle comes to a stop NOTE Once the first memory segment is fro zen the other can t be frozen Only by discon necting the main CPU connector can the sec ond memory se
26. 18 speed transmissions Depress the clutch to the floor shift into low then engage the clutch with the engine at or near idle speed to start the vehicle moving To shift from low direct to low overdrive move the splitter control button Fig 8 5 into the over drive forward position then immediately release the accelerator Press and release the clutch pedal After releasing the clutch accelerate again For 13 speed transmissions Shift upward from low to 1st gear 2nd etc until 4th gear double clutching between shifts and accelerating to 80 percent of engine governed speed See Fig 8 4 For 18 speed transmissions Shift upward from low overdrive to 1st direct by first moving the splitter control button into the direct rearward position Fig 8 5 Move the shift lever double clutching to the 1st gear posi tion Continue upshifting through the shift pattern Double clutch during lever shifts 1st to 2nd to 3rd to 4th single clutch during split shifts 1st direct to 1st overdrive etc When in 4th gear 13 speed transmissions or 4th overdrive 18 speed transmissions and ready to shift up to 5th gear use the range shift lever as follows For 13 speed transmissions While in 4th gear pull the range shift preselec tion lever up into high range The transmission will automatically shift from low to high range as the shift lever passes through neutral Then dis engage the clutch double clutch
27. 2 5 tronic engines are controlled by a microprocessor based computer This computer controls specific en gine and vehicle speed modes of operation to maximize vehicle fuel economy and performance Vehicles with these engine systems have a yellow engine check light and a red engine stop light in the lightbar located above the speedometer and tachom eter With the ignition switch on both lights come on for about two seconds then if there is no problem with the engine system the lights will go out When ever there is a problem within the electronic engine System one of the lights will come on and stay on as long as the problem exists If the yellow engine check light comes on while driv ing some features will not work but the vehicle can still be driven If the red engine stop light comes on while driving and if the engine will not accelerate pull off of the road and shut down the engine In ei ther situation have the problem repaired as soon as possible With the CELECT IV system if the system is pro grammed to shut down the engine shuts down 30 seconds after the red engine stop light comes on The ignition switch will restart the engine after shut down but if the potentially damaging problem still exists the engine will operate at the reduced speed or torque level allowed just prior to shutdown To check whether a vehicle is equipped with CELECT or with CELECT IV see the vehicle service manual The cruise contro
28. 5 12 6 Steering and Brake Systems Staenmng SysISm eere tica kac RR ner E bbe EE AE CREE IEEE EEEREN cde REEF OHSS 6 1 Brake SYSE od o ebbe qe Kang hes Kusa uad iqq NOIRS A ue RI DEE E E ose 6 1 Steering and Brake Systems Steering System General Information When there is no load on the vehicle and the front tires are pointed straight ahead the steering wheel spokes should be at the 4 and 8 o clock positions 10 degrees See Fig 6 1 See Group 46 of the Heavy Duty Trucks Service Manual for steering ad justment procedures 05 24 94 1 8 0 Clock 1460307a 2 4 0o Clock Fig 6 1 Power Steering Wheel Position with tires pointed straight ahead CAUTION Never steam clean or high pressure wash the steering gear Internal damage to gear seals and ultimately the steering gear can result Manual Steering Gear Lubrication When operating in temperatures continuously below 30 F 1 C using the wrong type of lubricant in the steering gear could make the steering wheel difficult to turn To prevent trouble in cold temperatures be sure that the steering gear lubricant complies with the cold weather recommendations specified in Group 46 of the Heavy Duty Trucks Maintenance Manual A WARNING Failure to comply with the cold weather recom mendations could cause inadequate steering 6 1 control which could result in an accident and possible physical injury Power Steering System Th
29. 7 4 EPA Emission Control Labels 1 2 EPAO7 Exhaust Emissions 1 2 Vehicle Noise Emission Control Label serri trasa 848200 ew doe es 1 2 EPAO07 Aftertreatment System ATSI Lino doo ect Ad teet d dub Oe Ede d fel Ether Start System 22 0000000 7 5 Exterior Switches leen 2 31 Battery Disconnect Switch Optional siss sem ahi ck hw ae ho aces 2 31 Federal Motor Vehicle Safety Standard FMVSS Labels 1 1 Fireinthe Cab llle 13 4 In Case of a Cab Fire 13 4 Fontaine Fifth Wheels 0085 10 12 Fifth Wheel Locking Operation uus ole ak Gece a ear Re ee aves 10 13 Fifth Wheel Lubrication 10 17 Fifth Wheel Slide Operation 10 15 General Information LL 10 12 FrestiAM cud ius UR dor d e EURO ae UP E 4 4 G Glove BOX 2 252545 4644 o y Try REA 3 3 Grab Handles and Access SIGNS sch eaeoedigetheded ES ex ied ded 3 1 Entering and Exiting the Passengers Side llllsun 3 2 Entering the Drivers Side 3 2 Exiting the Drivers Side 3 2 H Hazard Warning Elghls bre RR 13 1 Heating Sleeper Heater and Air Gondillohner uu ee oo om Oe a LS BPSS 4 4 au ME CPP m 4 2 High Altitude Operation llle 7 19 CUMMINS scacsoecns r RR we ROS Hed ee RE Res 7 19 Holland Fifth Wheels ssl 10 1 Fifth Wheel Locking OPENAUGIE
30. Also a slip resistant step pad is located on the top right corner of the driver s side lower cabinet n 4 0448 95 D 1600917 Passenger s Side Grab Handle Lower Cabinet Step Lower Cabinet Step Pad Driver s Side Grab Handle PON gt Fig 3 9 Upper Bunk Access IMPORTANT Make sure the upper bunk is folded down and locked into place before at tempting to access the upper bunk Accessing the Upper Bunk Using the Passenger s Side Cabinets 1 Grasp the passenger s side upper cabinet grab handles one in each hand Reach up as far as is comfortable 2 Place your left foot in the step built into the pas senger s side lower cabinet and pull yourself up to a standing position 3 4 Vehicle Access 3 Swing your right hip over the bunk and use the grab handles and your left foot to push yourself backwards onto the bunk Accessing the Upper Bunk Using the Driver s Side Cabinets 1 Grasp the driver s side upper cabinet grab handles one in each hand Reach up as far as is comfortable 2 Place your right foot on the slip resistant step pad on top of the driver s side lower cabinet and pull yourself up to a standing position on top of the lower cabinet 3 Swing your left hip over the bunk and use the grab handles and your right foot to push yourself backwards onto the bunk Sleeper Door The sleeper door is not intended for entry or exit The door is intended only as a convenient means t
31. Battery Disconnect Switch Vehicle Access Ignition and Lock Key 12 awd br EREREERERREE REEL ER KR RE RR OEE REEDE RIT Y ERTES 3 1 Gab Door Locks and Handles 252p bxa doe sersan d EEbesa n de kide tiie kanea gi EE daa dis 3 1 Grab Handles and Access Steps 00 0c cece eee ees 3 1 Door Windows and Vent WIDUDINS duode iepckn nes BEC EEG 4d a6 Hes Heke E eR eee be nee 3 2 Cab Door and Sleeper Compartment Vents 000 3 3 COVE BR 666555554546 06004 PGE OGRE O54 64h Od SG Enee ESE eeii HOE EADLG COST ERES 3 3 Circuit Breakor Holay Panel lt ecsseved ee sdee des ERERAXZTERREEWERERRERRTEXEZTERRRRXWRREES 3 3 Gab kr SIBaDBI ACCESS ora ors dahon eh exe teenie ke bo cit ck cp x PR ROSS MEE EQ P Reames 3 3 Upper Bunk Access 70 Inch Raised Roof SleeperCab 0 ccc eens 3 4 Sleeper DOG couch peines doedeo E Krieg Hawes RS WESmqe a 4A QUE towns d UR pu au 5 E 3 5 Baggage Compartiment DOOIS esce ER RR EE E RRRRERETERREERRRETEREFERA TITRES 3 5 Back of Cab Grab Handles Steps and Deck Plate 0 eee eens 3 5 Battery Box COVEl cexevescetesege see Ra ESENE Sees eeeode rene ee bbe de eeee OL sea ered ene 3 6 Rood TUNG socre tou 6 06 S 0 rtn RRL ES OCHS E HG HEOO EER HE OHM OLES 6 EE eSEE UNO E Os 3 6 Windshield Washer Reservoir cee eee eee RR RR RR rn 3 7 Vehicle Access Ignition and Lock Key One key operates the ignition switch and all of the door locks for the cab sleeper box and glove
32. Certain special road situations may affect the sys tem s ability to detect objects These situations in clude the effects of curves dips and hills which can provide an unexpected result NOTE A warning may sound when an object is detected in front of the vehicle even though the driver intends to turn away or stop before reach ing the object When an object is detected in a very sharp right or left hand turn the audible alarm will not sound When approaching a curve before turning into it alarms may sound and lights illuminate be cause of an object off of the road directly in line with your vehicle This will not occur when the brakes are applied Elevated obstacles such as overpasses and overhead signs may be detected when ap proaching a roadway descending to a lower elevation Vehicles cannot be detected on the other side of a hill An alarm will not sound until the object is within the antenna assembly s field of view On approaching a steep hill objects above the beam cannot be detected Generally the beam hitting the road surface does not cause an alarm Instruments and Controls Identification The side sensor only detects objects within its field of view next to the tractor A vehicle far ther back behind the field of view will not be detected The side sensor range is set to detect average sized vehicles 2 to 10 feet 0 5 to 3 meters away in the adjacent lane The side sensor provides a
33. Charge the air brake system with air Make sure that the air connections do not leak 9 Retract the trailer landing gear and secure the ratchet handle 10 Remove the chocks from the trailer tires 11 The load distribution on the front steering axle and rear drive axle s will have a direct effect on the steering control of the vehicle Determine the front and rear axle weights by weighing the vehicle on scales designed for this purpose The maximum axle weight ratings are shown on the Federal Motor Vehicle Safety Standard FMVSS label or Canadian Motor Vehicle Safety Standard CMVSS label attached to the left rear door post of the tractor The desired load on the axle is no less than 80 percent of the maximum axle weight rating but in no instances should the axle load exceed the maximum axle weight rat ing given on the FMVSS or CMVSS label Do not overload any tractor axle by improperly loading the trailer This could cause erratic steer ing and loss of vehicle control possibly resulting in serious personal injury or death Unlocking the Fifth Wheel Lock Mechanism 1 Apply the tractor parking brakes 10 4 Fifth Wheels and Trailer Couplings 2 Pull the trailer air supply valve to cut off the air supply to the trailer 3 Chock the front and rear of the trailer tires to prevent the trailer from moving Do not use the trailer air supply for parking trail ers not equipped with spring parking brakes This a
34. Console DCC replaces the shift lever and controls the transmission s shift patterns On newer models the Smart Shift controller replaces the DCC If your ve hicle is equipped with a SmartShift controller see the information under the heading Freight liner SmartShift Transmission Shift Control The Standard DCC Fig 8 13 has indicators for the three forward positions Drive Low 2nd gear and Low1 1st gear plus Reverse and Neutral positions Service and wait lamps are also located on the console The gear select handle contains only a gear select lever detent button The Enhanced DCC Fig 8 14 has indicators for the three forward positions Drive Hold and Low plus Reverse and Neutral positions Service and wait lamps are also located on the Transmissions A 02 16 98 1270063 Console Top View Select Handle Side View Indicator Lamps Gear Position Indicator Detent Button on wp Fig 8 13 Standard Driver Command Console DCC N E D J WY ES do X 5 2 L 4 B A 02 16 98 270064 A Console Top View B Select Handle Side View 1 Indicator Lamps 3 Upshift Button 2 Gear Position 4 Detent Button Indicator 5 Downshift Button Fig 8 14 Enhanced Driver Command Console DCC console The gear select handle contains up shift and downshift buttons and a gear select lever detent button The shifter performs shifts at the front portion of the transmission It preselects the shift to
35. Continue downshifting from 4th overdrive to 4th direct then 4th direct to 3rd overdrive 3rd over drive to 3rd direct etc Single clutch when split shifting direct to overdrive overdrive to direct Double clutch when making lever shifts 4th to 3rd 3rd to 2nd etc IMPORTANT Never use the clutch brake when downshifting or as a brake to slow the vehicle Eaton Fuller Deep Reduction Models Refer to the Eaton website for additional information www roadranger com General Information Deep Reduction 10 Speed RTO Models Eaton Fuller 10 speed RTO model transmissions have a 5 speed front section and a 2 speed rear range section with a deep reduction gear The low low deep reduction gear is used only when operating under adverse conditions Low gear in the front sec tion is used only for rough off highway conditions as a starting ratio The remaining four forward positions are used once in the low range and once in the high range See Fig 8 6 for the shift pattern noting that the 3rd 7th and 4th 8th shift positions in the RTX LL transmissions are opposite of the RTO LL transmissions A 1 B Lo Hi 5 8 Lo Hi 5 7 CDR 4 y INB G C N i i N M Mei iow 6 7 D iow 6 8 IW 2 7 3 w 4 2 4 E lt F 03 13 96 f260026a A All RTO D Down for Low Range Transmissions E Forward for IN B All RTX Transmissions F Rearward for OUT C Up for High Range 1 Deep Reduction Button Fig 8 6 Eaton Fuller
36. 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 A CAUTION Do not attempt to shift gears without using the clutch when the cruise control is engaged Fail ure to follow this precaution will result in a tem porarily uncontrolled increase in engine speed transmission damage and gear stripping could result 1 To cruise at a particular speed 1 1 Flip the ON OFF switch to ON 1 2 Accelerate to the desired speed 1 3 Push the SET RESUME switch to SET NOTE The cruise control will not work below 20 mph 32 km h 2 To disengage the cruise control 2 4 Flip the ON OFF switch to OFF or 2 2 Depress the brake pedal or 2 3 Allow vehicle speed to drop below 20 mph 32 km h To resume the preselected cruise speed briefly push the SET RESUME switch to RESUME Cruise will return to the last speed selected NOTE The resume vehicle speed memory is not maintained if the ignition is shut off or if the ON OFF switch is flipped to OFF Cruise speed can be adjusted up or down by push ing the RESUME accelerate or SET decelerate switch until the desired speed is reached The vehicle can be accelerat
37. Duty Trucks Maintenance Manual for intervals and procedures CAUTION Failure to lubricate the release bearing and link age as recommended could result in release bearing and clutch damage 7 24 Transmissions Eston Fuller Straight Stitt Models ixi REX EAT ERR KE Rue E RA ERO ROCA Re ER EUER 8 1 Eaton Fuller RHange Shit Models sio spueskecetreethESRESe tU EAS RERespEISFREA deg EE 8 2 Eaton Fuller Splitter and Range Shift Models 0 0000 eee ee 8 4 Eaton Fuller Deep Reduction Models 0 0 cee EREC EEE 8 7 Eaton Fuller Super 10 Top 2 and Lightning Semi Automated Transmissions 8 10 Eaton Fuller AutoShift Automated Transmissions 000 cee eee eee eee eee 8 13 Spicer Straight Shift Models iue E Rr ERR RR E RR REFERRE ET RKRIUEKER ERE RR ERE 8 15 Meritor Range Shit Models i6 dens kd RRRRUDP LARA RO RO FERRE ERR E FERRI S LER REREEP EE RES 8 16 Meritor Splitter and Range Shift Models sssleseeeeeelee ere 8 18 Meritor Engine Synchro Shift ESS Automated Models 0 000 cece eect eee ees 8 20 Transmissions Eaton Fuller Straight Shift Models Refer to the Eaton website for additional information www roadranger com General Information Eaton Straight Shift Eaton Fuller straight shift model transmissions are not synchronized They have seven forward speeds and one reverse speed See Fig 8 1 for the shift pattern They are designed for use
38. E ge de f Ras 2 17 VIGIL III Warning System Optional x2 ecom eR x ERR 2 18 Windshield Washer Reservoir 3 7
39. Engines and Clutches 09 21 2006 1610844 Fig 7 4 Request Inhibit Regen Switch CAUTION When starting a vehicle equipped with a manual transmission and clutch lockout switch the clutch pedal must be fully depressed during the entire start sequence Failure to do so can cause the pinion to release and re engage which could cause ring gear and starter pinion damage If a vehicle does not start on the first attempt make sure that the engine has completely stopped rotating before reapplying the starter switch Failure to do so can cause the pinion to release and re engage which could cause ring gear and starter pinion damage Moving a vehicle with the starter and or using the starter to bump the engine for maintenance pro cedures is strictly prohibited Use of these meth ods to bump the engine over or move the vehicle can cause the pinion to release and re engage which could cause ring gear and starter pinion damage IMPORTANT Ring gear and starter pinion dam age caused by improper starting procedures is not warrantable Caterpillar NOTE Before starting the engine read Chap ter 2 in this manual for detailed information on how to read the instruments and operate the controls 7 3 The information below contains guidelines for cold weather starting For additional information refer to Ether Start System Do not use any starting aid such as ether in en gines with an intake air preheater
40. Fig 5 2 Bostrom Air 715E High Back Seat Lumbar Support Move the lever forward or backward for more or less lower back support there are three positions to choose from Isolator Lockout To engage the isolator put the lever in the center position Lock it out by moving the lever to the right Height and Weight Adjustment There are 4 inches 102 mm of ride zone motion plus 2 inches 51 mm of height adjustment Pull the lever up to raise the seat and push the lever down to lower it The seat should be no less than 2 inches 51 mm from either the top or bottom position Seat Tilt Pull the lever up and the back and bottom cushions may be moved forward or backward by shifting your weight Bostrom Air 915 Seat Fig 5 3 Lumbar Support Adjustment Move the lever forward to increase lumbar support Move the lever rearward to decrease lumbar support Y 1 5 F N Ve E 04 16 96 Lumbar Support Adjustment Lever Back Cushion Tilt Lever Height Adjustment Knob Fore and Aft Seat Adjustment and Isolator Lever Seat Cushion Adjustment Lever f910146 o RON Fig 5 3 Bostrom Air 915 Seat Back Cushion Tilt Hold the lever rearward and lean forward or rearward to the desired position then release the lever 5 2 Seats and Seat Belts Height Adjustment Push the knob in to inflate the suspension and raise the seat height Pull the knob out to deflate the sus pension and lower the seat
41. Fuel Gauge Fuel Tach Engine Brake Switches Trailer Air Supply Valve Parking Brake Control Valve Fifth Wheel Air Slider Control Valve Switch Interaxle Differential Lockout Control Valve Switch Transmission Oil Temperature Gauge Forward Differential Oil Temperature Gauge Rear Differential Oil Temperature Gauge Engine Oil Temperature Gauge Turbocharger Boost Pressure Gauge Fuel Pressure Gauge Automatic Engine Idler Timer Intake Air Restriction Gauge Digital Clock Radio optional Fig 2 2 Instrument and Control Panel Layout upper dash EPA07 02 02 95 NOTE Instruments and controls and their locations may vary from those shown Ignition Switch Engine Start Button Engine Shutdown Override Button Mirror Heat Switch Right Side Power Mirror Fog Light Switch Utility Light Switch Panel Light Control Knob ON OO PONS Headlight Parking Light Switch Marker Light Taillight Interrupt Switch Windshield Wiper Washer Control Knob Intermittent delay Wiper Control Knob Auxiliary Heater Fan Switch Heater Air Conditioner Fan Switch Airflow Lever Slide Control Temperature Lever Slide Control Fig 2 3 Instrument and Control Panel Layout lower dash 2 2 Instruments and Controls Identification x z x IGNITION ENGINE START OVERRIDE MIRROR HT RH PWR MIRROR NS Does BA 4 5 x x 01 18 95 f600068a Ignition Switch Engine Start Bu
42. Light Oil Pressure Warning Light Low Water Warning Light Water Temperature Warning Light Engine Shutdown Light High Beam Indicator Light Low Air Pressure Warning Light ONDIN Right Turn Signal Light Fig 2 22 VIGIL Il and Kysor VIP Warning System Optional Engine Functions The system monitors engine coolant temperature coolant level and oil pressure e f the engine overheats a warning light comes on and a buzzer sounds The temperature that triggers the warning light and buzzer varies with engine type and is programmed into the system at the factory If the temperature contin ues to rise to critical levels the engine shut down light comes on and the engine will be shut down If the coolant level drops below a sensor in the cooling system the low water level light comes on After 5 seconds a buzzer sounds and after 30 seconds the system will shut down the engine If the oil pressure drops below a preset level the low oil pressure light comes on and a warning buzzer sounds If the oil pressure drops to a preset critical level the engine shut down light comes on and the engine will be shut down All shutdown features have an automatic over ride If the vehicle needs to be moved to a safe location after a shutdown just crank the en gine It will run for about 30 seconds before shutting down again Turn Signal Functions The system operates the turn signal relay and the in dicators Oth
43. MANUAL INCORPORATED INTO This VEHICLE IN COMPLIANCE WITH THE NOISE CONTROL ACT B THE USE THIS VEHICLE AFTER SUCH DEVICE OR ELEMENT OF DESIGN HAS BEEN REMOVED ORRENDEREDINOPERATIVE awe 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 EPAO07 Exhaust Emissions To meet January 2007 emissions regulations ve hicles with engines manufactured after January 1 2007 are equipped with an emission aftertreatment device There is a warning label on the driver s sun visor explaining important new warning indicators in the driver s message display that pertain to the after treatment system See Fig 1 8 Vehicle Identification EXHAUST AFTERTREATMENT SYSTEM INFORMATION INDICATOR WARNING LAMP S Level 2 Level 3 Indicator Lamp Filter Regeneration Filter Regeneration Parked Regeneration Parked Regeneration Required HEST High Exhaust Message s Recommended Necessary Required Engine Engine Shut Down System Temperature Derate Diesel P Filter is reaching Filter is now ilter has reached Filter has exceeded Flash Filter Condit
44. Maintenance 2 3 2 4 Tighten hose clamps as necessary but do not overtighten as hose life can be ad versely affected 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 contact your Freight liner Dealer 3 Check the steering wheel for excessive play 3 1 3 2 3 3 With the front tires straight ahead turn the steering wheel until motion is observed at the front wheels Align a reference mark on a ruler then slowly turn the steering wheel in the oppo site direction until motion is again detected at the wheels Measure the lash free play at the rim of the steering wheel Excessive lash exists if steering wheel movement exceeds 2 1 4 inches 57 mm with an 18 inch 450 mm steering wheel If there is excessive lash check the steer ing system for wear or incorrect adjust ment of the linkage and steering gear be fore operating the vehicle 4 Check the brake lining wear on all vehicles in cluding those with automatic slack adjusters Proper brake operation is dependent on periodic maintenance and inspection of the brake l
45. OFF or press the PAUSE button on the shift knob 3 To resume a previously selected engine speed 3 1 If the ON OFF switch on the instrument control panel is in the OFF position flip it to ON 3 2 Momentarily move the SET RESUME switch on the instrument control panel to RESUME or press the RESUME button on the transmission shift knob 3 3 To adjust engine speed up or down hold the SET RESUME switch on the instru ment control panel at SET to accelerate or at RESUME to decelerate until the desired speed is reached or press the SET button on the transmission shift knob to acceler ate or the RESUME button to decelerate until the desired speed is reached NOTE The resume engine speed memory is not maintained if the cruise control ON OFF switch is turned OFF or if the ignition is shut off Detroit Diesel Engine Operation Individual driving habits can make a difference in the performance and economy of any engine The rec ommendations below call attention to the techniques that can be employed to save fuel and extend the operating efficiency and life of a new Detroit Diesel engine for the longest possible time 7 13 All engines have an operating range in which the en gine performs most efficiently The operating range extends from maximum torque rpm at the low end to engine rated speed at the high end Detroit Diesel engines deliver best fuel economy when operated in the low and mid speed segments of the efficiency rang
46. ON 3 2 Momentarily move the SET RESUME switch on the instrument control panel to RESUME or push the RESUME button on the transmission shift knob Cruise will return to the last speed selected To adjust cruise speed up or down hold the SET RESUME switch on the instru ment control panel at SET to accelerate or at RESUME to decelerate until the desired speed is reached or press the SET button on the transmission shift knob to acceler ate or the RESUME button to decelerate until the desired speed is reached Engines and Clutches NOTE The resume vehicle speed memory is not maintained if the ignition is shut off or if the ON OFF switch is off for more than 10 seconds Power Takeoff PTO A power takeoff option is available for vehicles equipped with a DDEC system The PTO operates only when the vehicle is at a standstill Some vehicles have separate controls for the PTO In the case of a preset nonadjustable PTO engine speed there is only an on off switch labeled FAST IDLE If the vehicle is equipped with a variable PTO engine speed there are two controls an on off switch and a potentiometer knob Both of these are labeled GOVERNOR On other vehicles the PTO mode is activated by the ON OFF and SET RESUME cruise control switches located on the instrument control panel on the dash Fig 7 5 or by optional PAUSE RESUME or SET buttons on the transmission shift knob Fig 7 6 1 Operating the PTO With Separate P
47. Transmission Shift Pattern Operation Spicer Straight Shift 1 Always use 1st gear when starting to move the vehicle forward 2 Use the clutch brake to stop gear rotation when shifting into 1st or reverse when the vehicle is stationary The clutch brake is actuated by de pressing the clutch pedal all the way to the floor For normal upshifts and downshifts only a partial disengagement of the clutch is necessary to break engine torque 3 Double clutch only when shifting out of neutral or when shifting down into 1st Upshifting 1 Position the gear shift lever in neutral then start the engine Bring the air system pressure up to 100 to 120 psi 689 to 827 kPa 2 Press the clutch pedal to the floor Shift into 1st gear then engage the clutch with the engine at or near idle speed to start the vehicle moving Accelerate to engine governed speed 3 Once governed speed has been attained disen gage the clutch enough to break torque and move the shift lever to 2nd gear Then engage the clutch and accelerate back to engine gov erned speed 4 Continue shifting upward using the same se quence described in step 3 above See Fig 8 15 for the shift pattern Downshifting When downshifting shift progressively down through each successive lower gear as follows 1 Depress the clutch pedal enough to release the torque shift into the next lower gear and engage the clutch smoothly while accelerating the engine to
48. air cylinder underneath the top plate The air cylinder activates the operating rod The op erating rod is located on the left side of the fifth wheel for Castloc Il and Simplex II fifth wheels and on the right side for the Simplex fifth wheel assem bly On sliding fifth wheels the top plate is mounted on a sliding saddle plate which slides along the baseplate attached to the tractor frame The baseplate rails allow forward and rear movement of the slide assem bly for optimum weight distribution over the tractor axles Tapered slots in the baseplate rails aligned in 4 inch 102 mm increments provide for location of the fifth wheel along the baseplate Retractable spring actuated lockpins are positioned through the slots to hold the fifth wheel in the desired position The lock pins are retracted either manually or by an air operated cylinder controlled from the cab The manually operated slide contains an operating rod Fig 10 11 which unlocks both sides of the plate at the same time The air operated sliding saddle plate contains an air cylinder which moves the operating lever to unlock both sides of the plate at the same time The air cyl inder is activated by a two position air control valve in the tractor cab Fifth Wheels and Trailer Couplings Fifth Wheel Lock Mechanism for Trailer Kingpin Fig 10 12 04 08 96 1310446 Locked Position Jaw movement compresses spring Fully open Operating Le
49. are connected to a trailer and the pressure in both air systems is at least 65 psi 448 kPa the red knob must be pushed in It should stay in to charge the trailer air supply system and to release the trailer spring parking brakes it must be pulled out before disconnecting a trailer It must also 6 3 be pulled out when operating a vehicle without a trailer If pressure in both air systems drops to 35 to 45 psi 242 to 310 kPa the red knob automatically pops out exhausting the trailer air supply and apply ing the trailer service or spring parking brakes PUSH TO SUPPLY AND RELEASE M TRAILER NON BRAKES TRACTOR ONLY PARKING BRAKES PULL PARKING BRAKES CONTROL THEN PUSH TRAILER AIR CONTROL 08 27 93 1 Trailer Air Supply Valve Knob 2 Parking Brake Valve Knob 600503 Fig 6 3 Trailer Air Supply Parking Brake Control Panel The yellow diamond shaped knob Fig 6 3 in the control panel actuates the parking brake valve Pull ing out the knob applies both the tractor and the trailer spring parking brakes and automatically causes the trailer air supply valve knob to pop out CAUTION Do not use the spring parking brakes if the ser vice brakes are hot such as after descending a steep grade Also do not use the spring parking brakes during freezing temperatures if the ser vice brakes are wet To do so could damage the brakes if hot or cause them to freeze during cold weather If t
50. brackets are secure Check exhaust system mounted securely connected tightly no signs of leaks such as uu soot trails Remove chocks and test service brakes D25 Inspector Date Table 11 1 Daily Pretrip Inspection and Maintenance Checklist 11 2 Pretrip and Post Trip Inspections and Maintenance dico P Weekly Post Trip Inspections Checks pecan Manually drain air reservoirs that are equipped with automatic drain valves Inspect batteries and battery cables W1 Check wheel bearing lubricant level W2 Inspect steering components W3 Check serpentine drive belt condition W4 Check V belt tension W5 Inspect seat belts and tether belts W6 Inspector Date Table 11 2 Weekly Post Trip Inspection and Maintenance Checklist dis P s Monthly Post Trip Inspections Checks sessi Clean the battery terminals M1 Inspect radiator hoses and heater hoses M2 Check fluid level in the hydraulic clutch reservoir if applicable and if necessary fill with DOT 4 brake fluid Check steering wheel play M3 Check outer surfaces of the hood and body for visible surface breaks and damage Check hood tilt damper attached at both ends Inspect brake lining wear M4 Inspect driveshaft Inspector Date Table 11 3 Monthly Post Trip Inspection and Maintenance Checklist Pretrip and Post Trip Maintenance Procedures Whenever equipment requires adjustment r
51. by downshifting too soon or missing the full use of a gear by downshifting too late The shift points of any vehicle can be determined by a simple road test method Run the vehicle and determine the maximum road speed possible in every gear at the engine governed full load speed setting The top road speed possible in a gear would be the shift point for that gear The results should be recorded in the proper order of shifting and dis played inside the cab CAUTION Do not allow the engine to exceed its governed speed or serious engine damage could result T To slow the vehicle on downgrades and curves using the engine shift to a lower gear and allow the vehicle to decelerate in that gear The engine provides maximum braking effect when running at the top end of the operating range but it must not be allowed to exceed its full load rated rpm Continue to downshift as further re duction in vehicle speed is required If the ve hicle is above the allowable maximum speed of a lower gear use the service brakes to slow the vehicle to an acceptable speed where the trans mission may be downshifted safely Again the importance of knowing the shift points is demon strated IMPORTANT The engine governor has no con trol over engine rpm when the engine is being pushed by a loaded vehicle down a grade Use service brakes and gears in combination on 7 14 Engines and Clutches low this precaution could cause a collision
52. contacts and rotates the jaw into the locked position This action automatically moves the operating rod into the locked position This securely locks the jaw around the kingpin In the locked position the safety latch swings freely over the operating rod See Fig 10 14 Fifth Wheel Locking and Unlocking Locking the Fifth Wheel Lock Mechanism 1 Chock the front and rear of the trailer tires to prevent the trailer from moving CAUTION Before attempting to lock the fifth wheel lock mechanism of a sliding type fifth wheel the slide locking handle Fig 10 11 must be in the locked position This prevents the sliding member from 10 8 Fifth Wheels and Trailer Couplings 11 18 94 1 Safety Latch 1310448 2 Operating Rod Fig 10 14 Simplex Kingpin Locking Mechanism Safety Latch locked position moving rapidly to the far forward or rearward po sition which could damage the fifth wheel mem ber or kingpin 2 The fifth wheel jaw must be fully open Make sure that the operating rod is in the unlocked po sition The fifth wheel must be completely lubri cated with chassis or multi purpose grease For lubrication instructions see Group 31 of the Heavy Duty Trucks Maintenance Manual Keep the fifth wheel plate lubricated to prevent binding between the tractor and trailer A binding fifth wheel could cause erratic steering and loss of vehicle control possibly resulting in serious personal injury or death
53. device an engine malfunction indicator light MIL a diesel particulte filter DPF regen light and a high exhaust system temperature HEST light Details of the after treatment lights can be found in Chapter 7 under the heading EPAO07 Aftertreatment System ATS The other standard lights are the parking brake indi cator light and two antilock braking system ABS lights The other lights are for optional functions that may not be installed on all models Parking Brake Indicator Light The red parking brake indicator light Fig 2 19 comes on whenever the parking brakes are activated and the ignition is on Additional optional lights may be installed in the cen ter dash Instruments and Controls Identification 10 26 98 1600769b Parking Brake Indicator Light Tractor ABS Warning Light Wheel Spin Indicator Light Trailer ABS Warning Light Left Turn Signal Light Oil Pressure Warning Light Low Water Warning Light Water Temperature Warning Light High Beam Indicator Light Low Air Pressure Warning Light Right Turn Signal Light Tachometer 000020Ov gomr Speedometer Fig 2 19 Dash Assembly for VIGIL and Kysor Warning Systems Pre EPA07 Meritor WABCO Antilock Braking System ABS The Meritor WABCO Antilock Braking System ABS may have up to three of the following amber lights the first two are standard a tractor warning light TRAC ABS a wheel
54. disconnect possibly resulting in se rious personal injury or death 10 With the trailer wheels chocked and the brakes set check for clearance between the kingpin and the fifth wheel jaws by moving the tractor forward and backward against the locked kingpin There should be no slack between the tractor and the trailer If slack is present uncouple the trailer For adjustment instructions refer to the appli cable manufacturer s service information 10 14 Fifth Wheels and Trailer Couplings 11 Retract the trailer landing gear and secure the ratchet handle Remove the chocks from the trailer tires 12 The load distribution on the front steering axle and rear drive axle s will have a direct effect on the steering control of the vehicle Determine the front and rear axle weights by weighing the vehicle on scales designed for this purpose The maximum axle weight ratings are given on the Federal Motor Vehicle Safety Standard FMVSS label or Canadian Motor Vehicle Safety Standard CMVSS label attached to the left rear door post of the tractor The desired load on the axle is no less than 80 percent of the maximum axle weight rating but in no instances should the axle load exceed the maximum axle weight rat ing given on the FMVSS or CMVSS label Do not overload any tractor axle by improperly loading the trailer This could cause erratic steer ing and loss of vehicle control possibly resulting in serious personal in
55. ek peas Gag a ado ge Med Pd same Foreword beraten ae ae wee Gace Pale wae paar a 1 1 Instruments and Controls Identification llle 2 1 Vence ACCESS d p seep Gaye Shane ae eos te dag aid ag ae a are 3 1 Heater and Air Conditioner 0 ccc ee eee eee ene eens 4 1 Seatsand Seat DONS Ree 5 1 Steering and Brake Systems 0 0 0c cece eee 6 1 Engines and Cl tthes LEBER 7 1 THANSIMISSIONS CD a Whee tla a a di ate bd a a a E da Ea 8 1 ROILAKIES quusddoseaca soo oe ex x e n Rein e e E a E EE er era A 9 1 Fifth Wheels and Trailer Couplings sseeseeseen kB 10 1 Pretrip and Post Trip Inspections and Maintenance slllssss 11 1 Cab Appearance cadeau ded oon aO dca dic CR ded tig Baer X ded og eR ode de RR Ca 12 1 inen EIE aereas Voss euni Ud Svid oe Seen eda ee doi b b ERE ACE 13 1 o A rU 1 1 Vehicle Identification Federal Motor Vehicle Safety Standard FMVSS Labels Canadian Motor Vehicle Safety Standard CMVSS Labels 00 00 cee eee eee 1 2 Tire and Rim Labels EPA Emission Control Labels Vehicle Identification Vehicle Specification Decal The vehicle specification decal Fig 1 1 lists the ve hicle model identification number and major compo nent models It also recaps the major assemblies and installations shown on the chassis specification sheet One copy of the specification decal is at tached to the inside of the glove box
56. engaged for prolonged periods Use only when additional traction is needed under adverse road conditions Disengage the interaxle differential lockout before shifting the axle to a higher range When the interaxle differential lockout control valve is in the UNLOCK position the interaxle differential al lows differential action between the axles thereby compensating for different wheel speeds and varia tions in tire size Keep the interaxle differential lock out in the UNLOCK position for normal driving on roads where traction is good On 2 speed axles the interaxle differential must be in the UNLOCK position before attempting to shift the axles out of low or high range 9 4 10 Fifth Wheels and Trailer Couplings Holland Fifth Wheels 0000 lh 10 1 ASF Castloc I and Simplex Series Fifth Wheels lees 10 7 Fontaine Fifth Wheels 6 26 cc s00 00 506080 ee Rm RR ex RR RS ERRARE RR wens 10 12 Premier Trailer Couplings ci 60ee eee RAE ERR RUE ERE CER ERE EE REFEESA e Pesan ee 10 17 Holland Trailer Coupling Fifth Wheels and Trailer Couplings Holland Fifth Wheels General Information The 2535 and 2536 sliding fifth wheel models incor porate a Model FW8 3500 or 3600 fifth wheel Fig 10 1 equipped with an air operated release slide a double manual release slide or a single manual release slide Sliding fifth wheel assemblies are mounted on a baseplate which permits forward and rea
57. exhaust air from the suspension move the switch to LOWER A guard is positioned around the switch to prevent it from being accidentally activated CAUTION Never exhaust air from the suspension while driving If the air is exhausted the suspension will not absorb road shocks and could be dam aged 2 10 Instruments and Controls Identification ptus TRAILER gt D gt PARKING AS PX BRAKES P eU MUST BE APPLIED SUSPENSION AIR LOWER AUTO 01 18 95 f600545a Fig 2 14 Air Suspension Dump Valve Switch Optional AirLiner Plus Suspension Optional The AirLiner Plus suspension is used on vehicles with pusher or tag axles to improve traction perfor mance The system maintains an accurate leveling of frame height whether the vehicle is in motion or parked The Meritor WABCO ECAS Electronically Controlled Air Suspension system uses a height sensor mounted between the frame and the drive axle housing as well as other sensors to provide frame height information to a control unit mounted inside of the cab The electronic control unit quickly lowers or raises the frame height as necessary Al tering the height of the frame while the vehicle is parked can be performed using a hand held remote control unit Stand away from the rear of the vehicle when raising or lowering the height of the frame The ECAS system operates quickly and contact could result in personal injury For the optional automati
58. facilitate safe climbing up or down Accessing Back of Cab Area When climbing onto the deck plate use the grab handle and access steps see Fig 3 11 as follows 1 Facing the center of the deck plate grasp the grab handle with both hands Reach up as far as is comfortable 2 Place one foot on the bottom step and pull your self up 3 Place your other foot on the top step Vehicle Access 4 Move your lower hand to a higher position on the grab handle 5 Step onto the deck plate Exiting the Back of Cab Area When climbing down from the deck plate use the grab handle and access steps as follows 1 Facing the center of the deck plate grasp the grab handle with both hands Step one foot at a time to the top step Move your upper hand to a lower position on the grab handle 4 Move one foot to the bottom step Move your upper hand to a lower position on the grab handle 6 Step to the ground with your upper foot first Battery Box Cover To remove the battery box cover pull on the end of each holddown latch until the end clears the cover mounted catch See Fig 3 12 Pivot the latches out of the way then lift off the cover When installing the cover be sure it is positioned properly before fasten ing the latches Hood Tilting The hood can be tilted to a full open position A grab handle at the front of the hood provides a hand hold for hood tilting See Fig 3 13 Tilt assist springs FLD 1
59. feature A traction equalizer provides nor mal differential action where traction is good When one wheel begins to spin faster than the other clutch plates in the differential housing automatically en gage delivering power to both wheels There is no operator control with this feature A traction equalizer occasionally tends to slip in a jerking motion producing irregular intervals of sharp noises This generally occurs when the vehicle is op erating at low speeds on fairly sharp turns This con dition called slip stick is corrected by adding a fric tion modifier to the axle lubricant This additive tends to reduce the static coefficient of friction to a value equal to or lower than the sliding coefficient See Group 35 of the Heavy Duty Trucks Mainte nance Manual for additional information on friction modifiers and when to add them to axle lubricants A CAUTION Tire sizes on both rear wheels should be the same on axles equipped with a traction equalizer If not excessive wear may occur in the traction equalizer Meritor Drive Axles With Main Differential Lock The Meritor main differential lock is a driver controlled traction device operated from the vehicle cab A switch allows the driver to lock or unlock the differential An indicator light on the instrument panel comes on when the differential lock is engaged An optional buzzer can also be used to indicate differen tial lock engagement The main differential
60. for Caterpillar and Cummins engines or 20 inH O for Detroit Diesel engines See Group 09 of the Heavy Duty Trucks Service Manual for filter element replacement instructions or take the vehicle to an authorized Freight liner dealer NOTE After replacing the filter element reset the restriction indicator by pressing the rubber reset button 6 3 Inspect the secondary or safety filter ele ment in the air cleaner when replacing the primary element and replace it when clogged or dirty This element should be replaced with every third primary element replacement 6 4 Check the engine air intake piping from the air cleaner to the engine intake In spect the piping for loose connections cracks torn or 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 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 2 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 A CAUTION Operating the engine with the oil level below the minimum fill or add mark o
61. func tions It can also be used to set desired tem perature values 1 Activate Optimized Idle engine mode as fol lows 1 1 Set the parking brake 1 2 If it is tilted close and secure the hood 13 Start the engine and let it idle 1 4 Put the transmission in neutral and in the high range if so equipped 1 5 Turn on the cruise control IMPORTANT The cruise control must be turned on after the engine is idling If it was previously turned on turn off the cruise con trol then turn it on again 1 6 The dash light will begin blinking indicat ing that Optimized Idle is active The sys tem is now in the engine mode and after an initial phase in which the idle speeds up to 1000 or 1500 rpm depending on the outside temperature the engine will stop and start automatically to keep the battery charged and the engine oil warm The dash light stays on and shines steadily at this point 2 Activate the thermostat mode if so equipped as follows NOTE When the system is in the thermostat mode it is also in the engine mode It will continue to operate in the engine mode even if the thermostat mode is turned off Engines and Clutches 2 1 With the system in the engine mode set the cab and sleeper heater or air condi tioner controls to the highest setting 2 2 Turn on the thermostat by touching any of the four buttons See Fig 7 9 The display will flash the current sleeper temperature and the previous m
62. help to stay within the regulations Proper maintenance of the engine which is the re sponsibility of the owner operator is essential to keep the emission levels low Follow the directions in the Cummins Operation and Maintenance Manual and this manual for trouble free economical vehicle engine operation 1 Cummins diesel engines produce high horse power and peak torque characteristics at lower rpm Because of this it is not necessary to keep the engine wound up to deliver the required horsepower at the wheels These characteristics may also result in less shifting and make shifting at lower rpm to peak torque more practical 2 Depending on the vehicle gearing the posted speed limit can sometimes allow operation in ei ther of the top two gears however for improved operating efficiency fuel economy and engine life operate in the top gear at reduced rpm rather than in the next lower gear at the maxi mum rpm 3 Cruise at partial throttle whenever road condi tions and speed requirements permit This driv ing technique permits operating within the most economical power range of the engine 4 When approaching a hill open the throttle smoothly to start the upgrade at full power then shift down as desired to maintain the maximum vehicle speed The higher torque of Cummins engines may permit topping some grades without shifting 5 Cummins engines are designed to operate over a wide speed range More frequent
63. 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 Refer to Fig 1 6 for U S and Canadian tire and rim labels 10 31 95 1 Date of manufacture by month and year 2 Gross vehicle weight rating developed by taking the sum of all the vehicle s gross axle ratings 3 Gross axle weight ratings developed by considering each component in an axle system including suspension axle wheels and tires The lowest component capacity is the value used for the System 1080054 Fig 1 6 Tire and Rim Label EPA Emission Control Labels Vehicle Noise Emission Control Label A vehicle noise emission control label Fig 1 7 is attached either to the left side of the dashboard or to the top right surface of the frontwall between the dash and the windshield VEHICLE NOISE EMISSION CONTROL INFORMATION FREIGHTLINER CORPORATION DATE OF MANUFACTURE 1 96 THIS VEHICLE CONFORM U S EPA REGULATIONS FOR NOISE EMISSION APPLICABLE TO MEDIUM AND HEAVY TRUCKS THE FOLLOWING ACTS OR THE CAUSING THEREOF BY ANY PERSON ARE PROHIBITED BY THE NOISE CONTROL ACT OF 1972 A THE REMOVAL OR RENDERING INOPERATIVE OTHER THAN FOR PURPOSES OF MAINTENANCE REPAIR OR REPLACE ANY NOISE CONTROL DEVICE Ol ELEMENT OF DESIGN LISTED IN THE OWNERS
64. is driven with the ABS CHK switch On in the Up position the WHL SPIN light will illuminate continuously Under this condition turning the ABS CHK switch Off in the Down position while the vehicle is still in motion will only turn off the WHL SPIN light but will not restore ATC function performance To fully restore engine and ATC function capability the vehicle must be brought to a complete stop Then move the ABS CHK switch to Off in the Down posi tion The Meritor WABCO ABS system combines one front axle control channel with either one rear axle the 4 channel system or two rear axles the 6 channel system to form one control circuit For example the sensor and solenoid control valve at the left front axle form a control circuit with the sen sor s and solenoid control valve s on the right rear axle s If during vehicle operation the safety circuit senses a failure in any part of the ABS system a sensor solenoid control valve wiring connection short circuit etc the tractor warning light TRAC Steering and Brake Systems ABS comes on and the control circuit where the fail ure occurred is switched to normal braking action The remaining control circuit will retain the ABS ef fect Even if the ABS system is partially or completely inoperative normal braking ability is maintained The vehicle is not disabled IMPORTANT If any of the ABS warning lights do not work as described above or come
65. is activated by the headlight switch When the headlights are on the panel lamp knob Fig 2 8 controls the intensity of the instrument panel lamps Turn the knob counter clockwise to brighten them and clockwise to dim them Turning the knob counterclockwise to the peg will also turn off the panel lamps Headlight Switch and Daytime Running Lights A three position headlight switch Fig 2 8 is used to operate the exterior lights When the switch is up the headlights and all other vehicle lights are on All vehicle lighting is off when the switch is in the middle position When down the switch activates only the clearance instrument panel and marker lights and the taillights The switch for the headlight high beams is built into the turn signal lever When the headlights are on high beam a green light in the warning and indicator light module goes on The ignition switch must be on for the high beams to operate For vehicles built to operate in Canada switching on the ignition and releasing the parking brakes auto matically activates the headlight low beams later model vehicles or high beams earlier model ve hicles at half voltage as daytime running lights The daytime running lights will operate until the parking brakes are applied then they will switch off Turning on the regular headlights will override the daytime running lights The vehicle cannot be driven unless either the headlights or daytime running lights are a
66. is used only for start ing the engine 2 Keep the engine speed to a minimum An ac ceptable range is 1200 to 1600 rpm 7 8 Engines and Clutches 3 Select a gear that allows a smooth easy start without increasing engine speed above low idle or slipping the clutch Engage the clutch smoothly Jerky starts waste fuel and put stress on the drivetrain It is not necessary to accelerate Caterpillar elec tronic engines to governed speed in the lower gears to get the vehicle moving except in a high power demand situation such as starting on a grade 4 Continue to upshift until cruising speed is reached Use only the rpm needed to make an upshift into the next gear The engine speed needed to make an upshift increases as the ve hicle speed increases or if upshifts are made on uphill grades If the vehicle can be operated in a higher gear after reaching the desired speed select the highest gear available that will pull the load Experience with your vehicle will show you what rpm is needed to make upshifts under vari ous conditions This progressive shifting tech nique will lower fuel costs because the engine will be operating at the lowest rpm needed to pull the load Caterpillar electronic engines can be pro grammed to limit engine rpm while the vehicle is operated in the lower and higher gears This fea ture assists the driver in following progressive shifting techniques 5 On uphill grades begin downshifting when
67. keep the vehicle moving at the desired speed 2 Continue downshifting as conditions require using the same sequence described above When shifting down into 1st gear remember that 1st gear isn t synchronized Double clutch when shifting down into 1st gear IMPORTANT Never use the clutch brake when downshifting or as a brake to slow the vehicle Meritor Range Shift Models Refer to the Meritor website for additional informa tion www arvinmeritor com General Information Meritor Range Shift Range shift transmissions are typically upshifted by moving the shift lever through all of the low gear po sitions and then activating a range switch to provide an additional set of ratios in the high range using the same shift lever positions as used in low range The shift lever then is moved sequentially through each position as before but all the positions now provide a higher gear ratio The initial low gear is often used only in low range IMPORTANT Not all lever positions are used in each range and the shift patterns vary between transmissions Be sure to read the shift pattern decal on the dash for the operating instructions for the specific transmission installed in your vehicle 9 Speed Models Meritor 9 speed M MO RM RMO and RMX model transmissions have a 5 speed front section and a 2 speed auxiliary section The low gear in the front sections of the A and B ratio transmissions is used only as a starting ratio
68. neutral and completes the gear change after driver input The Electronic Control Unit ECU includes two controllers a transmission ECU and a system ECU The transmission ECU controls all trans mission shift functions and the system ECU manages all vehicle interfaces for transmission shift functions An electronic range valve controlled by the transmission ECU is used to perform range shifts Operation AutoShift A WARNING If the engine cranks in any gear other than neu tral have the vehicle serviced immediately If the vehicle is started in gear it will suddenly move forward or backward which could result in per sonal injury and damage to property and the transmission Start Up 1 With the parking brake applied press the clutch all the way down to the floor 2 Start the engine 3 Check to make sure the transmission is in neu tral 4 With the transmission in neutral release the clutch NOTE This allows the speed sensor on the input shaft to get a reading 5 Press down on the clutch again and release the parking brake 6 Select the desired starting gear 7 Release the clutch Reverse NOTE To drive in reverse first depress the clutch 1 Move the gear select lever to the R position 2 On 10 speed models select either LO or HI re verse by depressing either the downshift or up shift button Fig 8 14 on the gear select handle if equipped 8 14 Transmissions On 18
69. 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 the spot for 30 to 60 minutes For stubborn spots allow the hydrogen peroxide satu rated cloth to remain on the area overnight Use cau tion to prevent the solution from seeping into the seams or it will weaken the cotton thread Nail Polish and Nail Polish Remover Prolonged contact with these substances causes per manent damage to vinyl Careful blotting immediately after contact minimizes damage Do not spread the liquid during removal Shoe Polish Most shoe polishes contain dyes which penetrate vinyl and stain it permanently Shoe polish should be wiped off as quickly as possible using naphtha or lighter fluid If staining occurs try the same proce dure as that under 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 under 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 poin
70. oil contamination Fuel oil gasoline and other petroleum derivatives if allowed to contact the tires will soften the rubber and destroy the tire 20 Check the wheel nuts or rim nuts for indications of looseness Examine each rim and wheel com ponent 20 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 20 2 Examine the rim and wheel assembly components including rims rings flanges studs and nuts for cracks or other dam age 11 9 02 09 95 f400058 Fig 11 8 Dirt and Rust Streaks from the Stud Holes See Group 33 or Group 35 of the Heavy Duty Trucks Service Manual for service procedures on the studs and hubs and see Group 40 in the same manual for wheel and tire servicing or take the ve hicle to an authorized Freightliner dealer Have any worn or damaged wheel components replaced by a qualified person using the wheel manufacturer s instructions and the wheel indus try s standard safety precautions and equipment Otherwise a vehicle or workshop accident could occur possibly resulting in serious personal in jury or death 20 3 Have broken cracked 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 20 4 Mak
71. 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 pumpthe 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 drive appropriately for exist ing traffic and road conditions For example the ABS System cannot prevent an accident if the driver is speeding or following too closely on slippery road surfaces Trailer ABS Lamp Operation Antilock braking systems on tractors are designed to communicate with trailer ABS systems if they are compatible Compatibility will result in the illumination of the trailer ABS lamp during vehicle start up and fault detection The dash mounted lamp will operate as follows when a compatible trailer is properly connected to a tractor When the ignition key is turned to the ON posi tion the trailer ABS lamp will illuminate mo mentarily then turn off If the lamp comes on momentarily during ve hicle operation then shuts off a fault was de tected and corrected If the lamp comes on and stays on during ve hicle operation there is a fault with the trailer ABS Repair the trailer ABS system immedi atel
72. or loss of vehicle control possibly resulting in per sonal injury or property damage 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 long grades to keep the vehicle speed under control and the engine rpm below full load rated governed speed 8 Essential information regarding the operation and care of Allison automatic transmissions is con tained in the Allison Driver s Hanabook Applying the knowledge presented will not only make driv ing easier but will give the maximum benefits from an Allison equipped vehicle Maintenance literature is also available for driv ers of Allison equipped vehicles who desire trouble free performance and maximum life from their equipment These maintenance books are available from any authorized Detroit Diesel en 1 1 gine distributor 1 To cruise at a particular speed Flip the ON OFF switch on the instrument control panel to ON 9 As with all engines prolonged idling of Detroit 1 2 Diesel engines is not recommended An idling engine wastes fuel and left unattended is also unsafe A Detroit Diesel Electronic Control DDEC en gine can be equipped to shut off automatically after 5 minutes of idling The vehicle transmis sion must be in neutral and the parking brake 2
73. outlet Vacuum is measured in inH O inches of water Service the air cleaner when the vacuum reading equals the applicable level shown under Service in Table 2 5 Intake Air Restriction Indicator An intake air restriction indicator Fig 2 29 mea sures the vacuum on the engine side of the air cleaner at the air cleaner outlet If the yellow signal stays locked at or above the values shown in Table 2 5 after the engine is shut down service the air cleaner Then press the yellow button to reset the indicator Intake Air Restriction Engine Type Initial inH2O Service inH5O Cummins 12 25 Detroit Diesel 12 20 Caterpillar 15 25 Turbocharged engines must be checked at full load and governed en gine speed Table 2 5 Intake Air Restriction 01 18 95 Transmission Oil Temperature Gauge Forward Differential Oil Temperature Gauge Rear Differential Oil Temperature Gauge Engine Oil Temperature Gauge Turbocharger Boost Pressure Gauge Fuel Pressure Gauge Automatic Engine Idler Timer Intake Air Restriction Gauge Pana Pacific Digital Clock 1600512a o0 o0 AON Fig 2 28 Optional Gauges 01 18 95 1600148a Fig 2 29 Intake Air Restriction Indicator Fuel Pressure Gauge Optional A fuel pressure gauge Fig 2 28 registers output pressure of the fuel pump Whenever the engine is operating the fuel pressure reading should be con stant If the fuel pressure drops inves
74. preselection lever is in high range before moving the shift lever to neutral Leave the shift lever in neutral long enough to be sure the range section has shifted 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 With the lever in high range double clutch through neu tral and shift into the bottom gear of the high range Table 8 1 As the shift lever passes through neutral the transmission will automati cally shift from low range to high range Transmissions Eaton Fuller Shift Progressions TRANS LOW RANGE HIGH MODEL Off Highway On Highway RANGE 9 Speed BN R R Direct or yd 235 3 Vd 2394 R a Overdrive HS 7 BN RTor tW 5 4 JE BB RTX 260322 260323 260324 6 8 R R 9 Speed C 2154 E a Direct d A 54 Ds RTX P 1 8 1 X3 LIENS 1260325 1260325 260326 r S 8 R R 9 Speed AM pure E T Overdrive t 7 vba Wee RTO LW 27 3 LM aig wi 1260327 1260327 1260328 10 Speed LT KS l R R Direct or Oye R7 pe at iru J Overdrive LAA 4 tity ee At 6l 85 A0 RT or WSIS GMI 5 aa RTX 1260329 1260329 260330 ADU JN AD R R 10 Speed x adm reg rey R Pyle Overdrive ae c 64 Bg RTO Vo dU X3 X4 1260331 1260331 1260332 Table 8 1 Eaton Fuller Shift Progressions 6 With the transmission in high range shift pro gressively upward through each of the high range gears Table 8 1 d
75. pull up ward on the control lever While holding the control lever in this position move the steering wheel up ward or downward to the desired position Release the control lever to lock the steering wheel in place Make sure that the control lever is in the locked neutral position before driving the vehicle Never try to adjust the height of the steering wheel or tilt the steering column while driving the vehicle Doing so could cause loss of vehicle control personal injury and property damage Warning and Indicator Lights All of the standard and optional warning and indicator lights are housed in a lens and bezel assembly lo cated above the speedometer and tachometer For pre EPAO7 vehicles up to six rectangular indica tor lights may be installed on the center dash panel between the tachometer and speedometer See Fig 2 19 The pre EPAO7 standard installation in cludes one parking brake indicator light and two an tilock braking system ABS lights the tractor warn ing light and the wheel spin indicator light One other ABS light the trailer warning light is optional The other two lights represent a variety of optional func tions that may not be installed on all models For EPAO07 vehicles up to ten rectangular indicator lights may be installed on the center dash panel be tween the tachometer and speedometer See Fig 2 20 The EPAO7 standard installation includes three indicator lights for the after treatment
76. road condi tions To do so could result in damage to the axle gearing and excessive tire wear To unlock the interaxle differential move the lockout control valve to UNLOCK while maintaining vehicle speed after leaving the poor road conditions Let up momentarily on the accelerator to allow the shift then resume driving at normal speed Eaton Single Reduction Axles With Controlled Traction Differential The controlled traction differential system is a differ ential assembly incorporating a friction plate assem bly designed to transfer torque from the slipping wheel to the one with traction The unit is basically a multiple disc clutch designed to slip above predeter mined torque values This controlled slipping charac teristic at higher torque values enables the vehicle to negotiate turns in a normal manner Resistance to slippage at lower torque values enables the vehicle 9 2 Rear Axles to maintain an appreciable amount of tractive effort when one wheel encounters relatively poor traction A control valve Fig 9 3 in the cab is actuated by the driver to engage and disengage the controlled traction feature TN E DO NOT ENGAGE SZ E DURING dud d VIC USPIN OUT TRACTION CONTROL DIFFERENTIAL LOCK UNLOCK 10 04 93 1600307 Fig 9 3 Traction Control Differential Control Disengaged the axle has differential action all the time One wheel will spin independently of the other if slippe
77. separators use a ball valve with a handle that turns 90 degrees Older separators have a knurled brass valve that unscrews to open Allow the water to drain and close the valve finger tight For a Webb Model 525 see Fig 11 5 Turn the drain valve handle If nothing flows from the valve it may be blocked Use a pencil or screw driver to clear the valve Allow the water to drain and then close the valve Start the engine and raise the rpm for two or three minutes to purge any air from the fuel system For ConMet Models see Fig 11 6 Check the water level in the sight bowl if equipped To drain the water loosen the valve at the bottom and allow the water to run out Close and tighten the valve finger tight 02 09 95 1 Sight Bowl 2 Collected Water 470103 3 Drain Valve Fig 11 3 Racor Fuel Water 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 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 6 Pretrip
78. set shutdown time the CHECK ENGINE light will begin to flash at a rapid rate If the clutch pedal or service brake indicates position change during this final ninety seconds diagnostic lamp flash ing the idle shutdown timer will be disabled until reset After stopping the engine fill the fuel tank 7 18 Engines and Clutches 7 Check the crankcase oil level while the engine is stopped Maintain the oil level between the ADD and FULL marks on the dipstick 8 If freezing temperatures are expected allow the engine jacket water expansion tank to cool then check the coolant for proper antifreeze protec tion The cooling system must be protected against freezing to the lowest expected outside temperature Add permanent type antifreeze if required For additional information see Group 20 of the Heavy Duty Trucks Maintenance Manual 9 Repair any leaks perform minor adjustments tighten loose bolts etc Observe the vehicle mile age or the service meter reading if so equipped Perform periodic maintenance as instructed in the Lubrication and Maintenance Chart in the Caterpillar Operation and Maintenance Manage ment Manual Cummins 1 With the vehicle stopped apply the parking brakes and place the transmission in neutral 2 It is important to idle an engine three to five min utes before shutting it down This allows the lu bricating oil and the water to carry heat away from the combustion chamber bearings shaf
79. shifting than necessary does not allow proper utilization of this flexibility The driver who stays in top gear and uses the wider speed range will achieve the best fuel economy 6 The Cummins diesel engine is effective as a brake on downhill grades but care must be used Engines and Clutches not to overspeed the engine going downhill The governor has no control over engine speed when it is being pushed by the loaded vehicle Never turn off the ignition switch while going downhill With the engine still in gear fuel pres sure will build up against the shutdown valve and may prevent it from opening when the ignition key is turned on A CAUTION Engine overspeed engine speed exceeds high idle no load rpm can damage the engine 7 Use a combination of brakes and gears to keep the vehicle under control at all times and to keep the engine speed below the rated governed rpm Cruise Control The cruise control is activated by the ON OFF and SET RESUME switches on the dash Fig 7 5 or by optional PAUSE RESUME and SET buttons on the transmission shift knob Fig 7 6 The minimum speed at which cruise control can be used on Cum mins PACE and CELECT engines is 30 mph 48 km h WARNING Do not use the cruise control system when driv ing conditions do not permit maintaining a con stant speed such as in heavy traffic or on roads that are winding icy snow covered slippery or roads with a loose driving surface
80. shorten it by pulling on the loose end until the belt is snug but com fortable Be sure the belts are not twisted Bunk Restraint Operation See Fig 5 22 4 5 1 01 18 95 f910069a 1 Mattress 4 Link 2 Sleeper Wall 5 Belt Anchor 3 Buckle Fig 5 22 Bunk Restraint in 40 Inch Sleeper Shown 1 Starting at the foot of the bunk pull up the link end of the belt far enough to engage the buckle 2 Fasten the belt by pushing the link end into the buckle until they latch Make sure that the belt is not twisted Check the engagement by trying to pull the link out of the buckle If they come apart repeat this step If the problem continues re place the belt Repeat steps 1 and 2 for the other two belts located in the middle and upper portion of the bunk to lock the restraint in place NOTE On 60 inch raised roof cabs the upper bunk restraint if present pulls up in front of the bunk and fastens at the ceiling 3 To release the bunk restraint push the release button on the buckle at the head of the bunk and pull the link from the buckle Repeat this step for the other two buckles to completely release the bunk restraint NOTE When the sleeper compartment is not occupied the bunk restraint can be stored under the mattress Seats and Seat Belts Bunk Mattress To prevent damage to the bunk mattress and to en sure even wear it is recommended that the mattress be turned over on a monthly basis
81. sound again for 24 hours 3 3 If desired press the snooz button while the alarm is sounding to shut the alarm off for 3 minutes The alarm symbol will flash in the display when the button is pushed and will continue to flash until the alarm switch is moved or the alarm has sounded for 1 minute The snooze proce dure can be done as many times as de sired 3 4 Move the alarm switch to the right when you wish to shut off or cancel the alarm the alarm symbol will disappear Kysor Digital Clock Optional A Kysor digital clock Fig 2 14 has a constant red display which automatically adjusts the brightness for day or night The clock features a 24 hour alarm To set the time of day 1 1 Depress both of the time Set push but tons labelled Fast and Slow 12 00 A M will appear as the readout NOTE A small illuminated red dot in the upper left side of the clock above PM in dicates P M No dot indicates A M 1 2 A Advance to the correct time by pushing either the Fast or Slow push button 2 To set the alarm 2 1 Depress the alarm Set push button Ob serve that a red lamp above the word Alarm illuminates 2 2 Set the alarm time by using the same pro cedure that you used to set the time of day Remember to select either A M no red dot or P M red dot illuminates when setting the alarm time 2 3 After the desired alarm time appears de press the alarm Set push button again The readou
82. speed Depress the clutch pedal enough to release the Transmissions torque then shift into neutral Engage the clutch and bring the engine rpm up to governed speed Disengage the clutch shift into 4th gear and en gage the clutch smoothly Follow the same sequence to downshift from 4th into 3rd 3rd into 2nd and from 2nd into 1st gear IMPORTANT Never use the clutch brake when downshifting or as a brake to slow the vehicle Eaton Fuller Range Shift Models Refer to the Eaton website for additional information www roadranger com General Information Eaton Range Shift Range Shift transmissions are typically upshifted by moving the shift lever through all of the low gear po sitions and then activating a range switch to provide an additional set of ratios in the high range using the same shift lever positions as used in low range The shift lever then is moved sequentially through each position as before but all the positions now provide a higher gear ratio The initial low gear is often used only in low range Eaton Fuller Range Shift transmissions are not syn chronized in the front section but the range section is synchronized to prevent grinding gears during range shifts IMPORTANT Not all lever positions are used in each range and the shift patterns vary between transmissions Be sure to read the shift pattern decal on the dash for the operating instructions for the specific transmission installed in your
83. spin indicator light WHL SPIN and an optional trailer warning light TRLR ABS Vehicles built before July 1994 also have a DEEP SNOW MUD indicator light With the tractor ABS system the tractor warning light TRAC ABS comes on after the engine is started Fig 2 19 Once the vehicle moves faster than about 4 mph 6 km h the warning light goes out only if all of the tractors ABS components are work ing With the tractor and trailer ABS system the vehicle also has a trailer warning light labelled TRLR ABS Fig 2 19 After the engine is started the TRLR ABS light comes on if the trailer is equipped with a compatible 1600769c 03 14 2007 MIL Engine Warning Light DPF Regen Warning Light Hi Temperature Exhaust Warning Light Parking Brake Indicator Light Tractor ABS Warning Light Trailer ABS Warning Light Air Suspension Warning Light Left Turn Signal Light Oil Pressure Warning Light Low Water Warning Light Water Temperature Warning Light High Beam Indicator Light Low Air Pressure Warning Light Right Turn Signal Light Tachometer Speedometer 00 0o090280wv ommoom Fig 2 20 Dash Assembly for VIGIL and Kysor Warning Systems EPA07 ABS system Once the vehicle moves faster than about 4 mph 6 km h the TRLR ABS warning light goes out only if all of the trailers ABS components are worki
84. than about 4 mph 6 km h the TRLR ABS warning light goes out only if all of the trailers ABS components are working For more information on trailer ABS lamp operation see Trailer ABS Lamp Operation in this chapter A wheel spin indicator light WHL SPIN comes on if one of the drive wheels spins during acceleration 6 4 Steering and Brake Systems x x Ne D x x E v 05 31 95 1600771a 1 Parking Brake Indicator Light 2 Tractor ABS Warning Light 3 Wheel Spin Indicator Light 4 Trailer ABS Warning Light Fig 6 4 Warning and Indicator Lights Fig 6 4 The light goes out when the wheel stops spinning When the light comes on partially release the throttle pedal until the light goes out If slippery road conditions continue engage the axle lock CAUTION Do not engage the axle lock while the WHL SPIN light is on To do so could damage the rear axle See Chapter 9 Rear Axles for axle lock in structions If the vehicle is equipped with an electronic engine an automatic traction control ATC system may be installed On these vehicles the ATC system auto matically reduces wheel spin during reduced traction starts An ATC Function switch if equipped allows the driver to select from two levels of drive axle traction control assistance NORMAL reduces drive axle wheel spin on icy wet or sand covered roads DEEP SNOW MUD allows a higher thres
85. that are loose Monthly Post Trip Maintenance Procedures Battery posts terminals and related accessories contain lead and lead compounds chemicals known to the State of California to cause cancer and reproductive harm To prevent possible per sonal injury always wash your hands after han dling battery parts and related accessories 1 Clean the batteries 1 1 Remove any corrosion from the hold down and the top of the battery CAUTION Take care to keep the vent plugs tight so that the neutralizing solution does not enter any of the battery cells and damage the battery 1 2 Use a soda solution to neutralize the acid present then rinse off the soda solution with clean water 1 3 If the battery posts or cable terminals are corroded disconnect the terminals from the posts Clean them with a soda solution and a wire brush After cleaning connect the terminals to the battery posts then apply a thin coat of petroleum jelly to the posts and terminals to help retard corro sion 2 Inspect the radiator and heater hoses including the clamps and support brackets 2 1 Make sure the radiator inlet and outlet hoses are pliable and are not cracking or ballooning Replace hoses that show signs of cracking weakening or ballooning 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 Pretrip and Post Trip Inspections and
86. the engine rpm falls to 1200 rpm Fuel economy will be best if you let the engine lug back to around this speed before you downshift Downshift until a gear is reached in which the engine will pull the load Let the engine lug down if you can make it to the top of a hill without downshifting IMPORTANT Don t let the engine exceed 2300 rpm 2100 rpm if equipped with an exhaust brake 6 Ona downhill grade do not coast or put the transmission in neutral Select the correct gear that does not allow the engine to exceed its maximum speed Use the brakes to limit the ve hicle speed A simple rule to follow is to select the same gear or one gear lower that would be needed to go up the grade 7 9 7 As with any engine prolonged idling of Caterpil lar engines is not recommended An idling en gine wastes fuel and if left unattended is also unsafe Caterpillar engines can be programmed to shut off automatically after a specified idling time The vehicle transmission must be in neutral and the parking brake must be set for the automatic shut off option to work Cruise Control The cruise control is activated by the On Off and Set Resume switches on the dash Fig 7 5 or by optional Pause Resume and Set buttons on the transmission shift knob Fig 7 6 The minimum speed at which cruise control can be used on Cater pillar electronic engines is 30 mph 48 km h The minimum and maximum speed cruise control set lim
87. the armrest and counter clockwise to lower the armrest Swivel Seat Fig 5 13 A swivel seat option is available for the passenger s seat only A lever on the side of the seat base re leases the swivel mechanism allowing the seat to rotate on the base 04 16 96 1 Lever 910143 Fig 5 13 Swivel Seat Do not rotate the seat while the vehicle is in mo tion Doing so could increase the chance of per sonal injury in the event of a crash Seat Belts and Tether Belts General Information Seat belt assemblies are designed to secure persons in the vehicle to help lessen the chance of injury or the 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 Seat belt assemblies in the vehicle meet Federal Motor Vehicle Safety Standard 209 Type 1 and Type 2 requirements They are recommended for all persons weighing over 50 pounds 23 kg A child restraint system should also be provided for each child weighing 50 pounds 23 kg or less It should meet the requirements of Federal Motor Ve hicle Safety Standard 213 Child Restraint Systems When providing such a restraint system carefully read and follow all instructions pertaining to installa tion and usage for the child Make certain the child remains in the restraint system at
88. the right side Switch two thirds engine brake retarding capac ity or both switches full engine brake retarding capacity On vehicles equipped with a Cummins L10 or Caterpillar engine select either the left side switch or right side switch for one half engine brake retarding capacity or both switches for full engine brake retarding capacity 2 The engine brake activates when the driver s feet are removed from both the clutch and throttle pedals If it fails to activate stop the vehicle in a safe spot and check the adjustment of the throttle and clutch switches If no cause can be detected in the electrical system check the en gine brake system See Group 01 of the Heavy Duty Trucks Service Manual for instructions 3 To obtain maximum retarding maintain the top governed speed of the engine through appropri ate selection of gears when the engine brake is in use 4 When either the clutch or throttle pedal is de pressed the engine brake is deactivated A CAUTION If the engine brake fails to shut off when either the throttle or clutch pedal is depressed place the dash switch in the OFF position and do not use the engine brake until the throttle or clutch switch system is repaired If the engine brake fails to shut off when the dash switch is turned off the engine should be shut down and the en gine brake repaired before continuing operation Failure to do so could result in damage to the engine Clutches Ge
89. the steering wheel with your left hand Place your left foot on the top step and step up 6 Step into the cab with your right foot first Exiting the Driver s Side See Fig 3 3 Exit the cab from the driver s side as follows IMPORTANT Do not attempt to exit the cab while carrying any items in your hands 1 Grasp the steering wheel with your left hand and stand on the threshold facing into the cab 2 Place your left foot on the top step then grasp the grab handle with your right hand 3 Move your right foot to the bottom step 4 Step to the ground with your left foot Entering and Exiting the Passenger s Side Enter and exit the cab from the passenger s side using the same procedures given for entering and exiting the driver s side but using opposite hands and feet Instead of the steering wheel use the grab handle inside the upper forward corner of the pas senger s door opening See Fig 3 4 b zx 01 18 95 f720005a Fig 3 4 Grab Handle Door Windows and Vent Windows To lower the driver s side door window turn the crank handle clockwise See Fig 3 2 To lower the passen ger s side turn its handle counterclockwise See Chapter 2 for optional air window operating instruc tions 3 2 Vehicle Access To open either vent window push the vent window release lever button while pivoting the top of the re lease lever 90 degrees forward When the release lever clears the slide chan
90. trailer from moving CAUTION After moving the fifth wheel to the desired posi tion be sure the trailer landing gear will not at any time come in contact with the tractor frame or other components Make sure that the front of the trailer will not come in contact with the rear of the cab or with other components if they ex tend beyond the rear of the cab 6 Slowly move the tractor forward or backward until the fifth wheel is in the desired location 7 Apply the tractor parking brakes NOTE The fifth wheel may have to be moved slightly to enable the locking pin s to enter the fully locked position 8 Lock the sliding member in position using one of the following methods Check to be sure that the lockpins are seated in the holes Failure to achieve complete lockup may cause the trailer to detach from the tractor possibly resulting in serious personal injury or death 8 1 For air operated release models set the cab operated slide control switch to LOCK Visually inspect the lockpins to make sure that they are fully inserted in the slide rail holes 8 2 For manual release models disengage the slide locking handle from the guide plate The slide locking handle is spring loaded in the locked position and will seek the locked position when disengaged from the guide plate The fifth wheel may have to be moved slightly to enable the locking pins to fully enter the locked position When the slide lock control handle
91. uncage the spring parking brakes before resuming normal vehicle operation Brake System Operation Before driving the vehicle secure all loose items in the cab so that they will not fly forward during a full brake application Make sure that all passengers are wearing seat belts IMPORTANT An air brake proportioning system is used in tractor air brake systems When oper ating in bobtail mode the rear brake chambers whose axle load has been greatly reduced re ceive reduced or proportional air pressure while the front axle brake chambers receive full nor mal air pressure This results in a different brake pedal feel as the pedal seems to re quire more travel and or effort to slow or stop the vehicle However the air brake proportioning system actually improves vehicle control when the tractor is in the bobtail mode of operation When the tractor is towing a trailer the rear brake chambers will receive full normal appli cation air pressure 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 push the clutch pedal in and shift the transmission into Neutral Apply the spring parking brakes if the vehicle is to be parked IMPORTANT In the event of a total loss of ser vi
92. 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 any burning material such as a cigarette Always comply with the washer fluid manufacturer s rec ommended safety precautions 3 Check the coolant level in the surge tank See Fig 11 1 If the coolant is low add a 50 50 mixture of water and the type of antifreeze cur rently installed in your vehicle Fill the surge tank with coolant to the MAX line when the tank is cool If the surge tank was empty start the en gine after refilling and check the level again when the engine is at operating temperature 1 A lt p e O8 o 4L y f500030a eo N e e oa 1 Filler Neck Fig 11 1 Coolant Level Checking A CAUTION Coolant must be filled to the full line of the surge tank Low coolant could result in engine over heating which could cause engine damage 4 Inspect the radiator and charge air cooler 4 1 Inspect the radiator and charge air cooler for clogged fins Use compressed air or water directed from the fan side of the core to backflu
93. where especially corrosive ice removal chemicals are used may experience higher than normal rotor corrosion Tone rings should be routinely inspected for corro sion Severe corrosion of the integral ABS tone ring may cause the ABS warning lamp in the dash to illuminate due to false wheel speed readings If the ABS warning lamp illuminates at any time other than at vehicle start up have the problem repaired immedi ately 22 9 Inspect the slack adjusters 23 1 Meritor Slack Adjusters Check the boot for cuts tears or other damage Have it replaced if necessary 23 2 Gunite Slack Adjusters Inspect the slack adjuster for any signs of damage If dam aged have the slack adjuster replaced Inspect the slack adjuster boot for cuts or tears If the boot is damaged have it re placed See Fig 11 13 Ng 4 5 6 7 3 S 8 2 9 1 AN 06 17 2003 1421398 1 7 16 inch Adjusting 6 Clevis Nut 7 1 2 inch Clevis Pin 2 Grease Fitting 8 1 4 inch Clevis Pin 3 Boot 9 Grease Relief 4 Link Opening 5 Brake Chamber Piston 10 Slack Adjuster Spline Rod Fig 11 13 Gunite Automatic Slack Adjuster 23 3 Haldex Slack Adjusters Inspect each slack adjuster and anchor strap for dam age See Fig 11 14 Have any damaged components replaced Check that the control arm nut is fully re leased If the control arm is in the wrong position the brakes will drag 24 Check the air brake system for proper operation 2
94. which system has low air pressure The brake pedal will slow the vehicle but since one brake system will not be working stop ping distance will increase Bring the vehicle to a safe stop and have the air system repaired before continuing On tractor trailer vehicles if both the primary and secondary systems become inoperative the trailer service brakes or spring parking brakes will automati cally apply when air pressure drops below 35 to 45 psi 242 to 310 kPa The tractor spring parking brakes will automatically apply when air pressure drops below 20 to 30 psi 138 to 207 kPa On straight trucks spring parking brakes will apply when air pressure drops below 20 to 30 psi 138 to 207 kPa Do not wait for the brakes to apply automati cally when the warning light and buzzer first come on immediately bring the vehicle to a safe stop Be fore continuing operation of the vehicle correct the cause of the air loss Before the vehicle can be moved the spring parking brakes must be released by applying an external air source at the gladhands or by manually caging the parking brake springs WARNING Do not release the spring parking brakes and then drive the vehicle There would be no means of stopping the vehicle which could result in se rious personal injury or vehicle damage Before releasing the spring parking brakes make the connection to a towing vehicle or chock the tires After correcting the brake system problem
95. with on highway fuel economy engines where a minimum of shifting is desired and less gear reduction is acceptable 03 13 96 f260055a Fig 8 1 Eaton Fuller Straight Shift Model Transmissions Shift Pattern Operation Eaton Straight Shift 1 Always use 1st gear when starting to move the vehicle forward 2 Use the clutch brake to stop gear rotation when shifting into 1st or reverse when the vehicle is stationary The clutch brake is actuated by de pressing the clutch pedal all the way to the floor For normal upshifts and downshifts only a partial disengagement of the clutch is necessary to break engine torque 3 Use double clutching between all upshifts and downshifts 4 After your shifting ability improves you may want to skip some of the ratios This may be done only when operating conditions permit depend ing on the load grade and road speed IMPORTANT Never use the clutch brake when downshifting or as a brake to slow the vehicle 8 1 Upshifting 1 Position the gear shift lever in neutral then start the engine Bring the air system pressure up to 100 to 120 psi 689 to 827 kPa 2 Depress the clutch pedal to the floor Shift into 1st gear then engage the clutch with the engine at or near idle speed to start the vehicle moving Accelerate to engine governed speed 3 Once governed speed has been reached disen gage the clutch and shift the lever to neutral Engage the clutch allow t
96. 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 11 10 Pretrip and Post Trip Inspections and Maintenance 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 control resulting in property damage or personal injury 21 1 Check that the air brake chamber is mounted securely on its mounting bracket and that there are no loose or missing bolts 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 See if the chamber piston rod is in line with the slack adjuster Misalignment can cause the piston rod to rub on the non pressure chamber and cause a dragging brake See Group 42 of the Heavy Duty Trucks Service 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 11 11 22 21 4 Inspect the exterior surfaces of the cham ber for damage Make sure that breather holes in the non pressure section s are open and free of de
97. 1 3 57 1 3 4 03 13 96 f260155a A All Standard Models B RMO Models Only C Up for High Range D Down for Low Range Fig 8 17 Meritor 10 Speed Transmission Shift Patterns NOTE The 4th 9th and 5th 10th shift positions in the standard A and B ratio transmissions both direct drive and overdrive are opposite of the RMO model overdrive only transmissions Operation Meritor Range Shift Reverse To drive in reverse push the range selector lever down to put the transmission in the low range Push the clutch pedal to the bottom of travel so the clutch brake slows the transmission for initial gear engage ment Holding the clutch pedal at the bottom of travel shift into reverse Slowly release the clutch pedal to move the vehicle in reverse Upshifting 1 To drive forward make sure the vehicle is com pletely stopped and the range selector lever is pushed down to put the transmission in the low range Push the clutch pedal to the bottom of travel so the clutch brake slows the transmission for initial gear engagement Holding the clutch pedal at the bottom of travel shift into low 2 Slowly release the clutch pedal to begin moving the vehicle forward 3 To upshift into 1st gear only partial depression of the clutch pedal is needed Do not push the clutch pedal all the way to the floor and engage the clutch brake instead partially depress the Transmissions clutch pedal and move the shift lever
98. 13 1 Hazard Warning Light Tab To cancel the hazard warning lights push the turn signal control lever either up or down then return the lever to its neutral position Emergency Kit Optional An optional emergency kit package is located in the baggage compartment behind the driver s seat if the vehicle has a sleeper compartment If there is no sleeper compartment the emergency kit is located behind and between the seats The package includes one or more of each of the following fire extin guisher first aid kit and a triangular reflector and flare kit If there is an emergency while driving cautiously pull off the road paying attention to other traffic Turn on the hazard warning lights Place the flares and reflec tor along the side of the road to alert other drivers that an emergency situation exists 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 13 1 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 th
99. 1910037 Fig 5 8 Air Button Front and Rear Bottom Cushion Height To adjust the height of the front of the bottom cush ion lift the handle and pull up and forward to one of three settings To adjust the height of the rear of the bottom cushion rotate the handle clockwise to one of the three settings Fore and Aft Seat Adjustment Move the lever to the right and slide the seat Locked in settings are in 1 1 2 inch 38 mm incre ments See Fig 5 6 or Fig 5 7 5 5 National Cush N Aire Seats Model 195 Fig 5 9 Back Cushion Tilt To tilt the back cushion through a range of 12 de grees turn the knob and lean forward or backward 02 09 95 Back Cushion Tilt Knob Isolator Lockout Handle Height Adjustment Knob Fore and Aft Seat Adjustment Lever Front Bottom Cushion Height Handle Lumbar Support Knob f910071a OU OmN Fig 5 9 National Cush N Aire Seat Isolator Lockout Called a Chugger Snubber the isolator is locked out by moving the handle down Height Adjustment Push in the knob to inflate the suspension and raise the seat height Pull out on the knob to deflate the suspension and lower the seat height Fore and Aft Seat Adjustment Move the lever to the right and slide the seat forward or backward to the desired position Front Bottom Cushion Height To adjust the height of the front of the bottom cush ion lift the handle and pull forward or push back to the desir
100. 20 Conventionals or a torsion bar FLD 112 Conventionals help you to tilt the hood open and to return it to the operating position Stop cables FLD 120 Conventionals or hood straps FLD 112 Con ventionals prevent the hood from overtravel In the operating position the hood is secured to the lower cab side panels by a hold down latch on each side of the hood To Tilt the Hood 1 Apply the parking brakes 2 Release both hood hold down latches by pulling the end outward 09 24 2007 1 Steps 2 Grab Handle 1602335 3 Deck Plate Fig 3 11 Back of Cab Access 01 18 95 1540036a Fig 3 12 Battery Box Cover 3 6 Vehicle Access 01 18 95 880023a Fig 3 13 Hood Tilting 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 Using the bumper step and grab handle slowly tilt the hood until the stop cables or straps sup port it To Return the Hood 1 Grasp the grab handle and lift the hood to the 45 degree position 2 As the hood goes over center use the bumper step and grab handle to control the rate of de scent to the operating position 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 Windshield Washer Reservo
101. 4 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 eral times The air governor should cut in the air compressor at approximately 100 psi 689 kPa If the air governor does not 11 12 Pretrip and Post Trip Inspections and Maintenance 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 24 4 Check the air leakage in the system as follows With the parking brake spring brake ap 9 plied the transmission out of gear and the tires chocked charge the air system until cut out pressure of 120 psi 827 kPa is reached With the service brakes released shut down the engine wait one minute and note the air pressure gauge reading Ob serve the air pressure drop in psi kPa 10 11 2005 1421397 A Rotate the control arm toward the brake chamber per minute until you can feel it contacting the internal stop 1 Clevis 6 Control Arm Washers Charge the air system until cut out pres 2 Slack Adjuster and Nut sure of 120 psi 827 kPa is reached With 3 Clevis Pin 7 Anchor Strap Slo
102. 439 Fig 10 9 Plunger Positions CAUTION After moving the fifth wheel to the desired posi tion be sure the trailer landing gear will not at any time come in contact with the tractor frame or other components Make sure that the front of the trailer will not come in contact with the rear of the cab or with other components if they ex tend beyond the rear of the cab 7 Apply the tractor parking brakes NOTE The fifth wheel may have to be moved slightly to enable the locking plungers to enter the fully locked position 8 Lock the sliding member into position using one of the following methods Check to be sure that the slide plungers are in the locked position Failure to achieve complete lockup may allow disengagement of the tractor from the trailer possibly resulting in serious per sonal injury or death 8 1 For air operated models set the cab operated control switch to LOCK Visually check the slide plungers to make sure they are engaged in the fully locked posi tion 8 2 For double manual release models lift the plunger holdout latch on each side of the mounting brackets Then move the re lease plunger on each side of the mount ing brackets Fig 10 3 into the locked position Make sure that the slide plungers are engaged in the fully locked position See Fig 10 9 8 3 For single manual release models trip the release lever Fig 10 4 to allow the slide plungers to retract to the locke
103. 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 Ottawa Ontario Canada K1A ON5 For additional road safety information please visit the Road Safety website at www tc gc ca roadsafety menu htm STI 203 1 1 10P A24 00509 000 Printed in U S A Foreword 1989 2010 Daimler Trucks North America LLC All rights reserved Daimler Trucks North America LLC is a Daimler company No part of this publication in whole or part may be translated reproduced stored in a retrieval system or transmitted in any form by any means electronic mechanical photocopying recording or otherwise without the prior written per mission of Daimler Trucks North America LLC For additional information please contact Daimler Trucks North America LLC Service Systems and Documentation P O Box 3849 Portland OR 97208 3849 U S A or refer to www Daimler TrucksNorthAmerica com and www FreightlinerTrucks com Chapter o o 4o001i 0 Nh Contents Page Introduction Environmental Concerns and Recommendations Event Data Recorder Customer Assistance Center Reporting Safety Defects ens use K E RPeed
104. Control Valve Switch 21 Transmission Oil Temperature Gauge 22 Forward Differential Oil Temperature Gauge 23 Rear Differential Oil Temperature Gauge 24 Engine Oil Temperature Gauge 25 Turbocharger Boost Pressure Gauge 26 Fuel Pressure Gauge 27 Automatic Engine Idler Timer 28 Intake Air Restriction Gauge 29 Digital Clock 30 Radio optional Fig 2 1 Instrument and Control Panel Layout upper dash Pre EPA07 2 1 Instruments and Controls Identification 5 1e 0008000006 zx ISR 6 ff Se Rz 663 amp 3 as i zee Be 9 WEZ WEZ WO 19 il fF SB 14 Il Welt A i M SN ss HN v AOEO Cas 7 EN 2 N Ae EI O Were SD ae ANTA URA Xe e 2 ED 03 14 2007 f600831a NOTE Instruments and controls and their locations may vary from those shown Water Temperature Gauge 2 Engine Oil Pressure Gauge 3 Pyrometer 4 Tachometer 5 Warning and Indicator Light Module VIGIL and Kysor shown 6 Engine Malfunction Indicator Light MIL 7 DPF Regen Warning Light 8 High Temperature Exhaust Warning Light HEST 9 Parking Brake Indicator Light 10 Antilock Braking System ABS Tractor Warning Light 11 ABS Trailer Warning Light dash light for DDEC Optimized Idle if so equipped 12 Air Suspension Warning Light 13 Speedometer Odometer 14 Application Air Pressure Gauge 15 Dual System Air Pressure Gauge 16 Voltmeter
105. E TO THIS VEHICLE WHEN COMPLETED IS NOT SUBSTANTIALLY AFFECTED BY THE DESIGN OF THE CHASSIS CAB 09 28 98 f080023 Fig 1 4 Incomplete Vehicle Certification Label U S that the vehicle conforms to all applicable FMVSS regulations in effect on the date of completion Vehicle Identification 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 EG ohNAD 963 Transpo CMVSs o o o OvASV o 10 10 2006 1080024 Fig 1 5 Canadian National Safety Mark 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 attached to the left rear door post certify suitable tire and rim combinations that can be installed on the vehicle for the given gross axle weight rating See Fig 1 6 Tires and rims in stalled on the vehicle at the time of manufacture may have a
106. E der na oa RR eae 2 1 CONOIS as Teen e an eee he ee wings heck eee cca in tae rates od each ae ge ta Carla IN 2 1 Warning and Indicator Lights occ ceca dc ies eens sidad kaa tamaai a ress Meese E Reni Reims 2 13 Collision Warning System CWS Eaton VORAD EVT 300 Optional lle 2 20 DVS TUM IS BTE ETE TTE TCR TTPRRDTLITCRP m 2 25 Exterior Switches Instruments and Controls Identification Instrument and Control Panel Figure 2 1 Figure 2 2 and Figure 2 3 represent a portion of a typical Freightliner dash equipped with all of the standard and many of the optional instruments and accessories Most standard and optional instru ment gauges and switches can be mounted in this dash NOTE On SilverAero models switches for cruise control and manual control for the engine fan are standard If these features are not re quested dummy switches with blank labels are installed A warning and indicator light module located above the speedometer and tachometer houses all of the standard and optional warning and indicator lights Some of the controls discussed in this chapter are not dash mounted Controls Ignition Switch and Key The ignition switch Fig 2 4 can be turned to three positions Off Accessory and On In addition the same key locks and unlocks the cab doors bag gage door s and if equipped the bunk door s In the Off position the key slot is v
107. 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 service and maintenance manuals Custom built Freightliners are equipped with various chassis and cab components Not all of the informa tion contained in this manual applies to every ve hicle For details about components in your vehicle refer to the chassis specification pages included in all new vehicles and to the vehicle specification decal located inside the vehicle For your reference keep this manual in the vehicle at all times IMPORTANT Descriptions and specifications in this manual were in effect at the time of printing Freight liner Trucks reserves the right to discontinue models and to change specifications or design at any time without notice and without incurring obligation De scriptions and specifications contained in this publi cation provide no warranty expressed or implied and are subject to revisions and editions without no tice Environmental Concerns and Recommendations Whenever you see instructions in this manual to dis card materials you should first attempt to reclaim and recycle them To preserve our environment fol low appropriate environmental rules and regulations when disposing of materials Event Data Recorder This vehicle is equipped w
108. Freightliner Power 6000 or nonpower 5000 seat available from Dura Form These seats offer air lumbar infinite recline a map pocket a rear storage pocket and a pen glasses pocket The Power 6000 seat offers 6 way power adjustment Back Cushion Tilt To tilt the back cushion through a range of 10 de grees push down on the handle Move the back cushion to the desired position and release the lever Height Adjustment Push in the knob to inflate the suspension and raise the seat height Pull out on the knob to deflate the suspension and lower the seat height Isolator Lockout and Fore Aft Seat Adjustment Move the lever to the left to adjust the seat to the desired fore aft position Move the lever to the center position to lock out the isolator feature Move the lever to the right to engage the isolator 5 6 Seats and Seat Belts 02 09 95 f910003a Back Cushion Tilt Handle Height Adjustment Knob Isolator Lockout and Fore Aft Adjustment Lever Seat Cushion Adjustment Lumbar Support Lever Q RON Fig 5 11 Dura Form Fleetcruiser Seat Seat Cushion Adjustment To put the seat cushion in the upper position lift up ward on the front of the cushion then push rearward To put the seat cushion in the lower position pull for ward and then push downward Lumbar Support Rotate the lever on the right side of the back cushion to any of the three positions as desired Eldorado Seat Fig 5 12 Back Cus
109. Jumper Cables When using jumper cables follow the instructions below Batteries release explosive gas Do not smoke when working around batteries Put out all flames and remove all sources of sparks or intense heat in the vicinity of the battery Do not allow the ve hicles to touch each other Do not lean over the batteries when making connections and keep all other persons away from the batteries Failure to follow these precautions could lead to severe personal injury as a result of an explosion or acid burns CAUTION Make sure both starting 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 1 Apply the parking brakes and turn off the lights and all other electrical loads 2 Connect an end of one jumper cable to the posi tive terminal of the booster battery or jump start post if equipped and connect the other end of the cable to the positive terminal of the dis charged battery or jump start post if equipped See Fig 13 3 Do the next step exactly as instructed and do not allow the clamps of one cable to touch the clamps of the othe
110. KED WHEN VEHICLE IS IN MOTION 22 11571 3 02 09 94 f310047a Fig 10 8 Fifth Wheel Slide Control Switch 2 2 For double manual release slide models pull both plunger release handles Fig 10 3 outward from each side of the mounting brackets to the unlocked posi tion Position the plunger holdout latch in the groove of the plunger See Fig 10 9 For single lever release slide models use the release hook to pull the lever to the unlocked position Fig 10 7 Lift the re lease lever to the secure position behind the catch Visually check the slide plung ers to make sure they have released as shown in Fig 10 9 3 Lower the trailer landing gear just enough to re move the weight from the tractor 4 Pull the trailer air supply valve to cut off the air supply to the trailer 5 Chock the front and rear of the trailer tires to prevent the trailer from moving Do not use the trailer air supply for parking trail ers not equipped with spring parking brakes This applies the trailer service brakes only As air bleeds from the trailer brake system brake appli cation is lost This could allow the unattended vehicle to roll away possibly resulting in serious personal injury or death 6 Slowly move the tractor forward or backward until the fifth wheel is in the desired location Fifth Wheels and Trailer Couplings 01 24 96 A Locked engaged B Unlocked disengaged 1 Plunger f310
111. Low Range 1 Splitter Control Button Fig 8 4 Eaton Fuller 13 Speed RTO Model Transmissions Shift Patterns 18 Speed RTLO Models Eaton Fuller 18 speed RTLO model transmissions have eighteen forward speeds and four reverse con sisting of a 5 speed front section and a 3 speed aux iliary section The auxiliary section contains low and high range ratios plus an overdrive splitter gear One ratio in the front section low is used as a start ing ratio it is never used when the transmission is in high range The other four ratios in the front section are used once in low range and once again in high range however each of the five ratios low 1 2 3 4 in low range and each of the four ratios 5 6 7 8 in high range can be split with the overdrive splitter gear All of the eighteen speeds are controlled with one shift lever Built into the shift knob of the lever are a range preselection lever and a splitter control button on the side of the shift knob that control range se lection and gear splits respectively Operation Eaton Splitter and Range Shift IMPORTANT On 13 speed transmissions the shifter knob has an interlock feature that pre vents the splitter control button from being moved forward when the range preselection 8 5 lever is down in low range When in high range and the splitter control button is in the forward position the range preselection lever cannot be moved down 1 Whe
112. Maintenance 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 Heavy Duty Trucks Service Manual for instructions or take the vehicle to an authorized Freightliner dealer 1200036a B Belt Free Span 10 31 94 A Deflection Fig 11 16 Checking Belt Tension 6 Inspect the seat belts and tether belts Inspect and maintain seat belts as instructed below Worn or damaged seat belts could fail during a sudden stop or crash possibly resulting in serious injury or death IMPORTANT Seat belts have a finite life which may be much shorter than the life of the vehicle Regular inspections and re placement as needed are the only assur ance of adequate seat belt security over the life of the vehicle NOTE When any part of a seat belt needs replacement the entire seat belt must be replaced both retractor and buckle side 6 1 Check the web for fraying cuts or ex treme wear especially near the buckle latch plate and in the D loop guide area 6 2 Check the web for extreme dirt or dust and for severe fading from exposure to sunlight 6 3 Check the buckle and latch for operation and for wear or damage 6 4 Check the Komfort Latch for function and cracks or other damage 11 15 6 5 Check the web retractor for function and damage 6 6 X Check the mounting bolts for tightness and tighten any
113. Shift IMPORTANT The shifter knob has an interlock feature that prevents the splitter control button from being moved up when the range selection lever is down in the low range when the trans mission is in the high range and the splitter control button is up the range selection lever cannot be moved down Reverse To drive in reverse push the range selector lever down to put the transmission in the low range Push the clutch pedal to the bottom of travel so the clutch brake slows the transmission for initial gear engage ment Holding the clutch pedal at the bottom of travel shift into reverse Slowly release the clutch pedal to move the vehicle in reverse Upshifting 1 To drive forward make sure the vehicle is com pletely stopped and the range selector lever is pushed down to put the transmission in the low range Push the clutch pedal to the bottom of travel so the clutch brake slows the transmission for initial gear engagement Holding the clutch pedal at the bottom of travel shift into low 2 Slowly release the clutch pedal to begin moving the vehicle forward 3 To upshift into 1st gear only partial depression of the clutch pedal is needed Do not push the clutch pedal all the way to the floor and engage the clutch brake instead partially depress the clutch pedal and move the shift lever into neu tral 4 Release the clutch pedal and allow the engine to decelerate until the road speed and the engine
114. TO Controls 1 1 Setthe parking brake 1 2 Turn on the switch labeled GOVERNOR or FAST IDLE for vehicles with a preset PTO system 13 For vehicles with a variable PTO use the potentiometer knob to adjust the engine rpm 2 Operating the PTO Using Cruise Control Switches 2 1 To engage the PTO flip the ON OFF Switch on the instrument control panel to ON 2 2 Hold the throttle pedal until the tachometer indicates the desired speed 2 3 Momentarily move the SET RESUME Switch on the instrument control panel to SET or push the SET button on the trans mission shift knob 2 4 To disengage the PTO depress the brake pedal or clutch pedal or flip the ON OFF switch on the instrument control panel to OFF or press the PAUSE button on the shift knob 3 To resume a previously selected engine speed 3 1 If the ON OFF switch on the instrument control panel is in the OFF position flip it to ON 3 2 Momentarily move the SET RESUME Switch on the instrument control panel to RESUME or press the RESUME button on the transmission shift knob To adjust engine speed up or down hold the SET RESUME switch on the instru ment control panel at SET to accelerate or at RESUME to decelerate until the desired speed is reached or press the SET button on the transmission shift knob to acceler ate or the RESUME button to decelerate until the desired speed is reached Optimized Idle The Optimized Idle option on DDEC IIl equipped ve
115. This could cause an explosion resulting in serious personal injury or death 1 Before engine start up perform the engine pre trip inspection and daily maintenance checks in Chapter 11 Set the spring parking brakes Turn the ignition switch to the on position 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 NOTE The engine electronics supply the cor rect amount of fuel for starting the engine Pedal pressure is unnecessary 4 Turn the ignition switch to the start position Do not press down on the throttle pedal Release the switch the moment the engine starts If the engine does not start after 30 seconds of crank ing turn the ignition switch off 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 For air start systems check the air supply before starting the engine There must be 100 psi 689 kPa of air pressure available 5 Wait two minutes to allow the starter motor to cool Turn the ignition switch back to the on posi tion and try to start the engine again CAUTION If the oil pressure is less than 5 psi 35 kPa shut down the engine immediately to prevent serious damage If the vehicle is equipped with an auto matic shutdown sy
116. To deactivate the cruise control must be set for the automatic shutoff option to 2 1 Depress the brake pedal or clutch pedal work To start the engine follow the normal or start up procedure Hold the throttle pedal until the soeedom eter indicates the desired speed 13 Momentarily move the SET RESUME switch on the instrument control panel to SET or push the SET button on the trans mission shift knob 2 2 Flip the ON OFF switch on the instrument Engines equipped with DDEC will idle fast when cold As the engine warms up to operating tem perature the idle speed will decrease Warm the engine until idle speed is normal before operat ing the vehicle Cruise Control A DDEC engine may have cruise control The mini mum speed at which cruise control can be used is 35 mph 56 km h The cruise control is activated by the ON OFF and SET RESUME switches on the dash Fig 7 5 or by optional PAUSE RESUME and SET buttons on the transmission shift knob Fig 7 6 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 7 15 control panel to OFF or push the PAUSE button on the transmission shift knob To resume a preselected cruise speed 3 1 If the ON OFF switch on the instrument control panel is in the OFF position flip it to
117. ad speed 1 6 Move the shift lever to the next lower gear 2 To downshift through the rest of the gears re 1 1 Press the top portion of the shift intent peat the substeps above Before each downshift switch push the bottom of the shift intent switch into the 1 2 Apply pressure with the shift lever toward zum M 10 break torque The range the neutral position 1 3 Press the top portion of the shift intent 5 i pho s I iie Taa bci switch again far enough so that the n n ies ys a Fe ONENE switch goes into a second position inside OVE gear MALIS SAPPE the body of the shift handle Then release the switch See Fig 8 20 This will break Reverse torque 1 Press the system switch on the shift handle so 1 4 Immediately move the shift lever to the ence us ON position and the ESS system neutral position 2 Push the clutch pedal to the bottom of its travel 1 5 Allow engine rpm to slow down enough to synchronize with road speed so that the clutch brake stops the transmission input shaft from rotating 8 22 Transmissions 3 Move the shift lever and engage reverse 4 Slowly release the clutch pedal and move the vehicle in the reverse direction NOTE If a HI reverse range is required follow the steps below 5 Press the system switch on the shift handle so that it is in the OFF position and the ESS system is deactivated 6 Press the top portion of the shift intent switch to engage the HI range 7 Push the clutc
118. aded RO Rus ER E Pretrip and Post Trip Inspection Checklists s iuum REESE eS Pretrip and Post Trip Maintenance Procedures Daily Pretrip Maintenance Procedures 5 dx exp e men Monthly Post Trip Maintenance Procedures Weekly Post Trip Maintenance Procedures S Seat Belts and Tether Belts General Information sn Seat Belt Operation 0 Tether Belt Adjustment Seals Lecce ear Sade GB es He baat ee Bostrom Air 915 Seat leeren Bostrom Seat Air 715 SelMeS 22 4004 268 ba Sie eS yaks nix due Bostrom Smart Seat Model Subject Bostrom Talladega 900 Seat Dura Form Seats Eldorado Seat Freightliner AirChair General Information National Cush N Aire Il Seat National Cush N Aire Seats Model 135 zu item med anus Swivel Seat Sleeper Compartment Bunk Restraints Belt Adjustment Bunk Restraint Operation General Information Sleeper DOOF cns Exon Spicer Straight Shift Models General Information Spicer Straight Shift Operation Spicer Straight fer REP RCRUM Steering System General Information Manual Steering Gear Lubrication snl Power Steering System Tire and Rim Labels
119. age does not indi cate overall usage maintenance and lubrication in tervals for the engine and engine operated equip ment can be determined by operating hours Application Air Pressure Gauge Optional An application air pressure gauge Fig 2 27 regis ters the air pressure being used to apply the brakes and should be used for reference only The gauge will not register air pressure until the foot brake pedal is depressed or the trailer hand brake is applied Instruments and Controls Identification Dual System Air Pressure Gauge A dual system air pressure gauge Fig 2 27 regis ters the constant pressure in the primary and sec ondary air systems Normal pressure with the engine running is 100 to 120 psi 689 to 827 kPa in both Systems A low air pressure warning light and buzzer connected to both the primary and secondary sys tems activates when air pressure in either system drops below a minimum pressure of 64 to 76 psi 441 to 524 kPa When the engine is started the warning light and buzzer remain on until air pressure in both systems exceeds minimum pressure Fuel Gauge The fuel gauge Fig 2 27 indicates the level of fuel in the fuel tank s If equipped with a second op tional fuel gauge each fuel tank level is indicated on a separate gauge Intake Air Restriction Gauge Optional An intake air restriction gauge Fig 2 28 measures the vacuum on the engine side of the air cleaner at the air cleaner
120. ailed operating instructions of the heater air conditioner and the auxiliary heater x x 01 18 95 1600497 Fig 2 11 Heater Air Conditioner Controls 2 9 Jacobs Engine Brake Switches Optional Jake Brake controls consist of two dash mounted toggle switches Fig 2 12 which control the degree of engine braking In conjunction with these switches an engine mounted microswitch controlled by the throttle pedal and an under deck mounted mi croswitch controlled by the clutch pedal actuate the engine brake 10 26 98 Engine Brake Switch Interaxle Differential Lockout Control Valve Switch Fifth Wheel Air Slider Control Valve Switch Parking Brake Control Valve Knob Trailer Air Supply Valve Knob 1600507b or PR Ne Fig 2 12 Brake Switches and Control Valves See Chapter 7 under the heading Engine Braking System Optional for additional information Interaxle Differential Lockout Control Valve Switch Differential lockout standard on all dual drive ve hicles is driver actuated by means of a Lock Unlock control valve switch Fig 2 12 mounted on the control panel A red indicator light comes on whenever the interaxle differential is locked out switch is in the lock position no differential action between the drive axles A guard around the switch prevents it from being accidentally activated Instruments and Controls Identification Fifth Wheel Air Slider Control Valve Switc
121. all times when the vehicle is in motion 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 See Chap ter 11 for the inspection procedure Tether Belt Adjustment 1 Make sure the tether belt is attached to the cab deck and seat frame Also check that the belt webbing is correctly routed through the buckle as shown in Fig 5 14 2 To lengthen the tether belt turn the buckle at a right angle to the webbing then pull the bottom webbing strap through the buckle until the de sired length is reached See Fig 5 15 3 Adjust the seat to the highest ride position With no weight on the seat tighten each tether belt by pulling the middle webbing strap away from the buckle to remove all slack See Fig 5 16 Tether belts should not be so tight as to restrict move ment of suspension seats Be sure the straps are not twisted 5 8 Seats and Seat Belts f910072a 01 18 95 Fig 5 14 Tether Belt Routing 05 30 2006 910073 Fig 5 15 Lengthening the Tether Belt Seat Belt Operation Lap Belt Wea
122. and ATC blink code diagnos tics should only be performed when the vehicle is stopped If the vehicle is equipped with ATC turning on the ABS CHK switch will reduce engine speed to idle for three seconds and af fect ATC function performance If the vehicle is driven with the ABS CHK switch on in the up position the WHL SPIN light will illuminate continuously Under this condition turning the ABS CHK switch off in the down position while the vehicle is still in motion will only turn off the WHL SPIN light but will not restore ATC function performance To fully restore engine and ATC function capability the vehicle must be brought to a complete stop Then move the ABS CHK switch to off in the down posi tion See the brake system operating instructions in Chap ter 6 for more information Bendix Antilock Braking System ABS With the Bendix Antilock Braking System ABS the tractor warning light TRAC ABS comes on after the key is turned on Fig 2 19 The warning light goes out only if all of the tractor s ABS components are working properly If the tractor is attached to a trailer with a compatible ABS system the trailer ABS warning lamp TRLR ABS will also come on momentarily after the key is turned on Vehicles equipped with a Bendix ABS system may also be equipped with an automatic traction control ATC system The ATC system automatically con trols wheel spin during reduced traction starts T
123. and Post Trip Inspections and Maintenance 1470104 02 09 95 Fig 11 4 Davco Fuel Water Separator 02 09 95 1470105 Fig 11 5 Webb Fuel Water Separator 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 and the side and rear win dows then check the condition of the windshield wiper arms and blades 03 03 97 1 14701672 1 Drain Valve Fig 11 6 ConMet Fuel Water Separator 12 1 Replace the wiper arms if the wiper blades are not tensioned against the wind shield 12 2 Replace damaged or deteriorated wiper blades When cleaning windshields and windows always stand on the ground or on a secure ladder or platform Use a long handled window cleaner Do not use the cab steps tires fenders fuel tanks engine or under hood components to access the windshield or windows Doing so could cause a fall and result in an injury 13 Check the oil and air pressure warning systems 13 1 Check if the warning systems come on when the ignition is turned on and if not have the systems repaired 13 2 Start the engine then check that the oil and air pressure warning systems are op erating The buzzer should stop sounding wh
124. and investigate the cause to prevent further damage Do not operate the vehicle until the cause has been determined and corrected Forward and Rear Differential Oil Temperature Gauges Optional During normal operation forward and rear differential oil temperature gauges Fig 2 28 should read be tween 160 to 220 F 71 to 104 C for Meritor drive axles 180 to 200 F 82 to 93 C for Eaton drive axles Under heavy loads such as when climbing steep grades temperatures up to a maximum of 250 F 121 C are not unusual CAUTION A sudden increase in differential oil temperature that is not caused by a load increase may indi cate 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 Turbocharger Boost Pressure Gauge Optional A turbocharger boost gauge Fig 2 28 measures the pressure in the intake manifold in excess of atmos pheric pressure being created by the turbocharger Pana Pacific Digital Clock Optional A Pana Pacific clock Fig 2 28 has black characters on a constantly backlighted green display with a brightness that automatically adjusts for day or night The clock has a 24 hour alarm with a 3 minute snooze feature 1 To set the time of day 1 1 Push the Run Set lower switch to the right TIME SET position NOTE When the hour setting is for a time
125. and the label is located on the B dash panel See Fig 7 8 for the label appearance If equipped with the thermostat mode a thermostat is located in the sleeper above the bunk See Fig 7 9 a OPTIMIZED IDLE e ie TO USE IDLE ENGINE CAUTION CLOSE HOOD ENGAGE PARKING BRAKES TO AVOID PUT BADEN ON IN UNINTENTIONAL NEUTRAL AND VEHICLE MOVEMENT HI RANGE IF EQUIPPED DO NOT MOVE SHIFT THEN MOVE CRUISE SWITCH LEVER OR RANGE FROM OFF TO ON IF DESIRED TURN C SELECTOR WHEN V _THERMOSTAT ON det EQUIPPED L OPTIMIZED IDLE IS ON 11 13 96 1080062 Fig 7 8 Optimized Idle Dash Label 3 4 5 2 6 MODE 7 E Wi S LI 8 1 11 08 96 10 9 1601250 1 Down Button 2 Up Button 3 Upper Lower Temperature Icon 4 Temperature Display 5 Degrees Fahrenheit Indicator 6 Mode Button 7 Cooling Icon 8 Cool Heat Selection Button 9 Heating Icon 10 Degrees Celsius Indicator Fig 7 9 Optimized Idle Thermostat The thermostat consists of an LCD readout and four buttons 7 17 The display normally shows the temperature of the sleeper but changes accordingly as the buttons are pressed The button functions are as follows Up Button increases the set point and comfort zone Down Button decreases the set point and comfort zone Cool Heat Button detects either cooling or heating operation Mode Button scrolls through the various
126. andle 3 Window Release 7 Crank Handle Lever Button 8 Cab Door Vent 4 Slide Channel Fig 3 2 Door Interior Grab Handles and Access 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 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 Vehicle Access 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 the Driver s Side See Fig 3 3 01 18 95 1 Steering Wheel 2 Grab Handle f600066a 3 Top Step 4 Bottom Step Fig 3 3 Driver s Side Steps and Grab Handle When entering the cab from the driver s side use the grab handle and access steps as follows 1 Open the driver s door and place anything that you are carrying in the cab 2 Grasp the grab handle with your right hand Reach up as far as is comfortable 3 Place your right foot on the bottom step and pull yourself up Grasp
127. ange and the shift patterns vary between transmissions Be sure to read the shift pattern decal on the dash for the operating instructions for the specific transmission installed in your vehicle 13 Speed RTO Models Eaton Fuller 13 speed RTO model transmissions have thirteen forward speeds and two reverse speeds Each transmission consists of a 5 speed front section and a 3 speed auxiliary section The auxiliary section contains low and high range ratios plus an overdrive splitter gear See Fig 8 4 for the shift patterns All of the thirteen speeds are controlled with one shift lever Built into the shift knob of the lever are a range preselection lever and a splitter control button on the side of the shift knob that control range se lection and gear splits respectively Low gear in the front section is used only as a start ing ratio The remaining four forward positions are used once in the low range and once in the high range However each of the four high range gear positions can be split with the underdrive ratio RT 8 4 Transmissions models or overdrive ratio RTO models of the split ter gear Ratios cannot be split while the transmis sion is in low range Hi 55 771 R Dir OD Dir OD 1 k lt 3 N 6 6 8 8 LOW Dir OD Dir OD lt 2 gt lt 4 gt er m C D f260044a ua D gt Y 03 13 96 C Forward for Overdrive D Rearward for Direct A Up for High Range B Down for
128. another copy is inside the rear cover of the Owner s Warranty Infor mation for North America booklet COMPONENT INFORMATION MANUFACTURED BY MODEL VEHICLE ID NO USE VEHICLE ID NO WHEN ORDERING PARTS WHEELBASE DATE OF MFR ENGINE NO ENGINE MODEL TRANS NO TRANS MODEL MAIN FRT AXLE NO FRONT AXLE MODEL REAR AXLE NO REAR AXLE MODEL REAR AXLE NO RATIO IMRON PAINT CAB PAINT MFR CAB COLOR A WHITE 4775 PAINT NO CAB COLOR B BROWN 3295 CAB COLOR C BROWN 29607 CAB COLOR D DARK BROWN 7444 FOR COMPLETE PAINT INFORMATION SEE VEHICLE SPECIFICATION SHEET PART NO 24 00273 010 11 21 96 1080021 Fig 1 1 Vehicle Specification Decal U S Built Vehicle Shown NOTE Labels shown in this chapter are ex amples only Actual specifications may vary from vehicle to vehicle Federal Motor Vehicle Safety Standard FMVSS Labels NOTE Due to the variety of FMVSS certification requirements not all of the labels shown will apply to your vehicle Tractors with or without fifth wheels purchased in the U S are certified by means of a certification label Fig 1 2 and the tire and rim labels These labels are attached to the left rear door post as shown in Fig 1 3 If purchased for service in the U S trucks built with out a cargo body have a certification label Fig 1 4 attached to the left rear door post See Fig 1 3 In addition after completion of the vehicle a certifica tion label simil
129. ar to that shown in Fig 1 2 must be attached by the final stage manufacturer This label will be located on the left rear door post and certifies 1 1 s MFRDBY FRONT AXLE GAWR UNE e FIRST INTERMEDIATE AXLE GAWR E gwar SECOND INTERMEDIATE AXLE GAWR i VEHICLE ID NO THIRD INTERMEDIATE AXLE GAWR REAR AXLE GAWR THIS VEHICLE CONFORMS TO ALL APPLICABLE FEDERAL MOTOR VEHICLE SAFETY STANDARDS IN EFFECT ON THE DATE OF MANUFACTURE SHOWN ABOVE VEHICLE TYPE CLASSIFICATION TRUCK TRACTOR y 11 21 96 f080053 1 Date of manufacture by month and year 2 Gross vehicle weight rating developed by taking the sum of all the vehicle s gross axle ratings 3 Gross axle weight ratings developed by considering each component in an axle system including suspension axle wheels and tires The lowest component capacity is the value used for the system Fig 1 2 Certification Label U S H JIN 02 02 95 W LE d INS f600061b 1 Tire and Rim Labels 2 Certification Label Fig 1 3 Location of Labels CHAGSIS CAB MFD BY VEHICLE ID NUMBER THIS CHASSIS CAB CONFORMS TO FEDERAL MOTOR VEHICLE SAFETY STANDARD NOS 101 102 108 04 106107111 11 115 120 12 24 206 206 207208208 210302 THIS VEHICLE WILL CONFORM TO STANDARD NO IF IT IS COMPLETED IN ACCORDANCE WITH THE INSTRUCTIONS CONTAINED IN THE INCOMPLETE VEHICLE DOCUMENT FURNISHED PURSUANT TO 49CFR PART 568 CONFORMITY TO THE OTHER SAFETY STANDARDS APPLICABL
130. arnings will not sound again until the starter is cranked Once the starter is cranked the alarms will sound until system air and oil pressures reach mini mum levels If the lightbar doesn t operate as de scribed here test it For instructions see Group 54 of the Heavy Duty Trucks Service Manual Kysor Vehicle Instrumentation and Protection VIP System Optional The Kysor VIP system is an electronically controlled warning and engine shutdown system It also con trols the turn signal functions and various optional functions A solid state lightbar Fig 2 22 in the in strument panel contains displays for the functions Engine Functions The system monitors engine coolant temperature coolant level and oil pressure e f the engine overheats a warning light comes on and a buzzer sounds The temperature that triggers the warning light and buzzer varies with engine type and is programmed into the System at the factory If the temperature contin ues to rise to critical levels the engine shut down light comes on and the engine will be shut down If the coolant level drops below a sensor in the cooling system the low water level light comes on and a buzzer sounds After 30 seconds the system will shut down the engine The low coolant shutdown feature may be turned on or off by setting a DIP switch in the control mod ule If the oil pressure drops below a preset level the low oil pressure light comes on and a warning b
131. arting gear 1 With the vehicle stopped place the gear select lever in the D or H position to select a starting gear 2 Select the starting gear with the upshift or down shift buttons on the gear select handle Driving in the H Mode if equipped NOTE You must use the upshift and downshift buttons on the gear select handle to change gears while in the H hold mode 1 Depress the clutch pedal 2 Place the shift lever in the H mode 3 Select the starting gear you want 4 Slowly release the clutch pedal Upshifting NOTE In the H mode you the driver decide when to upshift and downshift 1 Accelerate 2 Press the upshift button on the gear select handle To skip shift press twice 3 The transmission automatically selects and shifts to the next gear Downshifting 1 Decelerate 2 Press the downshift button on the gear select handle To skip shift press twice 3 The transmission automatically selects and shifts to the next gear Spicer Straight Shift Models Refer to the Spicer TTC website for additional infor mation www ttcautomotive com General Information Spicer Straight Shift Spicer 7 speed series transmissions are synchro nized in all gears except 1st and reverse They have seven forward gears and one reverse gear See Fig 8 15 for the shift pattern Transmissions JL 6 S R pl v 2 pl 4 Ed 1 3 5 A 03 12 96 f260118 Fig 8 15 Spicer 7 Speed
132. as its own reservoirs plumbing and brake chambers The primary system operates the service brakes on the rear axle the secondary System operates the service brakes on the front axle Service brake signals from both systems are sent to the trailer Steering and Brake Systems 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 The rear service brakes will not work if the primary system loses air pressure but the front brakes and the trailer brakes will continue to work with second ary system air pressure Loss of secondary system air pressure makes the front axle brakes inoperative but rear service brakes and trailer brakes will operate through the primary system Before driving your vehicle allow time for the air compressor to build up at least 100 psi 689 kPa pressure in both the primary and secondary systems Monitor the air pressure system by observing the dual system air pressure gauge and the low air pressure warning light and buzzer The warning light and buzzer shut off when air pressure in both sys tems reaches 64 to 76 psi 441 to 524 kPa The warning light and buzzer come on if air pressure drops below 64 to 76 psi 441 to 524 kPa in either System If this happens check the dual system air pressure gauge to determine
133. at counter clockwise to adjust outlet air temperature Then turn the fan control knob to adjust the air flow level The system will automatically maintain the selected outlet air temperature 2 3 Whenever heat is not desired turn the rotary knob on the temperature rheostat counterclockwise as needed and turn off the fan 4 5 o y SPEAKERS ROFF LEFT O RIGH ae NN Il NS WH 01 18 95 1 Temperature Rheostat 2 Fan Control Knob 1600517a Fig 4 11 Control Panel for Automatic Temperature Control System Air Conditioning Sleeper Heater and Air Conditioner 1 If equipped with the manual temperature control do the following 1 1 Turn on the cab air conditioner For in structions refer to Air Conditioning 1 2 Make sure that the temperature control cable attached to the outlet duct at the foot of the bunk is pushed in all the way Turn the fan control knob to position 3 1 3 When the sleeper compartment cools to the desired temperature turn the fan con trol knob to adjust the air flow level If needed pull the temperature control cable out to adjust outlet air temperature Use the temperature control cable and the fan control knob as needed to help maintain the desired temperature 1 4 Whenever air conditioning is not desired pull the temperature control cable out as needed and turn off the fan NOTE Whenever the refrigerant compressor is operating the fan will always run a
134. between noon and midnight the small letters PM will appear in the lower left corner of the display no PM indicates an A M set ting 1 2 Advance the hour setting to the correct number by pushing and releasing the hour button as many times as needed Or if Instruments and Controls Identification the button is pressed and held in for longer than two seconds the numbers will continue to advance until the button is re leased 1 3 Advance the minute setting by repeatedly pushing or pushing and holding the minute button as needed 1 4 Push the Run Set switch to the middle RUN position To set the alarm time 2 1 Push the Run Set switch to the left ALARM SET position 2 2 Set the alarm time by using the same pro cedure that you used to set the time of day Remember to set the hour for A M no letters in the corner of the display or P M as desired 2 3 Return the Run Set switch to the middle RUN position The readout will return to the time of day setting To operate the alarm 3 1 With the alarm time set push the alarm upper switch to the left An alarm wave symbol and the letters AL will appear in the upper left corner of the display when the alarm is on 3 2 When the displayed time of day coincides with the alarm time the alarm will sound If the snooz button is not pushed or the alarm switch is not moved the alarm will automatically stop sounding after 1 minute and will not
135. bility of mid and high back air suspension seats it is possible to combine the seat back recline ad justment and the seat slide adjustment so that the seat back contacts the backwall It is the 2 12 Instruments and Controls Identification responsibility of the driver to adjust the seat to prevent damage to the seat and the cab interior Dome Light Switches For vehicles with a single dome light mounted on the roof inside of the cab the light is operated by a three position switch mounted in the dome light The switch provides both a low and a high intensity set ting in the middle position the dome light is off For vehicles with a single dome light and two reading lights mounted on the roof inside of the cab each light is operated by its own on off switch mounted in the dome light Tilt Steering Wheel The tilt steering wheel Fig 2 18 has a tilt range of 15 degrees and a telescoping range of 2 5 8 inches 67 mm A control lever is located just below the turn signal switch on the steering column 03 09 94 z 1460309a 1 Control Lever 2 Tilt Wheel Assembly Fig 2 18 Tilt Steering Wheel After adjusting the seat to the desired ride position unlock the steering column by pushing the control lever and holding it all the way down Tilt the steering column to the desired position then release the con trol lever to lock the steering column in place To adjust the height of the steering wheel
136. blinking yellow DPF lamp indicates that a parked regen is required immediately or an engine derate may occur 09 25 2006 f610815a Fig 7 2 Diesel Particulate Filter DPF Status Lamp 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 technician and a record must be maintained for warranty purposes The record must include date of cleaning or replacement vehicle mileage particulate filter part number and serial number 09 25 2006 f610814a Fig 7 3 Malfunction Indicator Lamp MIL The request inhibit regen switch Fig 7 4 located on the dash may have three selectable positions request regeneration default can include appropriate normal state condition either in an automatic regeneration or inhibit state e inhibit regeneration NOTE The regen switch can start an active regen only when at least one of two conditions exists either the DPF light is lit or the engine software calls for it If neither of those conditions exist the regen switch cannot cause a regen eration to happen The function of the switch will vary by the engine make and model in the vehicle See the engine op eration manual for switch operation details Engine Starting For cold weather starting refer to Ether Start Sys tem in this chapter 7 2
137. box IMPORTANT Each key is numbered Record the number so if needed a duplicate key can be made Cab Door Locks and Handles To unlock the driver s door from outside the cab in sert the key in the lockset and turn it one quarter turn clockwise See Fig 3 1 Turn the key counterclock wise to the original position to remove it Pull out on the paddle handle to open the door See Fig 3 1 01 18 95 1 Lockset 1 1720055a Paddle Handle Fig 3 1 Exterior Door Handle To unlock the passenger s door from outside the cab insert the key in the lockset and turn it one quarter turn counterclockwise Turn the key to the original position to remove it NOTE The cab door locks can be operated when the doors are open To lock a door from outside the cab insert the key in the lockset and turn it opposite the unlocking direc tion then close the door if it is open Or push down the inside lock button Fig 3 2 then close the door To lock either door from inside the cab push down the lock button Fig 3 2 then close the door if it is open Pull the integral grab bar Fig 3 2 when clos ing the door To open the door from the inside pull the door handle toward you See Fig 3 2 This will unlatch the door whether or not it is locked To unlock the door without unlatching it pull the lock button up 3 1 4 5 1 2 3 6 7 8 10 26 98 1720004b 1 Lock Button 5 Release Lever 2 Integral Grab Bar 6 Door H
138. bris See Group 42 of the Heavy Duty Trucks Service Manuato replace any damaged parts 21 5 On all parking brake installations make sure the end cover cap or dust plug is se curely snapped into place NOTE On most MGM parking brake cham bers equipped with an integral release bolt an end cover cap is installed over the re lease bolt 21 6 Check for rusted connections missing snap rings and damaged camshaft grease seals Have damaged or missing parts repaired or replaced Inspect the air brake lines 22 1 Check the clearance between the hoses and the exhaust manifold or other hot spots Excessive heat will cause material in the hoses to deteriorate rapidly or be come brittle Provide at least 6 inches 150 mm of clearance More clearance is recommended if the hose is located above the heat source 22 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 22 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 22 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 22 5 Observe the hose cover condi
139. c Engines Operator Control 2 5 Detroit Diesel Electronic Engine Control DDEC Operator Control saote ee eee oe oe RR 2 3 Dome Light Switches 2 13 Engine Start Button 22 222 nt aras 2 8 Ether Start Push Button Optional i v rus naota p wy ee eo ab ec og ob 2 6 Fifth Wheel Air Slider Control Valve Switch Optional Air Operated Sliding Fifth Wheel coner pani Gd 2 10 Fog Light Switch Optional 2 7 Fuel Tach Switch Optional 2 7 Hazard Warning Light Tab 2 12 Headlight Dimmer 204 2 12 Index Subject Headlight Switch and Daytime Running Lights Heater Air Conditioner Controls Standard and Auxiliary Heater Switch Optional Ignition Switch and Key Interaxle Differential Lockout Control Valve Switch Interrupt Switch Jacobs Engine Brake Switches Optional Left and Right Windshield Fan Switches Optional Ceiling Mounted Fans Low Voltage Disconnect Optional Manual Override Push Button Optional Engine Shutdown System Mirror Heat Switch Optional Panel Lamp Control Knob Parking Brake Control Valve and Trailer Air Supply Valve Power Mirrors Suspension Seat Adjustment Controls Tilt Steering Wheel Trailer Brake Hand Control Valve Lever Transmission Controls Turn Signal Lever Utility Light Switch Optional Windshield Wiper Washer Controls Dashboard Care Defogging and Defrosting Using Fresh Ai
140. c function to work the ve hicle must be equipped with a rear axle air suspen sion and ABS Automatic Traction Control is recom mended for optimal vehicle traction control Automatic Engine Idler Timer Optional A Henke automatic engine idler timer Fig 2 15 al lows the driver to select the idle time required for en gine shutdown The driver can turn off the ignition remove the ignition key lock the vehicle and leave it with the engine idling The automatic timer will shut the engine off at the end of the selected time y 1 2 p MM 2 Sf V4 4 mc AS 2 Oo sth WHEEL 42 3 str ALARM on lt Sux T 4 PM p 4 10 5 E KYSO e amp 7 BP O OQ 4 a orF VoL PULL MONO 01 18 95 PUSH aw s amp laio f600508a 1 Automatic Engine Idler Timer 2 Kysor Digital Clock Fig 2 15 Engine Idler Timer and Clock Cigarette Lighter Push the lighter in Fig 2 16 to heat the element The lighter will stay in and will automatically pop out when the element is hot 01 18 95 1 Cigarette Lighter 2 Air Window Control Valve Switch 3 Antenna Connection 4 CB Radio Connections f600146a Fig 2 16 Window Control Switch Air Window Control Valve Switch Optional Right Hand Air Window WARNING Before raising the window be sure that hands fingers and other body parts or objects are away from the window frame Otherwise serious physi cal injury could result Instruments an
141. ce them 17 Make sure all the exterior lights are working properly Check that all the lights and reflectors are clean See Fig 11 7 17 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 17 2 Test the high and low beams of the head lights 17 3 Replace light bulbs or sealed beam units that are not working 6 3 05 08 95 5 1000018a 1 Clearance Lights 5 Turn Signals and 2 Identification Lights Side Marker Lights 3 Fog Lights 6 Intermediate Turn 4 Headlights Signal Lights Fig 11 7 Exterior Lights 17 4 Be sure all reflectors and lenses are in good condition and are clean Replace any broken reflectors or lenses 18 Check tire inflation pressures using an accurate tire pressure gauge Tires should be checked when cool For inflation pressures and maximum loads per tire see the tire manufacturer s guidelines A weekly pressure loss of 4 psi 28 kPa or more in a tire may indicate damage The tire should be inspected and if necessary repaired or replaced 18 1 Be sure valve stem caps are on every tire and that they are screwed on finger tight 18 2 Inflate the tires to the applicable pressures if needed 18 3 If a tire has been run flat or underinflated check the wheel for proper lockring and side ring seating and possible w
142. ce brakes with full system air pressure use the parking brake control valve yellow knob to 6 2 Steering and Brake Systems bring the vehicle to a complete stop in the saf est location possible NOTE If equipped with main and auxiliary transmissions do not shift both transmissions into Neutral while the vehicle is rolling Shifting both transmissions back into gear would be diffi cult while the vehicle is rolling The trailer brake hand control valve Fig 6 2 actu ates the trailer service brakes independently from the vehicle chassis service brakes The valve can be partially or fully applied but in any partially on posi tion it will be overridden by a full application of the foot brake control pedal Moving the valve handle clockwise actuates the trailer brakes while moving it counterclockwise releases the trailer brakes The valve handle remains in the position selected until it is manually moved 11 06 98 1 Turn Signal Lever 2 Trailer Brake Hand Control Valve 3 Hazard Warning Light Tab f460002b Fig 6 2 Steering Column Mounted Controls Do not use the trailer service brakes for parking they are not designed for this purpose If air bleeds out of the trailer air tank during parking the vehicle could roll causing serious personal injury or property damage The red octagonal shaped knob Fig 6 3 in the con trol panel actuates the trailer air supply valve After the vehicle s air hoses
143. celerator pedal all the way down and keep it there as the vehicle moves up the grade If the engine contin ues to maintain a satisfactory road speed re main in that gear for the entire grade If the hill causes a steady decline in engine rpm downshift as required until the engine can main tain a stable uphill speed Make full use of each gear before going to a lower gear By remaining in a gear until arriving at the speed of the next lower gear the vehicle will top the grade in the best possible time on less fuel and fewer shifts Because of their constant horsepower over a wide speed range Detroit Diesel engines can be operated at full throttle at lower rpm than other engines This offers benefits in fuel economy and engine life And more than likely it will be pos sible to top most grades without downshifting When the vehicle starts into a grade allow the engine to lug down to maximum torque rpm be fore downshifting Downshift if required at maxi mum torque rpm also or at the predetermined road speed for the next lower gear Do not be afraid to lug the engine down It has more than enough torque at low rpm to keep a loaded vehicle moving against a grade and it won t harm the engine The driver who is not familiar with the vehicle s shift points can greatly improve driving skill by learning them for all gears By knowing rather than guessing where the shift points are it is possible to avoid overspeeding the engine
144. ciated with preparation of equipment for low temperature opera tion are winterization and arctic specifications Winterization of the engine and or components so that starting and operating are possible in the lowest temperature to be encountered requires A Proper lubrication with low temperature lubricat ing oils B Protection from the low temperature air The metal temperature does not change but the rate of heat dissipation is affected C Fuel of the proper grade for the lowest tempera ture D Heat to raise the engine block and component temperatures to at least 25 F 32 C for start ing in lower temperatures E Electrical equipment capable of operating in the lowest expected temperature All switches con nections and batteries in the electrical system should be inspected and kept in good condition to prevent losses through poor contacts Arctic specifications refer to the design of material and specifications of components necessary for sat isfactory engine operation in extremely low tempera tures to 65 F 54 C Contact the nearest Freight liner dealer or Cummins engine dealer to obtain the special items required 7 6 Engines and Clutches CAUTION Antileak antifreezes are not recommended for use in Cummins engines Although these anti freezes are chemically compatible with DCA water treatment the antileak agents may clog the coolant filters IMPORTANT Fuel heaters use
145. cient grease on the fifth wheel plate could result in erratic steering For lubrication instructions see Group 31 of the Heavy Duty Trucks Maintenance Manual Premier Trailer Couplings General Information Trailer couplings used only on trucks are attached to the rear closing crossmember The Premier 260 and 460 trailer couplings Fig 10 21 have a rigid pintle hook and are air adjusted An air chamber mounted forward of the coupling operates a push rod which pushes against a shoe inside the coupling The shoe maintains con stant pressure on the eye of the trailer drawbar when it s over the pintle hook This takes up any slack in the trailer connection providing smoother towing and less wear on the pintle hook The air pressure is acti vated when the trailer brakes are released The Premier 690 trailer coupling Fig 10 22 has a moveable pintle hook and is non air adjusted It is used for heavy duty applications Operation Trailer Hookup 1 Chock the front and rear tires of the trailer 2 Open the coupling Models 260 and 460 Fig 10 21 Pull up on the pawl lock then while squeezing the pawl wedges together lift up the pawl assembly Lift up the latch and push it up against the pawl as sembly locking the latch in place Model 690 Fig 10 22 Remove the linchpin from the handle then push in on the handle and turn it toward you Open the pintle hook by pull ing it down and toward you Release the handle
146. cks NOTICE Always make sure the connect hanger support keeps the trailer air hoses and electrical cables positioned so that they do not rub on anything Rubbing may wear through hoses or cables re sulting in air leaks or exposed or broken wires potentially affecting trailer brake or electrical sys tems 9 After lockup is completed connect the tractor to trailer air system lines and electrical cable to the trailer Take care to prevent dirt or foreign mate rial from entering the air system lines 10 Charge the air brake system with air Make sure that the air connections do not leak Adjust the jaw pin if there is more than 1 8 inch 3 mm clearance between the kingpin and the lock Incorrect adjustment could cause the trailer to disconnect possibly resulting in serious per sonal injury or death 11 With the trailer wheels chocked and the brakes set check for clearance between the kingpin and the fifth wheel jaws by moving the tractor forward and backward against the locked kingpin A clearance of approximately 1 16 inch 1 6 mm between the jaw and kingpin is allowable When clearance between the jaw and kingpin exceeds Fifth Wheels and Trailer Couplings 1 8 inch 3 2 mm adjust the jaw to restore the 1 16 inch 1 6 mm clearance between the jaw and kingpin For instructions see Group 31 of the Heavy Duty Trucks Service Manual 12 Retract the trailer landing gear and secure the ratchet handle 13 Rem
147. cle and its air hoses are connected to a trailer and the pressure in the air system is at least 65 psi 447 kPa push the trailer air supply valve knob in it should stay in to charge the trailer air supply system and release the trailer spring parking brakes Before disconnect ing a trailer or when operating a vehicle without a trailer pull the trailer air supply valve knob out See Chapter 6 under the heading Brake System for instructions regarding use of the trailer air supply valve and parking brake valve Controlled Traction Differential Control Valve Switch On vehicles equipped with an Eaton single drive rear axle a controlled traction differential feature is stan dard A control valve switch Fig 2 13 engages and disengages the controlled traction feature A guard is positioned around the switch to prevent it from being accidentally activated See Chapter 9 for complete operating instructions PETN N DO NOT S TN o2 ENGAGE Se ay DURING AL VO USPIN OUT n TRACTION CONTROL DIFFERENTIAL LOCK UNLOCK 10 04 93 1600307 Fig 2 13 Controlled Traction Differential Control Valve Switch Air Suspension Dump Valve Optional The air suspension dump valve allows the air in the vehicle air suspension to be quickly exhausted low ering the rear of the vehicle This makes it easier to connect to or disconnect from a trailer A control valve switch Fig 2 14 exhausts and fills the air sus pension To
148. ctivated Interrupt Switch A spring loaded interrupt switch Fig 2 8 temporarily deactivates the marker lights and taillights With the vehicle lights on raise and release the interrupt Switch to briefly turn off the marker lights and tail lights Windshield Wiper Washer Controls Air Wipers To operate the air wipers turn the Wash Wipe knob Fig 2 10 clockwise To increase wiper speed con tinue to turn the knob clockwise Turning the knob counterclockwise decreases wiper speed To turn the windshield wipers off turn the knob counterclockwise to its full stop When the wiper blades are parked release the knob x 01 18 95 1 Windshield Wiper Washer Control Knob 2 Intermittent delay Wiper Control Knob 1600433 Fig 2 10 Windshield Wiper Washer Controls The Delay switch controls intermittent operation with air wipers Rotating the knob clockwise in creases the time interval between wiper strokes Turn the knob clockwise until the desired interval is reached The longest delay is approximately 10 sec onds between strokes The delay knob operates the delay feature only it will not turn the wipers on IMPORTANT After using the intermittent wind shield wipers turn off the wiper control Fig 2 9 and the intermittent delay control If the wiper control is off but the intermittent con trol remains on that control will continue to cycle whenever the ignition is in the on or ac c
149. curs 5 Apply the tractor parking brakes 6 Make a visual and physical check for positive kingpin lockup When lockup has occurred the fifth wheel control handle will have moved to the locked position Make sure that the safety latch is down over the lock control handle See Fig 10 19 This will hold the control handle in the locked position 7 Release the tractor parking brakes Test for king pin lockup by pulling on the trailer against the chocks NOTICE Always make sure the connect hanger support keeps the trailer air hoses and electrical cables positioned so that they do not rub on anything Rubbing may wear through hoses or cables re sulting in air leaks or exposed or broken wires potentially affecting trailer brake or electrical sys tems 8 After lockup is completed connect the tractor to trailer air system lines and the electrical cable to l 2 pii 02 09 95 9 NOTE Make sure the safety latch is down when the control handle is locked A Unlocked 1 Safety Latch f310110a B Locked 2 Lock Control Handle Fig 10 19 Fontaine 5000 Series Fifth Wheel Locking and Unlocking the trailer Take care to prevent dirt or foreign material from entering the air system lines 9 Charge the air brake system with air Make sure that the air connections do not leak WARNING Eliminate slack between the trailer and the trac tor Incorrect fifth wheel adjustment could cause the trailer to
150. d Kingpin Lock Control Handle Plunger Holdout Latch Slide Plunger Release Handle one side each Plunger Release Spring 1310332b Bom Fig 10 3 Double Manual Release Slide sides of the sliding member A hook is used to move the lever to the locked and unlocked positions Fifth Wheels and Trailer Couplings 1310528 3 Plunger Adjustment 02 12 96 1 Release Lever 2 Up Shock Bushing Fig 10 4 Single Manual Release Slide Type B Kingpin Lock Mechanism Fig 10 5 The Type B kingpin lock mechanism utilizes two spring loaded lock halves The final forward motion of the kingpin into the open lock halves forces the locks to close in a 360 degree grip around the shoul der and neck of the kingpin positioning sliding yokes between the lock halves and tapered rib members of the fifth wheel understructure The kingpin can be released only by manually operating the kingpin lock control handle The adjustment nut will compensate for wear on the lock or kingpin Lockguard Fig 10 6 The Holland lockguard is a device that prevents a false lockup and is used with Type B kingpin lock mechanisms The Lockguard is a spring tensioned smooth surfaced tongue that the kingpin passes over and depresses when entering the lock mechanism The Lockguard will prevent the locks from engaging before the kingpin fully enters the locks If the kingpin enters the fifth wheel incorrectly and does not de pre
151. d 7th to 9th With the shift but ton forward 2nd to 4th 4th to 6th 6th to 8th 8th to 10th NOTE Lever only shifts skip an entire gear ratio and will require the engine rpm to decrease twice the amount of a normal shift 5 Combination button lever shift Preselect the next gear by sliding the shift button rearward Break torque by releasing the throttle and de pressing the clutch pedal Double clutch and move the shift lever to the next desired gear po sition The combination button lever shift is used for gear changes from 2nd to 3rd 4th to 5th 6th to 7th and 8th to 9th Downshifting A CAUTION Do not attempt a button only downshift at too high an engine speed generally above 1400 rpm Doing so could result in damage to the en gine transmission and or driveline 1 Button only shift With the throttle still applied preselect the next gear by sliding the shift button rearward Break torque by releasing the throttle or by depressing the clutch pedal Increase en gine speed to synchronize the engine speed with the transmission speed The shift will complete when the engine rpm has increased to the proper speed The button only shift is used for gear changes from 10th to 9th 8th to 7th 6th to 5th 4th to 3rd and 2nd to 1st CAUTION Do not attempt a lever only downshift at too high an engine speed generally above 1000 rpm Doing so could result in damage to the engine transmission and or drive
152. d Controls Identification A toggle switch Fig 2 16 controls the air window Push the switch up to raise the window or push it down to lower the window CB Radio Connections An antenna connection and positive and negative 7 power connections are provided for a CB radio See Fig 2 16 Turn Signal Lever The turn signal lever Fig 2 17 is mounted on the steering column Pushing the lever counterclockwise turns on the left turn signal lights pushing it clock wise turns on the right turn signal lights When one of the turn signal lights is on a green indicator light flashes at the far left or far right of the warning and indicator light panel To cancel the signal return the lever to the neutral position except when equipped with an optional self canceling switch 01 18 95 1 Turn Signal Lever 2 Hazard Warning Light Tab 3 Headlight Dimmer Push Button 4 Trailer Brake Hand Control Lever f460194a Fig 2 17 Turn Signal Lever Hazard Warning Light Tab The hazard warning light tab Fig 2 17 is located below the lever on the turn signal switch Activate the hazard warning lights by pulling the tab out When the hazard warning light tab is pulled out all of the turn signal lights and both of the indicator lights on the control panel will flash To cancel the warning lights move the turn signal lever up or down Headlight Dimmer The headlight dimmer Fig 2 17 may be a push but ton a
153. d a 3 speed rear section The driver must use the clutch to start and stop the vehicle 10 Speed RTO Models Eaton Fuller 10 speed RTO model transmissions have 10 forward speeds and two reverse speeds The transmission consists of a 5 speed front section and a 2 speed rear section The driver must use the clutch to start and stop the vehicle Both 10 and 18 speed AutoShift models are partially automated transmissions The driver does not need to break torque or increase or decrease engine speed to synchronize the shift The transmission sig nals the engine controller when to break torque and the engine controller automatically increases or de creases engine speed When engine speed is cor rect the transmission engages the next gear and signals the engine controller to resume operation The AutoShift system consists of the following com ponents The Gear Display Module Fig 8 12 mounted on the dashboard indicates the current gear position The display also flashes the next gear to be engaged while the transmission is in neu tral during a gear change 1 A 2 SOLID o NEN SOLID gc od eee FLASHING 5 SOLID 02 17 98 B 1270062 A Gear Display Module B Module Detail 1 Current Gear 2 9th Gear Engaged 3 In 9th Gear Preselected Toward 10th 4 Out Of Gear Waiting For Engine Transmission rpm To Synchronize 5 10th Gear Engaged Fig 8 12 Gear Display Module The Driver Command
154. d on vehicles with Cummins PACE or CELECT engine sys tems could cause high fuel temperatures that affect engine performance and operation of the electronic engine controls If a fuel heater is used make sure it has thermostatic controls If the fuel heater has a timer set the timer to acti vate only for a limited period of time before the engine starts Make sure the fuel heater is used only for starting the engine Detroit Diesel Preparations made in advance of winter and mainte nance performed during the cold months will help to ensure efficient engine starting and operation 1 Engine oil thickens as it gets colder slowing cranking speed When cold multigrade oil offers less resistance to the cranking effort of the en gine and permits sufficient rom to be developed to start the engine Refer to Lubricating Oil Rec ommendations in the Detroit Diesel Owner s and Operator s Guide for specific recommendations 2 When an engine equipped with a DDEC system is started at temperatures below 25 F 4 C the idle speed automatically increases to 900 rpm The injection timing is also advanced to de crease white smoke As the engine oil warms up the idle speed gradually decreases When the oil temperature reaches 122 F 50 C both the idle speed and the injection timing return to normal 3 During cold weather the batteries should be tested more frequently to ensure ample power for starting All electrical connections shou
155. d position Visually check the slide plungers to make sure they are in the locked position as shown in Fig 10 9 9 The amount of load distribution on the front steering axle and rear drive axle s will have a direct effect on the steering control of the vehicle Determine the front and rear axle weights by weighing the vehicle on scales designed for this purpose The maximum axle weight ratings are shown on the Federal Motor Vehicle Safety Standard FMVSS label or Canadian Motor Vehicle Safety Standard CMVSS label attached to the left rear door post of the tractor The desired load on the axle is no less than 80 percent of the maximum axle weight rating but in no instances should the axle load exceed the maximum axle weight rat ing given on the FMVSS or CMVSS label A WARNING Adjust the fifth wheel slide correctly and do not overload any tractor axle by incorrectly loading the trailer Incorrect slide adjustment or improper axle loading could cause erratic steering and loss of vehicle control possibly resulting in seri ous personal injury or death 10 6 Fifth Wheels and Trailer Couplings Fifth Wheel Lubrication The fifth wheel plate must be kept well lubricated with chassis grease to prevent friction and binding between the tractor fifth wheel plate and the trailer Friction and binding caused by insufficient grease on the fifth wheel plate could result in erratic steering For lubrication instructions see Gr
156. d strong alkaline cleansers Apply a wax specifically designed for fiberglass 12 1 Care of Chrome Parts To prevent rust keep chrome parts clean and pro tected at all times This is especially important during winter driving and in coastal areas where there is exposure to salt air When cleaning chrome parts use clean water and a soft cloth or sponge A mild detergent may also be used Sponge gently then rinse If necessary use a non abrasive chrome cleaner to remove stubborn rust or other material Do not use steel wool To help protect the chrome after cleaning apply a coat of polishing wax to the surface Never use wax on parts that are exposed to high heat such as ex haust pipes Dashboard Care Periodically wipe the dashboard with a water dampened cloth A mild detergent can be used but avoid using strong detergents CAUTION Do not use Armor All Protectant STP Son of a Gun or other equivalent treatments These cleaners contain vinyl plasticizers that can cause stress crazing in the interior plastic panels which can result in cracking of the panels Vinyl Upholstery Cleaning To prevent soiling frequent vacuuming or light brush ing to remove dust and dirt is recommended Harsh cleaning agents can cause permanent damage to vinyl upholstery To preserve the upholstery and pre vent damage carefully review the following sections for recommended cleaning procedures Waxing or refinishing impro
157. de tailed information Do not use any starting aid such as ether in en gines with an intake air preheater This could Engines and Clutches cause an explosion resulting in serious personal injury or death 4 f so equipped turn off the battery disconnect Switch after the engine is stopped to prevent bat tery discharge while the starter motor is cooling For starting below 0 F 18 C an optional cold weather starting assist is recommended For temperatures below 10 F 23 C consult your Caterpillar dealer for recommendations 5 When the customer parameters include cold mode operation and the coolant temperature is below 64 F 18 C the system puts the engine in cold mode limiting engine power advancing tim ing and adjusting the low idle to 600 rpm for C 15 engines or 800 rpm for C 10 and C 12 engines to improve warm up time The system will keep the engine in cold mode until the cool ant temperature rises above 82 F 28 C After the cold mode has been completed operate the vehicle at low load and low rpm until the engine coolant reaches the normal operating tempera ture of 189 F 87 C 6 Fuel cloud point is the temperature at which wax crystals become visible which is generally above the pour point of the fuel To keep the fuel filter elements from plugging with wax crystals the cloud point should be no higher than the lowest ambient temperature at which the engine must start C
158. dels Raise the operat ing rod so that it is free to move inward Make sure that the lockpins have seated in the base plate rail holes and the operating rod moves into the locked position Also the safety latch must drop downward so that it holds the operating rod in the locked position 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 Fifth Wheels and Trailer Couplings The maximum axle weight ratings are shown on the Federal Motor Vehicle Safety Standard FMVSS label or Canadian Motor Vehicle Safety Standard CMVSS label attached to the left rear door post of the tractor The desired load on the axle is no less than 80 percent of the maximum axle weight rating but in no instances should the axle load exceed the maximum axle weight rat ing given on the FMVSS or CMVSS label A WARNING Adjust the fifth wheel slide correctly and do not overload any tractor axle by incorrectly loading the trailer Incorrect slide adjustment or improper axle loading could cause erratic steering and loss of vehicle control possibly resulting in seri ous personal injury or death Fifth Wheel Lubrication WARNING Keep the fifth wheel plate lubricated to prevent binding between the tractor and trailer A binding fifth wheel could cause e
159. e procedure under 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 Leather Upholstery Cleaning Ay CAUTION Do not apply oil to or use oil based soaps on the upholstery Applying oil to leather upholstery will damage the original oil finish causing it to be come tacky in texture When soiled leather upholstery can be cleaned with warm water and a mild soap Using a cheese cloth rub the soiled area briskly Then use a clean damp cheese cloth and wipe away the soap residue Finish by wiping with a dry soft cloth 12 3 13 In an Emergency Hazard Waring MOMS uiuos eerizekE9 eR RR EI RR EXER er erbw tints quidera d 13 1 Emergency Kit Optional ascessi recips be demle ig EEE mea TEE ERRE NE Re nen EFL E NEA 2 13 1 TOWING 6 hes cee ened EEESGuRREE Ra sq RAEE EDE ERA EEEE AEEA RR Rd ENAERE RESAN 13 1 Emergency Starting With Jumper Cables Fire in the Cab In an Emergency Hazard Warning Lights The hazard warning light tab is located on the turn signal control lever See Fig 13 1 To operate the hazard lights pull the tab out All of the turn signal lights and both of the indicator lights on the control panel will flash 02 02 95 1460312 Fig
160. e Control Switches Standard Location 05 23 95 1260316 Fig 2 6 Transmission Shift Knob Buttons Caterpillar C 10 C 12 and C 15 Electronic Engine Operator Control The Caterpillar C 10 C 12 and C 15 electronic en gines use a computer electronic control module to automatically control engine timing and fuel injection The electronic features of these engines include an electronic governor fuel to air ratio control program mable engine ratings injection timing control fault analysis and recording and a data link used for pro gramming the electronic control module and trouble shooting the system 2 4 Instruments and Controls Identification All Caterpillar electronic engines have an engine check light in the lightbar located above the speed ometer and tachometer This warning light comes on or flashes if the engine oil pressure is low the cool ant temperature is high the intake manifold air tem perature is high the coolant level is low optional or whenever there is a problem within the electronic engine system Some vehicles equipped with Cater pillar electronic engines have an automatic engine shutdown option This option will shut off fuel to the engine if potentially damaging conditions are de tected See the engine manufacturer s service litera ture for troubleshooting procedures The cruise control and PTO governor options are controlled in one of two ways By two switches on the instru
161. e Differential Control In the UNLOCK position there is differential action between the two axles The differential compensates for different wheel speeds and variations in tire size Keep the interaxle differential unlocked for normal driving on roads where traction is good In the LOCK position the interaxle differential is locked out and the driveshaft becomes a solid con nection between the two axles Power entering the forward axle is also transmitted straight through to the rear axle so both axles turn together at the same speed The LOCK position should be used when the vehicle encounters poor traction conditions however it also increases drivetrain and tire wear and should be used only when improved traction is required Meritor Interaxle Differential Lockout Operation To lock the interaxle differential and achieve maxi mum pulling power when approaching slippery or poor road conditions move the lockout control valve to LOCK while maintaining vehicle speed before en countering the poor road conditions Let up momen tarily on the accelerator to engage the differential lock Proceed over poor road conditions with caution Do not wait until traction is lost and the tires are spinning before locking the interaxle differential A CAUTION Do not actuate the interaxle differential control valve while the tires are slipping Do not operate the vehicle continuously with the interaxle differ ential locked during extended good
162. e Electronic Control Module ECM which signals the fuel control system to increase or decrease engine rpm to match road 8 20 Transmissions speed The ECM also controls HI and LO range se lection in the auxiliary case on the rear of the transmission 02 17 98 1 Shift Intent Switch 1270058 2 System Switch Fig 8 19 ESS Shift Handle The system switch Fig 8 19 is the lower switch lo cated on the driver s side of the shift handle It con trols ESS system operation When in the down posi tion the system is operating and the word ON is visible on the switch In the up position the word OFF is visible the system is not operating and the transmission can be shifted manually The shift intent switch Fig 8 19 is the upper switch on the driver s side of the shift handle It has four positions and controls upshifting and downshifting by communicating to the ECM the driver s intention of changing gears NOTE If the system switch is OFF use the shift intent switch to select between ranges Push the top of the switch Fig 8 20 to select the HI range on upshifts and the bottom of the switch Fig 8 21 to select the LO range on downshifts A WARNING Make sure that the transmission is in neutral N when you start the vehicle If the vehicle is started in gear it will suddenly move forward or backward which could result in personal injury and damage to property and the transmission A B 02 17 98
163. e and produce maximum horsepower at rated speed which is also the recommended maximum speed of the engine IMPORTANT If a winterfront is used on a ve hicle with an electronic engine equipped with a charge air cooler make sure that there are slit openings distributed across the face of the win terfront to allow airflow through the entire charge air cooler core Do not use a winterfront with closed areas that block uniform air flow across any sections of the charge air cooler crossflow tubes This will adversely affect the operation and durability of the charge air cooler 1 It is seldom necessary to accelerate the engine to governed speed in the lower gears to get the vehicle moving except in a high power demand situation such as starting on a grade To conserve fuel start off in low gear and de velop only the engine speed needed to get roll ing Then increase engine speed gradually as upward gear shifting progresses As described by Detroit Diesel this progressive shifting technique will get the vehicle up to the desired cruising speed while minimizing noise emission and maximizing fuel economy A pro gressive shift pattern is illustrated in Fig 7 7 3 0 10 20 30 40 50 60 16 32 48 64 80 97 4 11 02 95 1250319 1 Governed RPM 2 Engine RPM 3 Idle RPM 4 Miles Kilometers Per Hour Fig 7 7 Progressive Shift Pattern Engines and Clutches NOTE A momentary hesitation in throttl
164. e battery ground cables A CAUTION Failure to remove the axle shafts when towing the vehicle with the rear wheels on the ground could result in damage to the transmission and other parts 2 Remove both drive axle shafts On dual drive axles if the vehicle is to be lifted and towed re move only the rearmost drive axle shafts On vehicles equipped with an air fairing remove both the forward and rearmost drive axle shafts if there is insufficient towing clearance 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 bear ings 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 to the vehicle frame Use protection to keep the chains from damaging the frame In an Emergency 5 Remove the bumper extension and chrome bumper if so equipped Remove the bumper fair ing if so equipped 6 On vehicles equipped with an air fairing adjust the trim tab to the lowest position CAUTION Do not pass a sling for example a rope or chain from one tow hook to another to fasten for tow ing see Fig 13 2 Known as reeving this prac tice is not perm
165. e for more than 20 minutes Heating Sleeper Heater and Air Conditioner 1 If equipped with the manual temperature control do the following Fig 4 10 1 1 With the engine at operating temperature pull the temperature control cable at tached to the outlet duct at the foot of the bunk all the way out Turn the fan control knob to position 3 1 2 When the sleeper compartment heats to the desired temperature push in the tem perature control cable to adjust outlet air temperature Then turn the fan control knob to adjust the air flow level Use the manual temperature control and the fan control knob as needed to help maintain the desired temperature 4 4 Heater and Air Conditioner SPEAKERS I OFF LEF RIGH tata NUS DOME LT READ LT 01 18 95 1 Fan Control Knob 1600516a Fig 4 10 Control Panel for Manual Temperature Control System 1 3 Whenever heat is not desired push the temperature control cable all the way in and turn off the fan 2 If equipped with either the Red Dot constant tem perature control CTC system or the Behr au tomatic temperature control system Fig 4 11 do the following 2 1 With the engine at operating temperature turn the rotary knob on the temperature rheostat all the way clockwise to HEAT Turn the fan control knob to position 3 2 2 When the sleeper compartment heats to the desired temperature turn the rotary knob on the temperature rheost
166. e 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 reser voir and other components Some models are also equipped with a separate hydraulic power cylinder on the right side of the front axle The power steering pump driven by the engine provides the power as sist for the steering system If the engine is not run ning there is no power assist If the power assist feature does not work due to hydraulic fluid loss steering pump damage or some other cause bring the vehicle to a safe stop Do not drive the vehicle until the cause of the problem has been corrected WARNING Driving the vehicle without the power assist fea ture of the steering system requires much greater effort especially in sharp turns or at low speeds which could result in an accident and possible injury Drivers should carefully use the power available with a power steering system If the front tires become lodged in a deep chuckhole or rut drive the vehicle out instead of using the steering system to lift the tires from the hole Also avoid turning the tires when they are against a curb as this places a heavy load on steering components and could damage them Brake System General Information A dual air brake system uses a single set of brake controls to operate two independent air brake sys tems Each system h
167. e re sponse will occur when a vehicle with a turbo charged engine is started on a grade Do not disengage the clutch The rpm will recover and the vehicle will accelerate up the grade 2 For city driving run in the highest gear possible and reduce engine speed This enables you to operate at a safe speed for traffic conditions while using less fuel and reducing noise Also when slowing down for reduced speed zones remain in your running gear and reduce engine rpm to stay within the speed limit Avoid down shifting until you are ready to return to highway cruising speed For highway cruising and for best fuel economy run the engine at 80 to 90 percent of rated rpm to maintain highway speed Engines with 1800 rpm ratings are exceptions and will provide fuel economy when run at their rated speed Proper gear selection should permit cruising in the economy range with no appreciable sacrifice in desired highway speed It is okay to operate below rated rpm at full throttle if you are satisfied with the way the ve hicle performs However there are times when hilly terrain high winds or other conditions make it impractical to operate without reserve power Such conditions are better met if the vehicle is operated in a lower gear with reserve power available for changes in terrain wind etc The proper use of gears will shorten time on hills and minimize the amount of shifting When start ing up a hill gradually depress the ac
168. e 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 Heavy Duty Trucks Ser vice Manual for more information Pretrip and Post Trip Inspections and Maintenance 02 09 95 M S 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 CAUTION Insufficient wheel nut torque can cause wheel shimmy resulting in wheel damage stud break age and extreme tire tread wear Excessive wheel nut torque can break studs damage threads and crack discs in the stud hole area Use the recommended torque values and follow the proper tightening sequence Do not loosen or remove the parking brake clamp ring for any purpose The parking emergency brake section of the brake chamber is not in tended to be serviced Serious injury or death may result from sudden release of the power spring Before doing any repairs or adjustments on a service parking brake chamber read the appli cable warnings and instructions in Group 42 of the Heavy Duty Trucks Service Manual 21 Inspect the air brake chamber and the air brake chamber pushrods See Fig 11 12 Do not operate the vehicle
169. e the driver to operate the engine brake at one third two thirds and full capacity or at half and full capacity WARNING Do not use the engine brake to shift gears Using the engine brake to shift gears could result in loss of vehicle control possibly causing personal injury and property damage Since the engine brake is most effective at rated en gine speed gear selection is very important Gearing down the vehicle within the limits of the rated engine speed makes the engine brake more effective Maxi mum braking occurs with the use of the lowest gear that does not exceed the rated engine speed A rule of thumb for gear choice is to select the gear that normally would be used to climb an approaching downhill grade Generally this same gear can be used with the engine brake for a controlled descent of the hill 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 IMPORTANT When descending a grade re member that frequent use of service brakes causes them to become hot which results in a reduction of their stopping ability Grade descent speed should be such t
170. ed 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 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 The HEST lamp does not signify the need for any kind of vehicle or engine service it only alerts the vehicle operator of high exhaust temperatures Make sure the engine exhaust pipe outlet is not directed at any person or Engines and Clutches at any surface or material that will melt burn or ex plode See Fig 7 1 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 ignite or melt common materials and to burn people The exhaust can remain hot after the vehicle has stopped moving A solid yellow diesel particulate filter DPF lamp indi cates that a parked regen is required soon and should be scheduled for the earliest convenient time See Fig 7 2 A
171. ed normally with the cruise control engaged Depress the throttle pedal as needed When the throttle pedal is released the ve hicle will return to the set cruise speed Shifting can be done normally with the cruise control engaged When the clutch pedal is depressed the cruise control disengages allowing the shift to be completed When the clutch pedal is released the cruise control reengages and adjusts engine rpm to return to the selected speed Stationary Throttle Control Operation This mode is used when the vehicle is parked and is engaged by operating the ON OFF and the SET RESUME switches Fig 7 5 as follows 1 With the engine idling flip the ON OFF switch to ON A light in the warning and indicator light module will come on 2 Depress and release the RESUME switch until the desired rpm is reached NOTE It may be necessary to depress and re lease the switch several times before engine speed increases 3 To reduce engine rpm depress and release the SET switch until the desired rpm is reached 4 To disengage the stationary throttle control 4 1 Flip the ON OFF switch to OFF or 4 2 Depress the clutch pedal IMPORTANT In the throttle control mode engine speed is controlled by positioning the 7 20 Engines and Clutches engine throttle linkage Engine governor characteristics and engine temperature may cause engine speed to vary Don t leave the vehicle unattended for long periods of time while
172. ed setting Seats and Seat Belts Lumbar Support Turn the knob for precise fit National Cush N Aire Il Seat Fig 5 10 Back Cushion Tilt To tilt the back cushion turn the knob and lean for ward or backward 11 02 95 d 1910128 Back Cushion Tilt Knob Lumbar Support Switch Height Adjustment Switch Fore and Aft Seat Adjustment Lever Bottom Cushion Front Height Handle Isolator Handle Back of Cushion Height Lever AVO OT SO Fig 5 10 National Cush N Aire Il Seat Height Adjustment To raise the seat push the rocker switch on the side of the seat up until the seat reaches the desired height To lower the seat push the rocker switch down until the seat reaches the desired height Fore and Aft Seat Adjustment Move the lever to the left and slide the seat forward or backward to the desired position Bottom Cushion Front Height To adjust the height of the front of the bottom cush ion lift the handle and pull forward or push back to the desired setting Lumbar Support Push the rocker switch on the side of the seat up to inflate lumbar support Push the rocker switch down to deflate lumbar support Back of Cushion Height To adjust the height at the back of the cushion rotate the lever to the desired setting Isolator Also called a Chugger Snubber the isolator is locked out by moving the handle down Dura Form Seats Fig 5 11 NOTE Some vehicles may be equipped with the
173. eel lockup 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 function and to protect the components from cor rosion Clean more frequently when unusually corrosive chemicals are being used The electronic control unit also has a safety circuit that constantly monitors the wheel sensors solenoid control valves and the electrical circuitry If only the tractor is equipped with an ABS system the tractor warning light TRAC ABS comes on after the engine is started See Fig 6 4 If all of the tractors ABS components are working the light should go out when the vehicle moves faster than about 4 mph 6 km h If equipped with the tractor and trailer ABS system the vehicle also has a trailer warning light labelled TRLR ABS Fig 6 4 After the engine is started the TRLR ABS light comes on if the trailer is equipped with a compatible ABS system Once the vehicle moves faster
174. eeving 13 2 In an Emergency 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 Rear Towing Hookup CAUTION Using a rear towing hookup on a vehicle equipped with a roof fairing could cause damage to the cab structure IMPORTANT Because of the possibility of ex cessive wind force which could cause damage to the cab do not use a rear towing hookup on any vehicle equipped with a roof fairing 1 Place the front tires straight forward and secure the steering wheel in this position 2 Disconnect the battery ground cables A CAUTION Failure to protect the frame rails from the chains could cause damage leading to eventual frame failure 3 On dual drive axles using 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 positioning the lifting and towing device is the sole responsibility of the towing vehicle operator 5 Lift the vehicle and secure the safety chains If extra clearance is needed remove the bumper extension if equipped 6 Connect the clearance lights taillights and sig nal lights Also connect any special towing lights required by local regulations 13 3 Emergency Starting With
175. en the preset minimum is reached If the air pressure in both systems is above the preset minimum when the engine is started test the low air pressure warning Pretrip and Post Trip Inspections and Maintenance system by lowering the pressure to below this range or until the warning system comes on The air pressure in both the primary and secondary air reservoir systems must be above 65 psi 448 kPa on most vehicles For vehicles with an optional Bendix dryer reservoir module DRM the cut out pres sure is 130 psi 896 kPa 14 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 14 1 Make sure that the horn works If a horn is not working have it repaired before trip departure 14 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 15 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 16 Check the operation of all the panel lights and 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 repla
176. en the vehicle is stationary The clutch brake is actuated by de pressing the clutch pedal all the way to the floor For normal upshifts and downshifts only a partial disengagement of the clutch is necessary to break engine torque Use double clutching between all upshifts and downshifts Never move the shift lever into low gear while in high range Do not preselect with the deep reduction button When making the shift from a deep reduction ratio to a low range ratio move the deep reduc tion button from a forward position to a rearward position then complete the shift immediately Never move the deep reduction button from a rearward position to a forward position when the transmission is in high range Do not shift from high range to low range at high vehicle speeds Do not make range shifts with the vehicle moving in reverse gear Never attempt to move the range preselection lever with the gear shift lever in neutral while the 10 A p X 9 Lo Hi 7A 49 8 1 R 22 4 4 DR DR Lo DR Lo b 5 4 N 3 2 5 2 7 i AAS i 3 8 10 2 14 33 5 5 DR Lo DR Lo DR Lo 1 03 13 96 A Eaton Fuller RT and RTX transmissions shift pattern 1 High Range 4 High Range 2 Low Range 5 Low Range 3 Deep Reduction B Lo Hi 75 10 R 22 55 DR DR Lo DR Lo 4 b N 1 7 5 m l Ter zes a 1 6 7 DR Lo DR Lo DR Lo f260045a Eaton Fuller RTO transmissions shift pattern 6 Forward for IN 7 Rearward for OUT
177. enance Manual for recommended 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 Heavy Duty Trucks Service Manual for instructions or take the vehicle to an authorized Freightliner dealer 3 4 Check the mounting bolts and pitman arm nut for tightness 3 2 Check the drag link nuts for missing cotter pins 10 11 2001 461916 i 2 Pitman Arm Pinch Bolt Nut 3 Drag Link Nut Steering Gear Mounting Bolt Fig 11 15 Steering Gear Fasteners 3 3 Inspect the steering driveshaft and steer ing linkage for excessive looseness or other damage 3 4 Tighten loose nuts and have damaged parts replaced as needed Check the condition of the serpentine drive belt Look for signs of glazing wear frayed edges damage breaks or cracks or oil contamination If a belt is glazed worn damaged or oil soaked have the belt replaced following the instructions in Group 01 of the Heavy Duty Trucks Service Manual CAUTION 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 arive 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 11 14 Pretrip and Post Trip Inspections and
178. ent Knob Fore and Aft Seat Adjustment and Isolator Knob Lumbar Support Knob NOP OM Fig 5 4 Bostrom Talladega 900 Seat Fore and Aft Seat Adjustment Hold the lever to the left and slide the seat forward or backward to the desired position Bottom Cushion Tilt Adjustment Rotate the knob to increase or decrease bottom cushion tilt Lumbar Support To increase lumbar support on LSO models press the plus sign on the control switch To decrease lum bar support on LSO models press the minus sign on the control switch To increase lumbar support on non LSO models rotate the knob forward To de crease lumbar support on non LSO models rotate the knob rearward Damper Adjustment Rotate the knob or push the switch to adjust the damper Seats and Seat Belts Bostrom Smart Seat Model Fig 5 5 Back Cushion Tilt The back angle has five positions in a 15 degree range To release the latch pull up on the handle 02 09 95 Seat Track Adjustment Lever Height Adjustment Lever Bottom Cushion Angle Knob Isolator Lockout Lever Back Cushion Tilt Handle Lumbar Support Knob f910039a OV dx qo s Fig 5 5 Bostrom Smart Seat High Back model shown Lumbar Support Turn the knob clockwise to increase support Isolator Lockout Push the lever back to actuate the back slap isolator push it forward to lock out this feature Height Adjustment Height adjustment in the ride zone is con
179. eplace ment repair addition of lubricants or a change of lubricants see the Heavy Duty Trucks Service Manual for procedures and specifications and see the Heavy Duty Trucks Maintenance Manual for lubri cant recommendations specifications and mainte nance intervals Specific references to the manual will be found where appropriate Daily Pretrip Maintenance Procedures 1 Drain manually drained air reservoirs Water and oil normally enter the air reservoir in the form of vapor because of the heat generated during compression After the water and oil con dense drain the resulting emulsion as follows 11 3 ded Open the wet tank valve The drain cock or pull chain drain is located on the for ward end of the supply air reservoir which is connected directly to the air compres sor Block the valve open WARNING 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
180. equipment when there is no air conditioning This control is an option when air conditioning is ordered It allows the AC VENT and HEAT modes to be used with either fresh or recirculated air When the mode control upper lever is at HEAT DEF or DEF the system draws in fresh air regardless of the FRESH RECIRC push button setting When the mode control is at MAX A C the system draws only recirculated air regardless of the FRESH RECIRC push button setting When the mode control is at A C and the FRESH RECIRC control is set for recirculation push button in the system functions the same as when the mode control is at MAX A C To prevent the buildup of fumes or odors inside the cab for ex ample from smoking do not operate the heater and air conditioning system in a recirculation mode for more than 20 minutes Defogging and Defrosting Using Fresh Air 1 Set the mode control upper lever to HEAT the fan switch to OFF and if so equipped the bunk fan switch to OFF before starting the engine See Fig 4 6 2 Remove any ice or snow from the outside of the windshield door windows and fresh air inlet grille 3 With the engine at operating temperature slide the temperature control lower lever to WARM 4 Move the mode control to DEF In this position the system is engaged to dehumidify the air be fore heating it unless the temperature at the evaporator coil is less than 32 F 0 C Warm dry air is directed to the wind
181. er Functions The system also controls several functions such as the headlight high beam indicator low air pressure warning light and control of indicators for six optional features The optional features can be any combina tion of the following transmission temperature axle temperature engine heater alternator no charge fifth wheel lock parking brake sand antilock mirror heater utility lights axle lock sludge ejector or any six that are specially ordered Additional Features When the ignition is turned on all of the LEDs in the lightbar will light and the low air and low oil pressure alarms will sound The lights and alarms will activate for two one second periods separated by a half sec ond pause This is a self test to indicate whether or not the lightbar is working After the test the LEDs not in use will turn off The low air and oil pressure warnings will not sound again until the starter is cranked Once the starter is cranked the alarms will sound until system air and oil reach minimum operat ing pressures If the lightbar does not operate as de scribed here test it For instructions see Group 54 of the Heavy Duty Trucks Service Manual Instruments and Controls Identification VIGIL III Warning System Optional The VIGIL III system is an electronically controlled warning system with maximum vehicle speed control vehicle overspeed reporting and optional engine shutdown It controls
182. ertical the key can be inserted and removed only in this position The low beam headlights taillights brake lights fog lights dome lights clearance lights turn signals hazard warning lights utility and baggage lights spotlights electric wipers horn CB radio power mir rors cigarette lighter clock refrigerator fuel heater electric oil pan heater and electric or diesel fired engine coolant preheaters can be operated in the off position regardless of whether the key is inserted or not In the Accessory position the key is turned coun terclockwise The auxiliary bunk fan windshield fan s radio or stereo system mirror heat ether start 02 02 95 1600831 NOTE Instruments and controls and their locations may vary from those shown Water Temperature Gauge Engine Oil Pressure Gauge Pyrometer Tachometer Warning and Indicator Light Module VIGIL and Kysor shown 6 Parking Brake Indicator Light 7 Antilock Braking System ABS Tractor Warning Light 8 9 QE Coq cx ABS Wheel Spin Indicator Light ABS Trailer Warning Light dash light for DDEC Optimized Idle if so equipped 10 Speedometer Odometer 11 Application Air Pressure Gauge 12 Dual System Air Pressure Gauge 13 Voltmeter 14 Fuel Gauge 15 Fuel Tach 16 Engine Brake Switches 17 Trailer Air Supply Valve 18 Parking Brake Control Valve 19 Fifth Wheel Air Slider Control Valve Switch 20 Interaxle Differential Lockout
183. es to hold the fifth wheel in the desired position See Fig 10 16 or Fig 10 17 1 EFi ked eq pe slc E ES las EET LSR x AX o 1 rg rey r rot fear o fo r rx rol fF X 25 07 25 95 1310189 1 Locking Wedge 2 Air Cylinder Fig 10 16 Air Operated Sliding Fifth Wheel Mount AWB Model The slide portion of the sliding model may be at tached to either an air operated release slide or a manual release slide The air operated release slide contains an air cylin der that locks and unlocks the fifth wheel slide See Fig 10 16 The air cylinder is activated by a two position air control valve in the tractor cab The manual release slide contains a slide locking control handle located on the left side of the fifth wheel which locks or unlocks the fifth wheel slide See Fig 10 17 10 12 Fifth Wheels and Trailer Couplings Gi t9 vL I a9 X r1 TgT Tg rT 3 o roi rj TO rol F 2 07 25 95 1310190 1 Locking Wedge 2 Sliding Release Pull Handle Fig 10 17 Manual Release Sliding Fifth Wheel Mount MWS Model Fifth Wheel Lock Mechanism for Trailer Kingpin See Fig 10 18 01 04 95 f310184c A Unlocked Position C Locked B Locking 1 Wedge 3 Trailer Kingpin 2 Jaw Fig 10 18 Fontaine Kingpin Lock Mechanism 10 13 The Fontaine fifth wheel lock mechanism for the trailer kingpin consists of a spring loaded jaw and a sliding wedge
184. ess of what optional features are selected how the DIP switches are set or what other warnings might be on Additional Features When the ignition switch is turned on and the starter is engaged all of the LEDs in the lightbar will light up as a check that they are working When the starter is released those LEDs not in use will turn off If the ignition switch is turned on and the engine is not cranked there will be no warning buzzer for any of the warning features The warning buzzer is trig gered by the start circuit if the engine is cranked re leasing the start switch turns on the buzzer After re leasing the starter the oil pressure buzzer sounds during the time engine oil pressure is rising Collision Warning System CWS Eaton VORAD EVT 300 Optional The Eaton VORAD EVT 300 is a computerized colli sion warning system CWS that uses front mounted and side mounted optional radar to continuously monitor vehicles ahead of and alongside your ve hicle The system warns of potentially dangerous situations by means of visual and audible alerts The system performs in fog rain snow dust smoke and dark ness To be detected objects must be within the radar beam s field of view and provide a surface area that can reflect back the radar beam The front looking antenna assembly transmits radar signals to and receives them back from vehicles and objects ahead This allows the determination of the distance to re
185. essory position Continued constant cycling will shorten the life of the intermittent wiper con trol Electric Wipers To operate the electric wipers turn the knob clock wise to the first position for low speed Turn the knob to the second position for high speed operation 2 8 Instruments and Controls Identification In electric wiper systems the delay feature is inte grated with the wiper switch between the stop and low speed positions Turn the knob between the stop and low speed until the desired interval is reached The longest delay is approximately 10 seconds be tween strokes CAUTION Do not move the wiper arms manually Wiper motor damage will occur if the arms are moved Windshield Washer Control To operate the windshield washers turn the wind shield wipers to the desired speed Push the Wash Wipe knob in to actuate the washers Hold the knob in for a constant stream of washer fluid Push the knob in and release it for intermittent streams of fluid Left and Right Windshield Fan Switches Optional Ceiling Mounted Fans Ceiling mounted defogger fans are operated by Low Off High toggle switches located in the base of the fan Heater Air Conditioner Controls Standard and Auxiliary Heater Switch Optional Heater air conditioner controls Fig 2 11 consist of two lever slide controls a four speed fan control switch and a switch for the optional auxiliary heater fan See Chapter 4 for det
186. essure Fuel Gauges and Voltmeter The voltmeter will normally show approximately 13 7 to 14 1 volts when the engine is running The voltage of a fully charged battery is 12 7 to 12 8 volts when the engine is stopped A completely discharged bat tery will produce only about 12 0 volts The voltmeter will indicate lower voltage as the vehicle is being started or when electrical devices in the vehicle are being used If the voltmeter shows an undercharged or over charged condition for an extended period have the 2 26 Instruments and Controls Identification charging system and batteries checked at a repair facility On a vehicle equipped with a battery isolator system the voltmeter measures the average voltage of all of the batteries when the engine is running When the engine is stopped the voltmeter shows only the gel cell battery voltage and does not indicate the voltage of the engine starting batteries CAUTION Gel cell batteries can be damaged if the battery voltage is allowed to drop below 12 0 volts or if the charging voltage is more than 14 1 volts Start the engine to recharge the gel cell before the battery becomes fully discharged If an exter nal charger is needed disconnect the gel cell battery and use only an external battery charger that has been approved for gel cell batteries Fuel Tach Gauge Optional The FloScan Fuel Tach Fig 2 27 is an electronic monitoring system that records fuel consumptio
187. eter Optional less 2 26 Speedometer l lille 2 25 Tachograph Optional 2 30 Tachlomeler is 56 sacras aces nm euo eae 2 25 Transmission Oil Temperature Gauge Optional rede bee WX eee we RE EE RS 2 29 Turbocharger Boost Pressure Gauge Optional 2 29 iioii P 2 26 Water Temperature Gauge 2 25 L Leather Upholstery Cleaning 12 3 Index Subject M Meritor Drive Axles With Main Differential Lock llle Meritor Engine Synchro Shift ESS Automated Models General Information ESS Operation ESS issus m Reo Meritor Interaxle Differential Lockout Operation llle Meritor Main Differential Lock Operation i 6c 9 Ry IER Meritor Single Drive Axles With Traction Equalizer essc RR Meritor Splitter and Range Shift Models aus dass p cer d uo o e d Roe aie iE General Information Meritor Splitter and Range Shift Operation Meritor Splitter and Range Shift 05 Meritor Tandem Drive Axles With Interaxle Differential Meritor Range Shift Models General Information Meritor Range Shift uestis Operation Meritor Range SOM ga suce ee eae EE CE Ye Premier Trailer Couplings General Information less OperatlDll ssc cu foe scs
188. from properly functioning 6 6 Engines and Clutches EPAO7 Aftertreatment System ATS usueseeseseseeseeeeeee eh 7 1 Engine Staing a Lue ed d COS ECOLE EUew Ed Ode xe dde Ra dec p od Roe q ded 7 2 Ether Start Systemi lt 602 dered ered ereedte eta Peseta ceheeeVes er eeu ene se pase vetoes Seuss 7 5 Gold Weather Operati m secre ed re E HORE CEO ERE OER DEARER DON AEO ee ca Pee 7 5 Engine BIGGIN 1 uesk sk RR EEEERER UR ERNAOKW WERE GG EE ERES ESERQUERENCEN EEN AEA RES RE ERS 7 7 PAGING DOO uus quias E03 RAS CEP AO ENS KRSR RAS ERA SCE ERES FP dE S QU ede wer 7 7 Engine ShuldoWll 2 sc0c isha tains eee eed page E ERG E EEEE EERTE ERI We RU REE eS eRe es 7 18 High Altitude Operation 242 5 50u eo cade Cee welee ee Uwe Keen ene deeb bye MEOW erase ens 7 19 Bendix Cruise Control System Optional anasare sareen 7 20 Engine Braking System Optional ss csacaess odaceapedseduadss P EReR ENS pbacae EE FERAE 7 21 20 a ee er Ri ee ee ee 7 22 Engines and Clutches EPAO07 Aftertreatment System ATS All on road diesel engines built after December 31 2006 EPAO07 engines must meet strict new guide lines for reduced emissions of particulate matter and nitrogen oxides NOx from the exhaust NOx is lim ited to just over 1 gram per brake horsepower hour g bhp hr and particulate matter cannot exceed 0 01 g bhp hr EPAO07 compliant engines require ultralow sulfur die sel ULSD fuel and they should never be run on
189. ge shifts with the vehicle moving in reverse gear 10 Never attempt to move the range preselection lever with the gear shift lever in neutral while the vehicle is moving Preselection with the range Transmissions alae preselection lever must be made prior to moving the shift lever out of gear into neutral After your shifting ability improves you may want to skip some of the ratios This may be done only when operating conditions permit depend ing on the load grade and road speed Upshifting 1 Position the gear shift lever in neutral Start the engine and bring the air system pressure up to 100 to 120 psi 689 to 827 kPa Position the range preselection lever down into low range See Fig 8 4 or Fig 8 5 03 13 96 A Up for High Range B Down for Low Range i Be db Dir OD R 1 1 3 7 DiroD Dir OD LOW LOW Dir OD N A J Y B On Uo im Ja On O oY o9 C D 1260157a C Forward for Overdrive D Rearward for Direct Splitter Control Button 3 4 Fig 8 5 Eaton Fuller 18 Speed RTLO Model Transmission Shift Patterns Make sure the splitter control button is in the di rect rearward position See Fig 8 4 or Fig 8 5 For 13 speed transmissions Depress the clutch to the floor shift into low or 1st gear then engage the clutch with the engine at or near idle speed to start the vehicle moving Accelerate to 80 percent of engine governed speed For
190. ght The adjustment is either manually controlled or air controlled de pending on the make of the seat Bottom Cushion Angle or Front and Aft Bottom Cushion Height This feature enables the occu pant to raise or lower the front or back of the bottom cushion This adjustment is easier to per form when all weight is removed from the seat 02 02 2001 1 2 3 4 Back Cushion Tilt Lumbar Support Isolator Feature Height Adjustment 3 4 Y X X 6 7 7 f910169a 5 Bottom Cushion Angle fore and aft bottom cushion height 6 Fore and Aft Seat Adjustment seat track adjustment 7 Seat Tilt 5 1 Fig 5 1 Seat Adjustments Seats and Seat Belts 6 Fore and Aft Seat or Seat Track Adjustment The entire seat moves forward or backward when this adjustment is made 7 Weight Adjustment On those seats with weight adjustment the feature is fully automatic By sit ting on the seat a leveling valve places you in the center of the ride zone Additional adjust ments are possible by using the height adjust ment feature Bostrom Seat Air 715 Series Fig 5 2 Back Cushion Tilt By lifting the lever up the back cushion angle posi tion may be moved either forward or backward Re lease the lever to lock the back cushion in place 01 18 95 Seat Tilt Lever Isolator Lockout Lever Height and Weight Adjustment Lever Back Cushion Tilt Lever Lumbar Support Lever f910033a o Rom
191. gment be preserved If you desire immediate downloading and interpretation of accident reconstruction data you must return the CPU to Eaton VORAD However after 30 days the frozen information will automatically clear if the vehicle is driven Maintenance and Diagnostics 1 Keep the antenna assembly and side sensor s free of a buildup of mud dirt ice or other debris that might reduce the system s range 2 The system tests itself continuously and evalu ates the results every 15 seconds If a problem is detected with the front radar system the red FAIL light on the DDU illuminates continuously as long as the failure is active The corresponding fault code is stored in the CPU s memory 3 Both active and inactive fault codes can be indi cated by the DDU when the system is placed in failure display mode Inactive faults are those that have occurred and have cleared Active faults are still present Fault codes provide the driver the ability to record the system faults dur ing a trip and to notify his maintenance depart ment or Eaton VORAD See Failure Display Mode Fault Codes below In this mode specific fault codes are indicated by the pattern of blinks of the driver display unit red FAIL light 4 Each fault code is a two digit number as shown in Table 2 1 The red FAIL light blinks the same number of times as the first digit a pause of ap proximately 3 4 of a second follows then the light blinks the same number of t
192. h Optional Air Operated Sliding Fifth Wheel Do not activate the fifth wheel air slider control valve when the vehicle is in motion Doing so could result in damage to the fifth wheel member kingpin cab or trailer and ultimately to the driv etrain A guard is positioned around the switch to prevent it from being accidentally activated The fifth wheel air slider valve permits repositioning of the sliding fifth wheel from inside of the cab Mov ing the air slider control valve switch Fig 2 12 to the lock position deactivates the control valve and locks the fifth wheel to the baseplate Moving the Switch to the unlock position activates the control valve and unlocks the fifth wheel slide mechanism allowing changes to the total length of the tractor trailer and changes to axle loads to comply with varying state or provincial laws A red indicator light if so equipped is illuminated whenever the fifth wheel slider is unlocked Parking Brake Control Valve and Trailer Air Supply Valve The yellow diamond shaped knob Fig 2 12 oper ates the parking brake valve Pull the knob out to apply both the tractor and the trailer spring parking brakes Push the knob in to release the tractor spring parking brakes Before the spring parking brakes can be released the air pressure in either air brake sys tem must be at least 65 psi 447 kPa The red octagonal shaped knob Fig 2 12 operates the trailer air supply valve After the vehi
193. h pedal to the bottom of its travel so that the clutch brake stops the transmission input shaft from rotating Move the shift lever and engage reverse Slowly release the clutch pedal and move the vehicle in the reverse direction See Fig 8 22 for two ESS 9 speed shift patterns and one ESS 10 speed shift pattern R 5 7 R 6 8 R 7 9 R 1 3 R 2 4 RjI2J 4 N N N ol 2 4 1 8 1 3 5 5 7 6 8 10 02 17 98 A B c 1270061 A 9 Speed Shift Pattern with LO B 9 Speed Shift Pattern C 10 Speed Shift Pattern Gear Fig 8 22 Meritor ESS 9 and 10 Speed Shift Patterns Rear Axles Meritor Single Drive Axles With Traction Equalizer P 9 1 Meritor Drive Axles With Main Differential Lock lllleee I 9 1 Meritor Main Differential Lock Operation 0 0 cee eee eee eee 9 1 Meritor Tandem Drive Axles With Interaxle Differential 0 0 0 cece eee eee eee 9 2 Meritor Interaxle Differential Lockout Operation 0 0 0 eee eee 9 2 Eaton Single Reduction Axles With Controlled Traction Differential lessen 9 2 Eaton 2 Speed Tandem Axles 002 cece eee 9 3 Eaton Iriteraxle Differential Lockout Operation s ceste n ee ve dhe eee eee eee Oke ees 9 3 Rear Axles Meritor Single Drive Axles With Traction Equalizer Some Meritor single drive axles are equipped with a traction equalizer which is a load sensing self actuating
194. hat the service brakes are used infrequently and that they remain cool thus retaining their effectiveness A driver may descend slower than control speed by selecting a lower gear one that will not overspeed the engine The engine brake retarding force will then be sufficient to cause vehicle deceleration Oc casional deactivation of the engine brake may be Engines and Clutches necessary to maintain the designated road speed under these conditions The engine brake can be used to stop a vehicle if the service brakes quit working By energizing the engine brake as soon as a service brake problem is apparent a retarding effect is applied to the vehicle As grade conditions permit the driver can progres sively downshift using the engine brake in each gear Eventually the engine brake will stop the ve hicle A WARNING Using the engine brake as a primary braking sys tem when the service brakes are operable is dan gerous This can cause long unpredictable stop ping distances possibly resulting in personal injury or property damage Whenever vehicle braking is required the engine brake may be used with the service brakes There is no time limit for operation of the engine brake 1 After the engine is warmed up and the vehicle is in motion turn on the dash toggle switches up position On vehicles equipped with a Cummins NTC en gine select either the left side switch one third engine brake retarding capacity
195. he 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 see the Heavy Duty Trucks Service Manual for procedures and specifications and see the Heavy Duty Trucks Maintenance Manual for 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 Daily Pretrip Inspections Checks Pr cedHre check off Reference Drain manually drained air reservoirs
196. he axle will shift to low range NOTE When parking the vehicle put the axle in the low range with the engine running Engage the clutch and transmission to be sure the axle has completed the shift into the low range Some vehicle motion is required to ensure en gagement of the axle IMPORTANT See Eaton Interaxle Differential Lockout Operation for precautions that must be taken when shifting axles in relation to the inter axle differential lockout Eaton Interaxle Differential Lockout Operation Interaxle differential lockout systems include a lock out control valve Fig 9 5 located in the cab and an air operated shift unit mounted on the forward rear axle When the interaxle differential lockout control valve is in the LOCK position the interaxle differential is locked out and the driveshaft becomes a solid con nection between the two axles Power entering the forward axle is also transmitted straight through to Rear Axles N j N gt DO NOT vam ve ENGAGE N AN DURING Sw USPIN OUT J INTER AXLE DIFFERENTIAL LOCK UNLOCK 01 19 95 f600306 Fig 9 5 Interaxle Differential Control the rear axle so both axles turn together at the same speed The LOCK position should be used when ad ditional traction is needed CAUTION Engage the lockout only when stopped or at slow speeds and never when the wheels are spinning Do not operate the axles on dry pavement with the lockout
197. he brakes are wet drive the vehicle in low gear and lightly apply the brakes to heat and dry them Allow hot brakes to cool before using the spring parking brakes Always chock the tires If the trailer is not equipped with spring parking brakes pulling out the yellow knob applies the tractor spring parking brakes and the trailer service brakes When the tractor and trailer parking brakes or trailer service brakes are both applied the trailer brakes are released by pushing in the red knob leaving the tractor parking brakes applied Air pressure in the primary or secondary reservoir must be at least 65 psi 447 kPa before the tractor spring parking Steering and Brake Systems brakes or the trailer service or spring parking brakes can be released On trailers not equipped with spring parking brakes chock the trailer tires before disconnecting the truck or tractor when parking just the trailer When parking a truck or tractor with a trailer combi nation vehicle and the trailer is not equipped with spring parking brakes apply the truck or tractor spring parking brakes If a trailer is not equipped with spring parking brakes do not park it or a combination vehicle by pulling out only the trailer air supply valve knob This would apply only the trailer service brakes If air were to bleed from the trailer brake system the trailer brakes would release possibly causing an unattended runaway vehicle CAUTION Never a
198. he engine speed to drop about 800 rpm the rpm drop may vary with engines of different governed speeds then dis engage the clutch Move the shift lever to 2nd gear then engage the clutch and accelerate to engine governed speed Continue shifting upward from 2nd to 3rd gear 3rd to 4th gear and 4th to 5th gear using the same sequence See Fig 8 1 for the shift pat tern 4 Again at governed speed disengage the clutch and shift into neutral Engage the clutch allow the engine speed to drop about 500 rpm rpm drop may vary with engines of different governed speeds then disengage the clutch Move the shift lever to 6th gear then engage the clutch and accelerate to engine governed speed Shift into 7th gear using the same sequence Downshifting When downshifting shift down from 7th gear through each lower gear as follows 1 Allow the engine speed to drop about 500 rpm rpm drop may vary with engines of different gov erned speeds below the governed speed De press the clutch pedal enough to release the torque then shift into neutral Engage the clutch and bring the engine rpm up to governed speed Disengage the clutch shift into gear and engage the clutch smoothly Follow the same sequence to downshift from 6th into 5th gear 2 When in 5th gear and ready for the next down shift allow the engine speed to drop about 800 rpm rpm drop may vary with engines of different governed speeds below the governed
199. he tachometer indicates the desired speed 13 Momentarily move the SET RESUME switch on the instrument control panel to SET or push the SET button on the trans mission shift knob 2 To disengage the PTO 2 1 Depress the brake pedal or clutch pedal Or 2 2 Flip the ON OFF switch on the instrument control panel to OFF or press the PAUSE button on the shift knob 3 To resume a previously selected engine speed 3 1 If the ON OFF switch on the instrument control panel is in the OFF position flip it to ON 3 2 Momentarily move the SET RESUME switch on the instrument control panel to RESUME or press the RESUME button on the transmission shift knob To adjust engine speed up or down hold the SET RESUME switch on the instru ment control panel at SET to accelerate or at RESUME to decelerate until the desired speed is reached or press the SET button on the transmission shift knob to acceler ate or the RESUME button to decelerate until the desired speed is reached NOTE The resume engine speed memory is not maintained if the ignition is shut off 7 11 Cummins Engine Operation Cummins diesel engines have been built by Cum mins to comply with the requirements of the Federal U S Clean Air Act Once the engine is placed in service the responsibility for meeting both state and local regulations is with the owner operator Good operating practices regular maintenance and proper adjustments are factors which will
200. he trailer from moving 4 Lower the trailer landing gear until the trailer rises about 1 2 inch 13 mm 5 Disconnect the tractor to trailer air system lines and electrical cable Plug the air lines to prevent dirt or foreign material from entering the lines CAUTION Before attempting to unlock the fifth wheel lock mechanism of a sliding type fifth wheel the slide operating rod Fig 10 11 must be in the locked position and the slide lockpins must be in the locked position fully inserted in baseplate rail slots This prevents the sliding member from moving rapidly to the far forward or rearward po sition which could damage the fifth wheel mem ber or kingpin 6 lf equipped with a manual kingpin lock release Release the kingpin lock mechanism by raising the safety latch to the rear and pulling the lock operating rod out and up into the lockset posi tion See Fig 10 13 The offset of the lock con trol upper rod should bottom against the plate casting above the hole If the operating rod can not be pulled to the lockset position back the tractor slightly to release the kingpin force against the jaw If equipped with a Touchloc air operated kingpin lock release Pull and hold the dash mounted control valve out approximately 2 to 3 seconds The air cylinder and slide cam see Fig 10 15 will rotate the safety indicator and move the lock control handle into the unlocked position then retract The safety indicator wil
201. he wheel spin indicator light WHL SPIN comes on if one of the drive wheels spins during acceleration Fig 2 19 The light goes out when the wheel stops spinning The Bendix system will either reduce en gine torque or apply gentle brake pressure to force the differential to drive the stationary or slowly spin ning wheel If slippery road conditions continue en gage the axle lock Instruments and Controls Identification 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 See Group 42 of the Heavy Duty Trucks Ser vice Manual for troubleshooting procedures See the brake system operating instructions in Chap ter 6 for more information VIGIL Warning System Standard Indicator Lights Standard indicator lights Fig 2 19 include 1 The green right and left turn signal lights flash on and off whenever the outside turn signal lights are flashing 2 The green high beam indicator light comes on when the headlights are on high beam Standard Warning Lights Standard red warning lights Fig 2 19 are for oil pressure water temperature and low air pressure Whenever conditions cause one or more of these lights to come on a warning buzzer also alerts the driver 1 The water temperature warning light and buzzer activate whenever the engine coolant tempera ture exceeds a preset point determi
202. heel rim or tire damage before adding air Moisture inside a tire can result in body ply separation or a sidewall rupture Dur ing tire inflation compressed air reservoirs and lines must be kept dry Use well maintained inline moisture traps and ser vice them regularly Pretrip and Post Trip Inspections and Maintenance 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 19 Inspect each tire for wear bulges cracks cuts penetrations and oil contamination 19 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 19 2 Inspect each tire for bulges cracks cuts and penetrations 19 3 Inspect each tire for
203. her nonbattery location then disconnect the other end of the cable 8 Disconnect the remaining cable from the newly charged battery or jump start post if equipped first then disconnect the other end Fire in the Cab The incidence of fire in heavy and medium duty trucks is rare according to data from the National Highway Traffic Safety Administration Federal Motor Vehicle Safety Standard 302 limits the flammability of specified materials used inside the cab but de spite this most materials will burn The cab of this vehicle contains urethane foam which is of concern in this respect A WARNING Urethane foam is flammable Do not allow any flames sparks or other heat sources such as cigarettes or light bulbs to contact urethane foam Urethane foam in contact with such heat Sources could cause a serious rapid fire which could result in death severe burns or gas poi soning as well as damage to the vehicle In Case of a Cab Fire As quickly as possible bring the vehicle to a safe stop apply the parking brake turn off the ignition and get out of the vehicle 13 4 Index Subject Page Air Conditioning Sleeper Heater and Air Conditioner 4 5 All GonaditioDif a s scere sioe st ahi a E eo 4 3 ASF Castloc Il and Simplex Series Fifth Wheels lll 10 7 Fifth Wheel Locking and UnlocRIng sx 22 a Row Boks A AS as ae 10 8 Fifth Wheel Lubrication
204. hion Tilt To tilt the back cushion through a range of 15 de grees turn the knob and lean forward or backward Isolator Called the Glide A Lator use the lever to engage or lock out the fore and aft isolator Fore and Aft Seat Adjustment Use the lever to move the seat forward or backward to the desired position 5 7 2 8 7 3 4 4 5 6 10 26 95 1910142 1 Lumbar Support Adjustment Knob vertical Armrest Angle Adjustment Back Cushion Tilt Knob Height Adjustment Lever Isolator Lever Fore and Aft Seat Adjustment Lever Air Ride Control Adjustment Knob Lumbar Support Adjustment Knob front to back 9 990PROM Fig 5 12 Eldorado Seat Height Adjustment Lift up the lever and add or remove body weight to adjust seat height to the desired position then firmly push the lever down into locking position Air Ride Control Adjustment Depress the air valve knob until the seat cushion is level Height adjustment should be made prior to air ride control adjustment Lumbar Support Adjustment Front to Back Turn the knob clockwise to increase lumbar support Turn the knob counterclockwise to decrease lumbar support pressure Lumbar Support Adjustment Vertical Optional Move the knob up or down to one of five positions for desired area of back support Seats and Seat Belts Armrest Angle Adjustment Optional Rotate the 9 16 inch bolt head on the back of each armrest clockwise to raise
205. hold of drive axle wheel spin to help burn through a thin layer of ice or to help throw off accumu lated mud or snow The DEEP SNOW MUD mode is indicated by a flashing WHL SPIN light To engage this mode the 6 5 ATC function switch must be in the NORMAL position when the vehicle is initially powered up Once the vehicle is started the ATC function switch can be set to the DEEP SNOW MUD position The ECU indi cates this change by a constant flashing of the WHL SPIN lamp or by illumination of the DEEP SNOW MUD light Fig 6 4 on vehicles built before July 1994 If the ATC function switch is in the DEEP SNOW MUD position when the vehicle is powered up the ECU will not accept this function change and will re main in the NORMAL mode Indication of this condi tion will be the absence of the flashing WHL SPIN light on vehicles built before July 1994 the absence of an illuminated DEEP SNOW MUD light To en gage the DEEP SNOW MUD mode in this situation change the position of the ATC function switch to the NORMAL mode After 2 seconds move the switch to the DEEP SNOW MUD position When this occurs the indicator light will activate as previously de scribed IMPORTANT ABS and ATC blink code diagnos tics should only be performed when the vehicle is stopped If the vehicle is equipped with ATC turning On the ABS CHK switch will reduce engine speed to idle for 3 seconds and affect ATC function performance If the vehicle
206. hrough 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 IMPORTANT Never use the clutch brake when downshifting or as a brake to slow the vehicle Eaton Fuller Super 10 Top 2 and Lightning Semi Automated Transmissions Refer to the Eaton website for additional information www roadranger com General Information Super 10 Top 2 Lightning Super 10 Top 2 and Lightning transmissions have 10 selective forward ratios and a 2 speed rear sec tion Half of the 10 speed ratios are shifted with the shift lever and the other half are shifted by moving the shift button See Fig 8 8 for the Super 10 and Top 2 shift knob and Fig 8 9 for the Lightning shift knob A Fuer y Fuller 1 C 09 25 96 A Shift Button B Gears 2 4 6 8 10 when button is forward C Gears 1 3 5 7 9 when button is rearward Fig 8 8 Super 10 and Top 2 Shift Knob 1260399 09 12 2002 1 Shift Button 2 Service Light f261190 Fig 8 9 Lightning Shift Knob There are three types of shifts used with these trans missions Button only and combination button lever shifts are both full gear changes The lever only shift skips a gear 8 10 Transmissions e The button only shif
207. ide Operation 1 Connect the trailer kingpin to the tractor fifth wheel For instructions refer to Fontaine 5000 Series Fifth Wheel Locking Operation in this chapter 2 After positive lockup of the fifth wheel lock mechanism has been accomplished release the slide using one of the following methods 2 1 For air operated release models set the cab operated control switch to UNLOCK 2 2 For manual release models lift the slide locking handle to disengage it from the guide plate Then pull out the handle Fig 10 20 until it is in the unlocked posi tion and can be positioned against the guide plate to hold it out The slide locking handle will stay in the unlocked position until it is manually disengaged from the guide plate 3 Lower the trailer landing gear just enough to re move the weight from the tractor 4 Pull the trailer air supply valve to cut off the air supply to the trailer Do not use the trailer air supply for parking trail ers not equipped with spring parking brakes Fifth Wheels and Trailer Couplings 05 19 94 S f 1310050 Fig 10 20 Fontaine 5000 Series Sliding Fifth Wheel Manual Release This applies the trailer service brakes only As air bleeds from the trailer brake system brake appli cation is lost This could allow the unattended vehicle to roll away possibly resulting in serious personal injury or death 5 Chock the front and rear of the trailer tires to prevent the
208. ie das 6 hain A Ala ae RR Ars eR 10 2 Fifth Wheel Lubrication 10 7 Fifth Wheel Slide Operation 10 5 General Information ls 10 1 Holland Trailer Coupling 10 18 Subject Page General Information aa 10 18 Operation 52 issus RR yy 10 19 Food INNO xeu perie dere Ete Rm X B 3 6 To Return the Hood 26i z e mns 9 7 To Tilt the Hood 2 0 0 0 eee ees 3 6 HVAC General Information 4 1 l Ignition and Lock Key 20 20 e eae 3 1 Instrument and Control Panel 2 1 Instruments llle 2 25 Ammeter Optional lll 2 29 Application Air Pressure Gauge Optional clus 2 27 Dual System Air Pressure Gange PCIE 2 28 Engine Hour Meter Optional 2 27 Engine Oil Pressure Gauge 2 25 Engine Oil Temperature Gauge Optional llus 2 29 Forward and Rear Differential Oil Temperature Gauges Optional 2 29 uel Gall cuc kone qd dae gd Bowls DRE 2 28 Fuel Pressure Gauge Opional se sr da sx sump ont m ee See ES 2 28 Fuel Tach Gauge Optional 2 27 Intake Air Restriction Gauge Optional 35 cack As ws RAWex lm ges eee eS 2 28 Intake Air Restriction NENG UCN Md 2 28 Kysor Digital Clock Optional 2 30 Pana Pacific Digital Clock Optional essar e eee t RESI tia 2 29 Pyrom
209. ift Transmissions Shift Patterns A B BN TN Hi 7 40 HUC 27X4 Pos i N N 1 6 8 10 D 65 85 9 WBS 173 4 03 13 96 f260043a A All RT and RTX Transmissions B All RTO Transmissions C Up for High Range D Down for Low Range Fig 8 3 Eaton Fuller 10 Speed Range Shift Model Transmissions Shift Patterns preselection lever must be made prior to moving the shift lever out of gear into neutral 5 Do not shift from high range to low range at high vehicle speeds 6 Use double clutching between all upshifts and downshifts After your shifting ability improves you may want to skip some of the ratios This may be done only when operating conditions permit depend ing on the load grade and road speed Upshifting 1 Position the gear shift lever in neutral Start the engine and bring the air system pressure up to 100 to 120 psi 689 to 827 kPa 8 3 2 Position the range preselection lever down into low range Depress the clutch pedal to the floor Shift into low or 1st gear Table 8 1 then engage the clutch with the engine at or near idle speed to start the vehicle moving Accelerate to 80 per cent of engine governed speed Shift progressively upward from low or 1st gear to the top gear in low range Table 8 1 double clutching between shifts and accelerating to 80 percent of engine governed speed CAUTION To prevent damage to the range section syn chros make sure the range
210. ift pattern Double clutch during lever shifts 6th to 7th to 8th single clutch during split shifts 6th direct to 6th overdrive etc Downshifting 1 Downshift from 8th overdrive to 8th direct without moving the shift lever Flip the splitter control but ton to the direct rearward position then imme diately release the accelerator and disengage the clutch Engage the clutch and accelerate the engine only after the transmission has shifted 2 Start the downshift from 8th direct to 7th over drive by flipping the splitter control button to the overdrive forward position then immediately double clutch through neutral moving the shift lever from 8th to 7th gear 3 Shift downward through each of the high range gears alternating the procedures in steps 1 and 2 above until reaching 5th direct 4 While in 5th direct and ready for the downshift to 4th 13 speed transmissions or 4th overdrive 18 speed transmissions push the range prese lection lever down Then double clutch through neutral and move the shift lever to the 4th gear position On 18 speed transmissions move the splitter control button to the overdrive forward position before engaging the clutch Do not move the control button while the shift lever is in neu tral 5 Continue downshifting from 4th to 1st as follows For 13 speed transmissions Downshift through the low range gears as condi tions require 8 7 For 18 speed transmissions
211. ignition or use the drive away feature The drive away feature allows the use of all the DDEC features Use the drive away feature as follows 5 1 If the engine is running Release the park ing brakes or put the transmission in gear If the engine is not running Start the en gine Release the parking brakes or put the transmission into gear 5 2 Let the engine return to base idle The active light will turn off Optimized Idle is now disabled and all the DDEC features are available Engine Shutdown Caterpillar CAUTION Stopping the engine immediately after it has been working under load can result in overheating and accelerated wear of the engine components Ex cessive temperatures in the turbocharger center housing will cause oil coking problems Follow the procedure outlined below to allow the en gine to cool 1 With the vehicle stopped apply the parking brakes Reduce the engine speed to low idle Place the transmission shift lever in neutral If the engine has been operating at low loads run it at low idle for 30 seconds before stopping If the engine has been operating at highway speed or at high loads run it at low idle for three minutes to reduce and stabilize internal engine temperatures before stopping Turn off the ignition key to shut down the engine If equipped with an idle shutdown timer it can be set to shut the engine down after a preset amount of time Ninety seconds before the pre
212. imes as the sec ond digit 5 Additional fault codes are blinked out at intervals of approximately 3 seconds After all of the fault codes have been blinked out a code 41 will be blinked out Failure Display Mode Fault Codes NOTE If the vehicle does not have ON OFF control on the DDU press and hold the volume knob after the ignition key is turned on and the 15 second self test is complete 1 Press and hold the DDU volume control and power ON OFF knob for at least 9 seconds The system will turn off if you release the knob before 9 seconds After 9 seconds the DDU FAIL light begins to blink out the fault codes After a 3 second interval additional fault codes if present will be blinked out A code 41 will be 2 24 Instruments and Controls Identification blinked out either if no faults are found or when all fault codes have been blinked out 2 Position the DDU range knob to the left to blink active fault codes and to the right to blink inac tive codes 3 To review test and clear all fault codes from System memory use a hand held diagnostic tool or ServiceRanger Instruments Tachometer A tachometer Fig 2 19 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 An optional tachometer is equipped with an engine hour meter to record co
213. ine is in good mechanical condition and the precautions necessary for cold weather operation are taken ordinary cold weather will not cause difficulty in starting or loss of efficiency If the engine does not start prime the fuel system When the use of unblended No 2 diesel fuel in win ter cannot be avoided install a thermostatically con trolled fuel heater Fuel heaters can prevent wax from clogging the fuel filters and formation of ice crystals from water in the fuel IMPORTANT If a fuel heater is used make sure it has thermostatic controls to prevent excessive heating of the fuel in warm weather Excessive heating of fuel can cause a loss of engine power For cold weather operation use the following guide lines 1 When starting the engine in temperatures below 32 F 0 C use engine lubricants of lower vis cosity See your engine operation and mainte nance manual for specifications 2 When the temperature is below freezing use suf ficient antifreeze solution in the cooling system to prevent freezing Refer to Group 20 of the Heavy Duty Trucks Maintenance Manual for specifications 3 During cold weather give more attention to the condition of the batteries Test them frequently to ensure sufficient power for starting Inspect all switches and connections in the electrical system and keep them in good condition to prevent losses through poor contacts See Group 15 of the Heavy Duty Trucks Service Manual for
214. ing the differential lock Briefly let up on the accelerator to relieve torque on the gear ing allowing the differential to fully lock The indica tor light should come on and the buzzer should sound on vehicles so equipped When the differential is fully locked the turning radius will increase be cause the vehicle understeers See Fig 9 1 Drive cautiously and do not exceed 25 mph 40 km h To unlock the main differential move the control Switch to the unlock position Briefly let up on the accelerator to relieve torque on the gearing allowing the differential to fully unlock NOTE If the differential lock system is con nected through the low speed range of the transmission shifting out of low speed range will also unlock the differential Rear Axles o Ld a 02 09 96 A Turning Radius When Differential is Locked engaged Understeer Condition B Turning Radius When Differential is Unlocked disengaged f350079a Fig 9 1 Turning Radius When the differential lock disengages the indicator light will go off and the buzzer will stop Meritor Tandem Drive Axles With Interaxle Differential Meritor tandem drive axles with an interaxle differen tial have a lockout feature Differential lockout is con trolled by a switch Fig 9 2 on the control panel DO NOT X ENGAGE 2 V DURING 54 VOU USPIN OUT c INTER AXLE DIFFERENTIAL LOCK UNLOCK 01 19 95 600306 Fig 9 2 Interaxl
215. inings 4 1 4 2 Check that brake linings are free of oil and grease 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 Heavy Duty Trucks Service Manual for lining re placement instructions and camshaft end play inspection Check the brake drums for wear and cracks Check that the inspection plugs in the dust shields or backing plates if so equipped are installed 11 16 12 Cab Appearance Cab Washing and Polishilg iub x RR EE ERR t ranere RR HEAR EEEREN ERARE deers 12 1 Gare OF Fiberglass PAIS auelasetibne itae APRECer PIS RORAus P IS aeaa E EDI PES PES 12 1 Care of Chrome PariS cc pieced re rewarad ed ECAR REET Ra e REX E P CERE PR eke wees ES 12 1 Dashboard Care 3 6 vacui e ri Heed edu OR bi 1 RHONE ICE OME be Ree en ROSES eh URS fd d 12 1 Vinyl Upholstery Cleaning xusswepxekkEe RU RR RE REXKERRROEX ERE headers eke eee RERO ERE 12 1 Velour Upholstery Cleaning 14s edbuehpa ER RAMDET SERAIS CD ERRAT Eb ERE EPA RES E 12 2 Leather Upholstery Cleaning isse caca a e a REIR EXTR EERREEdRAREERIEERTEFGREXGTEEKGO 12 3 Cab Appearance Cab Washing and Polishing To protect the finish of your new vehicle follow these guidelines carefully
216. into neu tral Release the clutch and allow the engine to de celerate until the road speed and the engine RPM match Partially depress the clutch pedal and move the shift lever into first gear Double clutch to continue upshifting until the top gear in the low range 4th gear in 9 speed models 5th gear in 10 speed models See 8 Release the clutch pedal and let the engine slow until the road speed and engine RPM match 9 Partially depress the clutch pedal and move the shift lever into the lowest gear in the high range 5th gear in 9 speed models 6th gear in 10 speed models 10 Double clutch to continue upshifting Downshifting 1 With the transmission in high range shift pro gressively downward to the bottom gear in high range 5th gear in 9 speed models 6th gear in 10 speed models double clutching between shifts See Table 8 3 When in the bottom gear of the high range shift pattern and ready for the next downshift push the range selection lever down into low range Double clutch through neutral and shift into the top gear of the low range shift pattern As the Table 8 3 Meritor Shift Progressions LOW RANGE HIGH MODEL Off Highway On Highway RANGE 5 7 n ay LS VEN IPAS R 9 Speed 2 xl TK ive 4 O4 Standard Low CS Ca m 1260322 1260323 f260324 6 8B R ATP Ley R 9 Speed 7 ead wu T fo 5 R Ratio 1 DG M9 260325 260326 5 8 9 Speed RIAN a RMO
217. ion capacity reaching maximum f maximum capacity maximum capacity A regeneration is in capacity progress Required Action Bring vehicle to To avoid engine Vehicle must be Vehicle must be parked and a highway speeds to derate bring vehicle parked and a Parked Parked Regeneration or Service Solid allow for an Automatic to highway speeds Regeneration must Regeneration must be performed I Exhaust Components Regeneration or to allow for an be performed Check engine operator s manual and exhaust gas are perform a Parked Automatic engine will begin for details engine will shut down I at high temperature Regeneration Regeneration or derate When stationary keep perform a Parked away from people and Regeneration as flammable materials Soon as possible or vapors For a driver performed Parked Regeneration vehicle must be equipped with a dash mounted Regeneration Switch See Engine Operator s Manual for complete Regeneration Instructions 24 01583 000B 06 29 2009 1080147 Fig 1 8 Sunvisor Warning Label It is a violation of federal law to alter exhaust plumb ing or aftertreatment in any way that would bring the engine out of compliance with certification require ments Ref 42 U S C S7522 a 3 It is the own er s responsibility to maintain the vehicle so that it conforms to EPA regulations 1 3 Instruments and Controls Identification instrument and Control Panel lt os eis se reae mak ke Reda Ee R
218. ir The windshield washer reservoir is located inside the left side baggage compartment See Fig 3 14 3 7 01 5 97 ee 1820192 1 Washer Reservoir 2 Baggage Compartment Door Fig 3 14 Windshield Washer Reservoir Heater and Air Conditioner HVAC General Information oce eb RR X ERERRTEERES P E RARGH ER ERE ArA T ERG ends O24 4 1 Defogging and Belrosung Using Fresh Air 2 1 42 reecuedcteveeugd eeewen RAS p ENEP CE ES 4 1 Head ooexedeck e e ake RCREEREEE RE REX ER EREA EEE EEERREEEG ees Ede qu ERE EE WS 4 2 AI COMSIIOMING oexcberextREbPeEbRb bee hee hehe dd be bee hae ae Rd re hehe Kk eek dee BSE bas 4 3 Fresh Air coke RIVE si S RRERRXGERP RERBA REP ERSEE ieee bse eebbaeues ous RR E xac ER RUM E Ed 4 4 Heating Sleeper Heater and Air Conditioner 0 000 4 4 Air Conditioning Sleeper Heater and Air Conditioner slesseslesleseeseesses 4 5 Heater and Air Conditioner HVAC General Information A dash mounted climate control panel Fig 4 1 al lows you to control all of the heating air conditioning defrosting and ventilating functions A four speed fan forces fresh or recirculated air to any selected air outlets at the windshield door win dows dashboard face and cab floor See Fig 4 2 All of the dash face outlets have adjustable louvers that pivot right and left and up and down The out lets can be closed by moving the louvers all the way down Windshield defrost outlet
219. issible in most industrial applica tions of towing and hoisting Reeving can overload the hooks and result in damage to the vehicle 7 Attach the towing device Due to the many vari ables that exist in towing positioning the lifting and towing device is the sole responsibility of the towing vehicle operator 8 On vehicles equipped with an air fairing mea sure the distance from the ground to the bumper or from the ground to a frame bracket 9 Lift the vehicle and secure the safety chains If extra towing clearance is needed remove the front wheels 10 On vehicles equipped with an air fairing repeat the measurement taken in step 8 The difference between the two measurements must not exceed 14 inches 36 cm If necessary lower the ve hicle Failure to lower the vehicle could result in the air fairing striking an overhead obstruction such as a bridge or overpass and causing vehicle dam age or personal injury 11 Connect the clearance lights taillights and sig nal lights Connect any special towing lights re quired by local regulations 12 Chock the disabled vehicle s tires and connect the towing vehicle s air brake system to the ve hicle being towed Then release the spring park ing brakes and remove the chocks 01 11 2006 IMPORTANT Do not reeve when towing 1 Tow Hook 1880694 2 Chain Fig 13 2 R
220. itch Optional The fog light switch Fig 2 9 operates the fog lights mounted on the bottom edge of the front bumper or recessed into the front bumper amp j 01 18 95 Fog Light Switch Utility Light Switch Panel Lamp Control Knob Headlight Parking Light Switch Marker Light Taillight Interrupt Switch 1600071a o RON Fig 2 9 Light Controls For vehicles built to operate in the United States the low beam headlights must be turned on before the fog lights can be turned on The fog lights won t go on if the high beam headlights are already on and switching from low beams to high beams will switch off the fog lights For vehicles built to operate in Canada the taillights and clearance lights must be on before the fog lights can be turned on Unless the headlight switch is all the way up headlights taillights clearance lights marker lights and panel lights on or down taillights clearance lights marker lights and panel lights on the fog light switch will not turn on the fog lights Instruments and Controls Identification Utility Light Switch Optional Utility lights can be swivel mounted on top of the cab mounted on the intake exhaust support or flush mounted in the back of the cab or bunk They are operated by the utility light switch Fig 2 8 which when turned on also illuminates a red indicator light on the dash Panel Lamp Control Knob The circuit to the panel lamps
221. ith 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 week ends for dealer referral vehicle information break down coordination or Fleetpack assistance Our people are knowledgeable professional and commit ted to following 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
222. ition switch and provides the driver with an extra 30 sec onds of engine operating time Standard DDEC III9 systems will shut down the en gine if sensors indicate an emergency engine condi tion such as low coolant level high coolant tempera ture or high oil temperature If such a condition occurs the yellow Check Engine light in the lightbar will glow If the problem gets bad enough to cause possible engine damage the DDEC III will gradually cut engine power down to 70 percent of original power At that point the red Shutdown Engine light will turn on and 30 seconds later DDEC III will shut down the engine Instruments and Controls Identification If DDEC III detects low oil pressure both the Check Engine and Shutdown Engine lights will go on and the engine will shut down in 30 seconds NOTE If the vehicle is in a hazardous place when the Shutdown Engine light goes on the driver must immediately press the Override Chk button or the engine will shut down in 30 seconds Pressing the button will give the driver an additional 30 seconds to move the vehicle If this is still not enough time the driver must press the button again for another 30 second delay before engine shutdown Once the engine has shut down cycle the ignition key off and then on and press the Override Chk button to restart the engine The cruise control and PTO governor options are controlled in one of two ways By two switches on
223. ix 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 Engines manufactured since 2007 must use ultralow sulfur diesel ULSD with 15 ppm sulfur content or less based on ASTM D2622 test procedure Failure to use ultralow sulfur diesel fuels may void the war ranty on emission components 9 1 Fuel should always be strained or filtered before being put into the tanks This will lengthen the life of the engine fuel filter and reduce the chances of dirt getting into the engine 9 2 Before installing the fuel cap clean the area with a rag or if necessary clean the cap with solvent 9 3 If needed prime the fuel system For priming procedures see the applicable engine manufacturer s manual 10 Drain the water from the fuel water separator as follows For a Racor Model 1000FG see Fig 11 3 Check the water level in the sight bowl To drain the water loosen the valve at the bottom of the bowl two full turns and allow the water to run out Close and tighten the valve finger tight For a Davco Model 321 see Fig 11 4 If the separator is equipped with a fuel filter and the filter has a vent at the top open the vent To drain the water open the drain valve at the bot tom of the separator Newer
224. jury or death Unlocking the Fifth Wheel Lock Mechanism 1 Apply the tractor parking brakes 2 Pull the trailer air supply valve to cut off the air supply to the trailer Do not use the trailer air supply for parking trail ers not equipped with spring parking brakes This applies the trailer service brakes only As air bleeds from the trailer brake system brake appli cation is lost This could allow the unattended vehicle to roll away possibly resulting in serious personal injury or death 3 Chock the front and rear of the trailer tires to prevent the trailer from moving 4 Lower the trailer landing gear until the weight is removed from the fifth wheel 10 15 5 Disconnect the tractor to trailer air system lines and electrical cable Plug the air lines to prevent dirt or foreign material from entering the lines A CAUTION Before attempting to lock or unlock the fifth wheel lock mechanism of a sliding type fifth wheel the slide locking handle if so equipped and the slide lockpins must be in the locked po sition fully inserted in the slider rail holes This prevents the sliding member from moving rapidly to the far forward or rearward position which could damage the fifth wheel member or kingpin 6 Release the kingpin locking mechanism by lifting the safety latch and pulling the lock control handle to the unlocked position See Fig 10 19 7 Slowly drive the tractor away from the trailer Fifth Wheel Sl
225. l 12 Shift upward through each of the high range gears alternating the procedures in steps 10 and 11 above Downshifting 1 Downshift from 8th overdrive to 8th direct without moving the shift lever Flip the splitter control but ton down to the direct drive position then imme diately release the accelerator and press and release the clutch pedal Accelerate the engine only after the transmission has shifted 2 To downshift from 8th direct to 7th overdrive flip the splitter control button up to the overdrive po sition then immediately double clutch through neutral moving the shift lever from 8th to 7th gear 3 Downshift through each of the high range gears alternating the procedures in steps 1 and 2 above until reaching 5th direct 4 While in 5th direct and ready for the next down shift push the range selection lever down into low range Double clutch through neutral and shift into 4th gear See Fig 8 18 As the shift lever passes through neutral the transmission will automatically shift from high range to low range 5 With the transmission in low range downshift through the low range gears as conditions re quire IMPORTANT Never use the clutch brake when downshifting or as a brake to slow the vehicle Meritor Engine Synchro Shift ESS Automated Models Refer to the Meritor website for additional informa tion www arvinmeritor com General Information ESS 9 Speed and 10 Speed M MO RS
226. l and PTO governor options are controlled in one of two ways By two switches on the instrument control panel Fig 2 5 The On Off switch turns on the cruise control option and the spring loaded Set Resume switch selects the cruise speed or resumes cruise control after slowing down For PTO operation the On Off switch turns on the PTO and the Set Resume switch either selects or resumes the engine operating speed or By three optional buttons on the transmission shift knob Fig 2 6 The Pause button allows the driver to temporarily interrupt cruise control The Resume button allows the driver to resume the cruise speed after slowing down The Set button allows the driver to select the cruise speed For PTO operation the Pause button temporarily interrupts PTO opera tion the Resume button resumes PTO operation at the previously selected engine speed and the Set Instruments and Controls Identification button is used to select the engine operating speed See Chapter 7 for complete instructions Ether Start Push Button Optional For cold weather starting the vehicle may be equipped with one of several manual control ether start systems To start the engine in cold weather push the ether button Fig 2 7 then start the en gine See the engine operating instructions in Chap ter 7 for additional information x T x 01 18 95 f600648a 1 Ether Start Push Button 2 Battery Boost Push Butto
227. l rotate towards the rear and the lock control handle upper shoul der will rest on the fifth wheel plate just above the rod hole When the lock control handle is in the out position the trailer may be uncoupled from the tractor If the air mechanism does not operate properly do not attempt to use the system Operate the fifth wheel manually until the air mechanism is repaired or replaced Under no circumstances should the vehicle be operated or the air mecha nism used when the spring brake section is caged 7 Slowly drive the tractor away from the trailer 10 10 Fifth Wheels and Trailer Couplings 2 4 3 5 4 6 8 10 17 96 1310544 1 Housing Weldment 6 Lever Bar 2 Air Oylinder 7 Lock Spring 3 Extension Spring 8 Lock 4 Slide Cam 9 Jaw 5 Lock Control Handle Fig 10 15 Touchloc Air Operated Lock Control Fifth Wheel Slide Operation 1 Chock the front and rear of the trailer tires to prevent the trailer from moving Connect the trailer kingpin to the tractor fifth wheel For instructions refer to Fifth Wheel Locking Operation in this chapter After positive lockup of the fifth wheel lock mechanism has been accomplished release the slide using one of the following methods 3 1 For air operated models set the cab operated control switch Fig 10 8 to UN LOCK 3 2 For manually operated models raise the safety latch and pull the slide operating rod Fig 10 11 outward until the sho
228. lashing WHL SPIN light To engage this mode the ATC func tion switch must be in the Normal position when the vehicle is initially powered up Once the vehicle is started the ATC function switch can be set to the Deep Snow Mud position The ECU indicates this change by a constant flashing of the WHL SPIN lamp or by illumination of the Deep Snow Mud light on vehicles built before July 1994 If the ATC function switch is in the Deep Snow Mud position when the vehicle is powered up the ECU will not accept this function change and will remain in the Normal mode Indication of this condition will be the absence of the flashing WHL SPIN light on ve hicles built before July 1994 the absence of an illu minated Deep Snow Mud light To engage the Deep Snow Mud mode in this situation change the position of the ATC function switch to the Normal mode After two seconds move the switch to the Deep Snow Mud position When this occurs the indicator light will activate as previously described The ABS Chk switch if equipped activates blink code diagnostics which are used to read ABS and ATC system fault codes on the WHL SPIN light This switch is located in the lower dash panel cover just below the ignition switch on the left side of the steer ing wheel When turned on in the up position blink code diagnostics are activated See Group 42 of the Heavy Duty Trucks Service Manual for trouble shooting procedures IMPORTANT ABS
229. lative speed of and angle to the target of vehicles and objects ahead The system uses this information to warn the driver of potentially dangerous situations Optional side sensor s mounted on the side of the vehicle also transmit and receive radar signals for a distance of 2 to 10 feet 0 5 to 3 meters alongside your vehicle The side sensor s provide a 15 degree vertical by 15 degree horizontal beam pattern The side sensor s can detect unseen vehicles and ob jects moving and stationary adjacent to your vehicle A WARNING The Eaton VORAD EVT 300 Collision Warning System CWS is intended solely as an aid for an alert and conscientious professional driver It is not intended to be used or relied on to operate a vehicle Use the system in conjunction with rear view mirrors and other instrumentation to safely operate the vehicle Operate this vehicle equipped with the EVT 300 Collision Warning System in the same safe manner as if the EVT 300 Collision Warning System were not present The EVT 300 Collision Warning System is not a substitute for safe normal driving procedures nor will it compensate for any driver impairment such as drugs alcohol or fatigue The EVT 300 Collision Warning System may pro vide little or no warning of hazards such as pe destrians animals oncoming vehicles or cross traffic Failure to drive safely and use the system prop erly could result in personal injury and or death and severe prope
230. ld be tight and in good condition to prevent losses through loose or corroded connections 4 The ether start system should be properly charged and in good working order 5 Ethylene glycol base antifreeze is recommended An inhibitor system is included in this type of an tifreeze and the corrosion protection is sufficient T as long as the recommended concentration range of 30 to 67 percent antifreeze to water by volume is employed See Group 20 of the Heavy Duty Trucks Maintenance Manual for cool ing system capacity and quantity of antifreeze required for the lowest anticipated temperature 6 Ifthe engine is to be operated in arctic tempera tures consult the nearest Freightliner dealer or an authorized Detroit Diesel engine dealer for information regarding availability of special cold weather equipment 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 Operator s 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 diesel engines have been built to comply with the requirements of the Federal U S Clean Air Act Once a
231. le or a vehicle with a new clutch check for clutch slippage during acceleration If the clutch slips decelerate until the clutch does not slip Allow the clutch to cool 15 to 30 seconds and then gradually accelerate again If the clutch continues to slip repeat the procedure If nec essary repeat the procedure up to five times If the clutch slips after five attempts stop the vehicle Allow the clutch to cool for at least one hour Notify your Freightliner dealer of the problem 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 Starting the Vehicle in the Proper Gear An empty truck can be started in a higher transmis sion gear ratio than when partially or fully loaded A good rule of thumb for the driver to follow is select the gear combination that allows you to start moving with an idling engine or if necessary just enough throttle to prevent stalling the engine After the clutch is fully engaged the engine should be accelerated to the correct rpm for the upshift into the next higher gear Gear Shifting Techniques Many drivers upshift into the next gear or even skip shift into a higher gear before the vehicle has reached the proper speed This type of shifting is almost as bad as starting off in a gear that is too high since the engine rpm and vehicle speed
232. level before the red stop engine lamp was illuminated The switch must be recycled after five seconds to obtain a sub sequent override CAUTION Using the override button so the engine operates for an extended period may result in engine dam age The operator has the responsibility to take action to avoid engine damage Caterpillar Engine Operation Proper operation and maintenance are key factors in obtaining the maximum life and economy of a vehicle engine Follow the directions in the Caterpillar Opera tion and Maintenance Management Manual and this manual for trouble free economical engine operation 1 Operate the engine at low load After normal oil pressure is reached and the temperature gauge begins to move the engine may be operated at full load Caterpillar electronic engines automatically idle at 900 to 1000 rpm for the correct warm up time after a cold engine start less than 40 F 5 C These electronic engine systems will reduce the idle speed to 600 rpm when the engine is warm enough to drive the vehicle IMPORTANT Fuel heaters used on vehicles with Caterpillar electronic engines could cause excessive fuel temperatures that affect engine performance and operation of the electronic en gine controls If a fuel heater is used make sure it has thermostatic controls If the fuel heater has a timer set the timer to activate only for a limited period of time before the engine starts Make sure the fuel heater
233. light illuminates continuously when no vehicle is detected by the side sen sor s See Fig 2 25 01 27 97 f601259 1 Red Alert Light vehicle or object detected 2 Photo Light Sensor 3 Yellow Indicator Light no vehicle or object detected Fig 2 25 Side Sensor Display Optional 2 The photo light sensor senses lighting conditions in the cab and automatically adjusts the intensity of indicator and alert lights 3 The red alert light illuminates when objects are detected by the side sensor s If the right turn signal is activated and the side sensor detects an object the red alert light will illuminate and the DDU speaker will sound a high frequency double tone This tone is sounded only once per activation of the turn signal The red light will also illuminate and stay on if a failure of the side sensor is detected Special Road Situations A WARNING The Eaton VORAD EVT 300 Collision Warning System CWS is intended solely as an aid for an alert and conscientious professional driver It is not intended to be used or relied on to operate a vehicle Use the system in conjunction with rear view mirrors and other instrumentation to safely operate the vehicle This system will not warn of many possible hazards Do not assume it is all clear if no alert lights are illuminated Failure to drive safely and use the system prop erly could result in personal injury and or death and severe property damage
234. line 2 Lever only shift Break torque by releasing the throttle and depressing the clutch pedal Double clutching move the shift lever to the next desired gear position The lever only shift is used to skip a full gear With the shift button rearward 9th to 7th 7th to 5th 5th to 3rd and 3rd to 1st With the shift but ton forward 10th to 8th 8th to 6th 6th to 4th and 4th to 2nd IMPORTANT Never use the clutch brake when downshifting or as a brake to slow the vehicle CAUTION Do not attempt a combination button lever down shift at too high an engine speed generally 8 12 Transmissions above 1400 rpm Doing so could result in dam age to the engine transmission and or driveline 3 Combination button lever shift With the throttle still applied preselect the next gear by sliding the shift button forward Break torque by releas ing the throttle and depressing the clutch pedal Double clutch and move the shift lever to the next desired gear position The combination button lever shift is used for gear changes from 9th to 8th 7th to 6th 5th to 4th and 3rd to 2nd Eaton Fuller AutoShift Automated Transmissions Refer to the Eaton website for additional information www roadranger com General Information AutoShift 18 Speed RTLO Models Eaton Fuller 18 speed RTLO model transmissions have 18 forward speeds and four reverse speeds The transmission consists of a 5 speed front section an
235. lity lights are installed in the back of the vehicle an indicator light comes on when they are in use Mirror heat indicator light An indicator light comes on whenever the mirror heat switch is on Low water warning light which is standard when a low water probe warning system or a four way engine shutdown system is installed A warning light comes on whenever the coolant level in the radiator drops below the low water probe Fifth wheel slider indicator light An indicator light comes on whenever the air operated lock pins on a fifth wheel are retracted from the baseplate the fifth wheel slider is unlocked Optional warning and indicator lights and their loca tions may vary because of different optional equip ment installed Other optional accessories and stan dard equipment that are or can be equipped with warning or indicator lights include engine heater parking brakes tire sanders spotlights oil level oil temperature cruise control system engine fan and other options 2 16 Instruments and Controls Identification VIGIL II Warning System Optional The VIGIL II system is an electronically controlled warning and engine shutdown system It controls the turn signal functions and various optional functions A solid state lightbar Fig 2 22 in the instrument panel contains displays for the functions 12 3456 7 8 X i 5 or Ea E E 1 oP er on A gt x 10 26 98 f600630b 1 Left Turn Signal
236. llar C 15 225 107 Cummins L10 212 100 Cummins NTC 212 100 Cummins NTC 444 220 104 Cummins C Series 212 100 Detroit Diesel 210 99 Table 2 2 Maximum Water Temperature Engine Oil Pressure Gauge The oil pressure gauge Fig 2 26 should read as shown in Table 2 3 Oil Pressure Idle Speed Rated Speed Engine Mogel psi kPa psi kPa 43 to 53 Caterpillar C 10 C 12 10 69 296 to 365 61 to 71 Caterpillar C 15 23 158 min 420 to 490 min Instruments and Controls Identification Oil Pressure Idle Speed Rated Speed Engine Mode psi kPa psi kPa 35 to 45 Cummins L10 10 69 min 241 to 310 35 to 45 Cummins NTCT 10 69 min 241 to 310 Cummins C Series 10 69 min 30 207 Detroit Diesel 12 83 50 345 min Oil pressures are given with the engine at operating temperature With the engine cold oil pressure may be higher t Individual engines may vary from the listed pressures observe and record pressures when the engine is new to serve as a guide for check ing engine condition Table 2 3 Oil Pressure A CAUTION A sudden decrease or absence of engine oil pressure may indicate mechanical 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 Pyrometer Optional A pyrometer Fig 2 26 register
237. lock provides maximum traction under slippery conditions When the differential lock is engaged the clutch collar completely locks the differential case gearing and axle shafts together maximizing traction of both wheels and protecting against spinout Under normal traction conditions do not engage the differential lock Operate the axle with differential action between both wheels 9 1 Be especially careful when driving under slippery conditions with the differential locked Though forward traction is improved the vehicle can still slip sideways causing possible loss of vehicle control personal injury and property damage Meritor Main Differential Lock Operation To lock the main differential and obtain maximum traction under slippery conditions move the control switch to the lock position A WARNING Lock the main differential only when the vehicle is standing still or moving less than 25 mph 40 km h Never lock the main differential when the vehicle is traveling down steep grades or when the wheels are slipping This could damage the differential or lead to loss of vehicle control causing personal injury and property damage NOTE On some vehicles the differential lock system is connected through the low speed range of the transmission If this system is used the transmission must be in the low speed range for the differential to fully lock If the vehicle is moving maintain a constant vehicle speed while engag
238. ly injury property damage or severe damage to the engine The red stop engine lamp illuminates to indicate that the engine protection system has been activated The conditions that will cause the red stop engine lamp to come on are high coolant temperature loss of coolant low oil pressure high soot level DPF uncontrolled DPF regeneration On some engines the engine ECU will derate the engine allowing it to run at low rpm and slow vehicle speed until the vehicle can be driven to a safe loca tion or to a service facility On other engines the en gine ECU will first derate the engine then if the con dition does not improve shut it down completely 30 seconds after the light comes on The driver must safely bring the vehicle to a stop on the side of the road before the engine shuts down To restart the engine override the shutdown com mand turn the ignition switch to OFF leave it there a few seconds and turn the switch to START The en gine will run for a short period and shut down again if the condition does not improve IMPORTANT Do not attempt to restart the en gine while the vehicle is moving Bring the ve hicle to a safe stop and restart the engine with the vehicle stopped Stop Engine Override Switch If the vehicle is equipped with a stop engine override SEO switch it can be used to override the shut down sequence This override resets the shutdown timer restoring power to the previous
239. m of a sliding type fifth wheel the slide locking handle if so equipped and the slide lockpins must be in the locked po sition fully inserted in the slider rail holes This prevents the sliding member from moving rapidly to the far forward or rearward position which could damage the fifth wheel member or kingpin 1 Chock the front and rear of the trailer tires to prevent the trailer from moving Fifth Wheels and Trailer Couplings Keep the fifth wheel plate lubricated to prevent binding between the tractor and trailer A binding fifth wheel could cause erratic steering and loss of vehicle control possibly resulting in serious personal injury or death 2 The kingpin lock mechanism must be fully open the fifth wheel plate must be completely lubri cated with chassis grease For lubrication in structions see Group 31 of the Heavy Duty Trucks Maintenance Manual 3 Position the tractor so that the fifth wheel lock opening is in line both vertically and horizontally with the trailer kingpin The kingpin should be in a position to enter the throat of the locking mechanism as shown in Fig 10 18 Adjust the trailer landing gear to give enough alignment height for positive kingpin lockup 4 With the fifth wheel lock opening aligned with the trailer kingpin back the tractor slowly toward the trailer making sure that the kingpin enters the throat of the locking mechanism Continue back ward motion until positive lockup oc
240. made to the crankshaft The Brake Saver does this by converting rotation energy into heat which is removed by the engine cooling system The BrakeSaver is controlled by the driver as neces sary by operating a lever on the instrument panel Brake pressure increases as the lever is moved to ward the ON position An air pressure gauge pro vides a relative indication of the braking force An oil temperature gauge indicates the heat in the Brake Saver during its operation If the temperature gauge indicates HOT the BrakeSaver control lever must be moved to the OFF position The oil temperature will decrease rapidly with the BrakeSaver off When the temperature reaches normal the BrakeSaver can be used CAUTION Do not engage the BrakeSaver and control the wheel speed with the accelerator The design of 7 10 Engines and Clutches the cooling system is for the control of the tem perature of the oil at full engine power or full BrakeSaver capacity but not both at the same time Power Takeoff PTO Governor Caterpillar electronic engines may be equipped with a PTO governor This mode is used only when the vehicle is parked The PTO mode is activated by the ON OFF and SET RESUME switches on the dash Fig 7 5 or by optional PAUSE RESUME and SET buttons on the transmission shift knob Fig 7 6 1 To engage the PTO 14 Flip the ON OFF switch on the instrument control panel to ON 1 2 Hold the throttle pedal until t
241. ment control panel Fig 2 5 The On Off switch turns on the cruise control option and the spring loaded Set Resume switch selects the cruise speed or resumes cruise control after slowing down For PTO operation the On Off switch turns on the PTO and the Set Resume switch either selects or resumes the engine operating speed By three optional buttons on the transmission shift knob Fig 2 6 The Pause button allows the driver to temporarily interrupt cruise control The Resume button allows the driver to resume the cruise speed after slowing down The Set button allows the driver to select the cruise speed For PTO operation the Pause button temporarily interrupts PTO opera tion the Resume button resumes PTO operation at the previously selected engine speed and the Set button is used to select the engine operating speed See Chapter 7 for complete instructions BrakeSaver Control Optional The BrakeSaver optional on Caterpillar C 15 en gines is operated by a lever mounted in the cab The lever controls the amount of oil being directed through the BrakeSaver The time required to fill the BrakeSaver with pressure oil to the point of maxi mum braking in the BrakeSaver is about 1 8 sec ondas Cummins PACE and CELECT Electronic Engines Operator Control Cummins PACE CELECT and CELECT IV are elec tronic fuel control systems installed on model L10 and for PACE only Big Cam IV engines These elec
242. n Fig 2 7 Ether Start and Battery Boost Controls Optional Low Voltage Disconnect Optional The optional Sure Power Low Voltage Disconnect LVD system monitors battery power when accesso ries are being used when the engine is shut down The system automatically turns off cab and sleeper accessories when voltage drops to 12 3 volts to en sure that there is enough battery power to start the vehicle An alarm sounds for one minute before ac cessories are turned off If no action is taken within that minute the LVD module will shut off power to predetermined cab and sleeper circuits and illumi nate an LED indicator on the LVD module located inside the baggage compartment These circuits will remain off until the LVD measures 13 0 volts applied to the system which can be done by starting the en gine After the engine is started the system will reset All vehicles equipped with LVD should have a sticker on the dash indicating the presence of the system Another sticker is located inside of the baggage com partment along with the LVD module Battery Boost Push Button and Optional Battery Isolator System A battery isolator system has two or three regular batteries to turn the starter motor and one or two gel cell batteries to provide power for cab and sleeper accessories when the engine is off The system uses an isolator relay which is normally open The relay isolates the engine starting batteries while the engine i
243. n 4 Lockguard Ph Fig 10 6 Lockguard Mechanism rear view possibly resulting in serious personal injury or A WARNING Adjust the locks correctly to a maximum clear ance of 1 8 inch 3 mm Incorrect adjustment of the lock could cause the trailer to disconnect 10 3 death 6 Make a visual check for proper kingpin lockup Release the tractor parking brakes Test for king pin lockup by pulling on the trailer against the Fifth Wheels and Trailer Couplings f a N 07 26 96 A Closed Position Locked 1 Release Arm 2 Release Handle 3 Lock Pin 1310532 B Open Position Unlocked 4 Hinged Lock Fig 10 7 Type A Kingpin Lock Mechanism chocks Check for correct maximum clearance between the lock halves If more than 1 8 inch 3 2 mm clearance exists between the lock halves the lock must be adjusted See Group 31 of the Heavy Duty Trucks Service Manual for adjustment procedures NOTICE Always make sure the connect hanger support keeps the trailer air hoses and electrical cables positioned so that they do not rub on anything Rubbing may wear through hoses or cables re sulting in air leaks or exposed or broken wires potentially affecting trailer brake or electrical sys tems 7 After lockup is completed connect the tractor to trailer air system lines and electrical cable to the trailer Take care to prevent dirt or foreign mate rial from entering the air lines 8
244. n and displays average miles per gallon The Fuel Tach provides you with immediate feedback showing a percentage difference between the current fuel con sumption rate and the total trip miles per gallon aver age The 0 point on the gauge means that the current fuel consumption rate is the same as the miles per gallon average of the total trip distance traveled Clockwise movement into the green zone of the gauge needle shows the percentage improvement in the current fuel consumption rate compared to the miles per gallon trip average Counterclockwise movement into the red zone of the gauge needle shows that the current fuel con sumption rate is higher than miles per gallon trip av erage Needle movement into the red zone means that the driver should shift the transmission or change vehicle speed to increase fuel efficiency as driving conditions permit The Fuel Tach system is operated by a toggle switch For switch operating instructions see Fuel Tach Switch in this chapter The Fuel Tach system installed in vehicles with elec tronic engines also displays fault codes correspond ing to any engine problems that might occur When the engine databus sends a fault code it interrupts the LED miles per gallon display for 60 seconds An F appears in the display together with the fault code for example F37 If the engine sends a single fault code the display blinks on and off for 60 sec onds while displaying the code
245. n engine is placed in service the responsibil ity for meeting both state and local regulations is with the owner operator Good operating practices regular maintenance and correct adjustments are factors that will help to stay within the regulations Proper maintenance of the engine which is the responsibility of the owner operator is essential to keep the emis sion levels low Engine Protection On electronic engines an engine protection system monitors all engine sensors and electronic compo nents and recognizes system malfunctions If a criti cal fault is detected an amber check engine warning lamp and a red stop engine lamp illuminate The standard parameters that are monitored for en gine protection are low coolant level high coolant Engines and Clutches temperature low oil pressure high soot level DPF and uncontrolled DPF regeneration Amber Check Engine Warning Lamp When the amber check engine warning lamp comes on for any reason the vehicle can still be operated and the driver can proceed to the required destina tion This condition should be reported to an autho rized service center as soon as possible Red Stop Engine Lamp When the red stop engine light illuminates most engines are programmed to shut down automati cally within 30 seconds The driver must immedi ately move the vehicle to a safe location at the side of the road to prevent causing a hazardous situation that could cause bodi
246. n neutral 2 Allow the engine to run at half speed or slower with no load for four to five minutes to cool the engine gradually and uniformly 3 Shut down the engine by turning the ignition key off High Altitude Operation Cummins Engines lose horsepower when operated at high alti tude because the air is too thin to burn as much fuel as at sea level This loss is about three percent for each 1000 feet 300 m altitude above sea level for a naturally aspirated engine Most turbocharged en gines are rated for higher altitudes than naturally as pirated engines An engine will have smoky exhaust at high altitudes unless a lower gear is used The engine will not demand full fuel from the fuel system unless the engine is altitude compensated by the use of a turbocharger Shift gears as needed to avoid excessive exhaust smoke Engines and Clutches Bendix Cruise Control System Optional General Information The Bendix cruise control system has two modes of operation cruise control and stationary throttle con trol The cruise control mode maintains a driver selected speed above 20 mph 32 km h The sta tionary throttle control mode provides operator control of the engine throttle position when the ve hicle is parked Cruise Control Operation The cruise control is activated by the ON OFF and SET RESUME switches See Fig 7 5 A light in the warning and indicator light module is on when the cruise control is engaged
247. n operating off road or under adverse condi tions always use low gear when starting to move the vehicle forward When operating on highway with no load or under ideal conditions use 1st gear when start ing to move the vehicle forward For all conditions use the highest gear that is still low enough to start the vehicle moving with the engine at or near idle speed and without slipping the clutch excessively 2 Use the clutch brake to stop gear rotation when shifting into low or 1st or reverse when the ve hicle is stationary The clutch brake is actuated by depressing the clutch pedal all the way to the floor For normal upshifts and downshifts only a partial disengagement of the clutch is necessary to break engine torque 3 Use double clutching between all upshifts and downshifts that require movement of the shift lever Splitting of the high range gears does not require movement of the shift lever 4 Never move the shift lever into low gear while in high range 5 Never move the splitter control button while in neutral 6 Do not preselect with the splitter control button After moving the control button complete the shift immediately 7 Except when downshifting from 5th direct to 4th gear never push the range preselection lever down into low range while operating in high range the splitter will become inoperative 8 Do not shift from high range to low range at high vehicle speeds 9 Do not make ran
248. n optional side sensor of objects alongside when the turn signal is activated in prepa ration for a lane change Additional tones indicate speaker volume system failure driver s card status and data extraction pass or fail 1 The green power on driver s card optional sta tus indicator light illuminates when the system is activated and the power on LED test is complete If the system is configured to require that the driver s card be read and it is not the ON light blinks continuously 2 Pushin the volume control and power ON OFF knob to turn power on or off Turn the knob left or right to increase or decrease speaker volume Press and hold the knob for 5 seconds and then release it to activate the failure display mode NOTE The system may be configured to have no on off capability and the volume may be con figured to allow only some volume control 3 The speaker is located under the top cover of the DDU It sounds audible tones to alert the driver to potential hazards Volume may be re stricted to a range above a minimum level NOTE This is a configurable electronic param eter 4 Rotate the range knob if enabled to change the first alert detection range from 3 to 2 seconds This will also change the second alert detection range from 2 to 1 75 seconds Push and hold the knob for 5 seconds to activate the accident re construction function and freeze the most recent data in half of the allocated memory Instr
249. ned by the engine manufacturer See the engine manual for this temperature 2 The oil pressure warning light and buzzer acti vate whenever the oil pressure falls below the minimum oil pressure recommended by the en gine manufacturer 3 The low air pressure warning light and buzzer activate whenever air pressure in the primary or secondary air reservoir falls below 64 to 76 psi 441 to 524 kPa When the ignition is turned on oil and air pressure warnings activate until the engine starts and mini mum pressures are exceeded If the low oil warning light remains lit after running the engine for 15 sec onds shut off the engine and determine the cause See the Heavy Duty Trucks Service Manual for repair procedures If the warning system does not activate when the ignition is turned on repair the system to provide warning protection for oil pressure coolant tem perature and brake system air pressure Optional Warning and Indicator Lights The most common optional warning and indicator lights Fig 2 19 consist of any combination of the following e Interaxle differential indicator light which is standard on all dual drive vehicles An indicator light illuminates whenever the interaxle differ ential is locked out switch is in the lock posi tion Automatic sludge ejector moisture ejection valve indicator light An indicator light comes on whenever the ejector is operating Utility light s indicator light If uti
250. nel push outward on the release lever When closing the vent window hold the release lever in the forward pivoted position and pull it inward When the outer edge of the lever clears the slide channel pivot the top of the lever 90 degrees rear ward The button will automatically pop out to lock the vent window Cab Door and Sleeper Compartment Vents To open any cab door vent Fig 3 2 or sleeper com partment vent Fig 3 5 push the vent handle out ward and to the right with your fingertips To close the vent turn your hand so that your fingers are pull ing on the handle from the front edge then pull in and back on the handle Use care to avoid pinching your fingers 01 18 95 1 Sleeper Compartment Vent 2 Handle Access Cutout f720059a Fig 3 5 Sleeper Door 3 3 Glove Box The glove box Fig 3 6 is located on the passen ger s side of the dash To lock the glove box insert the ignition key in the lockset with the key teeth pointing to the left then without pushing in on the lockset turn the key counterclockwise to vertical Do not turn the key clockwise to the original position to remove it To unlock the glove box insert the key and turn it clockwise to horizontal To open the glove box door push the door latch button lockset at the top center of the door 01 18 95 1600152a Fig 3 6 Glove Box Circuit Breaker Relay Panel The circuit breaker relay panel see Fig
251. neral Information The major reason why clutches wear out too soon is excessive 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 asked to do the job of a fluid coupling high tempera tures develop quickly and destroy the clutch Tem peratures generated between the flywheel driven discs and pressure plates can be high enough to cause the metal to flow and the friction facing mate rial to char and burn Heat and wear are practically nonexistent when a clutch is fully engaged But during the moment of engagement when the clutch is picking up the load it generates considerable heat An improperly ad justed or slipping clutch will rapidly generate suffi cient heat to destroy itself The most important items that a driver should be aware of to ensure long service life of the clutch in clude starting in the right gear clutch malfunctions and when to adjust a clutch Clutch Operation Eaton Valeo Clutch Break In With a newly installed Eaton Valeo clutch the clutch may slip for a short time while the friction surfaces break in However allowing the clutch to slip for more than two seconds can severely damage the clutch disc pressure plate and the flywheel 7 22 Engines and Clutches During initial operation of a new vehic
252. ng For more detailed information about TRLR ABS light operation see Chapter 6 IMPORTANT If any of the ABS warning lights do not work as described above or come on while driving repair the ABS system immedi ately to ensure full antilock braking capability The wheel spin indicator light WHL SPIN comes on flashing if one of the drive wheels spins during accel eration Fig 2 19 The flashing light goes out when the wheel stops spinning A label Fig 2 21 on the dash explains what actions should be taken when the WHL SPIN indicator light starts to flash If equipped with an electronic engine an automatic traction control ATC system may be installed On 2 14 Instruments and Controls Identification IF REAR WHEEL SPIN OCCURS PARTIALLY RELEASE THROTTLE PEDAL UNTIL WHEEL SPIN AMBER LIGHT EXTINGUISHES THEN ENGAGE AXLE LOCK 09 22 98 1600311a Fig 2 21 Dash Label these vehicles the ATC system automatically con trols wheel spin during reduced traction starts An ATC Function switch if equipped allows the driver to select from two levels of drive axle traction control assistance e NORMAL which reduces drive axle wheel spin on icy wet or sand covered roads e DEEP SNOW MUD which allows a higher threshold of drive axle wheel spin to help burn through a thin layer of ice or to help throw off accumulated mud or snow The Deep Snow Mud mode is indicated by a f
253. ng to move the vehicle and before than 30 seconds eliminate any leaks or picking up speed test the brakes with the foot replace the air compressor before operat pedal and parking brake control valve yellow ing the vehicle knob to be sure they will bring the vehicle to a 24 3 Check the air pressure reserve as follows safe stop 11 13 Pretrip and Post Trip Inspections and Maintenance Weekly Post Trip Maintenance Procedures Battery posts terminals and related accessories contain lead and lead compounds chemicals known to the State of California to cause cancer and reproductive harm To prevent possible per sonal injury always wash your hands after han dling battery parts and related accessories 1 Inspect the batteries and battery cables 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 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 Heavy Duty Trucks Maint
254. ngine is started it takes a while to get the lubricating oil film reestablished between the shafts and bearings and between the pistons and liners Bring the engine up to operating speed gradually as it warms up and develops stable oil pressure The oil pressure gauge indicates any drop in lu bricating oil pressure or mechanical malfunction in the lubricating oil system The operator should note the loss of oil pressure and shut down the engine before damage can occur 8 During the warm up period apply the load gradu ally until the oil temperature reaches 140 F 60 C For an engine starting a loaded vehicle the coolant temperature must be approximately 120 F 49 C Starting After Extended Shutdown or Oil Change Do the following steps after an oil change or after the engine has been shut down for more than three days 7 4 Engines and Clutches 1 Disconnect the wire from the fuel pump solenoid valve 2 Crank the engine until oil pressure shows on the gauge 3 Connect the wire to the fuel pump solenoid valve 4 Start the engine Refer to Engine Starting above Ether Start System Ether allows combustion with lower cylinder tempera tures A pressurized spray can or a rag dampened with fluid will usually provide quick starting to as low as 10 F 23 C Below this temperature some means of injecting a carbureted vapor directly into the intake manifold is necessary Caterpillar truck engines
255. ntenance Manual 3 Position the tractor so that the fifth wheel lock opening is in line both vertically and horizontally with the trailer kingpin The kingpin should be in a position to enter the throat of the locking mechanism to prevent a false lockup See Fig 10 6 Adjust the trailer landing gear to give enough alignment height so that the fifth wheel picks up the trailer on the fifth wheel ramps 4 With the fifth wheel lock opening aligned with the trailer kingpin back the tractor slowly toward the trailer making sure that the kingpin correctly en ters the throat of the locking mechanism When the trailer is picked up by the fifth wheel stop the tractor then continue slow backward motion until positive lockup occurs 5 Apply the tractor parking brakes 10 2 Fifth Wheels and Trailer Couplings 4 07 11 2000 A Closed Position Locked 1 Release Handle and Spring 2 Adjustment Nut 1310841 B Open Position Unlocked 3 Lock Halves 5 Sliding Yoke 4 Lock Pivot Fig 10 5 Type B Kingpin Lock Mechanism bottom view 11 07 94 D c 1310106a A Locks open B Locks closed C Kingpin correctly entering the lock Note how the depressed tongue allows lock halves to close completely around the neck and shoulder of the kingpin D Kingpin incorrectly entering the lock Note how the steel tongue prevents lock halves from closing preventing false lockup Fifth Wheel Plate Trailer 3 Kingpi
256. ntinuous operating hours of the engine In cases where actual mileage doesn t indicate overall usage maintenance and lubrication intervals for the engine and engine operated equip ment can be determined by operating hours Speedometer A speedometer Fig 2 19 registers speed in both miles per hour mph and kilometers per hour km h Standard speedometer gauges are equipped with a seven digit odometer that records total distance trav eled An optional speedometer is equipped with a seven digit odometer and a four digit odometer that records trip distance The trip odometer can be reset to zero by pressing a button near the lower edge of the gauge face Water Temperature Gauge During normal engine operation the water tempera ture gauge Fig 2 26 should read 175 to 195 F 79 to 91 C If the temperature remains below 160 F 71 C or exceeds the maximum temperature shown in Table 2 2 inspect the cooling system to determine the cause See the Heavy Duty Trucks Service Manual for troubleshooting and repair procedures x x Jy 200 TN E Zi Sx J SN i 3 y yf EA b y 300 600 900 1200 1500 DEG F 9 1809 Ot PYROMETER E x x 01 18 95 1600510a 1 Water Temperature Gauge 2 Oil Pressure Gauge 3 Pyrometer Fig 2 26 Water Temperature and Oil Pressure Gauges and Pyrometer Maximum Water Temperature Engine Model F C Caterpillar C 10 C 12 216 102 Caterpi
257. o stow or remove personal belongings in or from the Sleeper area To open the door from the inside push down on the lever handle at the bottom of the handle access cutout see Fig 3 5 To open the door from the outside insert the ignition key in the lockset Fig 3 10 Ref 1 and turn it one quarter turn clock wise Turn the key to the original position to remove it To close and lock the door push it closed until it latches IMPORTANT The sleeper doors are two stage latching When closing the doors ensure that they are completely latched to prevent wind noise and water intrusion Baggage Compartment Doors To open the baggage compartment door on the pas senger s side insert the ignition key in the lockset and turn it one quarter turn clockwise See Fig 3 10 Hold the key in this position while pulling outward on the baggage compartment door handle Turn the key to the original position to remove it To close and lock the door push it closed until it latches Use the same procedure to open the baggage com partment door on the driver s side but turn the key counterclockwise 3 5 01 18 95 1 Sleeper Door Lockset 2 Baggage Compartment Door Lockset 3 Baggage Compartment Door Handle f720006a Fig 3 10 Sleeper and Baggage Compartment Doors If the key is difficult to turn push inward on the door handle while turning the key Back of Cab Grab Handles Steps and Deck Plate A grab handle and steps
258. ode cool ing or heating selected If the cab needs to be cooled or heated the cool heat icon will flash 2 3 Choose either cool or heat by pressing the Cool Heat button Make sure the selection matches that of the cab controls IMPORTANT If the heat or cool selection of the thermostat does not match that of the cab the system will idle and cycle exces sively 2 4 Select Fahrenheit or Celsius by pressing and holding the Mode button until either the F or C is displayed 2 5 Select the temperature set point by press ing either the Up button or the Down but ton as applicable Holding the button will cause the display to count up or down rapidly When the desired set point is dis played release the button The set point is stored in memory 2 6 Select the temperature comfort zone by pressing the Mode button until the upper and lower temperature limit icon is dis played Then use the Up or Down button to select one of the three comfort zones of 4 F 2 C 7 F 4 C or 10 F 6 C To change the display to either Fahrenheit or Celsius press the Modebutton until only the F or C icon is flashing Press the Up or Down but ton to change to the desired value The main display will appear five seconds after the button is released To deactivate the thermostat mode and return to just the engine mode press the Mode button and hold it for three seconds To shut down Optimized Idle completely either turn off the
259. of the trailer 3 Disconnect the trailer air and electrical lines Plug the air lines to keep out dirt Take the weight of the trailer drawbar eye off the pintle hook 5 Open the coupling Fifth Wheels and Trailer Couplings 01 20 95 1310312a A Model 260 B Model 460 1 Pintle Hook 3 Pawl Assembly 5 Pawl Wedge 2 Latch 4 Pawl Lock 6 Shoe Fig 10 21 Premier 260 and 460 Trailer Couplings Holland Trailer Coupling General Information The Holland PH T 60 AL trailer coupling is de signed for use with trailers having a maximum gross weight of 10 000 Ibs 4536 kg It is a rigid type pintle hook used only on truck applications and is fas 3 tened to the rear closing crossmember of the vehicle See Fig 10 23 It is a non air adjusted coupling 01 20 95 1 Linchpin 3 Pintle Hook 2 Handle f310313a Fig 10 22 Premier 690 Trailer Coupling Models 260 and 460 Pull up on the pawl lock then while squeezing the pawl wedges together lift up the pawl assembly Lift up the latch and push it up against the pawl locking the latch in place Model 690 Remove the linchpin from the handle iis TOUR then push in on the handle and turn it toward 1 Lock 3 Latch you Open the pintle hook by pulling it down and 2 Cotter Pin 4 Pintle Hook toward you Release the handle locking the pintle hook open Fig 10 23 Holland PH T 60 AL Trailer Coupling 6 Slowly drive the
260. ontrol System IMPORTANT If the windows start to fog move the mode control to HEAT DEF or DEF and make sure the fan is on To defog the driver s door window turn the extreme left dash face outlet to direct airflow to the upper left In all 4 2 Heater and Air Conditioner Al c OFF f FRESH 1 MAX A C A C VEN HEAT HEAT DEF DEF ELA X og 5 E A 3 o COOL E mu z WARM RECIRC yy 4 e Ean 10 08 98 f830070c Fig 4 5 FRESH RECIRC Push Button B OFF 1 MAX A C A C VENT HEAT HEAT DEF DEF 28 l d C A 02 06 95 1830071a A Fan Switch at Position 4 B Mode Control at DEF C Temperature Control at WARM Fig 4 6 Settings for Defog Defrost B A OFF a d MAX AG AIC VENT MEAT HEAT DEF DEF o A O 3 LY cooL Xem ces f A C 02 06 95 1830074a A Fan Switch at Position 4 or lower as desired B Mode Control at HEAT C Temperature Control at WARM Fig 4 7 Settings for Maximum Heat positions of the mode control airflow is directed to the passenger s door window NOTE In mild weather the fan switch can be kept off since forward motion of the vehicle will provide airflow through the heater 4 If the vehicle has a sleeper with a rear climate control panel set the controls as desired For instructions refer to Heating Auxiliary Heater and Air Conditioner 5 When a comfortable temperature has been reached adjus
261. ouble clutching be tween shifts Downshifting 1 With the transmission in high range shift pro gressively downward to the bottom gear in high range double clutching between shifts CAUTION To prevent damage to the range section syn chros make sure the range preselection lever is in low range before moving the shift lever to neu tral Leave the shift lever in neutral long enough to be sure the range section has shifted 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 With the lever in low range double clutch through neutral and shift into the top gear of the low range As the shift lever passes through neu tral the transmission 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 IMPORTANT Never use the clutch brake when downshifting or as a brake to slow the vehicle Eaton Fuller Splitter and Range Shift Models Refer to the Eaton website for additional information www roadranger com General Information Eaton Splitter and Range Shift Combination splitter and range shift transmissions allow the choice of two splitter ratios in each lever position as well as the additional ratios provided in each lever position after shifting to the other range IMPORTANT Not all lever positions are used in each r
262. oup 31 of the Heavy Duty Trucks Maintenance Manual ASF Castloc Il and Simplex Series Fifth Wheels General Information The ASF Castloc Il and Simplex series fifth wheels are used for pulling trailers having the standard 2 inch diameter kingpin When installed as a station ary fifth wheel Fig 10 10 they are bracket mounted to the tractor frame in a position that best distributes the trailer load over the tractor axles When used as a sliding fifth wheel Fig 10 11 they are mounted on the Taperloc sliding mount air operated or manual release f310445 04 08 96 1 Baseplate 2 Bolted Stop 3 Baseplate Rail 4 Fifth Wheel Mount Slide Saddle Plate Safety Latch Operating Rod Operating Lever 9 1990 1310353b 3 Operating Rod 11 28 95 1 Lubricant Grooves 2 Safety Latch 4 Mounting Bracket Fig 10 10 Simplex Stationary Fifth Wheel The fifth wheel lock mechanism for the trailer kingpin consists of a rotating jaw that grips the trailer kingpin and a spring actuated lock The jaw rotates on a jaw pin during coupling and uncoupling operations King pin lockup occurs when the kingpin is forced into the jaw and the operating rod handle moves to the locked position The kingpin is released either by ac tivating a manual operating rod or if equipped with 10 7 Fig 10 11 Taperloc Slide Manually Operated Release Touchloc by a dash mounted release knob which activates an
263. our vehicle 8 11 CH a4 8 N R ANC Se LON k SN LENS LZ um b 2 b3 6 A M Ur 1 N 5 N O 12 14 1999 f261054 Fig 8 11 Top 2 and Lightning Shift Patterns with cruise control on Operation Super 10 Top 2 Lightning CAUTION Keep the transmission in gear at all times while the vehicle in motion Coasting in neutral could lead to transmission damage 1 When operating off highway or under adverse conditions always use low gear if so equipped when starting to move the vehicle When operating on highway with no load or under ideal conditions use 1st gear when start ing to move the vehicle For all conditions use the highest gear that is still low enough to start the vehicle moving with engine idling and without slipping the clutch ex cessively 2 Use the clutch brake to stop gear rotation when shifting into 1st or reverse when the vehicle is stationary The clutch brake is actuated by de pressing the clutch pedal all the way to the floor For normal upshifts and downshifts only a partial disengagement of the clutch is necessary to break engine torque 3 Do not make range shifts with the vehicle moving in reverse gear 4 The shift lever should not be moved to the center or left rail positions at vehicle speeds above 40 mph 65 km h Transmissions 5 Double clutch between all upshifts and down shifts 6 After your shifting ability improves you may want to skip some of the
264. ove the chocks from the trailer tires 14 The load distribution on the front steering axle and rear drive axle s will have a direct effect on the steering control of the vehicle Determine the front and rear axle weights by weighing the vehicle on scales designed for this purpose The maximum axle weight ratings are shown on the Federal Motor Vehicle Safety Standard FMVSS label or Canadian Motor Vehicle Safety Standard CMVSS label attached to the left rear door post of the tractor The desired load on the axle is no less than 80 percent of the maximum axle weight rating but in no instances should the axle load exceed the maximum axle weight rat ings given on the FMVSS or CMVSS label A WARNING Do not overload any tractor axle by improperly loading the trailer This could cause erratic steer ing and loss of vehicle control possibly resulting in serious personal injury or death Unlocking the Fifth Wheel Lock Mechanism 1 Apply the tractor parking brakes 2 Pull the trailer air supply valve to cut off the air supply to the trailer Do not use the trailer air supply for parking trail ers not equipped with spring parking brakes This applies the trailer service brakes only As air bleeds from the trailer brake system brake appli cation is lost This could allow the unattended vehicle to roll away possibly resulting in serious personal injury or death 3 Chock the front and rear of the trailer tires to prevent t
265. ows you to receive average miles per gal lon information for specific periods of time In this position the Fuel Tach system stays on and stores the average miles per gallon information in memory even if the engine is shut down In the IGN position the Fuel Tach system is on only when the ignition switch is on Shutting down the en gine cancels the information in memory With electronically controlled engines the digital dis play normally shows trip average miles per gallon If the engine datalink sends an electronic fault code the Fuel Tach interrupts the miles per gallon display for 60 seconds showing an F plus the fault code 2 7 for example F37 Fault codes are also stored in a history file for later viewing For engine fault code instructions see Fuel Tach Gauge in this chapter The Reset toggle switch cancels the information in memory used for calculating average miles per gal lon and erases the fault code history file To reset press and hold the reset switch The average MPG reading slowly blinks on and off for about 10 sec onds indicating that you are in the reset mode After erasing the memory the display blinks Er until you release the reset switch If you release the reset switch before the display changes to Er the engine fault code history will be displayed and the memory will not be erased After being reset the display will show 0 MPG until you drive at least 150 feet 46 m Fog Light Sw
266. point seat belt by pushing the link into the buckle until it latches See Fig 5 17 Give the belt a tug at the buckle If the buckle unlatches repeat this step If the problem contin ues replace the three point seat belt Seats and Seat Belts a f010004a Fig 5 17 Fastening the Three Point Belt Position the shoulder strap diagonally across your chest If desired engage the Komfort Latch as follows Pull on the shoulder strap to lessen the pressure of the strap on your shoulder and chest Allow no more than one inch 2 5 cm of slack between your chest and the shoulder harness More slack can significantly reduce the seat belt s effective ness in an accident or a sudden stop While holding the belt slack press the Komfort Latch lever up clamping the belt s webbing See Fig 5 18 and Fig 5 19 01 06 95 A 4 1910048a 1 Inch 2 5 cm Maximum Fig 5 18 Adjusting Shoulder Harness Clearance M N 3 X x x N 01 06 95 E N 1910006a Fig 5 19 Locking Komfort Latch 4 To unbuckle the three point seat belt push the button on the buckle as shown in Fig 5 20 If the Komfort Latch was used release it by giving the shoulder belt a quick tug If you lean forward against the shoulder belt the Komfort Latch will automatically release and will need to be reset Ie I 7 f910049a 01 18 95 Fig 5 20 Releasing the Three Point Seat Bel
267. pplies the trailer service brakes only As air bleeds from the trailer brake system brake appli cation is lost This could allow the unattended vehicle to roll away possibly resulting in serious personal injury or death 4 Lower the trailer landing gear until the weight is removed from the fifth wheel 5 Disconnect the tractor to trailer air system lines and electrical cable Plug the air lines to prevent dirt or foreign material from entering the lines CAUTION Before attempting to lock or unlock the fifth wheel lock mechanism of a sliding type fifth wheel the slide release plungers must be in the locked position flush with the mounting bracket edge This prevents the sliding member from moving rapidly to the far forward or rearward po sition which could damage the fifth wheel mem ber or kingpin 6 Release the kingpin locking mechanism by pull ing the kingpin lock control handle Fig 10 1 to the outward position 7 Slowly drive the tractor away from the trailer Fifth Wheel Slide Operation 1 Connect the trailer kingpin to the tractor fifth wheel For instructions refer to Holland Fifth Wheel Locking Operation in this chapter 2 After positive lockup of the fifth wheel lock mechanism has been accomplished release the sliding member using one of the following meth ods 2 1 For air operated models set the cab operated control switch Fig 10 8 to UNLOCK 10 5 5th WHEEL SLIDE MUST BE LOC
268. pply the service and spring parking brakes simultaneously To do so transmits exces sive input force to the brake components which could damage or cause eventual failure of brake actuating components Meritor WABCO Antilock Braking System ABS The Meritor WABCO Antilock Braking System ABS is an electronic wheel speed monitoring and control system that works with the standard air brake sys tem ABS passively monitors vehicle wheel speed at all times but controls wheel speed during an emer gency or reduced traction stop In normal braking applications the standard air brake system is in ef fect IMPORTANT For proper ABS system operation do not change tire sizes The sizes of the tires installed during production are programmed into the electronic control unit Installing different sized tires could result in a reduced braking force leading to longer stopping distances ABS includes signal generating tone wheels and sen sors located in the wheel hubs of each sensed axle The sensors transmit vehicle wheel speed informa tion to an electronic control unit ECU located be hind the passenger seat The ECU interprets the speed sensor signals and compares wheel speed wheel braking and vehicle speed If it senses wheel lockup the ECU signals the appropriate solenoid control valve to reduce braking During emergency braking the solenoid control valve constantly adjusts air pressure supply in the brake chambers to prevent wh
269. ps to a preset critical level the engine shut down light comes on and the engine will shut down if equipped with the shutdown feature All shutdown features have an automatic over ride If the vehicle needs to be moved to a safe location after shutdown just crank the engine It will run for about 30 seconds before shutting down again Turn Signal Functions The system operates the turn signal relay and the turn indicators Fig 2 23 The system features a special heavy duty relay for flashers capable of driving up to fourteen 32 candlepower bulbs Other Functions The system protects the starter by locking out the starter button whenever any of the following condi tions exist Voltage at the key switch is greater than 18 volts or less than 9 volts before the starter but ton is pressed The starter button has been pressed within the last two seconds Engine speed exceeds 350 rpm The starter has been cranked for a total of 30 seconds within the last minute the starter but ton is locked out for two minutes to allow the starter to cool NOTE If the lockout feature activates to let the starter cool the starter lockout warning light Fig 2 23 will be on for the two minute cooling period If the lockout feature activates for any other reason the light will glow only if the starter button is pressed within two seconds of the lockout occurring and it will be on only as long as the button is pressed
270. r Door Windows and Vent Windows Eaton 2 Speed Tandem Axles Dual Range 2 Speed Tandem Axle Operation With Multispeed Transmissions Eaton Fuller AutoShift Automated Transmissions Subject General Information AutoShift Operation AutoShift Eaton Fuller Deep Reduction Models General Information Deep Reduction Operation Deep Reduction Eaton Fuller Range Shift Models General Information Eaton Range Shift Operation Eaton Range Shift Eaton Fuller Splitter and Range Shift Models General Information Eaton Splitter and Range Shift Operation Eaton Splitter and Range Shift Eaton Fuller Super 10 Top 2 and Lightning Semi Automated Transmissions General Information Super 10 Top 2 Lightning Operation Super 10 Top 2 Lightning Eaton Interaxle Differential Lockout Operation Eaton Single Reduction Axles With Controlled Traction Differential Eaton Fuller Straight Shift Models General Information Eaton Straight Shift Operation Eaton Straight SRE us ufum el prr Emergency Kit Optional Emergency Starting With Jumper Cables Engine Braking System Optional Jacobs Engine Brake Engine Break In Engine Operation Caterpillar Engine Operation Cummins Engine Operation Detroit Diesel Engine Operation Engine Protection Engine Shutdown Caterpillar Cummins Detroit Diesel Index Subject Page Engine Staring ses reca oen rex RR SEES 7 2 Calerpillat i lier 7 3 Cummins and Detroit Diesel
271. r above the maxi mum fill or full mark could result in engine damage 8 Inspect the fuel tanks fuel lines and connections for leaks 11 5 02 09 95 1180002 1 Oil Check 2 Oil Fill Fig 11 2 Oil Level Checking 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 Heavy Duty Trucks Service 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 sudden loss of engine power possibly resulting in serious personal injury due to reduced vehicle control 9 Check the fuel level in the fuel tank s To keep condensation to a minimum fuel tanks should be filled at the end of each day Federal regulations prohibit filling a fuel tank to more than 95 percent of its liquid capacity Pretrip and Post Trip Inspections and Maintenance Never fill fuel tanks to more than 95 percent of their liquid capacity This could make them more likely to rupture from impact possibly causing fire and resulting in serious personal injury or death by burning Do not m
272. r cable Otherwise a spark could occur near a battery possibly resulting in Severe personal injury from explosion and acid burns In an Emergency A 10 18 94 2 1540027b A To Ground E To Starter B Connect 3rd F Connect 2nd C To Frame ground G Connect 1st D Connect Last 1 Booster Battery 2 Discharged Battery Fig 13 3 Jumper Connections 3 Connect one end of the second jumper cable to the negative terminal of the booster battery and connect the other end of the cable to a ground at least 12 inches 300 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 4 Start the engine of the vehicle with the booster batteries and let the engine run a few minutes to charge the batteries of the other vehicle 5 Attempt to start the engine of the vehicle with the batteries receiving the charge Do not operate the starter longer than 30 seconds and wait at least two minutes between starting attempts to allow the starter to cool 6 When the engine starts let it idle a few minutes Do the next step exactly as instructed and do not allow the clamps of one cable to touch the clamps of the other cable Otherwise a spark could occur near a battery possibly resulting in Severe personal injury from explosion and acid burns 7 Disconnect the grounded cable from the frame or ot
273. r lap belts only as described below In case of an accident or sudden stop injuries could re sult from misuse Lap belts are designed to be worn by one person at a time 1 Before driving the vehicle slowly pull the link end of the lap belt out of the retractor and pull it across your lap far enough to engage the buckle If the retractor locks too soon allow the belt to retract slightly then slowly pull it out again 5 9 05 30 2006 Fig 5 16 Shortening the Tether Belt 910074 2 Fasten the lap belt by pushing the link into the buckle until it latches Give the belt a tug at the buckle If the buckle unlatches repeat this step If the problem continues replace the lap belt 3 To unbuckle the lap belt push the button on the buckle to release the seat belt link NOTE Make sure the lap belt is completely re tracted when it is not in use Three Point Seat Belt With Komfort Latch A WARNING Wear three point seat belts only as described below In case of an accident or sudden stop in juries could result from misuse Three point seat belts are designed to be worn by one person at a time 1 Before driving the vehicle slowly pull the link end of the three point seat belt out of the retractor and pull it across your lap from outboard to in board far enough to engage the buckle If the retractor locks too soon allow the belt to retract slightly then slowly pull it out again 2 Fasten the three
274. r movement along notched rails Plungers are meshed into teeth on the baseplate to lock the slid ing mechanism Disengagement of the sliding mem ber is accomplished when the plungers are with drawn manually or air operated releasing the fifth wheel assembly so that it can be positioned for opti mum weight distribution over the tractor axles 7d b Gz A XA A ain 2 Z gt D gt J a 3 2 01 19 95 f310046a 1 Kingpin Lock Mechanism 2 Kingpin Control Handle 3 Mounting Bracket Fig 10 1 Holland Fifth Wheel The air operated release slide assembly Fig 10 2 contains a double ended air cylinder which locks and unlocks both sides of the sliding member at the same time The air cylinder is activated by a two position air control valve in the tractor cab The double manual release slide assembly Fig 10 3 contains two slide plunger release handles one on each side of the bracket assembly Both handles must be manually operated to lock and unlock each side of the sliding member The single manual release slide assembly Fig 10 4 has a single lever which locks and unlocks both 10 1 3 05 19 93 1310369 NOTE Baseplate rails not shown 1 Kingpin Lock Control Handle 2 Double Ended Air Cylinder 3 Slide Plunger Release Fig 10 2 Air Operated Release Slide Assembly 02 09 95 NOTE Baseplate rails not shown A Slide plunger must be flush with mounting bracket when locke
275. ratios This may be done only when operating conditions permit depend ing on the load grade and road speed 7 Avoid hunting for neutral by moving the gear shift lever from the left rail to right rail This action can cause excessive transmission wear 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 Depress the clutch pedal to the floor Shift into 1st gear then engage the clutch with the engine at or near idle speed to start the vehicle moving 3 Button only shift Preselect the next gear by sliding the shift button forward Break torque by releasing the throttle or by depressing the clutch pedal Decrease engine speed to synchronize the engine speed with the transmission speed The shift will complete when the engine rpm has decreased to the proper speed The button only shift is used for gear changes from 1st to 2nd 3rd to 4th 5th to 6th 7th to 8th and 9th to 10th 4 Lever only shift Break torque by releasing the throttle and depressing the clutch pedal Double clutching move the shift lever to the next desired gear position Decrease engine speed to syn chronize the engine speed with the transmission speed The shift will complete when the engine rpm has decreased to the proper speed The lever only shift is used to skip a full gear With the shift button rearward 1st to 3rd 3rd to 5th 5th to 7th an
276. returns to the fully in position visually and physi cally check the lockpins to make sure they are fully inserted into the holes in the slide rails Make sure the slide locking handle is locked in position against the guide plate 9 The amount of load distribution on the front steering axle and rear drive axle s will have a direct effect on the steering control of the vehicle Determine the front and rear axle weights by weighing the vehicle on scales designed for this purpose The maximum axle weight ratings are given on the Federal Motor Vehicle Safety Standard FMVSS label or Canadian Motor Vehicle Safety Standard CMVSS label attached to the left rear door post of the tractor The desired load on the axle is no less than 80 percent of the maximum axle weight rating but in no instances should the axle load exceed the maximum axle weight rat ing given on the FMVSS or CMVSS label 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 10 16 Fifth Wheels and Trailer Couplings loss of vehicle control possibly resulting in seri ous personal injury or death Fifth Wheel Lubrication The fifth wheel plate must be kept well lubricated with chassis grease to prevent friction and binding between the tractor fifth wheel plate and the trailer Friction and binding caused by insuffi
277. rides all others and is not affected by the range control knob setting IMPORTANT The system is disabled in turns with a radius of less than 750 feet 230 meters and when the brakes are applied 13 If your vehicle is traveling less than 2 mph 3 km h and an object is detected less than 15 feet 4 5 meters in front of your vehicle and the closing rate is more than 1 2 mph 1 km h the yellow alert light will illuminate and a low frequency double tone will sound This is the proximity alert NOTE All warnings apply only to objects within the maximum detection range and in your lane Proximity alert tones and vehicle closing 1 2 second and 2 second following interval tones are configured items All tones are disabled in sharp turns or when the brakes are applied If the configuration permits the 3 second and 2 second alert levels may be adjusted with the range control knob A single low frequency tone sounds when a system failure is detected A 2 22 Instruments and Controls Identification medium frequency tone sounds when the vol ume control level is changed Successful down loading of Eaton Vehicle Information Manage ment System EVIMS data will cause a double tone to sound Unsuccessful downloading will cause a low frequency tone to sound 14 A failure of the optional side sensor s will cause a continuous red light on the side sensor display to appear Side Sensor Display Optional 1 The yellow indicator
278. rol panel to SET or push the SET button on the trans mission shift knob 2 To disengage the cruise control 2 1 Depress the brake pedal or clutch pedal Or 2 2 Flip the ON OFF switch on the instrument control panel to OFF or push the PAUSE button on the transmission shift knob 3 To resume a preselected cruise speed 3 1 If the ON OFF switch on the instrument control panel is in the OFF position flip it to ON 3 2 Momentarily move the SET RESUME Switch on the instrument control panel to RESUME or push the RESUME button on the transmission shift knob Cruise will return to the last speed selected To adjust cruise speed up or down hold the SET RESUME switch on the instru ment control panel at SET to accelerate or at RESUME to decelerate until the desired speed is reached or press the SET button on the transmission shift knob to acceler ate or the RESUME button to decelerate until the desired speed is reached NOTE The resume vehicle speed memory is not maintained if the ignition is shut off BrakeSaver Optional The BrakeSaver optional on C 15 engines permits the operator to control the speed reduction of the vehicle on grades curves or anytime speed reduc tion is necessary but long applications of the service brakes are not desired During downhill operation the crankshaft is turned by the rear wheels through the drivetrain To reduce the speed of the vehicle an application of braking force can be
279. rque The range shift is automatic To skip a gear press the shift intent switch into the shift handle body while in neutral one time for every gear that is skipped IMPORTANT Use the clutch brake only when Downshifting initially engaging a gear with the vehicle stand i ing still 3 Push the clutch pedal to the bottom of its travel so that the clutch brake stops the transmission input shaft from rotating 4 Move the shift lever and engage a starting gear 5 Slowly release the clutch pedal NOTE If you do not shift the transmission out of neutral into a gear within two seconds the ESS system will time out and deactivate The trans mission returns to manual operation To reacti vate the ESS system press the shift intent switch again See the following procedures for upshifting and downshifting for instructions on how to use the shift intent switch Upshifting 1 To upshift into the next higher gear To downshift into the next lower gear 1 1 Press the bottom portion of the shift intent switch 1 2 Apply pressure with the shift lever toward the neutral position 1 3 Press the bottom portion of the shift intent switch again far enough so that the Switch goes into a second position inside the body of the shift knob Then release the switch See Fig 8 21 This will break torque 1 4 Immediately move the shift lever to the neutral position 1 5 Allow engine rpm to speed up enough to synchronize with ro
280. rratic steering and loss of vehicle control possibly resulting in serious personal injury or death The fifth wheel plate must be kept well lubricated with chassis grease to prevent friction and binding between the tractor fifth wheel plate and the trailer For lubrication instructions see Group 31 of the Heavy Duty Trucks Maintenance Manual Fontaine Fifth Wheels General Information The Fontaine sliding fifth wheel mount is designed to provide optimum axle loading for maximum tractor use with different lengths and types of trailers The sliding fifth wheel mount is used with the Fontaine H5092 series and 6000 7000 No Slack II series fifth wheels and is equipped with either an air operated release slide AWB or HAWB models or a manual release slide MWS or HMWS models On Fontaine fifth wheels kingpin release is accom plished by activating a manual lock control handle located on either the right side or left side of the fifth wheel Kingpin lockup occurs when the kingpin is forced into the jaws and the lock control handle moves to the locked position The fifth wheel top plate is mounted on a slide as sembly which is attached to slide rails that are mounted on the vehicle frame The slide rails permit forward and rearward movement of the slide assem bly allowing for optimum weight distribution over the tractor axles Slots are evenly spaced along the slide rails and re tractable lockpins are positioned through the hol
281. rty damage Driver Display Unit DDU NOTE All system controls are located on the DDU See Fig 2 24 Indicators to inform the driver about the system s operation are located on both the DDU and the optional side sensor display 2 20 Instruments and Controls Identification 3 5 2 6 ON fX at sc NA s as w GJ GOJ G Wd 1 7 VOLUME ALERTS RANGE EATON VORAD 1 9 L EESHIQUEOG ES J 10 15 98 8 1610258 1 Red System Failure Indicator Light Green Power ON Driver s Card Status Indicator Light Volume Control and Power ON OFF Knob Speaker Range Knob Green SC Indicator Light DARN 7 Photo Light Sensor 8 Drivers Identification Card Slot 9 Red Alert Light 10 Orange Alert Light 11 Yellow Alert Light 12 Distance Danger Alert Lights Fig 2 24 Driver Display Unit EVT 300 The DDU controls system power range for vehicle warnings speaker volume and all other system func tions At the lower front edge of the DDU a slot is provided to insert the optional driver s identification card Alert and indicator lights advise of multiple warning levels system power system failure and if so configured failure of the driver to insert the identi fication card A light sensor automatically adjusts alert and indica tor light brightness depending on cab lighting condi tions A small speaker provides audible alert tones to warn of closing on an object ahead and when equipped with a
282. ry conditions are encountered Engaged wheel slippage and spinout are minimized NOTE The controlled traction differential can be engaged at any speed except during spinout Eaton 2 Speed Tandem Axles Each axle of the 2 speed tandem contains a high range single reduction gear set and a low range double reduction gear set The operator selects the desired axle range by moving the range preselection lever located on the shifter knob Fig 9 4 Dual Range 2 Speed Tandem Axle Operation With Multispeed Transmissions NOTE See Chapter 8 Transmissions for de tailed information on how to use the range pre selection lever On multispeed transmission applications the 2 speed axle should be used as a dual range Use the low range when operating off highway or when starting out with a heavy load on highway After the vehicle is 9 3 U lt gt D gt 01 19 95 A High Range f260056a B Low Range Fig 9 4 Range Preselection Lever moving on the highway the axle can be shifted to high range To shift the axle to the high range Make sure the interaxle differential lockout is disengaged keep the throttle pedal down move the range preselection lever to high release the throttle pedal until the axle shifts then accelerate To shift the axle to the low range Keep the throttle pedal down move the range preselection lever to low release and depress the throttle pedal quickly to increase engine rpm T
283. s Conditions ROGO RO Du Rod ROC 09 f i mu P 6p 4 inel 15 Speed RTO y rod ZA ba ba bat i LS Y XT o 6 7 E gt C9 1260341 1260342 1260343 i 260344 R OR n R C T Lo R NT Le R 7 D Speed RT and RTX VI TIR mr 29 15 Y Y CY NY MY E SERES GR o9 o8 NT INS VA P 260345 260346 1260347 1260348 8 9 Table 8 2 Eaton Fuller Shift Progressions Transmissions 8 With the transmission in high range shift pro gressively upward through each of the high range gears Table 8 2 double clutching be tween shifts Alternate Upshifting Procedures 15 Speed Transmissions Only The shift from deep reduction to low range can also be made from 2nd 3rd or 4th gear of deep reduc tion but must be made to the next gear lower in the low range The shift from 2nd gear of deep reduction to 1st gear in low range or 3rd gear of deep reduc tion to 2nd gear in low range and 4th gear of deep reduction to 3rd gear in low range is an upshift and the same procedure should be followed as that shown for shifting from 5th gear of deep reduction to 4th gear in low range See step 5 under Upshifting Downshifting 1 With the transmission in high range shift pro gressively downward to the bottom gear in high range double clutching between shifts 2 When in the 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 t
284. s and the passenger s door window defrost outlet have nonadjustable lou vers The bunk outlet on the right hand wall of the bunk has two sets of vertical louvers that operate like the horizontal dash face louvers m 1 MAX A C A C VENT HFA HEAT DEF DEF pA COOL ES 2 02 03 95 f830069a Fig 4 1 Climate Control Panel An auxiliary heater and air conditioner unit is stan dard when there is a sleeper compartment The unit is installed in the sleeper baggage compartment and uses the cab s refrigerant system for air conditioner operation The unit is equipped with a separate evaporator coil expansion valve and fan It is also equipped with its own heater core and water valve independent of the cab heater On vehicles with a 60 inch sleeper the auxiliary unit s climate control panel Fig 4 3 or Fig 4 4 is located in the shelf area with a 40 inch sleeper it is mounted on the left front wall On vehicles with a 48 inch or 70 inch SleeperCab the control panel is mounted on the left rear wall or the rear overhead storage compartment NOTE Shutting off the heater supply gate valve if equipped on the engine limits the ability to control air conditioning temperature in the cab and in the sleeper With the valve shut off warm coolant is no longer available from the engine and the outlet air temperature controls can t be used to change air temperature 4 1 A FRESH RECIRC push button Fig 4 5 is standard
285. s are too far apart requiring the clutch to absorb the speed difference as heat For transmission operating in structions see Chapter 8 in this manual The clutch brake is applied by fully depressing the clutch pedal Its purpose is to stop the transmission gears from rotating in order to engage the transmis sion gears quickly in making an initial start A CAUTION Never apply the clutch brake when making down shifts or upshifts The clutch pedal should never be fully depressed before the transmission is put in neutral If the clutch brake is applied with the 7 23 transmission still in gear a reverse load will be put on the gear At the same time it will have the effect of trying to stop or decelerate the vehicle with the clutch brake Rapid wear of the friction discs will take place necessitating frequent re placement Considerable heat will be generated which will be detrimental to the release bearings and transmission front bearings Excessive Vehicle Overload or Overloading the Clutch Clutches are designed for specific vehicle applica tions and loads These limitations should not be ex ceeded CAUTION Overloading will not only result in damage to the clutch but also to the entire powertrain Riding the Clutch Pedal Riding the clutch pedal is very destructive to the clutch since partial clutch engagement permits slip page generating excessive heat Riding the clutch pedal will also put a constant thru
286. s not running so that the engine can still be started even if the gel cell battery has been used to the point of complete discharge When all four batteries have a charge the engine can be started in the normal manner by turning the ignition key to the Start position and pressing the starter push button To start the engine when the gel cell battery is drained press and hold the BATT BOOST push but ton Fig 2 6 while pressing the starter push button This will temporarily close the isolator relay and con nect the engine starting batteries to the ignition Switch for engine starting The isolator relay is closed only while the engine is running or the BATT BOOST push button is de pressed With the engine running all four batteries are connected in parallel allowing the alternator to charge them all in addition to supplying power for all vehicle loads When the engine is not running the gel cell provides all of the vehicle s electrical needs except for turning the starter motor The gel cell is longer lived and cheaper to use than a standard wet cell but it can take a charge only within an extremely narrow range 13 8 to 14 1 volts At 14 volts a gel cell has a very high charge accep tance rate Because a truck charging system oper ates at approximately 14 volts under normal condi tions a gel cell will never need to be recharged with an external charger A CAUTION Do not attempt to charge a gel cell with a stan
287. s reached or press the SET button on the transmission shift knob to acceler ate or the RESUME button to decelerate until the desired speed is reached NOTE The resume vehicle speed memory is not maintained if the ignition is shut off Power Takeoff PTO Governor Cummins electronic engines may be equipped with a PTO governor This mode is used only when the ve hicle is parked The PTO mode is activated by the ON OFF and SET RESUME switches on the dash Fig 7 5 or by optional PAUSE RESUME and SET buttons on the transmission shift knob Fig 7 6 1 To engage the PTO 1 1 Flip the ON OFF switch on the instrument control panel to ON 1 2 Hold the throttle pedal until the tachometer indicates the desired speed 7 12 Engines and Clutches 13 Momentarily move the SET RESUME switch on the instrument control panel to SET or push the SET button on the trans mission shift knob IMPORTANT Two PTO engine speeds can be preset on PACE and CELECT engines With the ON OFF switch on move the SET RESUME switch to SET to reach the first preset value or move the switch to RE SUME for the second preset value After one preset value has been selected you must turn the ON OFF switch off then turn it back on before using the second preset value 2 To disengage the PTO 2 1 Depress the brake pedal clutch pedal or throttle pedal CELECT engines only or 2 2 Flip the ON OFF switch on the instrument control panel to
288. s the exhaust tem perature near the turbocharger Normal exhaust tem peratures are listed in Table 2 4 Normal Exhaust Temperature Engine Model F C Caterpillar C 10 C 12 935 to 1290 500 to 700 Caterpillar C 15 950 to 1050 510 to 566 Cummins L10 800 to 1000 430 to 540 NOTE A pyrometer is set to ambient tempera ture When the engine is cold the pyrometer indicates the approximate outside temperature Do not attempt to adjust the pyrometer to zero degrees Voltmeter The voltmeter Fig 2 27 indicates the vehicle charg ing system voltage when the engine is running and the battery voltage when the engine is stopped By monitoring the voltmeter the driver can be aware of potential charging system problems and have them fixed before the batteries discharge enough to create starting difficulties 01 18 95 1600511 Application Air Pressure Gauge Dual System Air Pressure Gauge Voltmeter Fuel Gauge FloScan Fuel Tach oO e ON Cummins NTC 750 to 950 400 to 510 Cummins C Series 1290 700 max Detroit Diesel 700 to 950 370 to 510 Table 2 4 Normal Exhaust Temperature Variations in engine load can cause exhaust tem peratures to vary If the pyrometer reading shows that exhaust temperature exceeds normal throttle less fuel to the engine until the exhaust temperature is reduced Shift to a lower gear if the engine is over loaded Fig 2 27 Air Pr
289. sh any material restricting airflow 4 2 nspect the radiator and charge air cooler for damage and accumulated debris Straighten bent or damaged fins to permit airflow across all areas of the cores NOTE When traveling through areas of high insect concentration it may be necessary to clean the exterior of the radiator or the charge air cooler core as often as every 200 miles 320 km 4 3 On vehicles equipped with air condition ing also inspect and clean the condenser If clogged the condenser can restrict air flow through the radiator 4 4 Check the radiator for leaks If leaks are found have the radiator repaired or re placed See Group 20 of the Heavy Duty Trucks Service Manual for instructions or take the vehicle to an authorized Freight liner dealer 5 Inspect the engine and chassis wiring Check for loose wiring chafed insulation and damaged or loose hold down clamps Tighten loose wires or hold down clamps replace dam aged wiring or clamps 6 Inspect the air intake system for leaks or dam age CAUTION Failure to maintain a sealed air intake system could allow the entry of dirt and contaminants into the engine This could adversely affect en gine performance and result in engine damage 6 1 Check the intake air restriction indicator Pretrip and Post Trip Inspections and Maintenance 6 2 Replace the primary filter element in the air cleaner if the yellow signal stays locked at 25 inH O
290. shield IMPORTANT If equipped with a FRESH RECIRC push button the system draws in fresh air when the mode control upper lever is at HEAT DEF or DEF regardless of the FRESH RECIRC push button setting NOTE At DEF airflow is directed to the wind shield outlets and the extreme left and right dash face outlets To defrost the driver s door window turn the extreme left dash face outlet to direct airflow to the upper left In all positions of the mode control airflow is directed to the pas senger s door window Heater and Air Conditioner 7 02 09 95 1830350b 1 Dash Face Outlet driver s door window defrost outlet 6 Blower Motor 2 Windshield Defrost Outlet 7 Floor Outlet 3 Fresh Air Inlet 8 Recirculated Air Inlet 4 Passengers Door Window Defrost Outlet 9 Dash Face Outlet 5 Dash Face Outlet Fig 4 2 Air Outlet and Inlet System x x w UN VY COOL N HEAT SPEAKERS B orr SPEAKERS BFF a EFT O RIGHT 2 LEFT LC RIG En N rs P Bez N Z v EN YY a LN Pd DOME LT READ LT TN S DOME LT READ LT 0 x x 02 03 95 1600514a 02 03 95 1600515a Fig 4 3 Control Panel for a Manual Temperature Control Cable System Heating 1 With the engine at operating temperature set the mode control to HEAT See Fig 4 7 2 Slide the temperature control to WARM 3 Turn on the fan switch to the desired speed Fig 4 4 Control Panel for Automatic Temperature C
291. speed models four reverse gears are available Select either low range low split 1R low range high split R high range low split 1H high range high split H 3 Release the clutch NOTE The clutch must be used for starting and stopping Driving in the D Mode NOTE The drive mode is used for normal driv ing conditions 1 Fully depress the clutch 2 Move the gear select lever from neutral to drive NOTE The clutch must be fully depressed to shift from neutral to drive 3 Upshifting and downshifting are performed auto matically with no driver interaction required NOTE The clutch must be used for starting and stopping Parking the Vehicle 1 With the clutch pedal depressed move the gear select lever to neutral 2 Ensure that a solid N appears on the gear dis play module See Fig 8 12 NOTE If the gear display does not show a solid N the transmission is not yet in neutral 3 Set the parking brakes 4 Slowly release the clutch pedal Selecting the Starting Gear push button equipped gear select handle only NOTE On vehicles equipped with upshift and downshift buttons Fig 8 14 on the gear select handle enhanced DCC you may select the starting gear The gear you select is only active while the vehicle is running The transmission resets to the default starting gear after you have shut off the engine Depending on the vehicle s load you may select gears 1 through 5 as the st
292. ss the tongue the locks are unable to close Type A Kingpin Lock Mechanism Fig 10 7 The Type A kingpin lock mechanism utilizes a single hinged lock and a cam arm The final forward motion of the kingpin into the open lock forces the hinged lock to pivot on a pin and close around the kingpin The lock is held in place by a spring loaded plunger The kingpin can be released only by manu ally operating the release handle The adjustment nut will compensate for wear on the lock or kingpin Fifth Wheel Locking Operation Locking the Fifth Wheel Mechanism CAUTION Before attempting to lock or unlock the fifth wheel lock mechanism of a sliding type fifth wheel the slide release plungers must be in the locked position flush with the mounting bracket edge This prevents the sliding member from moving rapidly to the far forward or rearward po sition which could damage the fifth wheel mem ber or kingpin 1 Chock the front and rear of the trailer tires to prevent the trailer from moving A WARNING Keep the fifth wheel plate lubricated to prevent binding between the tractor and trailer A binding fifth wheel could cause erratic steering and loss of vehicle control possibly resulting in serious personal injury or death 2 The kingpin lock mechanism must be fully open and the fifth wheel plate must be completely lu bricated with chassis grease For lubrication in structions see Group 31 of the Heavy Duty Trucks Mai
293. ssions Operation Eaton Range Shift 1 When operating off highway or under adverse conditions always use low gear if so equipped when starting to move the vehicle When operating on highway with no load or under ideal conditions use 1st gear when start ing to move the vehicle except when equipped with a 9 speed RTO transmission then always start in low gear For all conditions use the highest gear that is still low enough to start the vehicle moving with engine idling and without slipping the clutch ex cessively 2 Use the clutch brake to stop gear rotation when shifting into low or 1st or reverse when the ve hicle is stationary The clutch brake is actuated by depressing the clutch pedal all the way to the floor For normal upshifts and downshifts only a partial disengagement of the clutch is necessary to break engine torque 3 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 8 2 Transmissions A SHES 7 coe E 3 D N i Y s 6 8 E LOW n 4 03 13 96 A All RT and RTX B Transmissions B All RTO Transmissions C All RTX P Transmissions B C i 5 8 Hi 6 8 SEP 4 wy i J 4 N N AS 6 B 7 Iw ZJ X3 a7 ig dE 1260027a D Up for High Range E Down for Low Range Fig 8 2 Eaton Fuller 9 Speed Range Sh
294. st load on the re lease bearing which can thin out the lubricant Re lease bearing failures can be attributed to this type of misuse Holding the Vehicle on an Incline With a Slipping Clutch A slipping clutch accumulates heat faster than it can be dissipated resulting in early clutch failures Never use the clutch as a hill holder Coasting With the Clutch Released Pedal Depressed and the Transmission in Gear Coasting with the clutch released and the transmis sion in gear can cause high driven disc rpm through multiplication of ratios from the final drive and trans mission A WARNING 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 Engines and Clutches be thrown off the disc Flying debris could cause injury to persons in the cab 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 Reporting Erratic Clutch Operation Promptly Reporting erratic clutch operation as soon as pos sible will give maintenance personnel a chance to inspect and lubricate the clutch components make necessary internal clutch and linkage adjustments etc Clutch free pedal is a decreased resistance felt at the top of the clutch pedal stroke See Fig 7 11 With the clutch pedal in this range the clutch is fully
295. stem the engine will shut down after 30 seconds Engines and Clutches 6 C 10 C 12 and C 15 engines may be operated at low load and speed once the engine oil pres sure has reached 10 to 20 psi 69 to 138 kPa When the engine has reached the normal operat ing temperature of 189 F 87 C the engine may be operated at full load Cummins and Detroit Diesel NOTE Before starting the engine read Chap ter 2 in this manual for detailed information on how to read the instruments and operate the controls On vehicles equipped with a neutral start switch the transmission must be in neutral before the engine can be started 1 Before engine start up perform the engine pre trip inspection and daily maintenance checks in Chapter 11 of this manual 2 Setthe spring parking brakes CAUTION Protect the turbocharger during the start up by not opening the throttle or accelerating the en gine above 1000 rpm until normal engine idle oil pressure registers on the gauge 3 Setthe throttle idle hold down the clutch pedal 4 Make sure the transmission is in neutral Ay CAUTION 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 5 Turn on the ignition switch NOTE A manual override knob provided on the forward end of the electric shutdown valve al lows the valve to be opened in case of electric po
296. stem functions the same as when the mode control is at MAX A C To prevent the buildup of fumes or odors inside the cab for example from smoking do not operate the heater and air conditioning system in a recirculation mode for more than 20 minutes NOTE The mode control must be at either A C or MAX A C and the fan switch must be on for the air conditioning system to work Fresh Air 1 Move the mode control to VENT or HEAT See Fig 4 9 In the VENT position air comes out of the dashboard outlets but not out of the floor out lets In the HEAT position air comes out of the floor outlets and the outlets on either end of the dashboard but the center dashboard outlets are closed Al OFF 1 MAX A C AIC VENT HEAT HEAT DEF DEF Ne SS ee 3 F 7j EET E WARM A N 02 06 95 1830073a A Fan Switch at Position OFF Through 4 as Desired B Mode Control at VENT or HEAT C Temperature Control at COOL Fig 4 9 Settings for Maximum Ventilation 2 Setthe temperature control to COOL for no heat ing or move it toward WARM for heat 3 Setthe fan switch at the desired speed IMPORTANT If equipped with a FRESH RECIRC push button Fig 4 5 the system draws only recirculated air when the mode con trol lever is at VENT or HEAT and the push but ton is in To prevent the buildup of fumes or odors inside the cab for example from smok ing do not operate the heater or ventilation system in a recirculation mod
297. sty or smoky set the mode control at MAX A C and keep the windows and vent closed to prevent drawing in dust or smoke On vehicles with the FRESH RECIRC push button recirculated air can be selected either with the push button in or by setting the mode control to MAX A C 5 Move the temperature control to COOL In this position no heat is given off by the heater 6 Turn the fan switch to the highest speed 4 Heater and Air Conditioner A OFF 1 MAX A C AIC VENT HEAT HEAT DEF DEF mum 3o8 h see E zi 3 WARM 4 02 06 95 f830185a A Fan Switch at Position 4 or lower as desired B Mode Control at A C C Temperature Control at COOL Fig 4 8 Settings for Cooling with A C 7 As soon as cool air is flowing from the dash board outlets close the windows Adjust the fan Switch setting as desired 8 If the air from the vents is too cold move the temperature control toward WARM to adjust the temperature IMPORTANT A FRESH RECIRC push button Fig 4 5 is standard equipment when there is no air conditioning This control is an option when air conditioning is ordered It allows the AC VENT and HEAT modes to be used with either fresh or recirculated air When the mode control is at MAX A C the system draws only recirculated air regardless of the FRESH RECIRC push button setting When the mode control is at A C and the FRESH RECIRC con trol is set for recirculation push button in the sy
298. t NOTE The Komfort Latch does not have to be released in an emergency situation The Kom fort Latch will release by itself under rough road or other abnormal conditions Make sure the three point seat belt is completely retracted when it is not in use 5 10 Seats and Seat Belts Sleeper Compartment Bunk Restraints General Information On vehicles equipped with a sleeper compartment bunk restraints should be used whenever the sleeper compartment is occupied and the vehicle is moving Restraints are designed to lessen the chance of in jury or the amount of injury resulting from accidents or sudden stops For this reason Daimler Trucks North America LLC urges the use of bunk restraints when the sleeper compartment is occupied in a mov ing vehicle Do not use the sleeper compartment while the vehicle is in motion unless a bunk restraint is installed and used Not using the bunk restraint increases the chance of injury or the degree of injury from accidents or sudden stops to all oc cupants of the vehicle Belt Adjustment See Fig 5 21 2 ZZ 1 4 1 3 01 06 95 f910068a A Pull on the loose end to shorten the belt 1 Buckle 3 Link 2 Belt Release Button Fig 5 21 Belt Adjustment 1 Make sure the belt is attached to the bunk sup port and sleeper wall 2 To lengthen the belt tip the link end downward and pull the link until it connects with the buckle 3 After the belt is connected
299. t a very Heater and Air Conditioner low speed even with the fan control knob in the Off position This prevents ice from forming on the evaporator especially during humid weather If equipped with either the Red Dot constant tem perature control CTC system or the Behr au tomatic temperature control system do the fol lowing 2 1 Turn on the cab air conditioner For in structions refer to Air Conditioning 2 2 Turn the rotary knob on the temperature rheostat all the way counterclockwise to COOL Turn the fan control knob to posi tion 3 2 3 When the sleeper compartment cools to the desired temperature turn the rotary knob on the temperature rheostat clock wise to adjust outlet air temperature Then turn the fan control knob to adjust the air flow level The system will automatically maintain the selected outlet air temperature 2 4 Whenever air conditioning is not desired turn the rotary knob on the temperature rheostat clockwise as needed and turn off the fan NOTE Whenever the refrigerant compressor is operating the fan will always run at a very low speed even with the fan control knob in the Off position This prevents ice from forming on the evaporator especially during humid weather 4 6 Seats and Seat Belts SOAS crc e te iR MM LM c E T 5 1 Seat Belts and Tether Belts llis RRRRRR RR RR reris 5 8 Sleeper Compartment Bunk Restraints 00 c eee eee e 5 11 B
300. t 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 upholstery shampoo or the foam from a mild detergent When using a sol vent or a dry cleaning product follow 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 carefully to the spot from the outer edge to the center Pat and blot with a clean dry cloth Repeat several times as necessary turning cloths so that the stain does not redeposit on the fabric Sugar and Water Based Stains Apply water based detergent or cleaner working in circular motions Pat and blot as dry as possible Re peat if necessary before drying thoroughly 12 2 Cab Appearance Chewing Gum or Wax Harden the gum or wax with an ice cube wrapped in a plastic bag then scrape 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 sam
301. t is a gear split shift that occurs by moving the shift button The lever only shift occurs when the shift lever is moved without moving the shift button e The combination button lever shift is a gear ratio change that occurs when both the shift button and the shift lever are moved The small red service light on the Lightning shift knob illuminates for a few seconds when the engine is turned on This confirms that the transmission electronics are operating properly NOTE If the service light stays on or flashes or does not illuminate when the engine starts take the vehicle to an authorized Freightliner or Eaton service facility as soon as possible See Fig 8 10 for the Super 10 shift pattern which is also used by Top 2 and Lightning when the cruise control is off Top 2 and Lightning transmissions are equipped with the Top 2 feature that allows the trans mission with cruise control on to automatically shift between the top two gears 9th 10th without the need for a button only shift See Fig 8 11 LOXR gt 4 8 R 09 24 96 1260397 NOTE The Top 2 and Lightning transmissions use the Super 10 shift pattern when cruise control is off Fig 8 10 Super 10 Shift Pattern IMPORTANT Not all lever positions are used in each range and the shift patterns vary between transmis sions Be sure to read the shift pattern decal on the dash for the operating instructions for the specific transmission installed in y
302. t the end of the turn signal lever or a lift handle type built into the turn signal lever To operate the push button type dimmer press the button once to change from low beam to high beam headlights press it again to cancel the high beam lights To operate the lift handle type dimmer pull the turn signal lever up to change from low beam to high beam headlights or from high beam back to low beam When the headlights are on high beam a green light on the indicator light panel comes on For vehicles built to operate in the United States switching from low beams to high beams will switch off the fog lights NOTE The ignition switch must be on for the high beams to work Trailer Brake Hand Control Valve Lever This lever is used for applying the trailer brakes with out applying the truck or tractor brakes and is mounted on the steering column See Fig 2 17 See Chapter 6 under the heading Brake System for operating instructions Transmission Controls If so equipped the transmission range control valve and splitter valve are attached to the gearshift knob Transmission shift pattern labels are located on the header or sun visor above the driver s windshield See Chapter 8 for complete transmission operating instructions Suspension Seat Adjustment Controls All adjustment controls for a suspension seat are lo cated on the seat base See Chapter 5 for complete instructions IMPORTANT Due to the maximum adjusta
303. t the fan switch setting and tem 4 3 perature control as needed to maintain the tem perature IMPORTANT If equipped with a FRESH RECIRC push button Fig 4 5 the system draws in fresh air when the mode control upper lever is at HEAT DEF or DEF regardless of the FRESH RECIRC push button setting However when the mode control lever is at HEAT and the push button is in the system draws only recircu lated air To prevent the buildup of fumes or odors inside the cab for example from smok ing do not operate the heater and air condi tioning system in a recirculation mode for more than 20 minutes Air Conditioning IMPORTANT Operate the air conditioner at least five minutes each month even during cool weather This helps prevent drying and cracking of tubing seals reducing refrigerant leaks in the system Operate the air conditioner only after the engine compartment is warm and the inte rior of the cab is 70 F 21 C or higher During cold weather the heater can be operated at the same time to prevent discomfort 1 If the cab is hot inside temporarily open the win dows to let the hot air out 2 Setthe mode control to VENT and turn the fan switch off before starting the engine Start the engine Move the mode control to A C See Fig 4 8 With the control at A C fresh air is drawn into the cab With the control at MAX A C the air in side the cab is recirculated IMPORTANT If the outside air is du
304. t the parking brakes released and the ser 4 Manual Adjusting Nut 8 Anchor Strap vice brake applied shut down the engine 5 Control Arm 9 Brake Chamber wait one minute and note the air pressure gauge reading Observe the air pressure ig 11 14 Hal A ic Slack Adj i i Fig 11 14 Haldex Automatic Slack Adjuster drop in psi kPa per minute cut in and out as described above it must If leakage exceeds the limits shown in be adjusted to these specifications If the Table 11 4 repair all areas of leakage be air governor cannot be adjusted or re fore driving the vehicle paired replace it before operating the ve hicle Maximum Allowable Service Brake Air Leakage 24 2 Check the air pressure buildup time as Air Leakage in psi follows Description kPa Per Minute With the air system fully charged to 120 Released Applied psi 827 kPa make one full brake appli Truck or Tractor Only 2 14 3 21 cation and note the air pressure reading Truck or Tractor w Single Trailer 3 21 4 28 on the gauge Continue to reduce the air Truck or Tractor w Two Trailers 5 35 6 42 pressure by moderate brake applications Table 11 4 Maximum Allowable Service Brake Air to a maximum of 90 psi 620 kPa then Leakage run the engine at governed rpm If the time required to raise the air pressure to 120 psi 827 kPa from the pressure 25 Test the service brakes noted after one brake application is more When starti
305. t will return to the time of day and the red lamp will go out 2 4 To set the alarm depress the alarm On push button Observe that a red dot on the right side of the time of day readout is illuminated The alarm is now set and when the displayed time of day coincides with the alarm time the alarm will sound 2 5 To cancel or shut off the alarm depress the alarm On push button again The red dot on the face of the clock will go out Tachograph Optional A Sangamo tachograph Fig 2 30 indicates and records vehicle speed time and distance traveled It also records the length of time the engine is oper ated when the vehicle is stationary A warning light comes on whenever a preestablished speed limit is exceeded 2 30 Instruments and Controls Identification Da S i I Hi zu 01 18 95 f600151a Fig 2 30 Tachograph Optional Exterior Switches Battery Disconnect Switch Optional The switch is used whenever service operations re quire that the batteries be disconnected It is also used whenever the vehicle is placed out of service for extended periods to prevent battery discharge See Fig 2 31 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 01 18 95 f600150a Fig 2 31
306. that are not equipped with automatic drain D1 valves Check windshield washer reservoir fluid Inspect wheel seal and hub cap for leakage Check surge tank coolant level Inspect radiator and charge air cooler Check engine for fuel oil or coolant leaks Inspect engine and chassis wiring Inspect air intake system Check intake air restriction indicator mounted on air intake Check engine oil level Check power steering fluid level Inspect fuel tank s fuel lines and connections Check fuel level Check fuel water separator Inspect front and rear suspension components Inspect headlights mirrors and window glass and windshield wipers Check doors open without difficulty and close securely Adjust driver s seat then align rearview and downview mirrors Check dash mounted intake air restriction indicator Check oil and air pressure warning systems Check horn windshield wipers and windshield washer Check heater defroster and optional mirror heat controls Check backup alarm Check panel lights and interior lights Check exterior lights and reflectors Check tire pressure Inspect tire condition Inspect rims and wheels Check automatic transmission fluid level Inspect air brake chambers and pushrods Inspect air brake lines Inspect slack adjusters Check air brake system operation Inspect frame rails missing bolts crossmembers bent or loose Check mud flaps aren t damaged at least 10 inches above the ground and
307. the DDU A high pitched tone will sound when the driver s identification card has been successfully read One low tone will sound if the driver s card has been unsuccessfully read If so configured a repeated low tone will sound if the system is on and the requested driver s card has not been inserted 9 The yellow alert light illuminates when an object is detected within the system s maximum range of 350 feet 107 meters on a straight road Range is reduced in curves by the turn radius of the curve This light also illuminates when the proximity alarm threshold is crossed 10 The yellow and orange alert lights illuminate when your vehicle is within a 3 second following interval behind another vehicle in the same lane If you are within a 2 second following interval and closing on the vehicle ahead a warning tone will also sound 11 The yellow orange and red alert lights illuminate when you are 1 second and less than 1 second behind a vehicle If the vehicle ahead is opening the interval no tone will sound If you are closing the interval double tones will sound Within a 1 2 second or less following interval opening or closing the tones will repeat twice per second 12 If a stationary vehicle or object or an object moving less than 3 4 mph 5 5 km h in the same lane is detected within 220 feet 67 meters and within 3 seconds all three alert lights will illumi nate and the double tones will sound This warn ing over
308. the instrument control panel Fig 2 5 The On Off switch turns on the cruise control option and the spring loaded Set Resume switch selects the cruise speed or resumes cruise control after slowing down For PTO operation the On Off switch turns on the PTO and the Set Resume switch either selects or resumes the engine operating speed or By three optional buttons on the transmission shift knob Fig 2 6 The Pause button allows the driver to temporarily interrupt cruise control The Resume button allows the driver to resume the cruise speed after slowing down The Set button allows the driver to select the cruise speed For PTO operation the Pause button temporarily interrupts PTO opera tion the Resume button resumes PTO operation at the previously selected engine speed and the Set button is used to select the engine operating speed See Chapier 7 for complete instructions If the vehicle is equipped with Optimized Idle the cruise control On Off switch is also used to control this option Optimized Idle can be used to keep the engine oil warm recharge the battery and maintain sleeper temperature when the vehicle is parked for long periods See Chapter 7 for more information and complete operating instructions 03 30 94 1600705 A If equipped with Jacobs engine brake controls the cruise switches may be installed here The location may vary depending on other vehicle options Fig 2 5 Cruis
309. the stationary throttle control feature is being used Engine Braking System Optional Jacobs Engine Brake A Jacobs engine brake is a hydraulic electric engine attachment that converts a diesel engine into an air compressor This is done by changing engine ex haust valve operation it engages or disengages in less than one fourth of a second An engine brake is not a substitute for a service braking system except in emergencies The controls consist of e dual dash switches Fig 7 10 which are on off toggle switches NTON lt JAKE BRAK 08 20 93 f600087 Fig 7 10 Engine Brake Switches a clutch switch which is a transmission mounted microswitch that actuates when the driver removes his foot from the clutch pedal a throttle switch which is an engine mounted microswitch that actuates when the driver re moves his foot from the throttle pedal Jacobs Engine Brake Operation Do not use the engine brake if road surfaces are slippery Using the engine brake on wet icy or snow covered roads could result in loss of ve hicle control possibly causing personal injury and property damage 7 21 To engage the engine brake one or both of the dash Switches must be on up and both the clutch and throttle pedals must be fully released To disengage the engine brake depress the throttle or clutch pedal or turn both dash switches off down De pending on the engine type dual dash switches en abl
310. the turn signal functions and various optional functions A solid state lightbar Fig 2 23 in the instrument panel contains displays for the functions 1 2 3 4 5 6 7 8 9 10 w get A om ER e CE Gn orc or or 345 A m 6 10 26 98 1600292b 1 Left Turn Signal Light Oil Pressure Warning Light 3 Starter Lockout Warning Light 4 Low Water Warning Light 5 Water Temperature Warning Light 6 Engine Shutdown Light 7 MHigh Beam Indicator Light 8 Overspeed Light 9 Low Air Pressure Warning Light 10 Right Turn Signal Light Fig 2 23 VIGIL IIl Warning System Optional Engine Functions The system monitors engine coolant temperature coolant level and oil pressure e If the engine overheats a warning light Fig 2 23 comes on and a buzzer sounds The temperature that triggers the warning light and buzzer varies with engine type and is pro grammed into the system at the factory If the temperature continues to rise to critical levels the engine shutdown light comes on and the engine will shut down if equipped with the shutdown feature If the coolant level drops below a sensor in the cooling system the low water level light comes on After 5 seconds a buzzer sounds and after 30 seconds the system shuts down the engine if equipped with the shutdown feature If the oil pressure drops below a preset level the low oil pressure light comes on and a warning buzzer sounds If the oil pressure dro
311. through neutral move the shift lever to 5th gear engage the clutch and accelerate the engine For 18 speed transmissions While in 4th overdrive pull the range shift prese lection lever up into high range The transmis sion will automatically shift from low to high range as the shift lever passes through neutral Move the shift lever double clutching to the 5th gear position Just before making final clutch en gagement move the splitter control button to the direct rearward position then engage the clutch and accelerate Do not move the control button while the shift lever is in neutral Shift up through the high range gears as follows For 13 speed transmissions To shift from 5th direct to 5th overdrive move the splitter control button Fig 8 4 into the overdrive forward position then immediately release the 8 6 Transmissions accelerator Press and release the clutch pedal After releasing the clutch accelerate again Continue upshifting through the shift pattern Double clutch during lever shifts 6th to 7th to 8th single clutch during split shifts 6th direct to 6th overdrive etc For 18 speed transmissions To shift from 5th direct to 5th overdrive move the splitter control button Fig 8 5 into the overdrive forward position then immediately release the accelerator Press and release the clutch pedal After releasing the clutch accelerate again Continue upshifting through the sh
312. tigate the cause and make the necessary repairs 2 28 Instruments and Controls Identification Ammeter Optional An ammeter measures current flowing to and from the battery When the batteries are charging the meter needle moves to the plus side of the gauge when the batteries are being discharged the needle moves to the minus side Engine Oil Temperature Gauge Optional During normal operation the engine oil temperature gauge Fig 2 28 should read 180 to 225 F 82 to 107 C for Cummins en gines 190 to 235 F 88 to 113 C for Caterpillar en gines e 200 to 230 F 93 to 110 C for Detroit Diesel engines Under heavy loads such as when climbing steep grades temperatures which exceed the normal oil temperature range for a short period are not unusual A CAUTION A sudden increase in engine oil temperature 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 engine until the cause has been determined and corrected Transmission Oil Temperature Gauge Optional During normal operation the transmission oil tem perature gauge Fig 2 28 reading should not ex ceed 250 F 121 C for Eaton Fuller transmissions A CAUTION A sudden increase in transmission oil tempera ture that is not caused by a load increase may indicate mechanical failure Bring the vehicle to a safe stop
313. tinuously variable over a 6 inch 152 mm range Move the lever up or down to raise or lower the seat Weight Adjustment The seat automatically adjusts itself regardless of the driver s weight When unoccupied the seat automati cally moves to the adjusted height position Bottom Cushion Angle The front portion of the cushion can be adjusted to any of six positions rotate the knob to the desired angle Seat Track Adjustment Seat tracks have nine adjustment positions with a total of 4 inches 102 mm of travel To unlatch the seat move the lever to the left Freightliner AirChair Fig 5 6 Back Cushion Tilt Pull on the handle and move it to your choice of one of four settings 02 09 95 A Lumbar Support Knob Rear Bottom Cushion Height Handle Isolator Lockout Handle Fore and Aft Seat Adjustment Lever Front Bottom Cushion Height Handle Height Adjustment Air Button Back Cushion Tilt Handle f910035a NOORON Fig 5 6 Freightliner AirChair Lumbar Support Rotate the knob for precise fit Isolator Lockout To lock out the fore and aft isolator feature move the handle to the left See Fig 5 7 5 4 Seats and Seat Belts 02 09 95 f910002a 1 Fore and Aft Seat Adjustment Lever 2 Isolator Lockout Handle Fig 5 7 Seat Adjustment Height Adjustment Push the air button to raise the seat pull the air but ton to lower the seat See Fig 5 6 or Fig 5 8 05 30 2006
314. tion 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 Pretrip and Post Trip Inspections and Maintenance 23 22 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 Check for kinked or twisted hoses A seven percent twist in the hose can re duce its life by up to 90 percent A twisted hose under pressure tends to untwist which may loosen the fitting Reconnect hoses that are twisted NOTE The front brake lines flex continu ously in vehicle operation so they require special examination Give particular attention to the areas near where they connect to the front air brake chambers This inspection requires two people one in the driver seat and another to inspect the brake line con nections at the wheels 22 7 22 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 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
315. tions On vehicles equipped with a Neutral start switch the transmission must be in Neutral before the engine can be started 2 3 Manual Override Push Button Optional Engine Shutdown System If the vehicle is equipped with an engine shutdown system with a manual override push button Fig 2 4 simultaneously depress the engine start button and the manual override push button Once the engine has started release the engine start but ton but continue to depress the override push button until the warning bell stops Mirror Heat Switch Optional One or both outside door mirrors can be heated to keep them defrosted Whenever the mirror heat switch Fig 2 4 is on an indicator light illuminates on the warning and indicator light module Power Mirrors Both outside mirrors can be equipped with an electri cal remote control Move the toggle switch Fig 2 4 to adjust the mirror Detroit Diesel Electronic Engine Control DDEC Operator Control The DDEC system is centered around a computer that is programmed to automatically control engine timing and fuel injection providing maximum engine performance and fuel economy Some DDEC II systems have an automatic engine shutdown option This option will shut down the en gine if potentially damaging conditions are detected An override button on DDEC II engines this button is labelled Override is provided for emergency situ ations It is mounted to the right of the ign
316. ts etc This is especially important with turbo charged engines Bearings and seals in the turbocharger are sub jected to the high heat of combustion exhaust gases While the engine is running this heat is carried away by oil circulation but if the engine is stopped suddenly the turbocharger tempera ture may rise as much as 100 F 56 C The ex treme heat may cause bearings to seize or oil seals to leak 3 Do not idle the engine for excessively long peri ods Long periods of idling are not good for an engine because the combustion chamber tem peratures drop so low the fuel may not burn completely This will cause carbon to clog the injector spray holes and piston rings and may result in stuck valves If the engine coolant temperature becomes too low raw fuel will wash the lubricating oil off the cylinder walls and dilute the crankcase oil there 7 19 fore all moving parts of the engine will suffer from poor lubrication 4 If the engine is not being used shut it down by turning the ignition key off CAUTION Stop the engine at the first sign of malfunction Almost all malfunctions give some warning to the operator before significant damage occurs Many engines are saved because alert operators heed the warning signs sudden drop in oil pressure unusual noises etc and immediately shut down the engine Detroit Diesel 1 With the vehicle stopped apply the parking brakes and place the transmission i
317. tton Manual Override Push Button Mirror Heat Switch Right Side Power Mirror Switch o RON Fig 2 4 Ignition Start Override Mirror Switches System air dryer backup lights and all of the electri cal systems that are operable in the Off position are operable in the Accessory position In the On position the key is turned clockwise All electrical systems are operable Low air and oil pressure warning lights and buzzer operate until the engine is started and pressure is built up The engine can be started and operated only when the ignition switch is on For vehicles built to operate in Canada switching on the ignition and releasing the parking brakes auto matically activates the headlight low beams later model vehicles or high beams earlier model ve hicles at half voltage as daytime running lights The daytime running lights will operate until the parking brakes are applied then they will switch off Turning on the regular headlights will override the daytime running lights The vehicle cannot be driven unless either the headlights or daytime running lights are activated Engine Start Button A CAUTION Do not push the engine start button with the en gine running To do so could result in starter damage With the ignition switch on push the engine start but ton Fig 2 4 to engage the electric or air starter See the applicable engine operating instructions in Chapier 7 for complete starting instruc
318. uec bI 40446244 x 7 24 Cold Weather Operation less 7 5 Gaterpillat Ases ades ix Rm ERA RINGS 7 5 Subject Page CUMMINS ua icm sect oe to op ea eet ek omy a 7 6 Detroit Diesel 0 0002 ee eee 7 7 Collision Warning System CWS Eaton VORAD EVT 300 Optional iss err RR s 2 20 Driver Display Unit DDU 2 20 Failure Display Mode Fault Poo c MCN CEDE 2 24 In Case of Accident 0 2 24 Maintenance and DIAQNOSUGCS s pue aaa a de Roa Ms 2 24 Side Sensor Display Optional sc se 26 wie a pe Rei UE 2 23 Special Road Situations 2 23 COMMONS 5 ss state moau a tate a a del acie aha A n ed 2 1 Air Suspension Dump Valve Optional s eci saderen nim Y 2 10 Air Window Control Valve Switch Optional Right Hand Air Window sosise seci aane a ee ie 2 11 AirLiner Plus Suspension Optional ssr xxr Dat m re m RR 2 11 Automatic Engine Idler Timer Optional 51 42 b dade hoods 2 11 Battery Boost Push Button and Optional Battery Isolator System 00 ee eee 2 6 BrakeSaver Control Optional 2 5 Caterpillar C 10 C 12 and C 15 Electronic Engine Operator Control lt os segades gapapa iaiia 2 4 CB Radio Connections 2 12 Cigarette Lighter llle 2 11 Controlled Traction Differential Control Valve SCM M ce ee ki i Seed Saas wom Gate ae Met 2 10 Cummins PACE and CELECT Electroni
319. ulder is outside of the operating rod support then lower the operating rod as far as it will go Lower the trailer landing gear just enough to re move the weight from the tractor 10 11 5 Pull the trailer air supply valve to cut off the air supply to the trailer CAUTION After moving the fifth wheel to the desired posi tion be sure the trailer landing gear will not at any time come in contact with the tractor frame or other components Make sure that the front of the trailer will not come in contact with the rear of the cab or with other components if they ex tend beyond the rear of the cab 6 Slowly move the tractor forward or backward until the fifth wheel is in the desired location 7 Apply the tractor parking brakes WARNING Check to be sure that the lockpins are seated in the holes and that the operating rod is in the locked position with the safety latch securing the operating rod Failure to achieve complete lockup may cause the trailer to detach from the tractor possibly resulting in serious personal injury or death NOTE The fifth wheel may have to be moved slightly to enable the locking pins to enter the fully locked position 8 Lock the sliding member into position using one of the following methods For air operated models Set the cab operated control switch to LOCK Visually inspect the lock pins to make sure they have seated in the base plate rail holes For manually operated mo
320. uments and Controls Identification NOTE The system may be configured to pre vent adjustment of the range levels 5 The red system failure indicator light illuminates if a system problem is detected Press and hold the volume control knob for 5 seconds to display fault codes The fault codes will be blinked out as a pattern of flashes on this indicator light See Table 2 1 for fault codes Fault Codes blink codes Fault Code Suspect Failure 11 Central Processing Unit CPU 12 CyberCard 13 Driver Display Unit DDU 14 Antenna Assembly 15 Right Side Sensor 16 Left Side Sensor 21 Right Turn Signal 22 Left Turn Signal 23 Brake 24 Speed 25 SmartCruise 31 J1587 32 J1939 33 VBUS 34 DDU Communications 35 Antenna Assembly Communications 41 No Fault or End of Fault Codes Table 2 1 Fault Codes or Blink Codes 6 The green SC indicator light will flash 8 times if the range knob is pressed to store accident re construction information It will also flash 8 times after the system is activated after the power on LED test is finished and if accident reconstruc tion data was previously stored 7 The photo light sensor senses lighting conditions in the cab and automatically adjusts the intensity of the indicator and alert lights 8 If the system s configuration requires insert the driver s identification card in the slot at the lower front edge of
321. ummins 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 colder the temperatures the greater the amount of modification required and yet with the modifications applied the engines must still be capable of operation in warmer climates without extensive changes The following information is provided to engine own ers operators and maintenance personnel on how the modifications can be applied to get satisfactory performance from their diesel engines There are three basic objectives Reasonable starting characteristics followed by practical and dependable warm up of the en gine and equipment e A unit or installation which is as independent as possible from external influences Modifications which maintain satisfactory oper ating temperatures with a minimum increase in maintenance of the equipment and accesso ries If satisfactory engine temperature is not maintained higher maintenance cost will result due to increased engine wear Special provisions to overcome low temperatures are definitely necessary whereas a change to a warmer climate normally requires only a minimum of revision Most of the accessories should be designed in such a way that they can be discon nected so there is little effect on the engine when they are not in use The two most commonly used terms asso
322. unk Mattress Seats and Seat Belts Seats General Information See Fig 5 1 When adjusting seats unless otherwise noted all adjustments should be made while seated and be fore the engine is started Due to the maximum adjustability of mid and high back air suspension seats it is possible to combine the seat back recline adjustment and the seat slide adjustment so that the seat back contacts the back wall It is the responsibility of the driver to adjust the seat to prevent damage to the seat and the cab inte rior Keep hands tools and other objects away from the scissor points under the seats Failure to do So could cause personal injury The following is a description of adjustments that can be made to various Freightliner installed seats Not all seats have all of the adjustments listed below Back Cushion Tilt This adjustment enables the back cushion to pivot forward or backward 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 Isolator Lockout This feature referred to as back slap isolator Chugger Snubber or isola tor reduces the amount of road shock by isolat ing the occupant from the vehicle s motion and allowing the upper seat to move in a simple pen dulum motion A lockout feature is used when ever the isolator is not desired Height Adjustment The entire seat moves up or down when adjusting the hei
323. urn the soot to ash Over the course of a workday however passive regeneration cannot always keep the ATD filter clean so the filter must undergo active regeneration In active regeneration GA extra fuel is injected into the exhaust stream to su perheat the soot trapped in the DPF and turn it to ash Active regeneration happens only when the ve hicle is moving above a certain speed determined by the engine manufacturer Consult manufacturers documentation for details Both active and passive regeneration happen auto matically without driver input NOTE Caterpillar engines do not use a DOC Cat engines burn diesel fuel at the regeneration head to superheat the exhaust and burn the trapped soot to ash Engine software monitors and controls this process 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 outlets are directed away from structures trees vegetation flammable materi als and anything else that may be damaged or injur
324. uzzer sounds If the oil pressure drops to a preset critical level the engine shut down light comes on and the engine will be shut down All shutdown features have an automatic over ride If the vehicle needs to be moved to a safe location after a shutdown just crank the en gine It will run for about 30 seconds before shutting down again Turn Signal Functions The system operates the turn signal relay and the in dicators Other Functions The system also controls several functions such as the headlight high beam indicator low air pressure warning light and intermittent buzzer dimming of the turn signal indicators when the headlights are turned on and control of indicators for six optional features Fig 2 22 The optional features can be any combi nation of the following e transmission temperature axle temperature engine heater alternator no charge Instruments and Controls Identification e fifth wheel lock parking brake sand antilock mirror heater utility lights axle lock sludge ejector or any six that are specially ordered Three of the six optional indicators can trigger the warning buzzer The buzzer feature can be activated at the factory or in the field by setting DIP switches on the control module The low air pressure buzzer is an intermittent signal all other warning buzzers give a constant signal When the air pressure is low the buzzer will sound intermittently regardl
325. vehicle 9 Speed RT RTO and RTX Models Eaton Fuller 9 speed range shift model transmissions have a 5 speed front section and a 2 speed rear range section The low gear in the front sections of the RT 8609 and A and B ratio transmissions is used only as a starting ratio The high gear in the front section of the P ratio transmissions is used only as the top gear The remaining gear positions of the above transmissions are used once in the low range and once in the high range See Fig 8 2 for the shift patterns noting that the 3rd 7th and 4th 8th shift positions in the RT direct ratio and RTX B overdrive ratio transmissions are opposite of the RTO overdrive ratio transmissions The RTX P ratio transmissions have the 1st 5th shift positions where LO is in the A and B ratio transmis sions The top gear in the RTX P ratio transmissions is called 9th gear 10 Speed RT RTO and RTX Models Eaton Fuller 10 speed range shift model transmis sions have ten selective evenly spaced forward ra tios Each transmission consists of a 5 speed front section and a 2 speed rear range section The ten forward speeds are obtained by twice using a 5 speed shift pattern the first time in low range the second time in high range See Fig 8 3 for the shift patterns noting that the 4th 9th and the 5th 10th shift positions in the RT direct ratio and RTX overdrive ratio transmissions are directly opposite in the RTO overdrive ratio transmi
326. vehicle away from the trailer 10 18 Fifth Wheels and Trailer Couplings Operation Trailer Hookup 1 Chock the front and rear tires of the trailer 2 Remove the cotter pin then lift the lock and raise the latch 3 Back up the vehicle until the drawbar eye is over the pintle hook 4 Lower the trailer until the drawbar eye rests on the pintle hook 5 Close the latch then insert the cotter pin NOTICE Always make sure the connect hanger support keeps the trailer air hoses and electrical cables positioned so that they do not rub on anything Rubbing may wear through hoses or cables re sulting in air leaks or exposed or broken wires potentially affecting trailer brake or electrical sys tems 6 Hook up the trailer s electrical and air lines 7 Remove the chocks from the trailer s tires Trailer Release 1 Apply the truck and trailer parking brakes Do not use the trailer air supply for parking trail ers not equipped with spring parking brakes This applies the trailer service brakes only As air bleeds from the trailer brake system brake appli cation is lost This could allow the unattended vehicle to roll away possibly resulting in serious personal injury or death 2 Chock the front and rear tires of the trailer 3 Disconnect the trailer air and electrical lines Plug the air lines to keep out dirt 4 Take the weight of the trailer drawbar off the pintle hook 5 Open the latch by first remo
327. ver 4 Jaw Eccentric Pin Safety Latch 5 Lock Jaw 6 Spring PN ODP Fig 10 12 ASF Castloc Il and Simplex Series Kingpin Locking Mechanism Operation The Castloc Il and Simplex Series fifth wheel lock mechanism consists of a rotating jaw and a spring actuated lock that grips the trailer kingpin The jaw rotates on an eccentric pin during coupling and un coupling operations The spring actuated lock holds the jaw in the locked position once kingpin lockup has occurred In the locked position there is approximately 1 16 inch 1 6 mm clearance between the jaw and king pin The jaw eccentric pin can be removed and ro tated to compensate for wear and maintain an approximate 1 16 inch 1 6 mm clearance during service Placing the operating rod in the lockset position moves the lock away from the jaw This action un locks the jaw so that it can be rotated by movement of the kingpin When the tractor is moved out from under the trailer the kingpin will rotate the jaw until the jaw is in the unlocked position allowing the king pin to move out of the mechanism With the jaw in the fully open position the operating rod drops out of the lockset position and the fifth wheel is ready for coupling See Fig 10 13 04 08 96 310447 1 Safety Latch 2 Operating Rod locked 3 Operating Rod unlocked Fig 10 13 Simplex Kingpin Locking Mechanism Locking and Unlocking During coupling the kingpin
328. ves 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 several times as necessary Cab Appearance If dirt is deeply imbedded use a soft bristle brush after applying the soap If dirt is extremely difficult to remove wall washing preparations normally found around the home can be used Powdered cleaners such as those used for sinks and tiles are abrasive and must be used with caution as they can scratch the vinyl or give it a per manent dull appearance Chewing Gum Harden the gum with an ice cube wrapped in a plas tic bag then scrape off with a dull knife Any remain ing traces of gum can be removed with an all purpose light oil peanut butter will also work and wiped off Tars Asphalts and Creosote Each of these items stains vinyl after prolonged con tact They should be wiped off immediately and the area carefully cleaned using a cloth dampened with naphtha Paint Shoe Heel Marks Paint should be removed immediately Do not use paint remover or liquid type brush cleaner on vinyl An unprinted cloth dampened with naphtha or tur pentine may be used Use care to prevent contact with parts of the upholstery that are
329. ving the cotter pin then lift up the lock and raise the latch 6 Slowly drive the vehicle away from the trailer 10 19 11 Pretrip and Post Trip Inspections and Maintenance Pretrip and Post Trip In us diea ete abii ee eee ee ee ee re ee ee ee 11 1 Pretrip and Post Trip M ROGUNGS pt M Ge ee 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 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 t
330. ween transmissions Be sure to read the shift pattern decal on the dash for the operating instructions for the specific transmission installed in your vehicle 8 18 Transmissions 13 Speed Models Meritor 13 speed transmissions have thirteen forward speeds and two reverse speeds Each transmission consists of a 5 speed front section and a 3 speed auxiliary section The auxiliary section contains low and high range ratios plus an overdrive splitter gear See Fig 8 18 Hi 5 5 77 1 R Dir OD Dir OD Ni Lo 1 3 ONS A W amp jm N Y B E N 6 6 8 8 X LOW Dir OD Dir OD p 2 4 gt 03 13 96 A Up for High Range B Down for Low Range f260154a C Up for Overdrive D Down for Direct 1 Splitter Control Button Fig 8 18 Meritor 13 Speed Transmission Shift Pattern All of the thirteen speeds are controlled with one shift lever Built into the shift knob of the lever are a range selection lever and a splitter control button on the side of the shift knob that control range selec tion and gear splits respectively Low gear in the front section is used only as a start ing ratio The remaining four forward positions are used once in the low range and once in the high range However each of the four high range gear positions can be split with the overdrive ratio of the splitter gear Ratios cannot be split while the trans mission is in low range Operation Meritor Splitter and Range
331. wer failure To use the override open it by turning the knob fully clockwise Return it to the run position after repair IMPORTANT For Detroit Diesel engines pump ing the accelerator before or during cranking will not aid in starting If the engine won t start check the main engine power fuses they may have blown The fuses are located along the main engine electrical harness on the left frame rail near the batteries If needed replace the fuses Be sure to find the cause of the blown fuses as soon as possible NOTE Some starters are equipped with an op tional thermostat If overcranking occurs the thermostat breaks the electrical current to the starter motor until the motor has cooled 6 Press the start button Release the button the moment the engine starts If the vehicle is equipped with an automatic en gine shutdown system with a manual override push button press the override button while pressing the engine start button Once the en gine has started release the engine start button but continue to press the override push button until the warning bell stops If the vehicle is equipped with a battery isolator system and the gel cell battery is completely discharged press and hold the battery boost push button while pressing the starter push but ton This will temporarily disconnect the isolated battery while connecting the engine starting bat teries to the ignition switch for engine starting 7 When the e
332. with direct injection are de signed to start at temperatures above 10 F 12 C without using start systems If the temperature is below 10 F 12 C a start system may be neces sary and or crankcase oil may need to be heated Jacket water heaters are often used to assist starting in cold temperatures The cold start system approved for use on Cummins engines has been based upon starting aid capabili ties to 25 F 32 C A WARNING If using a cold weather start system be sure to follow the manufacturer s instructions regarding its use handling and storage Many starting flu ids are in capsules or pressure cans and im proper usage can be dangerous Do not attempt to use any type of vapor compound start system near heat or open flame Engine damage due to an explosion or fire in the intake manifold could result Do not breathe the ether fumes doing so could result in personal injury Cold Weather Operation IMPORTANT If a winterfront is used on a ve hicle with an electronic engine equipped with a charge air cooler make sure that there are slit openings distributed across the face of the win 1 5 terfront to allow airflow through the entire charge air cooler core Do not use a winterfront with closed areas that block uniform air flow across any sections of the charge air cooler crossflow tubes This will adversely affect the operation and durability of the charge air cooler Caterpillar If the eng
333. y to ensure full antilock braking capability The Trailer ABS lamp will not illuminate unless a compatible trailer is connected to the tractor IMPORTANT If a compatible trailer is connected and the lamp is not illuminating momentarily when the ignition key is turned to the ON posi tion it is possible that the lamp is burned out Automatic Slack Adjusters Automatic slack adjusters are required on all vehicles equipped with air brakes manufactured after October 20 1994 Automatic slack adjusters should never be manually adjusted except during routine maintenance of the foundation brakes e g replacing shoes dur ing slack adjuster installation or in an emergency situation When the brake pushrod stroke exceeds the legal brake adjustment limit on a vehicle there is likely a mechanical problem with the foundation brake com ponents or the adjuster is improperly installed Visit a repair facility as soon as possible when brakes equipped with automatic slack adjusters are determined to be out of adjustment 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

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