Business Class m2 Driver's Manual PDF

Foreword
Introduction dealer referral, vehicle information, breakdown coor-

dination, or Fleetpack assistance. Our people are
This manual provides information needed to operate knowledgeable, professional, and committed to fol-
and understand the vehicle and its components. lowing through to help you keep your truck moving.
More detailed information is contained in the Owner’s
Warranty Information for North America booklet, and
in the vehicle’s workshop and maintenance manuals.
Reporting Safety Defects
If you believe that your vehicle has a defect which
Custom-built Freightliner vehicles are equipped with could cause a crash or could cause injury or
various chassis and cab components. Not all of the
death, you should immediately inform the National
information contained in this manual applies to every
Highway Traffic Safety Administration (NHTSA) in
vehicle. For details about components in your ve-
hicle, refer to the chassis specification pages in- addition to notifying Daimler Trucks North America
cluded in all new vehicles and to the vehicle specifi- LLC.
cation decal, located inside the vehicle. If the NHTSA receives similar complaints, it may
For your reference, keep this manual in the vehicle open an investigation, and if it finds that a safety
at all times. defect exists in a group of vehicles, it may order a
recall and remedy campaign. However, NHTSA
IMPORTANT: Descriptions and specifications in cannot become involved in individual problems
this manual were in effect at the time of printing. between you, your dealer, or Daimler Trucks North
Freightliner Trucks reserves the right to discon- America LLC.
tinue models and to change specifications or
design at any time without notice and without To contact NHTSA, you may call the Vehicle
incurring obligation. Descriptions and specifica- Safety Hotline toll-free at 1-888-327-4236 (TTY:
tions contained in this publication provide no 1-800-424-9153); go to www.safercar.gov; or
warranty, expressed or implied, and are subject write to: Administrator, NHTSA, 1200 New Jersey
to revisions and editions without notice. Avenue, SE, Washington, DC 20590. You can also
obtain other information about motor vehicle safety
from www.safercar.gov.
Environmental Concerns and
Canadian customers who wish to report a safety-
Recommendations related defect to Transport Canada, Defect Investi-
Whenever you see instructions in this manual to dis- gations and Recalls, may telephone the toll-free
card materials, you should first attempt to reclaim hotline 1-800-333-0510, or contact Transport
and recycle them. To preserve our environment, fol- Canada by mail at: Transport Canada, ASFAD,
low appropriate environmental rules and regulations Place de Ville Tower C, 330 Sparks Street, Ot-
when disposing of materials. tawa, Ontario, Canada K1A 0N5.
For additional road safety information, please visit
Event Data Recorder the Road Safety website at: www.tc.gc.ca/
This vehicle is equipped with one or more devices roadsafety.
that record specific vehicle data. The type and
amount of data recorded varies depending on how
the vehicle is equipped (such as the brand of engine,
if an air bag is installed, or if the vehicle features a
collision avoidance system, etc.).
Customer Assistance Center

Having trouble finding service? Call the Customer
Assistance Center at 1-800-385-4357 or 1-800-FTL-
HELP. Call night or day, weekdays or weekends, for
STI-455-4 (9/11)
A24-01238-000
Printed in U.S.A.
Foreword
© 2001–2011 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.
Contents
Chapter Page
Introduction, Environmental Concerns and Recommendations,
Event Data Recorder, Customer Assistance Center, Reporting
Safety Defects . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Foreword
1 Vehicle Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.1
2 Vehicle Access . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.1
3 Instruments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.1
4 Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.1
5 Cab Features . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.1
6 Heater, Ventilator and Air Conditioner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.1
7 Engines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.1
8 Drivetrain . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.1
9 Steering and Brake Systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.1
10 Fifth Wheels and Trailer Couplings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.1
11 Pretrip and Post-Trip Inspections and Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11.1
12 Cab Appearance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12.1
13 In an Emergency . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13.1
14 Headlight Aiming . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14.1
15 Hybrid Electric Vehicle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15.1
16 Natural Gas Vehicle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16.1
Index . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I.1
1
Vehicle Identification
Vehicle Specification Decal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.1
Federal Motor Vehicle Safety Standard (FMVSS) Labels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.1
Canadian Motor Vehicle Safety Standard (CMVSS) Labels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.2
Tire and Rim Labels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.2
EPA Emission Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.2
Vehicle Specification Decal 1 3

The vehicle specification decal lists the vehicle
model, identification number, and major component
models. It also recaps the major assemblies and in-
stallations shown on the chassis specification sheet. 11/14/2001 2 f080118
One copy of the specification decal is attached to the 1. Date of Manufacture: by month and year
driver’s side sunvisor; another copy is inside the rear 2. Gross Vehicle Weight Rating: developed by taking
cover of the Owner’s Warranty Information for North the sum of all the vehicle’s gross axle ratings
America booklet. An illustration of the decal is shown 3. Gross Axle Weight Ratings: developed by
in Fig. 1.1. considering each component in an axle system–
including suspension, axle, wheels, and tires–and
using the lowest component capacity as the value
COMPONENT INFORMATION for the system
MANUFACTURED BY USE VEHICLE ID NO. Fig. 1.2, Certification Statement, U.S.

WHEN ORDERING PARTS
MODEL
VEHICLE ID NO.
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) FOR COMPLETE PAINT INFORMATION
PAINT NO. CAB COLOR B: BROWN (3295)
CAB COLOR C: BROWN (29607)
SEE VEHICLE SPECIFICATION SHEET 1
CAB COLOR D: DARK BROWN (7444)
PART NO. 24−00273−010
11/21/96 f080021
Fig. 1.1, Vehicle Specification Decal, U.S.-Built Vehicle

Shown
NOTE: Labels shown in this chapter are ex-

amples only. Actual specifications may vary from 2
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. 11/13/2001 f080117
1. Tire and Rim Information

Tractors with or without fifth wheels purchased in the
2. Certification Statement
U.S. are certified by means of a certification state-
ment (Fig. 1.2) and the tire and rim information, com- Fig. 1.3, Label Location
bined into one label. This label is attached to the left
rear door post, as shown in Fig. 1.3.
If purchased for service in the U.S., trucks built with-
out a cargo body have an incomplete certification
label (Fig. 1.4) attached to the left rear door post. In
addition, after completion of the vehicle, a certifica- 11/14/2001 f080120
tion label similar to that shown in Fig. 1.2 must be
attached by the final-stage manufacturer. This label Fig. 1.4, Incomplete Vehicle Certification Label, U.S.
will be located on the left rear door post and certifies
1.1
that the vehicle conforms to all applicable FMVSS given gross axle weight rating. Tires and rims in-
regulations in effect on the date of completion. stalled on the vehicle at the time of manufacture may
have a higher load capacity than that certified by the
Canadian Motor Vehicle Safety tire and rim label. If the tires and rims currently on
the vehicle have a lower load capacity than that
Standard (CMVSS) Labels shown on the tire and rim label, then the tires and
rims determine the load limitations on each of the
In Canada, tractors with fifth wheels are certified by axles.
means of a "Statement of Compliance" label and the
Canadian National Safety Mark (Fig. 1.5), which are See Fig. 1.6 for U.S. and Canadian tire and rim la-
attached to the left rear door post. In addition, tire bels.
and rim information (Fig. 1.6) is also included in the
label attached to the left rear door post. EPA Emission Control
Vehicle Noise Emission Control Label
A vehicle noise emission control label (Fig. 1.7) is
attached either to the left side of the dashboard or to
the top-right surface of the frontwall between the
dash and the windshield.
VEHICLE NOISE EMISSION CONTROL INFORMATION

FREIGHTLINER CORPORATION DATE OF MANUFACTURE 01/96
THIS VEHICLE CONFORMS TO U.S. EPA REGULATIONS FOR NOISE EMISSION
APPLICABLE TO MEDIUM AND HEAVY TRUCKS.
10/10/2006 f080024 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 REPLACEMENT, OF ANY NOISE CONTROL DEVICE OR
ELEMENT OF DESIGN (LISTED IN THE OWNER’S MANUAL) INCORPORATED INTO THIS
Fig. 1.5, Canadian National Safety Mark VEHICLE IN COMPLIANCE WITH THE NOISE CONTROL ACT.
B. THE USE THIS VEHICLE AFTER SUCH DEVICE OR ELEMENT OF DESIGN HAS
BEEN REMOVED OR RENDERED INOPERATIVE. 24−00273−020
10/06/98 f080026
1 2
Fig. 1.7, Vehicle Noise Emission Control Label
IMPORTANT: Certain Freightliner incomplete

vehicles may be produced with incomplete noise
11/14/2001 f080119 control hardware. Such vehicles will not have a
1. Gross Weight Rating By Component in Axle System vehicle noise emission control information label.
2. Gross Vehicle Weight Rating By Component in For such vehicles, it is the final-stage manufac-
Vehicle As a Whole turer’s responsibility to complete the vehicle in
Fig. 1.6, Tire and Rim Information conformity to U.S. EPA regulations (40 CFR Part
205) and label it for compliance.
If purchased for service in Canada, trucks built with-
out a cargo body and tractors built without a fifth EPA07 and EPA10 Emission Control
wheel are certified by a "Statement of Compliance"
label, similar to Fig. 1.2. This label must be attached To meet EPA07 and EPA10 emissions regulations for
by the final-stage manufacturer after completion of vehicles domiciled in the USA or Canada, engines
the vehicle. The label is located on the left rear door manufactured after December 31, 2006 (EPA07) or
post, and certifies that the vehicle conforms to all December 31, 2009 (EPA10) are equipped with an
applicable CMVSS regulations in effect on the date emission aftertreatment system. Vehicles domiciled
of completion. outside of the USA and Canada may not have after-
treatment equipment, depending upon local statutory
emissions guidelines. There is a warning label
Tire and Rim Labels (placement will vary), for important new warning indi-
Tire and rim labels certify suitable tire and rim combi- cators in the driver’s message display, that pertain to
nations that can be installed on the vehicle, for the the aftertreatment system.
1.2
It is a violation of US federal law to alter exhaust

plumbing or aftertreatment in any way that would
bring the engine out of compliance with certification
requirements. (Ref: 42 U.S.C. S7522(a) (3).) It is the
owner’s responsibility to maintain the vehicle so that
it conforms to EPA regulations.
1.3
2
Vehicle Access
Cab Door Locks and Handles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.1
Grab Handles and Access Steps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.1
Cab Entry and Exit, Vehicles With Two Steps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.2
Cab Entry and Exit, Vehicles With One Step . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.4
Back-of-Cab Access . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.5
Battery Access . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.6
Hood Opening and Closing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.7
Fuse Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.8
Vehicle Access
Cab Door Locks and Handles 1 2

One key operates the ignition switch and all of the
door locks. 3 4
IMPORTANT: Each key is numbered. Record

the number so a duplicate key can be made, if
needed.
To unlock the driver’s door from outside the cab, in-
sert the key in the lockset and turn it one-quarter turn
clockwise (Fig. 2.1). To remove the key, turn it coun-
terclockwise to its original position. Pull out on the
door pull handle to open the door.
2
1
10/25/2001 f720398
To open the door from the inside, lift up on the door lever
(arrow).
1. Lock Button
3 2. Armrest/Handle
3. Door Lever
4. Window Crank
5. Inner Door Grab Handle (optional)
10/22/2001 f720397
Fig. 2.2, Door Interior
1. Key 3. Door Pull Handle
2. Lock To open the door from the inside, lift up on the door
Fig. 2.1, Exterior Door Handle
lever. This will unlatch the door whether or not it is
locked. If it is open, close the door by pulling the
To unlock the passenger’s door from outside the cab, inner door grab handle.
insert the key in the lockset and turn it one-quarter To lock either door from inside the cab, slide the lock
turn counterclockwise. Turn the key clockwise to the button downwards (Fig. 2.3). To unlock the door
original position to remove it. without unlatching it, push the lock button upwards. A
NOTE: The cab door locks can be operated red dot will show below the lock button when it is
when the doors are open. unlocked.
To lock a door from outside the cab, do either one of

the following:
Grab Handles and Access
• Insert the key in the lockset and turn it in the
Steps
direction opposite to the unlocking direction For ease of entry and exit, there are three grab
(counterclockwise for the driver’s door, clock- handles, one on the A-pillar, one on the inner B-pillar,
wise for the passenger’s door). Close the door and an optional one on the inside of the door. In ad-
if it is open. dition, the steering wheel may be used to provide
• Push down the inside lock button (Fig. 2.2). secure handholds. There are one or two access
Close the door. steps to provide secure footholds.
2.1
Vehicle Access
Use the cab access system (grab handles, access

steps, and steering wheel) to enter or exit the cab.
Entering from the Driver’s Side

2 To enter the cab from the driver’s side, do the follow-
ing steps (Fig. 2.4):
1
1
10/24/2001 f720401
Move the button down to lock, and up to unlock (arrows).
The door is unlocked when the red dot shows.
1. Door 3. Red Dot
2. Lock Button
Fig. 2.3, Door Lock Button 5
NOTE: The A-pillar grab handle is not installed

on the driver’s side. 2
4
The grab handles, access steps, and steering wheel
are all part of the cab access system. Use these
"helping hands" when getting into, or out of, the cab. 3
They will increase your security and comfort.
11/02/2001 f720399
Cab Entry and Exit, Vehicles 1. Steering Wheel
2. B-Pillar Grab Handle
With Two Steps 3. Bottom Step
4. Top Step
WARNING 5. Inner Door Grab Handle (optional)
Fig. 2.4, Cab Access System, Driver’s Side
Wet or dirty shoe soles greatly increase the
chance of slipping or falling. If your soles are wet 1. Use the door pull handle to open the driver’s
or dirty, be especially careful when climbing door, and place anything that you are carrying in
onto, or down from, the back-of-cab area. the cab.
Always maintain three-point contact with the 2. Grasp the B-pillar grab handle with both hands.
back-of-cab access supports while entering and Reach up as far as is comfortable.
exiting the back-of-cab area. Three-point contact
means both feet and one hand, or both hands 3. Place your right foot on the bottom step, and pull
and one foot, on the grab handles, steps, and yourself up.
deck plates. Other areas are not meant to sup- 4. Place your left foot on the top step.
port back-of-cab access, and grabbing or step-
ping in the wrong place could lead to a fall, and 5. Grasp the steering wheel with your left hand, and
personal injury. step up.
Be careful not to get hands or feet tangled in 6. Step into the cab with your right foot first, and
hoses or other back-of-cab equipment. Careless- grasp the steering wheel with your right hand.
ness could cause a person to trip and fall, with
possible injury.
2.2
Vehicle Access
NOTE: You can also use the inner door grab

handle, if available, as a support when getting
up or down from the bottom step.
5
4
Exiting from the Driver’s Side
To exit the cab from the driver’s side, do the follow-
IMPORTANT: Do not attempt to exit the cab
while carrying any items in your hands.
1. If you wish to take any items with you, after you
exit the cab, place them in an accessible location
on the seat or cab floor. Make sure they will not
get in your way as you exit. 3
WARNING 2
Always face in when exiting the cab. Do not at- 1
tempt to exit with your back to the cab, as you 10/23/2001 f720400
would going down a flight of stairs. It is easier to 1. Bottom Step

slip or lose your balance. If you slip when exiting 2. Top Step
in this way, there is a greater likelihood of per- 3. B-Pillar Grab Handle
sonal injury. 4. Sidewall Grab Handle (optional)
5. A-Pillar Cover Grab Handle
2. Grasp the steering wheel with both hands. Place
your left foot on the top step, and stand on the Fig. 2.5, Cab Access System, Passenger’s Side and
threshold, facing into the cab. Back of Cab
3. Move your right hand to the B-pillar grab handle. 3. Place your left foot on the bottom step and step
up to the upper step with your right foot.
4. Move your right foot to the bottom step.
4. Move your right hand to the A-pillar cover grab
5. Move your left hand to the B-pillar grab handle. handle.
6. Step to the ground with your left foot first. 5. Place your left foot on the top step and step up.
7. Retrieve from the cab any items that you wish to 6. Move your left hand to the A-pillar cover grab
take with you. handle.
NOTE: You can also use the inner door grab 7. Step into the cab with your left foot first.
up or down from the bottom step. NOTE: You can also use the inner door grab
Entering from the Passenger’s Side up or down from the bottom step.
To enter the cab from the passenger’s side, do the Exiting from the Passenger’s Side
following steps (Fig. 2.5):
To exit the cab from the passenger’s side, do the fol-
1. Open the passenger’s door, and place anything lowing steps (Fig. 2.5):
that you are carrying in the cab.
2.
Grasp the B-pillar grab handle on the door with
both hands. while carrying any items in your hands.
1. If you wish to take any items with you, after you
exit the cab, place them in an accessible location
2.3
Vehicle Access
on the seat or cab floor. Make sure they will not ness could cause a person to trip and fall, with
get in your way as you exit. possible injury.
Use the cab access system (grab handles, access
WARNING steps, and steering wheel) to enter or exit the cab.
Always face in when exiting the cab. Do not at- Entering from the Driver’s Side
tempt to exit with your back to the cab, as you
would going down a flight of stairs. It is easier to To enter the cab from the driver’s side, do the follow-
slip or lose your balance. If you slip when exiting ing steps (Fig. 2.4):
in this way, there is a greater likelihood of per-
1. Use the door pull handle to open the driver’s
sonal injury.
door, and place anything that you are carrying in
2. Grasp the A-pillar cover grab handle with both the cab. Use the door armrest/handle and, if
hands, then place your right foot on the top step available, the inner door grab handle, as a sup-
while standing up from the seat facing inward. port if needed.
3. Place your left foot on the top step. 2. Grasp the B-pillar grab handle with both hands.
Reach up as far as is comfortable.
4. Move your left hand to the B-pillar grab handle.
3. Place your right foot on the step, and pull your-
5. Move your left foot to the bottom step. self up.
6. Move your right hand to the B-pillar grab handle. 4. Step into the cab with your left foot.
7. Step to the ground with your right foot first. 5. Grasp the steering wheel with your left hand.
8. Retrieve from the cab any items that you wish to 6. Step into the cab with your right foot, and grasp
take with you. the steering wheel with your right hand.
NOTE: You can also use the inner door grab NOTE: You can also use the inner door grab
handle, if available, as a support when getting handle, if available, as a support when getting
up or down from the bottom step. up or down from the bottom step.
Cab Entry and Exit, Vehicles Exiting from the Driver’s Side
With One Step To exit the cab from the driver’s side, do the follow-
WARNING IMPORTANT: Do not attempt to exit the cab
while carrying any items in your hands.
Wet or dirty shoe soles greatly increase the
chance of slipping or falling. If your soles are wet 1. If you wish to take any items with you, after you
or dirty, be especially careful when climbing exit the cab, place them in an accessible location
onto, or down from, the back-of-cab area. on the seat or cab floor. Make sure they will not
get in your way as you exit.
Always maintain three-point contact with the
back-of-cab access supports while entering and
exiting the back-of-cab area. Three-point contact WARNING
means both feet and one hand, or both hands
and one foot, on the grab handles, steps, and Always face in when exiting the cab. Do not at-
deck plates. Other areas are not meant to sup- tempt to exit with your back to the cab, as you
port back-of-cab access, and grabbing or step- would going down a flight of stairs. It is easier to
ping in the wrong place could lead to a fall, and slip or lose your balance. If you slip when exiting
personal injury. in this way, there is a greater likelihood of per-
sonal injury.
Be careful not to get hands or feet tangled in
hoses or other back-of-cab equipment. Careless-
2.4
Vehicle Access
2. Grasp the steering wheel with both hands. Place

your left foot on the step, and stand on the WARNING
threshold, facing into the cab.
Always face in when exiting the cab. Do not at-
3. Move your right hand to the B-pillar grab handle. tempt to exit with your back to the cab, as you
4. Move your left hand to the B-pillar grab handle. would going down a flight of stairs. It is easier to
slip or lose your balance. If you slip when exiting
5. Move your right foot onto the step. in this way, there is a greater likelihood of per-
6. Step to the ground with your left foot first. sonal injury.
7. 2. Grasp the A-pillar cover grab handle with both

Retrieve from the cab any items that you wish to
take with you. hands, then place your right foot on the step
while standing up from the seat facing inward.
NOTE: You can also use the inner door grab 3. Place your left foot on the step.
up or down from the bottom step. 4. Move your left hand to the B-pillar grab handle.
5. Move your right hand to the B-pillar grab handle.
Entering from the Passenger’s Side
6. Step to the ground with your right foot first.
To enter the cab from the passenger’s side, do the
following steps (Fig. 2.5): 7. Retrieve from the cab any items that you wish to
take with you.
1. Open the passenger’s door, and place anything
that you are carrying in the cab. NOTE: You can also use the inner door grab
2. Grasp the B-pillar grab handle with both hands. up or down from the bottom step.
3. Place your left foot on the step and step up to
the cab with your right foot. Back-of-Cab Access
4. Move your right hand to the A-pillar cover grab
When trailer air and electrical connections cannot be
handle.
reached conveniently from the ground, Federal Motor
5. Move your left hand to the A-pillar cover grab Carrier Safety Regulations require commercial carri-
handle. ers to provide back-of-cab access.
6. Step into the cab with your left foot. Optional grab handles are mounted on each cab
sidewall, or on the left sidewall only. See Fig. 2.6.
NOTE: You can also use the inner door grab Steps are mounted either on the fuel tank(s) or on
handle, if available, as a support when getting metal brackets. When a deck plate is necessary, it is
up or down from the bottom step. mounted across the top of the frame rails.
Exiting from the Passenger’s Side IMPORTANT: Climb onto, and down from, back-
of-cab access facing in toward the vehicle, as
To exit the cab from the passenger’s side, do the fol- you would on a ladder. Do not climb up or down
lowing steps (Fig. 2.5): facing out away from the vehicle.
while carrying any items in your hands. WARNING
1. If you wish to take any items with you, after you Wet or dirty shoe soles greatly increase the
exit the cab, place them in an accessible location chance of slipping or falling. If your soles are wet
on the seat or cab floor. Make sure they will not or dirty, be especially careful when climbing
get in your way as you exit. onto, or leaving, the back-of-cab area.
Always maintain three-point contact with the
back-of-cab access supports while entering and
2.5
Vehicle Access
2. Place one foot on the bottom step and pull your-

self up.
3. Place your other foot on the top step.
4. Move your lower hand to a higher position on the
grab handle.
5. Step onto the deck plate.
Climbing Down from Back-of-Cab

To climb down from the back-of-cab area:
2 1. Grasp the sidewall grab handle with both hands.
2. Step one foot at a time onto the top step.
3
3. Move your upper hand to a lower position on the
grab handle.
4. Move one foot to the bottom step.
5. Move your upper hand to a lower position on the
grab handle.
1
6. Step to the ground with your upper foot first.
Battery Access
Battery Compartment
1
09/28/2007 f602336 The battery compartment is located in the lower part
1. Steps 3. Deck Plate of the cab beneath and to the rear of the driver’s
2. Grab Handle door. It is fastened by a quarter-turn fastener. To
open the battery access door, turn the quarter-turn
Fig. 2.6, Back-of-Cab Access Supports (typical)
fastener with a small screwdriver. See Fig. 2.7.
exiting the back-of-cab area. Three-point contact
means both feet and one hand, or both hands
and one foot, on the grab handles, steps, and
deck plates. Other areas are not meant to sup-
port back-of-cab access, and grabbing or step-
ping in the wrong place could lead to a fall, and
personal injury.
Be careful not to get hands or feet tangled in
hoses or other back-of-cab equipment. Careless-
ness could cause a person to trip and fall, with
possible injury.
Entering Back-of-Cab
When climbing onto the deck plate, do the following:
10/25/2001 f543934
1. Grasp the sidewall grab handle with both hands.
Reach up as far as is comfortable. Open the battery access door by turning the quarter-turn
fastener (arrow) with a small screwdriver.
Fig. 2.7, Battery Compartment, Closed
2.6
Vehicle Access
With the battery access door open (Fig. 2.8), it is NOTE: Whenever battery power is discon-
easy to get access to the battery terminals for clean- nected, clocks and electronically tuned radios
ing, charging, or emergency jump starting. must be reset.
4
1 01/18/95 f600150a
10/24/2001 f543933
1. Top Step Fig. 2.9, Cab (Battery) Isolation Switch
2. Battery
3. Cab Hood Opening and Closing
4. Battery Access Door
The hood can be raised to a full-open position. A tor-
Fig. 2.8, Battery Compartment, Open sion bar helps you to raise the hood, and to lower it
to the operating position. Hood restraint cables pre-
To close the battery access door, do the following vent the hood from overtravel. A hood damper limits
steps: the closing speed. In the operating position, the hood
1. Swing the battery access door to line up the is secured to the cab-mounted half-fenders by a
quarter-turn fastener with the hole in the cab hold-down latch on each side of the hood.
door frame.
2. Close the battery access door and check to be
To Open the Hood
sure the quarter-turn fastener is engaged with 1. Apply the parking brakes.
the hole.
2. Release both hood hold-down latches by pulling
3. Turn the fastener one-quarter turn. the ends outward. See Fig. 2.10.
Cab (Battery) Isolation Switch CAUTION

The cab isolation switch (see Fig. 2.9) is located on
the cab floor at the left of the driver’s seat, or inside Do not let the hood free-fall to the full-open posi-
the battery box. The battery isolation switch reduces tion. To do so could cause damage to the hood
the power to the cab and engine power wiring. Use it or hood straps.
whenever the vehicle is to be put out of service for 3. Standing in front of the hood, raise the rear of
extended periods. the hood upward until it reaches the over-center
IMPORTANT: The battery disconnect switch position (45 degrees from vertical). Then slowly
bring it to a stop.
does not completely isolate the batteries from
the electrical system. For service operations that To Close the Hood
require that the batteries be disconnected, al-
ways shut down the engine and remove the 1. Push the hood over center.
negative battery cables.
2.7
Vehicle Access
Fuse Identification, Main Fuse Box

Pos.
3 Description Fuse Color Rating
No.
F1 VCU (MBE900 only) Red 10 Amp
2
F2 Blower Motor Green 30 Amp
F3 Engine ECU Yellow 20 Amp
Transmission Control
F4 Green 30 Amp
Unit
4 F5 Ignition Switch Tan 5 Amp
F6 Spare — —
F7 Bulkhead Module Green 30 Amp
1 F8 ICU Red 10 Amp
10/24/2001 f880555 Transmission Control
F9 Yellow 20 Amp
1. Fender 3. Latch Handle Unit
2. Latch Hook 4. Half-Fender F10 Door Locks (optional) Red 10 Amp
F11 Mirrors (optional) Blue 15 Amp
Fig. 2.10, Hood Hold-Down Latch F12 Radio/Diagnostics Yellow 20 Amp
2. As the hood goes over center, the damper auto- F13 Chassis Module Green 30 Amp
matically slows its rate of descent. If needed, you L/H Power Windows
F14 Blue 15 Amp
can also slow its rate of descent with your hand. (optional)
3. Make sure the hood is flush with the cowl, then F16 ABS ECU Blue 15 Amp
secure the hood by engaging both hood hold- F17 Chassis Module Green 30 Amp
down latches.
IMPORTANT: Make sure that both hold-down F19 Chassis Module Green 30 Amp
latches are fully engaged before operating the F20 Bulkhead Module Green 30 Amp
vehicle. F21
R/H Power Windows
Blue 15 Amp
(optional)
Fuse Identification F22 Bulkhead Module
F23 Spare
Green
—
30 Amp
—
Main Fuse Box/PDM F24 Spare — —
F25 Spare — —
The main fuse box, also known as the power distri-
F26 Spare — —
bution module, or PDM, is located under the hood on
M1 Battery Power — 125 Amp
the left front fender just forward of the bulkhead mod-
ule. See Fig. 2.11. To open the fuse box, pull down M2 Battery Power — 125 Amp
on the wire clips holding the lid on the fuse box. M3 Battery Power — 150 Amp
A sticker inside the lid of the fuse box shows the lo- Table 2.1, Fuse Identification, Main Fuse Box
cations of the fuses and describes the circuit(s) that
each fuse protects (see Fig. 2.12). See Table 2.1 for
descriptions of a typical set of fuses. The fuses in the Trailer and Taillight Fuse Boxes
main fuse box are mini blade-type fuses. Battery The trailer fuse box and the taillight fuse box, on ve-
power fuses, located near the batteries, are bolt-in hicles so equipped, are mounted on a bracket with
megafuses. the chassis module on the left-hand frame rail aft of
Because the electrical system is multiplexed, no re- the cab, or on a crossmember at the end of the
lays are needed. The multiplexing module performs frame rail. These may be referred to as the chassis
the functions normally provided by relays. fuse box or chassis PDM. See Fig. 2.13 for trailer
fuse and relay information, and Fig. 2.14 for taillight
fuse and relay information.
2.8
Vehicle Access
These fuse boxes contain mini blade-type fuses, 12-

volt mini relays, and 12-volt micro relays.
2
09/28/2004 f544528
09/25/2001 f543935
Fig. 2.13, Trailer Fuse Box Diagram
1. Bulkhead Module 2. Main Fuse Box
Fig. 2.11, Location of the Main Fuse Box
10/25/2001 f543936
10/07/2004 f544541
Fig. 2.12, Main Fuse Box Diagram
Fig. 2.14, Taillight Fuse Box Diagram
2.9
3
Instruments
Instrumentation Control Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.1
Warning and Indicator Lights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.6
Overhead Instrument Panel, Optional . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.10
Speedometer and Tachometer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.10
Standard Instruments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.11
Optional Instruments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.14
Collision Warning System, Eaton VORAD EVT–300 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.17
Instruments
Instrumentation Control Unit There can be up to eight gauges on the driver’s in-
strument panel (six electronic and two mechanical).
Figure 3.1 shows a typical set of instruments for ve- Only the air gauges operate mechanically.
hicles equipped with the M2 instrument cluster The M2 instrument cluster has the capability to drive
(ICU3-M2).
independent stand-alone gauges such as those in-
Figure 3.2 shows a more basic instrument cluster. stalled on the auxiliary dash panel. Figure 3.3 shows
The tachometer and the transmission temperature a typical dash.
gauge are not shown.
The M2 instrument cluster (ICU3-M2) is on vehicles
Dash Message Center
with engines manufactured before January 1, 2007, The dash message center is the heart of the instru-
and the ICU3X is on vehicles with engines manufac- ment cluster. It has two parts, a set of 26 warning
tured January 1, 2007 or later. They can be differen- and indicator lights similar to those found on a con-
tiated by their ISO icons. ventional lightbar, and a dash driver display screen.
2 3 4 5
12
11 10 9
09/10/2009 f610525a
NOTE: This instrument cluster is shown with the U.S. speedometer, which shows miles per hour (mph) more prominently
than kilometers per hour (km/h).
1. Engine Oil Pressure Gauge 6. Primary Air Pressure Gauge 10. Tachometer (optional)
2. Dash Message Center 7. Mode/Reset Switch 11. Transmission Temperature Gauge
3. Dash Driver Display Screen 8. Secondary Air Pressure Gauge (optional)
4. Headlight High-Beam Indicator 9. Speedometer (U.S. version) 12. Coolant Temperature Gauge
5. Fuel Level Gauge
Fig. 3.1, Gauge Layout, Typical, U.S. (EPA10 shown)
3.1
Instruments
1 2 3 4
5
9
10
7
09/10/2009 8 f610526c
NOTE: This instrument cluster is shown with the NAFTA speedometer, which shows km/h more prominently than mph.
1. Engine Oil Pressure Gauge 5. Primary Air Pressure Gauge 8. Speedometer (NAFTA version)
2. Dash Message Center 6. Mode/Reset Switch 9. Headlight High-Beam Indicator
3. Dash Driver Display Screen 7. Secondary Air Pressure Gauge 10. Coolant Temperature Gauge
4. Fuel Level Gauge
Fig. 3.2, Gauge Layout, Basic (EPA10 shown)
The driver display screen is a one-line by seven- If service miles or service hours has been exceeded,
character liquid crystal display (LCD) that normally either Fig. 3.5 or Fig. 3.6 will come up before the
shows odometer readings. Below this display is a fault screen (if faults are present. If no faults are
smaller one-line by three-character LCD that shows present and service hours or miles are exceeded,
voltmeter readings. either Fig. 3.5 or Fig. 3.6 will stay displayed unti the
park brake is released with the engine running, or
The dash message center houses all of the standard
the mode button is pressed.
and optional warning and indicator lights. Warning
messages and diagnostic fault codes will appear in When the ignition is turned on, all the electronic
the driver display screen. For more information on gauges complete a full sweep of their dials, the
this system, see under the heading "Ignition Se- warning and indicator lights light up, and the buzzer
quence" in this chapter. sounds for 3 seconds.
Ignition Sequence NOTE: The air gauges do not sweep.

The following lights illuminate during the ignition se-
The dash message center goes through a prescribed quence:
ignition sequence each time the ignition switch is
turned on. See Fig. 3.4 for the ignition sequence. • Fasten Seat Belt Warning
• Low Battery Voltage Warning
3.2
Instruments
2
3
4
10/11/2001 f610578
NOTE: Instruments and controls, and their locations, may vary from those shown.
1. L/H Control Panel 4. Auxiliary Dash Panel
2. Instrumentation Control Unit (ICU3-M2) 5. Climate Control Panel
3. R/H Control Panel
Fig. 3.3, Dash Panel Layout (typical)
• High Coolant Temperature Warning sequence through all the levels (100%, 75%,
50%, 25%, 10%, 5%, 0%) when the gauge
• Low Engine Oil Pressure Warning
sweep is completed. (if equipped with EPA10-
• Low Air Pressure Warning compliant engine)
• Parking Brake On Indicator NOTE: While the engine and ABS warning lights
• All engine indicator/warning lights, including
illuminate during the ignition sequence, they are
Check Engine, HET, DPF, and Stop Engine not controlled by the instrument cluster but by
their own system ECU (electronic control unit).
• Check trans and Trans temp (if equipped)
When the ignition switch has been turned on, the
• Cruise control active indicator ICU performs a self-test, looking for active faults.
• Low fuel and Low DEF level lamp in Fuel During the first half of the self-test, all segments of
the display illuminate as follows:
Gauge (if equipped with EPA10-compliant en-
gine) • First line (odometer): "888888.8"
• The DEF level bar graph in the Fuel Gauge will • Second line (units): "TRIP MI KM HOURS"
illuminate full scale (100% - all 4 segments w/
green LEDs) during the gauge sweep and then
3.3
Instruments
HEADLIGHTS ON
POWER ON
/ IGNITION OFF
IGNITION ON
123456.7
MI
ICU PERFORMS SELFTEST:
ODOMETER ELECTRONIC GAUGE NEEDLES
SCREEN SWEEP, WARNING/INDICATOR
LIGHTS COME ON, BUZZER SOUNDS
IF NO FAULTS IF FAULT DETECTED

WERE DETECTED
*
** ABS 11
123456.7
MI
FAULT CODE
12.3 VOLTS
SCREEN
PARK BRAKE
RELEASED − MOVING
**
123456.7 RELEASE PARK BRAKE
MI
12.3 VOLTS
10/26/2009 f040804
* HOURS SERVICE or MI SERVICE may display
** If the key was cycled off wile displaying Trip Miles, Trip Hours, or Ambient Air Temperature, that screen will be dis-
played instead of odometer miles, when the key is cycled ON without any faults.
Fig. 3.4, Ignition Sequence
• Third line (voltmeter): "88.8 % VOLTS SER-

VICE"
HOURS • Fourth line: "SPN ENGINE"
SERVICE During the second half of the self-test, the software
10/26/2009 f040805 revision level is displayed.
If there are no active faults, the driver display screen
Fig. 3.5, Service Hours Exceeded displays the odometer.
If, however, the instrument cluster has received ac-
tive fault codes from other devices, it displays them
MI one after the other until the parking brake is re-
leased, or the ignition switch is turned off. Once the
SERVICE parking brake is released, the dash message center
10/26/2009 f040806 displays the odometer again.
NOTE: If active faults are present, take the ve-
Fig. 3.6, Service Miles Exceeded
hicle as soon as possible to an authorized
Freightliner service facility.
3.4
Instruments
If the fault is a serious problem that requires immedi-

ate attention, the engine protection system will acti-
vate. In most cases, the check engine light will illumi- PUSH−
nate also.
MODE
Some examples of faults requiring immediate atten-
tion include: HOLD−
• High coolant temperature RESET
• Low air pressure
09/25/99 f610340
• Low coolant level
• Low engine oil pressure Fig. 3.7, Mode/Reset Switch
NOTE: The check engine light does not illumi- When the odometer reading is displayed and the
nate for a low air pressure fault. parking brake is applied:
The legend "SERVICE ENGINE" can appear on the • Press the mode/reset switch once and the trip
driver display screen as an active fault code. If this distance will display.
legend appears, it means the trip miles (or hours) • Press the mode/reset switch a second time
have gone beyond the next required service interval, and the trip hours (engine hours) will display.
as set by the vehicle operator.
• Press the mode/reset switch again and the
IMPORTANT: If the legend "SERVICE ENGINE" temperature screen will be displayed (if
does appear on the driver display screen while equipped).
operating the vehicle, bring the vehicle to an
• Press the mode/reset switch again and the SE-
authorized Freightliner service facility when LECT screen and the current units, MI or KM,
convenient. will display.
Odometer • Press the mode/reset switch again and the
temperature alert screen will be displayed (if
The odometer is set to display in either miles or kilo- equipped).
meters, depending on the primary scale of the
speedometer. The legend, either "MI" or "KM," illumi- • Press the mode/reset switch again and the
nates between the odometer and the volts display diagnostics/service screen will display.
when the engine is running or the headlights are • Press the mode/reset switch again and the
turned on. enggine miles (kilometers) screen will display.
The odometer is a seven-digit display with a decimal • Press the mode/reset switch again and the en-
point, until the vehicle has traveled 999,999.9 miles gine hours screen will display.
or kilometers (km). At one million miles (km), the
odometer resets itself to "1000000," without the deci- • Press the mode/reset switch again and the set
mal point, and can continue up to 9,999,999. The up screen will display
odometer only displays significant figures (no leading • Press the mode/reset switch againe to return
zeros). to the odometer reading.
Mode/Reset Switch To reset trip miles and/or trip hours to zero, press the
mode/reset switch for 1 second or longer. To toggle
The mode/reset switch (Fig. 3.7) is located on the between MI (miles) or KM (kilometers), press the
right side of the instrument cluster. The mode/reset mode/reset switch while in the SELECT screen.
switch is used to scroll through the displays on the
message display screen, and to reset the trip dis-
tance and trip hours values to zero.
3.5
Instruments
Warning and Indicator Lights NOTE: If the check engine light illuminates dur-
ing vehicle operation, take the vehicle directly to
There can be up to 26 warning and indicator lights an authorized Freightliner service facility.
(telltales) installed in the dash message center. See
Fig. 3.8 for 2004 engines, or see Fig. 3.9 for EPA07 Engine Protection Warning
engines, or see Fig. 3.10 for EPA10 engines. There
are four rows of lights. Lights installed in the top row
are optional and their positions may vary. The lights WARNING
in the bottom three rows are installed in fixed posi-
tions on all vehicles. Most are standard, but a few When the red STOP engine lamp illuminates,
are optional. most engines are programmed to shut down au-
tomatically within 30 seconds. The driver must
Check Engine Indicator immediately move the vehicle to a safe location
at the side of the road to prevent causing a haz-
The amber check engine indicator light (CHECK EN- ardous situation that could cause bodily injury,
GINE legend) illuminates when certain faults are de- property damage, or severe damage to the en-
tected. If a critical engine condition exists (for ex- gine.
ample, low oil pressure, low coolant level, high The red Stop Engine, or Engine Protect, warning
coolant temperature, high DPF soot level, or uncon- light illuminates to indicate that the protection system
trolled DPF rengeneration), the check engine light available for the engine has been activated. On
will illuminate to alert the driver to correct the condi- some engines, the engine ECU will derate the en-
tion as soon as possible. If the condition gets worse, gine, allowing it to run, but at lower rpm and slower
the engine protection light will illuminate. vehicle speed. The vehicle may be driven to a safe
location or to a service facility.
1 2 3 4 5 6 7 8 9
10 11 12 13 14 15
WHEEL WASH INTAKE WATER WHEEL LOW CHECK ENG LOW

LOCK FLUID HEATER IN FUEL SPIN WATER TRANS FAN FUEL
BRAKE
16 17 18 19 20 21
03/05/2002 22 23 24 25 26 27 f610593a
Typical installation shown. Location of legends installed in the top row may vary, and other legends may be specified.
1. Wheel Lock Warning (optional) 9. Low Fuel Warning (optional) 18. Fasten Seat Belts Warning
2. Low Washer Fluid Indicator 10. Check Engine Indicator 19. Brake System Warning/Parking
(optional) 11. Engine Protection Warning Brake On Indicator
3. Intake Heater On Indicator 12. No Charge Indicator (optional) 20. Not Used
(optional) 13. Tractor ABS Indicator 21. Air Restriction Indicator (optional)
4. Water In Fuel Indicator (optional) 14. Transmission Overheat Indicator 22. Left-Turn Signal Arrow
5. Wheel Spin Indicator (optional) (optional) 23. Low Battery Voltage Warning
6. Low Coolant Warning (optional) 15. Trailer ABS Indicator (as applies) 24. Dash Driver Display Screen
7. Check Transmission Indicator 16. Low Oil Pressure Warning 25. High Beams On Indicator
(optional) 17. High Coolant Temperature 26. Low Air Pressure Warning
8. Engine Fan On Indicator (optional) Warning 27. Right-Turn Signal Arrow
Fig. 3.8, Warning and Indicator Lights, ICU3-M2 Pre-’07 Dash Message Center
3.6
Instruments
1 2 3 4 5 6 7
OPT OPT OPT OPT OPT OPT OPT OPT OPT
ABS ABS
8 9 10 11 12 13
14 15 16 17 18 19
10/18/2006 f610850
Typical installation shown. Location of legends installed in the top row may vary, and other legends may be specified.
1. Optional Indicator 8. Low Oil Pressure Warning 14. Left-Turn Signal
2. Check Engine Indicator 9. High Coolant Temperature 15. Low Battery Voltage Warning
3. Stop Engine Indicator 10. Fasten Seat Belt Warning 16. Driver Display Screen
4. Malfunction Indicator Light (MIL) 11. Parking Brake On Warning 17. High Beams On Indicator
5. Tractor ABS Indicator 12. Diesel Particulate Filter (DPF) 18. Low Air Pressure Warning
6. Transmission Temperature Status Lamp 19. Right-Turn Signal
Indicator 13. High Exhaust System
7. Trailer ABS Indicator Temperature (HEST) Warning
Fig. 3.9, Warning and Indicator Lights, ICU3X EPA07 Dash Message Center
3 5 11 13 15
1 2 4 6 7 8 9 10 12 14
AIR WASH *WAIT* WHEEL LOW CHECK **IDLE**

FILTER FLUID TO START *OPT 4* SPIN WATER TRANS MGMT OPT 9
CHECK STOP ABS ABS
TRIP MI KM HOURS
VOLTS SERVICE
SPN ENGINE
17 19 21 24 26 28
16 18 20 22 23 25 27 29
10/26/2009 f611076
1. Air Filter Indicator 12. Transmission Temperature 22. Driver Display Screen
2. Check Engine Indicator Indicator 23. High Beams On Indicator
3. Washer Fluid Indicator 13. Idle Manager Indicator 24. Parking Brake On Warning
4. Stop Engine Indicator 14. Trailer ABS Indicator 25. Brake Air—Low Air Pressure
5. Wait to Start 15. Blank for Optional Indicator Warning
6. Malfunction Indicator Light (MIL) 16. Left-Turn Signal 26. Diesel Particulate Filter (DPF)
7. Blank for Optional Indicator 17. Low Oil Pressure Warning Status Lamp
8. Wheel Spin Indicator 18. Low Battery Voltage Warning 27. Cruise Control Enabled Indicator
9. Low Water Indicator 19. High Coolant Temperature 28. High Exhaust System
10. Tractor ABS Indicator 20. Water in Fuel Indicator Temperature (HEST) Warning
11. Check Transmission Indicator 21. Fasten Seat Belt Warning 29. Right-Turn Signal
Fig. 3.10, Warning and Indicator Lights, ICU3X EPA10 Dash Message Center
3.7
Instruments
On other engines, the engine ECU will shut down the Emergency Buzzer
engine. It will at first derate the engine, and, if the
condition does not improve, shut it down completely The emergency buzzer sounds during the ignition
30 seconds after the light comes on. The driver must sequence and whenever one of the following condi-
safely bring the vehicle to a stop on the side of the tions exists:
road before the engine shuts down. • The engine oil pressure falls below the preset
To restart the engine (override the shutdown com- level shown in Table 3.1.
mand) turn the ignition switch to OFF, leave it there a
• The coolant temperature rises above the pre-
few seconds, and turn the switch to START. The en-
set level shown in Table 3.2.
gine will run for a short period and shut down again if
the condition does not improve. • The air pressure falls below the preset level,
which is 65 psi (448 kPa).
IMPORTANT: Do not attempt to restart the en-
gine while the vehicle is moving. Bring the ve- • The parking brake is set with the vehicle mov-
hicle to a safe stop and restart the engine with ing at a speed greater than 2 miles per hour.
the vehicle stopped.
Warning and Indicator Lights

Indicates an undesirable engine condition is detected or
CHECK Check Engine (amber) recorded. If the condition gets worse, the stop engine or
engine protection light will illuminate.
Indicates a serious fault which requires the engine shut down
immediately. The engine ECU will reduce the maximum
engine torque and speed, and, if the condition does not
improve, will shut down the engine within 30 seconds of the
STOP
Stop Engine or Engine Protect light illuminating. The driver must safely bring the vehicle to
(red) a stop on the side of the road and shut down the engine as
soon as the red light is seen. If the engine shuts down while
the vehicle is in a hazardous location, the engine can be
restarted after turning the key to the OFF position for a few
seconds.
Slow (10-second) flash, indicates a regeneration is in
progress, and the driver is not controlling the engine idle
speed.
High Exhaust System Temperature Solid illumination indicates a regeneration is in progress, with
(HEST) (amber) high exhaust temperatures at the outlet of the tail pipe, if the
speed is below 5 mph (8 km/h). It does not signify the need
for service; it only alerts the vehicle operator of high exhaust
temperatures. See the engine operation manual for details.
Solid illuminated indicates a regeneration is required.
Change to a more challenging duty cycle, such as highway
driving, to raise exhaust temperatures for at least 20
minutes, or perform a parked regeneration. See the engine
Diesel Particulate Filter (DPF) operation manual for details.
Status (amber)
Blinking indicates that a parked regeneration is required
immediately. An engine derate and shutdown will occur. See
the instructions in the engine operation manual to perform a
stationary regeneration.
Indicates an engine emissions-related fault, including, but not
Malfunction Indicator Lamp (MIL)
limited to the aftertreatment system. See the engine
(amber)
operation manual for details.
3.8
Instruments

Indicates a problem with the ABS is detected. Repair the
Tractor ABS (amber) tractor ABS immediately to ensure full antilock braking
capability.
Trailer ABS (amber) Indicates a fault is detected with the trailer ABS.
Flashes on and off whenever the outside turn signal lights

Left-Turn Signal (green)
are flashing.
Flashes on and off whenever the outside turn signal lights

Right-Turn Signal (green)
are flashing.
High-Beam Indicator (blue) Indicates the headlights are on high beam.
For EPA07, activates with a buzzer when air pressure in the

primary or secondary air reservoir falls below 64 to 76 psi
Low Air Pressure Warning (red) (440 to 525 kPa).
For EPA10, activates when suspension air is low.
Activates with a buzzer when air pressure in the primary or
Low Air Pressure Warning (red) secondary air reservoir falls below 64 to 76 psi (440 to 525
kPa). (EPA10)
Activates with a buzzer when the coolant temperature goes
High Coolant Temperature Warning
above a maximum level specified by the engine
(red)
manufacturer (see the engine manual).
Activates with a buzzer when engine oil pressure goes below

Low Engine Oil Pressure Warning
a minimum level specified by the engine manufacturer (see
(red)
the engine manual).
Intake Heater (amber) Indicates the intake air heater is active. Wait to start.
(EPA07)
Indicates the parking brake is engaged, or hydraulic brake

Parking/Emergency Brake Warning fluid pressure is low. A buzzer activates when the vehicle is
BRAKE (BRAKE!) (red) moving over 2 mph (3 km/h) with the parking brake set.
(EPA07)
Indicates the parking brake is engaged, or hydraulic brake
Parking/Emergency Brake Warning fluid pressure is low. A buzzer activates when the vehicle is
(BRAKE) (red) moving over 2 mph (3 km/h) with the parking brake set.
(EPA10)
Cruise Control Activated (green) Indicates the cruise control is active.
Illuminates for 15 seconds when the ignition key is turned to

Fasten Seat Belt Warning (red)
the ON position.
3.9
Instruments
Water in Fuel Warning (amber) Indicates that the fuel could contain water.
Low Battery Voltage Warning (red) Indicates battery voltage is 11.9 volts or less.
NO
CHARGE No Charge Warning (amber) Indicates an alternator charge output failure.
Check Transmission Temperature Indicates high transmission temperature.
Check Transmission Indicates a transmission issue.
Overhead Instrument Panel, Speedometer and Tachometer

Optional Speedometer
The overhead instrument panel (Fig. 3.11), if in- Three kinds of speedometer face (Fig. 3.12) are
stalled, holds the citizen’s band (C/B) radio, a micro- available. The U.S. version of the speedometer regis-
phone clip, and any switches that can not be accom- ters speed in both miles per hour (mph) and kilome-
modated on the driver’s or auxiliary dash panels. ters per hour (km/h), with mph in the larger numbers.
The underside of the overhead console also holds The NAFTA version of the speedometer face re-
the sun visors and the optional dome/reading light verses this arrangement, with km/h in the larger
assembly. For more information on the dome/reading numbers. The metric only version (not shown) shows
light assembly, see Chapter 4. km/h exclusively.
1 2 3 4
04/19/2002 f680028
1. Storage Area with Netting 3. Microphone Clip
2. C/B Radio 4. Dome/Reading Light Assembly
Fig. 3.11, Overhead Instrument Panel
3.10
Instruments
Tachometer, Optional point, the engine will derate or shut down, depending
on the type of engine protection system installed.
The tachometer (Fig. 3.12) 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. 50
PSI
20 25 45
35 55
15 70
30 90
25 50
65 0 100
10 30
110
15 75 OIL
130
5 10
5 85
0 RPM km/h 10/09/2001 f610528
X100 MPH
Fig. 3.13, Engine Oil Pressure Gauge
1 2 Oil Pressure*
10/09/2001 f610527
At Idle Speed: At Rated RPM:
Engine Model
1. Tachometer 2. Speedometer psi (kPa) psi (kPa)
Detroit Diesel 14 (97) min. 55 (350) min.
Fig. 3.12, Speedometer and Tachometer
Cummins 15 (103) 35 (241) min.
Standard Instruments Mercedes-Benz
MBE900
7 (50) 36 (250)
Standard instruments are supplied with the instru- Caterpillar 3126 10–20 (69–138) 30–45 (207–310)
ment cluster and should be present on every vehicle, * Oil pressures are given with the engine at operating temperature. With
with the following exceptions: the engine cold, oil pressure may be higher. Individual engines may vary
from the listed pressures; observe and record pressures when the engine
• The tachometer is optional on all vehicles. is new to create a guide for checking engine condition.
Table 3.1, Oil Pressure Specifications
• The transmission temperature gauge is op-
tional on all vehicles.
Coolant Temperature Gauge
Engine Oil Pressure Gauge
NOTICE
NOTICE
A sudden increase in coolant temperature may
A sudden decrease or absence of oil pressure indicate engine or cooling system failure. Bring
may indicate mechanical failure. Bring the vehicle the vehicle to a safe stop and investigate the
to a safe stop and investigate the cause to pre- cause to prevent further damage. Do not operate
vent further damage. Do not operate the engine the engine until the cause has been determined
until the cause has been determined and cor- and corrected.
rected.
During normal engine operation, the coolant tem-
The engine oil pressure gauge (Fig. 3.13) displays perature gauge (Fig. 3.14) should read 175 to 195°F
the current engine oil pressure. If engine oil pressure (79 to 91°C). If the temperature remains below 160°F
falls below the preset levels shown in Table 3.1, first (71°C) or exceeds the maximum temperature shown
the check engine light will illuminate, and, if the con- in Table 3.2, inspect the cooling system to determine
dition does not improve, the engine protection light the cause. See the M2 Workshop Manual for trouble-
will also illuminate and the buzzer will sound. At this shooting and repair procedures.
3.11
Instruments
If coolant temperature rises above the preset levels

shown in Table 3.2, first the check engine light will
illuminate, and, if the condition does not improve, the
engine protection light will also illuminate and the
buzzer will sound. At this point, the engine will derate 200 275
or shut down, depending on the type of engine pro-
tection system installed. F
125 350
TRANS
150 200 10/30/2001 f610600
F° Fig. 3.15, Transmission Fluid Temperature Gauge
Under heavy loads, such as when climbing steep

100 250 grades, temperatures may, for limited periods, climb
WATER above those given here.
10/09/2001 f610565 Fuel Level Gauge, Pre-EPA10

Fig. 3.14, Coolant Temperature Gauge On vehicles that are pre-EPA10 compliant, the fuel
level gauge indicates the level of diesel in the fuel
Maximum Coolant Temperature tank(s). See Fig. 3.16. A single fuel gauge is stan-
dard. If equipped with a second (optional) fuel gauge,
Engine Make Temperature: °F (°C)
each fuel tank level is indicated on a separate
Detroit Diesel 215 (101)
gauge.
Cummins 225 (107)
Mercedes-Benz 222 (105)
MBE900
Caterpillar 3126 230 (110)
1/2
Table 3.2, Maximum Coolant Temperature
Transmission Fluid Temperature

Gauge E F
The transmission fluid temperature gauge is optional
FUEL
and available on all vehicles.
During normal operation, the transmission fluid tem- 10/09/2001 f610566
perature gauge (Fig. 3.15) reading should not ex-
ceed 250°F (121°C) at the sump. Fig. 3.16, Fuel Level Gauge, Pre-EPA10
NOTICE Fuel/Diesel Exhaust Fluid (DEF)

Gauge, EPA10
A sudden increase in transmission fluid tempera-
For engines that are EPA10 compliant, the fuel and
ture that is not caused by a load increase may
DEF levels are measured in a dual purpose fuel/DEF
indicate mechanical failure. Bring the vehicle to a
gauge. See Fig. 3.17.
safe stop and investigate the cause to prevent
further damage. Do not operate the vehicle until The diesel fuel level is indicated at the top of the
the cause has been determined and corrected. gauge, with a low-fuel warning lamp that illuminates
3.12
Instruments
1/2
ULTRA LOW SULFUR
DIESEL FUEL ONLY
4 E F
1
DEF
E F
3
2
08/21/2009 f611045
1. Diesel Fuel Level 4. Low Fuel Warning
Indicator Lamp (amber at 1/8
2. DEF Level Indicator tank of fuel)
3. Low DEF Warning
Lamp (amber below 2
10% DEF)
Fig. 3.17, Fuel/DEF Gauge, EPA10 10/22/2009 f610567
1. Primary Air Pressure Gauge
amber when the diesel fuel level registers 1/8th of 2. Secondary Air Pressure Gauge
capacity. The DEF level is indicated in the lightbar on
the lower portion of the gauge. There is a low DEF Fig. 3.18, Air Pressure Gauges
level warning lamp that illuminates amber when the
DEF level reaches 10% of capacity. See Chapter 11, buzzer, connected to both the primary and secondary
for details of the DEF gauge functions. systems, activate when air pressure in either system
drops below a minimum pressure of 65 to 75 psi
Primary and Secondary Air Pressure (448 to 517 kPa).
Gauges When the engine is started, the warning light and
buzzer remain on until air pressure in both systems
exceeds minimum pressure.
WARNING
If air pressure falls below minimum pressure, the
Voltmeter
braking ability of the vehicle will be limited. Slow The voltmeter is a digital readout located on the bot-
the vehicle down and bring it to a gradual stop. tom line of the dash message center whenever the
Do not attempt to move the vehicle until air pres- ignition switch is turned on. See Fig. 3.8 for 2004
sure has risen above the minimum level. Moving engines, or see Fig. 3.9 for EPA07 engines, or see
a vehicle without adequate braking power could Fig. 3.10 for EPA10 engines.
cause an accident resulting in personal injury or
death. It indicates the vehicle charging system voltage when
the engine is running and the battery voltage when
Air pressure gauges (Fig. 3.18) register the pressure the engine is stopped. By monitoring the voltmeter,
in the primary and secondary air systems. Normal the driver can be aware of potential charging system
pressure with the engine running is 100 to 120 psi problems and have them fixed before the batteries
(689 to 827 kPa) in both systems. discharge enough to create starting difficulties.
Air pressure gauges are required on all vehicles with The voltmeter will normally show approximately 13.7
air brakes. A low-air-pressure warning light and to 14.1 volts when the engine is running. The voltage
3.13
Instruments
of a fully charged battery is 12.7 to 12.8 volts when Axle Oil Temperature Gauges,
the engine is stopped. Battery voltage under 12.0
volts is considered a low battery, and a completely Forward and Rear
discharged battery will produce only about 11.0 volts.
The voltmeter will indicate lower voltage as the ve- NOTICE
hicle is being started or when electrical devices in
the vehicle are being used. A sudden increase in oil temperature that is not
If the voltmeter shows an undercharged or over- caused by a load increase may indicate mechani-
charged condition for an extended period, have the cal failure. Bring the vehicle to a safe stop and
charging system and batteries checked at a repair investigate the cause to prevent further damage.
facility. Do not operate the engine until the cause has
been determined and corrected.
Optional Instruments During normal operation, optional axle oil tempera-
ture gauges (Fig. 3.20), both forward and rear,
Optional instruments are not found on every vehicle. should read between 160 and 220°F (71 and 104°C)
They are stand-alones, not driven by the instrument for Meritor™ drive axles.
cluster, and are usually located on the auxiliary dash
panel. They are listed here in alphabetical order, to
make the information easier to find.
Ammeter
An optional ammeter (Fig. 3.19) measures current
flowing to and from the battery. When the batteries
are being charged, the meter needle moves to the
plus side of the gauge; when the batteries are being
discharged, the needle moves to the minus side. A
consistent negative reading when the engine is run-
ning indicates a possible problem with the charging
system.
10/10/2001 f610571
Fig. 3.20, Axle Oil Temperature Gauge

grades, temperatures up to a maximum of 250°F
(121°C) are not unusual.
Digital Clock
The optional digital clock (Fig. 3.21) has black char-
acters 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 three-
10/10/2001 f610573
minute snooze feature.
1. To set the time of day:
Fig. 3.19, Ammeter
1.1 Push the Run/Set (lower) switch to the
right (TIME-SET position).
NOTE: When the hour setting is for a time
between noon and midnight, the small letters
3.14
Instruments
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 sound again for 24 hours.
3.3 If desired, press the SNOOZ button while
the alarm is sounding to shut the alarm off
10/11/2001 f610576
for 3 minutes. The alarm symbol will flash
in the display when the button is pushed
Fig. 3.21, Digital Clock
and will continue to flash until the alarm
"PM" will appear in the lower left corner of switch is moved or the alarm has sounded
the display; no "PM" display indicates an for one minute. The snooze procedure can
be done as many times as desired.
A.M. setting.
3.4 Move the alarm switch to the right when
1.2 Advance the hour setting to the correct
you wish to shut off or cancel the alarm;
number by pushing and releasing the hour
the alarm symbol will disappear.
button as many times as needed. Or if the
button is pressed and held in for longer
than 2 seconds, the numbers will continue
Engine Oil Temperature Gauge
to advance until the button is released.
1.3 Advance the minute setting by repeatedly
NOTICE
pushing, or pushing and holding the A sudden increase in oil temperature that is not
minute button as needed. caused by a load increase may indicate mechani-
1.4 Push the Run/Set switch to the middle cal failure. Bring the vehicle to a safe stop and
(RUN) position. investigate the cause to prevent further damage.
Do not operate the engine until the cause has
2. To set the alarm time: been determined and corrected.
2.1 Push the Run/Set switch to the left
(ALARM-SET position). NOTICE
2.2 Set the alarm time by using the same pro-
A sudden increase in oil temperature that is not
cedure that you used to set the time of
caused by a load increase may indicate mechani-
day; remember to set the hour for A.M.
cal failure. Bring the vehicle to a safe stop and
(no letters in the corner of the display), or
investigate the cause to prevent further damage.
P.M. as desired.
Do not operate the engine until the cause has
2.3 Return the Run/Set switch to the middle been determined and corrected.
(RUN) position; the readout will return to During normal operation, the optional engine oil tem-
the time-of-day setting. perature gauge (Fig. 3.22) should read in the follow-
3. To operate the alarm: ing temperature range:
• 177 to 203°F (81 to 95°C) for Mercedes-Benz
MBE900 engines;
3.15
Instruments
• 160 to 195°F (71 to 91°C) for Caterpillar 3126

engines;
• 200 to 260°F (93 to 126°C) for Detroit Diesel
and Cummins engines.
grades, temperatures that exceed the normal oil tem-
perature range for a short period are not unusual.
10/10/2001 f610568
Fig. 3.23, Intake-Air Restriction Indicator
10/10/2001 f610569
NOTE: Rain or snow can wet the filter and
cause a higher than normal reading temporarily.
Fig. 3.22, Engine Oil Temperature Gauge
Intake-Air Restriction Vacuum Readings
Under heavy loads, such as when climbing steep Engine Make* Initial inH2O Service inH2O
grades, temperatures that exceed the normal oil tem- Cummins 12 25
perature range for a short period are not unusual. If Detroit Diesel 12 20
the temperature returns to normal when the load de-
Mercedes-Benz 12 20
creases, there is no problem.
Caterpillar 15 25
Intake-Air Restriction Indicator * Turbocharged engines must be checked at full load and governed en-
gine speed.
The intake-air restriction indicator measures the Table 3.3, Intake-Air Restriction Vacuum Readings
vacuum on the engine side of the air cleaner at the
air cleaner outlet. On standard installations, it is Vehicles may be equipped with an optional go/no-go
mounted on the intake air piping in the engine com- restriction indicator without graduations (Fig. 3.24).
partment.
As an option for easier viewing, the intake-air restric- Pyrometer
tion indicator (Fig. 3.23) can be mounted on the A pyrometer registers the exhaust temperature near
dash, usually on the right-hand control panel. the turbocharger. Normal exhaust temperatures are
Intake-air restriction vacuum is measured in inches of 700 to 1100°F (370 to 595°C). See Fig. 3.25.
water (inH2O). Variations in engine load can cause exhaust tem-
If the yellow signal stays locked in the red zone, at or peratures to rise as high as 1100°F (600°C). If the
above the values shown in Table 3.3 after the engine pyrometer reading shows that exhaust temperature
is shut down, the air cleaner needs to be serviced. exceeds normal, reduce fuel to the engine until the
The indicator then needs to be reset by pressing the exhaust temperature is reduced. Shift to a lower gear
black button on the bottom of the indicator. if the engine is overloaded.
Variations in engine load can cause exhaust tem-
peratures to vary. If the pyrometer reading shows
3.16
Instruments
04/08/2005 f090431
Fig. 3.24, Manual-Reset Air Restriction Indicator, Go/ 10/10/2001 f610574

No-Go
Fig. 3.26, Turbo Boost Pressure Gauge
Collision Warning System,

Eaton VORAD EVT–300
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
10/10/2001 f610570
operate the vehicle. Operate this vehicle,
equipped with the EVT–300 Collision Warning
Fig. 3.25, Pyrometer System, in the same safe manner as if the EVT–
300 Collision Warning System were not present.
that exhaust temperature exceeds normal, reduce
fuel to the engine until the exhaust temperature is The EVT–300 Collision Warning System is not a
reduced. Shift to a lower gear if the engine is over- substitute for safe, normal driving procedures,
loaded. nor will it compensate for any driver impairment,
such as drugs, alcohol, or fatigue.
Turbocharger Boost Pressure Gauge The EVT–300 Collision Warning System may pro-
vide little or no warning of hazards such as pe-
A turbocharger boost pressure gauge (Fig. 3.26) destrians, animals, oncoming vehicles, or cross
measures the pressure in the intake manifold, in ex- traffic.
cess of atmospheric pressure, being created by the
turbocharger. On vehicles with SmartCruise, the vehicle will not
deactivate cruise control for stationary targets,
such as a car stopped in your traveling lane.
Failure to drive safely and use the system prop-
erly could result in personal injury and/or death
and severe property damage.
The Eaton VORAD EVT–300 is a computerized colli-
sion warning system (CWS) that uses front-mounted
3.17
Instruments
(and side-mounted) radar to continuously monitor mode, and if so configured, failure of the driver
vehicles ahead of and alongside your vehicle. to enter the ID card.
NOTE: The side-mounted radar is optional and • A photo light sensor automatically adjusts alert
not installed on all vehicles with a CWS. and indicator light brightness depending on cab
lighting conditions.
The CWS warns of potentially dangerous situations
by means of visual and audible alerts. It performs in • A small speaker provides audible alert tones to
fog, rain, snow, dust, smoke, and darkness. To be warn of closing on an object ahead and, when
detected, objects must be within the radar beam’s equipped with an optional side sensor, of ob-
field of view and provide a surface area that can re- jects alongside when the turn signal is acti-
flect back the radar beam. The beam sweeps an vated in preparation for a lane change.
area of 12 degrees in the horizontal plane and 5 de- • Additional tones indicate speaker volume, sys-
grees in the vertical plane. This allows the determi- tem failure, driver’s card status, and data ex-
nation of the distance to, relative speed of, and angle traction pass or fail.
to the target of vehicles and objects ahead.
See Table 3.4 for descriptions of the various alert
The forward-looking antenna transmits radar signals lights and tones.
to, and receives them back from, vehicles and ob-
jects ahead. It only reports those that are within your Alert Lights and Tones, DDU
lane. Road curvature information is provided by a
Light Tone Description
yaw rate sensor in the CPU, which shapes the radar
Yellow None Object detected (first alert).
detection zone to the curve. The yaw sensor also
functions during turns. Proximity alarm with vehicle
Yellow Double moving at less than 2 mph (3
An optional side sensor(s), not installed on all ve- km/h).
hicles with a CWS, is mounted on the side of the ve- Yellow
Following distance 2-3 seconds
hicle. It transmits and receives radar signals for a and None
(second alert).
distance of 2 to 10 feet (0.5 to 3 meters), alongside Orange
your vehicle. The side sensor can detect unseen ve- Yellow
hicles and objects alongside your vehicle, moving and Single
(target vehicle slows).
and stationary, in a 15-degree vertical by 15-degree Orange
horizontal beam pattern. Yellow,
Orange Double
Refer to the Eaton website for additional information, (target vehicle slows).
and Red
www.roadranger.com. Yellow, Continuous
Following distance 1/2 second or
Orange (twice per
less (or slow-moving vehicle).
Driver Display Unit (DDU) and Red second)
NOTE: All system controls are located on the Table 3.4, Alert Lights and Tones, DDU
Driver Display Unit (DDU).
Use the following instructions to operate the DDU
The DDU contains the controls and indicators controls and interpret the data provided by the CWS:
needed to operate the system. See Fig. 3.27. Indica-
tors to inform the driver about the system’s operation 1. Push in the volume control and power ON/OFF
are located on both the DDU and the optional side knob to turn power on or off. Turn the knob left
sensor display. or right to increase or decrease speaker volume.
The DDU controls system power, range for vehicle NOTE: The system may be configured to have
warnings, speaker volume, and all other system func- no on/off capability. If the vehicle does not have
tions. At the lower front edge of the DDU, a slot is ON/OFF control at the DDU, hold in the volume
provided to insert the optional driver’s identification control knob while turning the ignition switch to
(ID) card. the ON position.
• Alert and indicator lights advise of multiple
warning levels, system power, failure display
3.18
Instruments
3 4 5
2 6
ON SC
FAIL
1 7
VOLUME WARNING LEVEL RANGE
11 10 9
EATON VORAD
12
04/06/2001 8 f610486
1. Red System Failure Indicator Light 7. Photo Light Sensor
2. Green Power ON/Driver’s Card Status Indicator Light 8. Driver’s ID Card Slot
3. Volume Control and Power ON/OFF Knob 9. Red Alert Light
4. Speaker 10. Orange Alert Light
5. Range Control Knob 11. Yellow Alert Light
6. Green SC Indicator Light 12. Distance/Danger Alert Lights
Fig. 3.27, Driver Display Unit (EVT-300)
2. At startup, a power-on LED test takes place. All NOTE: The system may be configured so that
the indicator and alert lights illuminate. The range control can not be adjusted by the driver.
green SC indicator light will flash eight times.
6. Proximity Alarm: If your vehicle is traveling less
3. If the system’s configuration requires, insert the than 5 mph (8 km/h) and an object is detected
driver’s ID card in the slot at the lower front edge less than 15 feet (4.5 meters) in front of your ve-
of the DDU. A high-pitched tone will sound when hicle, and the closing rate is less than 2 mph (3
the driver’s ID card has been successfully read. km/h) but more than 1/2 mph (1 km/h), the prox-
One low tone will sound if the driver’s card has imity alarm activates (the yellow alert light illumi-
been unsuccessfully read. nates and a low-frequency double tone sounds).
NOTE: The green power ON light blinks continu- NOTE: All warnings apply only to objects within
ously if the system is on, configured to require a the maximum detection range and in your lane.
driver’s ID card, and the card is not inserted. Proximity alarm tones and vehicle-closing 1/2-
4. The speaker is located under the top cover of second and two-second following interval tones
the DDU. It sounds audible tones to alert the are configured items.
driver to potential hazards. 7. First Alert: The yellow alert light illuminates when
NOTE: The system may be configured so that an object is detected within the system’s maxi-
volume control may be restricted to a range mum range of 350 feet (107 meters) on a
above a minimum level. straight road. Range is reduced in curves by the
turn radius of the curve. This light also illumi-
5. To adjust the first alert detection range from 3 nates when the proximity alarm threshold is
seconds down to 2 seconds, rotate the range crossed.
control knob from left to right. This will also
change the second alert detection range from 2
8. Second Alert: Both the yellow and orange alert
lights illuminate when your vehicle is within a
seconds down to 1.75 seconds.
3.19
Instruments
3-second following interval behind another ve-

hicle 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. 1
9. Third Alert: All three alert lights, yellow, orange,
and red, illuminate when you are 1 second (or
less than 1 second) behind a vehicle. If the ve- 2
hicle 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 fol-
3
lowing interval, opening or closing, the tones will
repeat twice per second.
10. If a stationary vehicle or object, or an object
moving less than 3.4 mph (5.5 km/h), is detected
within 220 feet (67 meters) and within 3 seconds,
all three alert lights will illuminate and the double
tones will sound. This warning overrides all oth- 01/27/97 f601259
ers and is not affected by the range control knob 1. Red Alert Light (vehicle or object detected)
setting. 2. Photo Light Sensor
3. Yellow Indicator Light (no vehicle or object detected)
IMPORTANT: The system is disabled in turns
with a radius of less than 750 feet (230 meters), Fig. 3.28, Side Sensor Display (EVT-300)
and when the brakes are applied.
3. The red alert light illuminates when objects are
11. All tones are disabled in sharp turns or when the detected by the side sensor(s).
brakes are applied. If the configuration permits,
the three-second and two-second alert levels 3.1 If the right turn signal is activated and the
may be adjusted with the range control knob. A side sensor detects an object, the red
single low-frequency tone sounds when a system alert light will illuminate and the DDU
failure is detected. A medium-frequency tone speaker will sound a high-frequency
sounds when the volume control level is double tone. This tone is sounded only
changed. once per activation of the turn signal.
12. Successful downloading of Eaton Vehicle Infor- 3.2 The red light will also illuminate and stay
mation Management System (EVIMS) data will on if a failure of the side sensor is de-
cause a double tone to sound. Unsuccessful tected.
downloading will cause a low-frequency tone to
sound. Special Road Situations
13. The photo light sensor senses lighting conditions
and automatically adjusts the intensity of the indi- WARNING
cator and alert lights.
The Eaton VORAD EVT–300 Collision Warning
System (CWS) is intended solely as an aid for an
Side Sensor Display alert and conscientious professional driver. It is
1. The yellow indicator light (Fig. 3.28) illuminates not intended to be used or relied on to operate a
continuously when no vehicle is detected by the vehicle. Use the system in conjunction with rear-
side sensor(s). view mirrors and other instrumentation to safely
operate the vehicle. This system will not warn of
2. The photo light sensor senses lighting conditions many possible hazards. Do not assume it is "all
and automatically adjusts the intensity of indica- clear" if no alert lights are illuminated.
tor and alert lights.
3.20
Instruments
Failure to drive safely and use the system prop-

erly could result in personal injury and/or death WARNING
and severe property damage.
Heavy rain or water spray at the side sensor may
Certain special road situations may affect the sys- cause both the yellow and red lights on the side
tem’s ability to detect objects. These situations in- sensor display to illuminate at the same time.
clude the effects of curves, dips, and hills that may Under these conditions the system is temporarily
provide an unexpected result: unable to provide adequate warnings.
NOTE: A warning may sound when an object is Failure to drive safely and use the system prop-
detected in front of the vehicle even though the erly could result in personal injury and/or death
driver intends to turn away or stop before reach- and severe property damage.
ing the object.
NOTE: A continuous fixed object on the right
• When an object is detected in a very sharp side of the vehicle such as a guard rail, wall,
right- or left-hand turn, the audible alarm will tunnel, or bridge may cause the side sensor
not sound. alert light to stay on.
• When approaching a curve, before turning into
it, alarms may sound and lights illuminate be- In Case of Accident
cause of an object off the road, directly in line
The optional accident reconstruction capability pro-
with your vehicle. This will not occur when the
vides two segments of system data, one of which
brakes are applied.
can be stored in system memory.
• Elevated obstacles such as overpasses and
1. Push and hold the DDU range knob for at least 5
overhead signs may be detected when ap-
seconds to store the first segment.
proaching a roadway descending to a lower
elevation. IMPORTANT: If the range knob is pushed again,
• Vehicles cannot be detected on the other side a fail tone will sound.
of a hill. An alarm will not sound until the object 2. Within 6 seconds, the green SC indicator light
is within the field of view of the antenna as- will blink rapidly 8 times, confirming that the data
sembly. has been saved.
• On approaching a steep hill, objects above the 3. After the first segment is saved, the second seg-
beam cannot be detected. Generally, the beam ment runs continuously but only contains the last
hitting the road surface does not cause an 10 minutes (approximately) of system data.
alarm.
NOTE: Once the first memory segment is fro-
• The side sensor only detects objects within its zen, the other can’t be frozen. Only by discon-
field of view, next to the tractor. A vehicle far- necting the main CPU connector can the sec-
ther back, behind the field of view, will not be
detected.
ond memory segment be preserved. You must
return the CPU to Eaton VORAD for download-
• The side sensor range is set to detect average ing and interpretation of accident reconstruction
sized vehicles, 2 to 10 feet (0.5 to 3 meters) data.
away, in the adjacent lane. The side sensor
provides a 15-degree vertical by 15-degree 4. The system will cease recording data 30 sec-
horizontal beam pattern. onds after the vehicle comes to a stop.
• The radar beam of the CWS will detect near 5. After 30 days from the date the memory was fro-
range cut-ins of approximately 30 feet (9 zen, the information will be cleared automatically.
meters) or less, depending on the angle of en-
trance into the lane in front of your vehicle. Maintenance and Diagnostics
IMPORTANT: Servicing the Eaton VORAD EVT–
300 Collision Warning System should be done
3.21
Instruments
only by qualified technicians. Special skills and 6.5 If no faults are found, or after all the cur-
equipment are required. Take your vehicle to an rent fault codes have been issued, a code
authorized Freightliner service facility for repairs, 41 is blinked out to indicate the end of the
or contact Eaton VORAD at (800) 826-4357. sequence.
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 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 memory.
3. When the system is placed in failure display
mode, both active and inactive fault codes can
be indicated by the DDU. Inactive faults are
those that have occurred and have been cleared.
Active faults are those that are still present.
4. Fault codes provide the driver the ability to
record the system faults during a trip and to no-
tify his maintenance department or Eaton
VORAD. In this mode, specific fault codes are
indicated by the pattern of blinks of the driver
display unit red FAIL light.
5. Each fault code is a two-digit number, as shown
in the Eaton VORAD Collision Warning System
Driver Instructions. The red FAIL light blinks the
same number of times as the first digit, a pause
of approximately 3/4 of a second follows, then
the light blinks the same number of times as the
second digit.
6. Display the fault codes.
6.1 Press and hold the DDU volume control
and power ON/OFF knob for at least 9
seconds.
IMPORTANT: The system will turn off if you
release the knob before 9 seconds have
passed.
6.2 Continue pressing the knob until the FAIL
light begins to blink.
6.3 After 9 seconds, the DDU FAIL light be-
gins to blink out the first fault code.
6.4 After finishing one code, the system waits
3 seconds, and then begins the next fault
code.
3.22
4
Controls
Ignition Switch and Key . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.1
Electrical System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.1
Lighting Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.1
Multifunction Turn Signal Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.5
Horn Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.7
Powertrain Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.8
All-Wheel-Drive Controls, Optional . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.12
Braking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.13
Adjustable Steering Column . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.14
Other Dash-Mounted Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.14
Heater/Air Conditioner Control Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.15
Seat Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.16
Controls
Ignition Switch and Key WARNING

The ignition switch (Fig. 4.1) has four positions: AC-
CESSORY, OFF, ON, and START. In addition, the Do not attempt to modify, add, splice, or remove
same key locks and unlocks the cab doors. electrical wiring on this vehicle without authoriza-
tion from Freightliner Engineering. Doing so
could damage the electrical system and result in
a fire that could cause serious personal injury or
property damage.
There are two new electrical modules, a master mod-
ule located near the frontwall (bulkhead module) and
a slave module located between the frame rails
(chassis module).
This new wiring system features intelligent controls
that blink to show switch activity and error conditions.
These controls cannot be distinguished by their ap-
pearance, only by their function.
09/12/2001 f610509 For more information about these controls, see under
the headings "Axle Switches" and "Suspension
Fig. 4.1, Ignition Switch Positions Dump Switch."
In the OFF position, the key slot is vertical; the key
can be inserted and removed only in this position. Lighting Controls
The following can be operated in the off position (re- The lighting controls mentioned under this heading
gardless of whether the key is inserted): The low- generally operate through switches located on the
beam headlights, taillights, brake lights, road lights, dash.
dome lights, clearance lights, turn signals, hazard
warning lights, horn, CB radio, power windows, ciga- Two types of dash switches are used:
rette lighter, clock, and electric oil pan heater. • Paddle switches with a single paddle located in
In the ACCESSORY position, the key is turned coun- the center of the switch. The paddle can be
terclockwise. The radio, stereo system, mirror heat, raised or lowered to perform a function.
air dryer, backup lights, and all of the electrical sys- • Rocker switches that can be pressed at either
tems that are operable in the off position are oper-
the upper or lower end to perform a function.
able in the accessory position.
Certain rocker switches are guarded to prevent
In the ON position, the key is turned clockwise and them from being switched on or off acciden-
all electrical systems are operable. The low air pres- tally.
sure and low oil pressure warning lights (or mes-
When the panel lights are on, most switch legends
sages) and buzzer operate until the engine is started
are backlit with a colored light, usually green. This
and pressure is built up.
allows the driver to find the switch more easily in the
dark. When the switch is on, the switch icon is nor-
Electrical System mally backlit with a colored light, usually amber.
Some switch icons are dead-fronted (not visible until
The Business Class® M2 features a new type of the switch is turned on). When turned on, some
electrical system, different from any previous vehicle. switches are illuminated from within by a red or
Multiple electrical signals are carried along a simpli- amber LED (light-emitting diode).
fied set of wires, reducing the size of wiring bundles.
There are significantly fewer wires overall, meaning
less chance of damage, shorts and other problems.
Control Panels
The left-hand control panel (Fig. 4.2) contains a lou-
vered window outlet for the face vents of the heating,
4.1
Controls
ventilation, and air conditioning system (HVAC), and The HVAC climate control panel is on a separate
four switches arranged in a vertical line, usually the panel below the auxiliary dash panel, between the
headlight, panel light increase/decrease, and the two cupholders.
cruise control On/Off and Set/Resume switches.
Exterior Light Controls
Headlight/Parking Light Switch
2
The headlight/parking light switch (Fig. 4.3) is a
3 paddle switch located on the left-hand control panel
above the cruise control switches. When the paddle
is lowered, the parking lights illuminate (the front turn
signals, the cab marker and identification lights, and
4 the taillights). When the paddle is raised, the low-
beam headlights illuminate, along with all the parking
1 lights. To turn off all lights, return the paddle to the
center position.
10/15/2001 f610579a
1. Left-Hand Control Panel

2. Instrumentation Control Unit
3. Right-Hand Control Panel
4. Radio Panel
5. Auxiliary Dash Panel 10/15/2001 f610580
Fig. 4.2, Switch and Gauge Panels Raise the paddle to illuminate the headlights, low beam.
The instrument cluster (ICU3-M2) is located right be- Lower the paddle to illuminate the parking lights.
hind the steering wheel. No controls are installed on Fig. 4.3, Headlight/Parking Light Switch
the standard instrument cluster.
NOTE: The front turn signal is the amber lens in
The right-hand control panel (Fig. 4.2) usually con-
tains the transmission push-button shift selector (on each headlight unit. The low-beam headlight is
vehicles with automatic or automated transmission) the top clear lens in each headlight unit.
and the trailer brake lever (hand control valve). On When the headlights or parking lights are on, the
vehicles with manual transmission, a variety of panel lights also illuminate. An amber light in the
switches are installed here. If there is a dash- switch backlights either the top icon (for headlights
mounted air-restriction indicator, it is often mounted and parking lights) or the bottom icon (for parking
here. lights only).
The radio panel contains two louvered dash outlets
for the face vents of the HVAC, one on either side of Panel Light Increase/Decrease Switch
the radio (if installed). When the panel lights are on, they can be either
The auxiliary dash panel (Fig. 4.2) below the radio brightened or dimmed by using the INCR/DECR
panel contains the marker interrupt switch, the air rocker switch just below the headlight switch
brake valve knobs, the cigarette lighter, and a variety (Fig. 4.4). To brighten the panel lights, press on the
of switch options. upper part of the rocker (at the INCR legend). To dim
4.2
Controls
the panel lights, press on the lower part of the rocker

(at the DECR legend).
05/09/2002 f610581
Raise the paddle to flash the marker lights.

10/29/2001 f610598 Fig. 4.5, Marker Light Interrupt Switch
Fig. 4.4, Panel Light Increase/Decrease Switch The low beam headlights must be turned on before
the road lights can be turned on. The road lights will
When the panel lights are on, both legends are back- not illuminate if the high beam headlights are already
lit in green. on, and switching from low beams to high beams will
switch off the road lights.
Daytime Running Lights
To turn the road lights on, press on the upper part of
Switching on the ignition and releasing the parking the rocker (at the road light icon). See Fig. 4.6. To
brakes automatically activates the daytime running turn the road lights off, press on the lower part of the
lights, if equipped. The daytime running lights will rocker (at the ROAD LAMP legend).
operate until the parking brakes are applied or the
headlights are turned on.
NOTE: Daytime running lights are standard on
all Canadian vehicles.
The daytime running lights illuminate at about two-
thirds of normal power.
Marker Light Interrupt Switch

The marker light interrupt (MRKR INT) paddle switch
temporarily flashes the marker lights and taillights
(Fig. 4.5). With the vehicle lights on, raise the paddle
10/15/2001 f610582
to briefly turn off the marker lights and taillights. With
the vehicle lights off, raise the paddle to briefly turn
Fig. 4.6, Road Light Switch
on the marker lights and taillights.
Turning off the vehicle lights automatically turns off When the road lights are on, the road light icon is
the marker lights. When the panel lights are on, the backlit in amber. When the panel lights are on, the
marker light icon and MRKR INT legend are backlit ROAD LAMP legend is backlit in green.
in green.
Utility Light Switch, Optional
Road Light Switch, Optional The utility light switch operates one of the following
The road light (ROAD LAMP) rocker switch operates lights or sets of lights:
the optional road lights, which are recessed into the • A single round utility light swivel-mounted in
front bumper or mounted on the lower edge of a cut- the center of the cab roof;
out in the center of the front bumper.
4.3
Controls
• Two round utility lights mounted in fixed posi-

tions on each side of the cab roof;
• Two flush-mounted utility lights mounted on the
back of the cab, one on each side.
To turn the utility light(s) on, press in on the upper
part of the utility light (UTLY LAMP) rocker switch
(Fig. 4.7). To turn the utility light(s) off, press on the
lower part of the rocker (at the UTLY LAMP legend).
10/15/2001 f610584
Fig. 4.8, Spotlight Switch
Dome Lights
Diffuse dome lights are installed on all cabs. The
standard dome light has a clear lens and is installed
on the back of the cab above the rear window. See
Fig. 4.9 for the rear dome light.
10/15/2001 f610583
Fig. 4.7, Utility Light Switch
When the utility lights are on, the diagonal light beam
icon is backlit in red. When the panel lights are on,
the UTLY LAMP legend is backlit in green.
Spotlight, Optional
The spotlight switch operates one of the following
lights or sets of lights:
• A single spotlight and pivoting handle assembly
mounted on the driver’s door;
10/16/2001 f543926
• Two spotlights and pivoting handle assemblies
To remove the lens, press in at the mounting tabs
mounted, one on each side, on both the driv- (arrows).
er’s and passenger’s doors.
Fig. 4.9, Rear Dome Light
To turn the spotlight(s) on, press in on the upper part
of the spotlight (SPOT LAMP) rocker switch On cabs with an overhead console, there is an op-
(Fig. 4.8). To turn the spotlight(s) off, press on the tional overhead dome light assembly containing a
lower part of the rocker (at the SPOT LAMP legend). diffuse dome and a clear reading light. See Fig. 4.10
When the spotlight(s) is on, the diagonal light beam for the optional dome/reading lights on the overhead
icon is backlit in red. When the panel lights are on, console.
the SPOT LAMP legend is backlit in green.
Light Replacement
Interior Lights and Light Controls Rear Dome Light
The interior lights include dome lights, red map To replace the rear dome light (Fig. 4.9), do the fol-
lights, and clear reading lights. lowing steps:
4.4
Controls
Clear Reading Lights, Optional

1 Clear reading lights are available as a option. They
are included only in the light assembly installed in
2 the overhead console, located next to the diffuse
dome light in the same fixture (Fig. 4.10). Like the
dome lights, the reading lights are door-activated.
Multifunction Turn Signal

3
Switch
The multifunction turn signal switch is attached to the
10/17/2001 f610587 steering column, just below the steering wheel, on
1. Overhead Console 3. Light Assembly the left-hand side. This switch has the following
2. Trimplate functions:
Fig. 4.10, Overhead Console Dome Lights • The turn signals
• The windshield wipers and washers
1. Press in on the lens at the four mounting tabs
(arrows). • The headlight high beams
2. Replace the bullet-type bulb and install the lens • The hazard warning flasher
on the lamp base with the button at the bottom.
See Fig. 4.11 for the multifunction switch and its
Overhead Console Dome/Reading Lights component parts.
To replace the overhead console dome/reading lights
(Fig. 4.10), do the following steps:
4
1. Remove the tapping screws that attach the lamp
assembly and trimplate to the overhead console.
5
2. Separate the lamp assembly from the trimplate
and disconnect the wiring harness.
1
3. Replace the lamp assembly. 2
4. Snap the lamp assembly and trimplate together.
3
5. Connect the lamp assembly to the wiring har-
ness.
11/16/2001 f820386
6. Insert the tabs on the trimplate into the slots on
the overhead console attachment plate. Press down on the upper part of the rocker to activate
the hazard warning flashers.
7. Center the lamp assembly in the headliner cutout 1. Washer Button
and install the center tapping screw. 2. Wiper Control Dial
3. Turn Signal Lever
8. Install the remaining tapping screws. 4. Hazard Flasher (red rocker switch)
5. Multifunction Switch Module
Dome Light Switches
Fig. 4.11, Multifunction Turn Signal Switch
In the standard cab, there is one dome light switch in
the driver’s door that turns on the diffuse dome light Turn-Signal Controls
when the driver’s door is opened. In one option, two
switches are installed, so that the diffuse dome light The turn signal lever (Fig. 4.12) is mounted on the
turns on when either the driver’s or passenger’s door steering column. Moving the lever down turns on the
is opened.
4.5
Controls
left turn signal lights; moving it up turns on the right

turn signal lights.
2
1 3
4
5
10/29/2001 f820383
Rotate the control dial away from you to turn the wipers
on, or speed them up.
10/17/2001 f820384 Rotate the control dial towards you to slow the wipers
down, or turn them off.
Move the lever down to turn on the left turn signals.
1. Washer Button
Move the lever up to turn on the right turn signals. 2. OFF Position
3. Delay Positions
Fig. 4.12, Turn Signal Controls 4. Wipers On, Low Speed
5. Wipers On, High Speed
When one of the turn-signal lights is on, a green indi-
cator arrow flashes at the far left or far right of the Fig. 4.13, Wiper/Washer Controls
warning and indicator light panel.
the control dial clockwise as far as it will go (to the
The lever automatically returns to the neutral position
OFF setting) turns the wipers off.
(self-cancels the switch) when the steering wheel
returns to the straight ahead position after a turn. To The washers are operated by a yellow button at the
cancel the signal manually, move the lever to the very end of the turn signal lever. To operate the
neutral position. washers, press the button in and hold it in until you
want the washers to stop.
Windshield Wiper/Washer Controls
Headlight High Beams
CAUTION Push the turn signal lever forward, towards the wind-
shield, to turn on the high-beam headlights. Pull the
Do not move the wiper arms manually. Wiper turn signal lever back to its original position to turn
motor damage will occur if the arms are moved. them off. See Fig. 4.14.
The wipers are operated by a rotary switch in the When the high beam headlights are on, a blue light
wiper control dial, which is on the end of the turn sig- illuminates on the instrument cluster between the ta-
nal lever. See Fig. 4.13. There are five delay set- chometer and speedometer. For vehicles built to op-
tings, marked on the dial by lines of increasing erate in the United States, switching on the high
length, and two steady speed settings, LO and HI. beams will switch off the road lights.
Rotating the control dial forward (in a counterclock- NOTE: The ignition switch must be on for the
wise direction) turns the wipers on. If they are al- high beams to work.
ready on, rotating the handle further forward (to a
faster speed setting) increases the speed of the wip- With the headlight low beams on, pull the lever back-
ers through the various delay settings, and to LO and ward, towards the steering wheel, to flash the high
then HI. beams (turn them on momentarily).
Rotating the control dial in the opposite direction
(clockwise) causes the wipers to slow down. Rotating
4.6
Controls
The button for the electric horn is located in the cen-

ter of the steering wheel. To sound the horn, press
1 down on the button. See Fig. 4.15.
10/17/2001 f820385
Move the lever away from you to turn on the high beams. 10/17/2001 f461918
Move the lever back to its original position to turn them To sound the electric horn, press down on the horn
off. button.
Move the lever towards you to flash the high beams 1. Horn Button
momentarily.
Fig. 4.15, Electric Horn Control
1. Turn Signal Lever 2. Boot
Fig. 4.14, Headlight High Beams Air Horn, Optional

The headlight low beams remain on continuously Single and dual air horns are available as options.
during high beam operation. If the low beam head- The air horn is controlled by a wire lanyard hanging
lights are turned off by use of the headlight switch, down just inboard on the driver’s door. See Fig. 4.16.
the high beams turn off also. Pull downward on the lanyard to sound the air horn.
Hazard Warning Flasher

The hazard warning light flasher (Fig. 4.11) is a red
rocker switch located on the top of the multifunction
switch module. When the flashers are activated, all
of the turn signal lights (front, side, and rear) and the
two green indicator arrows on the control panel will
blink on and off.
To flash the hazard warning lights, press down on
the upper part of the rocker (towards the dash). To
stop the hazard warning lights, press down on the
lower part of the rocker (towards the steering wheel).
10/17/2001 f610592
Horn Controls To sound the air horn, pull down on the lanyard (arrow).
NOTE: It is possible to have both the electric Fig. 4.16, Air Horn Control
and the air horn installed on one vehicle.
Electric Horn
A single electric horn is standard. Dual electric horns
are available as an option.
4.7
Controls
Powertrain Controls above the paddle and SET/CST below the

paddle.
After-Treatment System (ATS)
Request/Inhibit Regen Switch
A parked regen of the ATS can be initiated with the
request/inhibit regen switch. It may also be used to
inhibit the vehicle from performing an automatic
regen. See Fig. 4.17. 1
The style and function of switch will vary with the en-
gine make and model. See the engine operation
manual for operation details.
09/13/2001 f610510
To turn cruise control on, press the upper half of the On/
Off (rocker) switch. To turn cruise control off, press the
10/02/2006 f610848 lower half of the On/Off (rocker) switch.
1. Cruise Control On/Off (rocker) Switch
Fig. 4.17, Request/Inhibit Regen Switch 2. Cruise Control Set/Resume (paddle) Switch
Cruise Control Switches Fig. 4.18, Cruise Control Switches, Dash-Mounted
NOTE: For more information about cruise con-

CAUTION trol operation, see Chapter 7.
Do not attempt to shift gears without using the
clutch pedal when the cruise control is engaged.
Engine Brake Switch, Optional
Failure to follow this precaution will result in a The engine brake switch controls the degree of en-
temporarily uncontrolled increase in engine gine braking. Normally there are two paddle
speed; transmission damage and gear stripping switches, a two-position On/Off Switch to activate the
could result. engine brake, and a two-position HI-LO Switch to
On standard models, cruise control is activated by control the amount of engine braking.
two dash switches. See Fig. 4.18. On some models, To turn the two-position On/Off Switch on, raise the
cruise control can be activated by a button on the paddle. When the two-position switch is on, an
transmission shift knob. amber LED (light-emitting diode) illuminates inside
• The On/Off Switch—this two-position rocker the switch.
switch bears the legend SPD CNTL on the To turn the two-position HI-LO Switch on high, raise
lower half of the switch. When cruise control is the paddle (at the HI-LO icon). To turn the two-
on, an amber light illuminates in the top part of position HI-LO Switch on low, lower the paddle (at
the switch. the ENG BRK legend). See Fig. 4.19.
• The Set/Resume Switch—this three-position A three-position switch is used on MBE900 engines
paddle switch bears the legend RES/ACC equipped with both the regular engine brake and the
constant-throttle (decompression) brake. It works the
4.8
Controls
1 2
10/17/2001 f610588 11/28/2001 f610589
1. On/Off Switch 2. HI-LO Switch

Fig. 4.20, Exhaust Brake Switch
Fig. 4.19, Engine Brake Switches
same as the two-position HI-LO switch, except that

there is a third (off) position when the switch is left at
its normal position.
The engine brake turns off automatically or when the
clutch pedal is pressed. On vehicles without a clutch
pedal, the brake pedal can be used to deactivate the
engine brake. For more information about engine
brake operation, see Chapter 7.
When the panel lights are on, the HI-LO icon is back-
lit in amber on the HI-LO switch. On both switches,
03/31/2009 f610589a
the ENG BRK legend is backlit in green when the
panel lights are on. Fig. 4.21, Exhaust Brake Switch
Exhaust Brake Switch, Optional To turn the engine fan on, press on the upper part of
the rocker (at the fan icon). See Fig. 4.22.
The optional exhaust brake is controlled by a dash-
mounted rocker switch to help slow the vehicle when When the engine fan is running, the fan blade icon is
the accelerator is released. See Chapter 7 under the backlit in amber. When the panel lights are on, the
heading "Exhaust Braking System, Optional" for addi- ENG FAN legend is backlit in green.
tional information.
To turn the exhaust brake on, press on the upper
part of the rocker (at the light inside the switch). The
exhaust brake turns off automatically. See Fig. 4.20
or Fig. 4.21.
When the exhaust brake switch is on, an amber LED
illuminates inside the switch. When the panel lights
are on, the EXHST BRK legend is backlit in green.
Engine Fan Switch, Optional

The engine cooling fan can be turned on by the en- 01/04/2011 f610590
gine fan switch (ENG FAN legend). The fan will con-
tinue to operate for a set amount of time and then Fig. 4.22, Engine Fan Switch
turn off unless the coolant temperature is high
enough to continue the fan operation.
4.9
Controls
Transmission Controls
If so equipped, the transmission range control valve
and splitter valve are attached to the gearshift knob.
Transmission shift pattern labels are located inside
the cab. See Chapter 8 for complete transmission
operating instructions.
On vehicles with standard Allison On-Highway Series
automatic transmission, the shift selector is lever-
activated. The display mounted on the steering col-
umn provides four forward ranges and one reverse
range. See Fig. 4.23. 01/22/2003 f610638
Fig. 4.24, Overdrive Lockout Switch

1 On vehicles with Allison MD Series automatic trans-
mission or Eaton Autoshift automated transmission, a
push-button shift selector provides four, five, or six
forward ranges and one reverse range. See Chap-
ter 8 for more information about the push-button shift
selector.
2
Axle Switches
All axle switches contain a red LED (light-emitting
diode) that illuminates the switch from within when
the switch is turned on (the upper part of the rocker
3 is pressed). The legend under the LED, if any, is not
visible until the switch is turned on.
IMPORTANT: A guard is positioned around all
axle switches to prevent unintentional activation.
01/22/2003 f270119 NOTE: For more information on axle switch
1. All Series, Standard (without park) function, see Chapter 8.
2. 1000/2400 Series, Optional (with park)
3. 2000 Series, Optional (with auto-apply parking Differential Lock Switch
brake)
Fig. 4.23, Steering Column-Mounted Shift Controls CAUTION

When the transmission is in D (drive), the vehicle will Differential lock should only be engaged when
operate in the overdrive (5th) gear. To shift down into the vehicle is stopped or moving slowly at low
the direct drive (4th) gear, use the overdrive lockout throttle. This will prevent internal axle damage.
switch (O/D legend). See Fig. 4.24. The transmission
will shift into 4th gear and remain in that gear unless The differential lock switch is a two-position guarded
a range inhibitor is active, such as engine overspeed. rocker switch. See Fig. 4.25. It causes the wheels on
See Chapter 8 for more information about range each axle governed by the switch to rotate together.
inhibitors. It is also known as side-to-side wheel lock.
To shift to fourth gear, press on the upper part of the To lock the wheels together, press the upper half of
rocker (at the LED). The LED will come on and stay the rocker momentarily (at the LED). To turn off dif-
illuminated until the bottom part of the rocker switch ferential lock, press the upper half of the rocker
is pressed. again.
4.10
Controls
To lock the axles together, press the upper half of the

rocker momentarily (at the LED). To turn off interaxle
lock, press the upper half of the rocker again.
When the panel lights are on, the double-axle icon is
backlit in green.
IMPORTANT: The interaxle lock rocker switch is
guarded to prevent unintentional switch activa-
tion. This switch does not have a diagnostic
10/26/2001 f610596
blink function when inactive.
Fig. 4.25, Differential Lock Switch Axle Shift Switch

When the panel lights are on, the double-axle icon is
backlit in green.
CAUTION
IMPORTANT: The differential lock switch is To prevent transmission and axle damage, make
guarded to prevent unintentional switch activa- sure the automatic transmission is in high range
tion. If the LED in the switch begins to blink dur- when performing an axle shift with the vehicle
moving.
ing normal operation, when the switch has not
been activated, this indicates an error condition. The axle shift switch is a two-position guarded rocker
Bring the vehicle to an authorized Freightliner switch installed on vehicles with two-speed axles.
service facility as soon as possible. See Fig. 4.27.
Interaxle Lock Switch
CAUTION
The interaxle lock should not be engaged on a
vehicle with obviously spinning wheels. Engage-
ment at high speed or power can damage the
axle(s).
The interaxle lock switch is a two-position guarded 10/26/2001 f610594
rocker switch installed on vehicles with dual drive
axles. See Fig. 4.26. It causes both axle shafts to Fig. 4.27, Axle Shift Switch
rotate together.
To shift the axle from low speed to high speed, press
the upper half of the rocker momentarily (at the
LED). To turn the axle shift off (switch from high
speed back to low speed), press the upper half of
the rocker again.
NOTE: On vehicles with tandem drive axles,
there is an interlock that prevents a 2-speed
axle from shifting whenever the interaxle lock is
on.
10/26/2001 f610595 When the panel lights are on, the AXLE SHIFT leg-
end is backlit in green.
Fig. 4.26, Interaxle Lock Switch
IMPORTANT: The axle shift switch is guarded to
prevent unintentional switch activation. If the
4.11
Controls
LED in the switch begins to blink during normal AWD Range Switch
operation, when the switch has not been acti-
vated, this indicates an error condition. Bring the
vehicle to an authorized Freightliner service fa-
CAUTION
cility as soon as possible. To prevent damage to the transfer case and the
driveline, stop the vehicle and apply the parking
All-Wheel-Drive Controls, brake before using the range switch.
Optional The AWD range switch is used under similar condi-
tions to those of the axle shift switch on a two-speed
All-wheel-drive (AWD) allows the driver to direct rear axle. Use the high range when driving at normal
driveline power to all four axles, front and rear. Two speeds under off-road conditions, or on non-paved
switches are used to control AWD: an AWD operation surfaces. Use the low range when extra traction is
switch used to activate all-wheel-drive, and an AWD needed at lower speeds; for example, under condi-
range switch used to select the high or low range. tions of mud, snow, or ice. This switch should be
AWD controls are not multiplexed. used only when AWD has been engaged.
In most cases, the AWD range switch is a two-
AWD Operation Switch position rocker switch with the legends LO RANGE
The AWD operation switch is a two-position rocker at the upper end and HIGH RANGE at the lower
switch with a light-emitting diode (LED) that illumi- end. On vehicles with a power take-off unit (PTO),
nates when AWD is engaged. The legend LOCKED the three-position switch has a neutral (N-TRL) posi-
is underneath the LED on the upper half of the tion in the middle. See Fig. 4.29. When the panel
switch. On the lower half is the legend AWD. See lights are on, the HIGH RANGE legend is backlit in
Fig. 4.28. When the panel lights are on, the AWD green.
legend is backlit in green.
1 2
LO LO
RANGE N−TRL
LOCKED
HIGH HIGH
AWD RANGE RANGE
08/10/2006 f610807 07/21/2006 f610808
1. Two-Position Switch
Fig. 4.28, AWD Operation Switch 2. Three-Position Switch
To engage AWD, press the upper half of the rocker Fig. 4.29, AWD Range Switches
switch. The LED illuminates to indicate that AWD is
engaged. To turn off AWD, press the lower half of the Two-Position Switch (no PTO)
switch. The LED goes out to indicate the AWD is no
longer engaged. On vehicles without a PTO, high range is considered
standard operation. To activate the low range, press
When AWD is engaged, the LOCKED legend is the upper half of the switch. When the low range is
backlit in red. In addition, a red indicator with the leg- activated, the LO RANGE legend is backlit in red. In
end T-CASE ENGAGED displays on the dash mes- addition, a red indicator with the legend T-CASE LO
sage center. RNG displays on the dash message center. To
switch back to HIGH RANGE, press the lower half of
the switch.
4.12
Controls
Three-Position Switch (with PTO) Trailer Air Supply Valve

IMPORTANT: Always use the N-TRL switch po- The red octagonal-shaped knob (Fig. 4.30) on the
sition when operating the PTO. auxiliary dash panel operates the trailer air supply
valve. After the vehicle and its air hoses are con-
On vehicles with a PTO, neutral is considered stan-
nected to a trailer, and the pressure in the air system
dard operation (switch in the middle position). An
is at least 65 psi (448 kPa), the red knob must be
amber indicator with the legend T-CASE NTRL dis-
pushed in (and should stay in) to charge the trailer
plays on the dash message center.
air supply system and release the trailer spring park-
To activate the high range, press the lower half of the ing brakes. Before disconnecting a trailer or when
switch. No indicator displays on the dash message operating a vehicle without a trailer, the red knob
center with the high range activated. Press the upper must be pulled out.
half to return to N-TRL. See Chapter 9 under the heading "Dual Air Brake
To activate the low range, press the upper half of the System" for further information about the trailer air
switch. A red indicator with the legend T-CASE LO supply valve.
RNG displays on the dash message center. On the
switch, the LO N-TRL legend is backlit in red. Press Trailer Brake Lever
the lower half to return to N-TRL, and then press the
The trailer brake lever (hand control valve) is used
lower half again to select HIGH RANGE.
for applying the trailer brakes without applying the
truck or tractor brakes. It is usually mounted on the
Braking right-hand control panel. See Fig. 4.31. See Chap-
ter 9 under the heading "Dual Air Brake System" for
Parking Brake Control Valve operating instructions.
The yellow diamond-shaped knob (Fig. 4.30) on the
auxiliary dash panel operates the parking brake con-
trol valve (park brake switch). Pulling the yellow knob
applies the tractor parking brakes (spring brakes).
Pushing in the knob releases the tractor parking
brakes. Before the parking brakes can be released,
the air pressure in either air brake system must be at
least 65 psi (448 kPa).
1
2
10/17/2001 f610591
Fig. 4.31, Trailer Brake Lever
Meritor™ WABCO® Antilock Braking

03/10/99 f610291
System (ABS)
1. Trailer Air Supply Valve (red knob)
2. Parking Brake Control Valve (yellow knob) The Meritor WABCO Antilock Braking System (ABS)
has an amber tractor indicator light (TRACTOR ABS
Fig. 4.30, Brake Valve Control Knobs
legend) and, if equipped with automatic traction con-
See Chapter 9 under the heading "Dual Air Brake trol (ATC), an amber wheel spin indicator light
System" for further information about the parking (WHEEL SPIN legend). See Fig. 4.32.
brake control valve.
4.13
Controls
On vehicles equipped with a compatible trailer, there

is also an amber trailer indicator light (TRAILER ABS
legend).
5
See the brake system operating instructions in Chap- 1
ter 9 for more information about ABS.
2
1 3
10/12/2000 f610454 4
1. Tractor ABS Indicator 3. Trailer ABS Indicator
2. Wheel Spin Indicator
(optional)
Fig. 4.32, ABS Indicator Lights
Adjustable Steering Column

To tilt the steering column, press down on the foot
pedal located below the steering column. Tilt the 07/19/2006 f610799
steering column up or down to the desired position. 1. Multifunction Turn 4. Adjustable Steering
Release the foot pedal to lock the steering column in Signal Switch Column foot Pedal
place. See Fig. 4.33. 2. Headlight Switch 5. Steering Wheel
3. Ignition Switch
To telescope the steering column, press down on the
foot pedal located below the steering column. Pull Fig. 4.33, Adjustable Steering Column
the steering wheel closer to you or push the steering
wheel farther away from you. Release the foot pedal Cigarette Lighter
to lock the steering column in place.
Push in the lighter to heat the element. The lighter
will stay in and will automatically pop out when the
Other Dash-Mounted Controls element is hot.
Windshield-Fan Switches, Optional CB Radio Connections
Ceiling-mounted defogger fans are operated by
LOW/OFF/HIGH toggle switches located in the base An antenna connection and positive (+) and negative
of the fan. (–) power connections are provided for a CB radio.
4.14
Controls
Suspension Dump Switch Normal Response: The LED in the switch blinks
while the suspension is deflating or filling. When it is
completely deflated, the LED comes on steady and
NOTICE stays illuminated. In normal operation, the suspen-
sion may dump or fill so quickly that the blinking of
Do not operate the vehicle over uneven ground the switch is barely noticeable.
such as ramps, speed bumps, curbs, etc. with
the air springs deflated. Doing this may lead to If operation of the switch is not possible for any rea-
air bag separation from the piston, preventing the son (vehicle is moving faster than 5 mph, ignition is
suspension air springs from reinflating. turned off, etc.), the LED will stop blinking and turn
off.
NOTICE Slow Response: If operation of the switch is slowed
for any reason (by cold weather, low air pressure,
Never exhaust air from the suspension while etc.), the switch will continue to blink until the sus-
driving. When the air is exhausted, the suspen- pension completes a dump or fill. As in the normal
sion will not absorb road shocks, and compo- response, the LED comes on steady and stays illumi-
nents may be damaged. nated when the suspension if fully deflated.
The suspension dump switch is a two-position Abnormal Response: If the LED blinks for more than
guarded rocker switch (Fig. 4.34). It allows the air in 10 seconds, the suspension dump mechanism may
the vehicle air suspension to be quickly exhausted, not be operating properly. Bring the vehicle to an au-
lowering the rear of the vehicle. This makes it easier thorized Freightliner service facility for testing.
to connect to, or disconnect from, a trailer. If the ignition is turned off while the vehicle is in
dump mode, the power to the dump solenoid is cut
off to prevent battery drain, and the suspension sys-
tem will autofill the rear air springs. The suspension
will also autofill if the vehicle is operated with the
suspension dumped, and the speed is over 5 mph
(e.g. -- driver forgot to inflate the bags or there was a
system failure).
Suspension Autofill Override Valve

10/26/2001 f610597
The suspension autofill override option is a dash air
valve, that keeps the suspension deflated when the
Fig. 4.34, Suspension Dump Switch ignition is turned off. To operate it, turn off the ignition
then push the override valve knob. See Fig. 4.35.
To lower the rear of the vehicle quickly, press the When the ignition is turned on, the override valve will
upper half of the rocker momentarily (at the LED). To release automatically, and the suspension will autofill.
raise the suspension to its normal height, press the The suspension dump switch will then operate nor-
upper half of the rocker again. mally as described previously.
When the panel lights are on, the tractor icon is
backlit in green. Heater/Air Conditioner Control
IMPORTANT: The suspension dump switch is Panel
Standard controls (Fig. 4.36) for the heating, ventila-
tion. This switch does not have a diagnostic tion, and air-conditioning system (HVAC) consist of
blink function when inactive. an eight-speed fan switch, an air selection switch,
When the suspension dump switch is pressed, three and a temperature control switch. On vehicles with
responses are possible: a normal response, a slow air conditioning, the panel also contains a telltale
response, and an abnormal response. LED and an air recirculation button. See Chapter 6
for detailed operating instructions for the HVAC.
4.15
Controls
1
SH TO
PU
2
09/11/2007 f321102
10/05/2001 f910481
Fig. 4.35, Suspension Autofill Override Valve 1. Three-Person Seat
2. Seat Slide Lever
1 2 3
Fig. 4.37, Full Bench Seat
2 adjustment so that the seat back contacts the back-

1 3 wall. It is the responsibility of the driver to adjust the
seat to prevent damage to the seat and the cab inte-
0 4
rior.
All adjustment controls for a suspension seat are lo-
cated on the seat base. See Chapter 5 for complete
instructions.
10/03/2001 f831452
1. Fan Switch
2. Air Selection Switch
3. Temperature Control Switch
Fig. 4.36, HVAC Climate Control Panel, Standard
Seat Controls
Bench Seat Adjustment Controls
The standard bench seat has one control: the seat
slide lever. See Fig. 4.37. The two-person bench
seat and the non-suspended passenger seat have
no controls.
Suspension Seat Adjustment Controls

All controls for adjusting air suspension seats are
located within easy reach of the occupant.
Due to the maximum adjustability of mid- and high-
back air suspension seats, it is possible to combine
the seat back recline adjustment and the seat slide
4.16
5
Cab Features
Windows . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.1
Mirrors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.1
Seats . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.2
Seat Belts and Tether Belts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.7
Air Bag, Optional . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.9
Cab Amenities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.10
Windshield Washer Reservoir . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.11
Cab Features
Windows Mirrors
Standard windows operate mechanically using a The standard outside mirrors are mounted on the
hand crank. door frame. There is a primary rear view mirror and a
convex mirror.
Power windows are optional, and can be installed on
one side or both sides. One power window switch
(window icon) will be installed on the dash for each
Mirror Heat Switch, Optional
window. See Fig. 5.1. If your vehicle is equipped with One or both outside door mirrors can be heated to
power windows, press up to raise the window; press keep them clear of fog, frost, and ice.
down to lower the window. Releasing the switch
causes the window to stop. To heat the mirrors, press the upper part of the mir-
ror heat switch (MIRR HEAT) on the dash. See
Fig. 5.3. When the mirror heat switch is on, an
amber indicator light illuminates inside the switch.
MIRR
HEAT
10/09/2001 f610522
Press up to raise the window; press down to lower the
window. Releasing the switch causes the window to stop.
10/09/2001 f610524
Fig. 5.1, Power Window Switch To heat the mirrors, press up; press down to turn off the
heat.
Standard vent (wing) windows do not open. Operat-
ing vent windows are optional. To open the operating Fig. 5.3, Mirror Heat Switch
vent window, turn the latch on the window and push
the window open. See Fig. 5.2. The mirror heat switch is a smart switch (fully multi-
plexed).
Power Mirrors, Optional

The main outside mirrors, if heated, can be equipped
with an electrical remote control located on the driv-
er’s door. See Fig. 5.4.
1 To select the mirrors on the left-hand side, press the

left side of the mirror select switch. To select the mir-
rors on the right-hand side, press the right side of the
mirror select switch.
The keypad has four arrow keys, pointing up, down,
2 left, and right. To adjust the mirror position, press the
keypad in the direction you want the mirror to move.
10/05/2001 f670096
1. Latch 2. Vent Window Down View Mirror, Optional
Fig. 5.2, Operating Vent Window (optional) A down view mirror can be installed on the top of the
passenger door frame to allow the driver a view of
5.1
Cab Features
the area adjacent to the right side of the cab. See Unless otherwise noted, all seat adjustments should
Fig. 5.5. be made while seated and before the engine is
started.
Due to the high degree of adjustability found in high-
2
back air suspension seats, it is possible to set the
seat back recline adjustment and the seat slide ad-
justment in such a combination that the seat back
1 will come into contact with the rear wall of the cab. It
is the responsibility of the driver to adjust the seat to
prevent damage to the seat and the cab interior.
The following is a description of adjustments that are
available on one or more seats. Not all seats have all
of the adjustments listed below.
10/05/2001 f610523 1. Seat Slide (fore-and-aft): When this adjustment is
To adjust the mirror position, press the keypad on the
made, the entire seat moves forward or back-
door in the direction you want the mirror to move. ward on its track (Fig. 5.6).
1. Mirror Select Switch 2. Keypad
Fig. 5.4, Power Mirror Switch Pad
B
10/05/2001 f720396 10/05/2001 f910482
1. Mirror A. Seat Slide (fore-and-aft) Adjustment

B. Isolator Feature
Fig. 5.5, Down View Mirror (optional)
Fig. 5.6, Seat Slide Adjustment and Isolator Feature
Seats 2. Isolator: This feature (also referred to as back-
General Information slap isolator or Chugger-Snubber®) reduces the
amount of road shock by isolating the occupant
from the motion of the vehicle, and allowing the
WARNING upper seat to move in a simple pendulum mo-
tion. Whenever the isolator is not desired, it can
Keep hands, tools, and other objects away from be locked out (Fig. 5.6).
the scissor points under the seats. Failure to do
so could cause personal injury. 3. Lumbar Support: Lumbar support changes the
shape of the seat back to give more or less sup-
port to the occupant’s lumbar (lower back) area.
5.2
Cab Features
This adjustment is either mechanical or air con-

trolled, depending on make and model of the
seat (Fig. 5.7).
B
A
10/05/2001 f910484
A. Backrest Tilt B. Seat Cushion Tilt
Fig. 5.8, Cushion Tilt Adjustments
10/05/2001 f910483
A. Lumbar Support B. Headrest Adjustment
Fig. 5.7, Lumbar Support and Headrest Adjustment
4. Headrest: When this adjustment is made, the

upper part of the backrest (back cushion)
changes angle to provide head and upper back A
support (Fig. 5.7).
5. Backrest Tilt: This adjustment pivots the backrest
forward or backward (Fig. 5.8).
6. Seat Cushion Tilt: This adjustment raises or low-
ers the front and/or back of the seat (bottom)
cushion. This adjustment is easier to perform
when all weight is removed from the seat
(Fig. 5.8).
10/05/2001 f910485
7. Seat Tilt: When this adjustment is made, the seat A. Ride Height
assembly, both backrest and seat cushion, tilts
forward or backward (Fig. 5.8). Fig. 5.9, Ride Height Adjustment
8. Ride Height Adjustment: The entire seat moves mal driving conditions, the seat should not top or
up or down when adjusting the ride height. The bottom against the limits of the vertical travel.
adjustment is either manual or air controlled, de-
pending on the make and model of the seat 10. Ride Firmness: A firmer ride gives a better feel
(Fig. 5.9). for the road but less protection against uneven-
ness in the road surface. A softer ride smooths
9. Damper: When you sit on the seat, a leveling out the bumps.
valve places you in the center of the ride zone.
When the damper is adjusted properly under nor-
5.3
Cab Features
Bench Seats
The three-person full bench seat is standard. See
Fig. 5.10.
1
7
6 2
3
4
5
10/10/96 f910131
2 1. Backrest Tilt Lever

2. Air Lumbar Support Control Valve (optional)
10/05/2001 f910481
3. Damper Adjustment Switch
1. Three-Person Seat 4. Height Adjustment Switch
2. Seat Slide Lever 5. Seat Cushion Tilt Knob
6. Seat Slide and Isolator Lever
Fig. 5.10, Full Bench Seat 7. Lumbar Support Knob (standard)
The full bench seat has a seat slide adjustment to Fig. 5.11, Bostrom Seat
allow more or less leg room for the driver and pas-
sengers. Release the seat slide lever and push back- Lumbar Support
wards or forwards to move the seat along its track.
To increase lumbar support, rotate the lumbar sup-
High-back air suspension seats are optional for both port knob forward. To decrease lumbar support, ro-
driver’s and passenger’s seats. Also available are a tate the knob rearward.
non-suspended passenger’s seat, and a two-person
bench seat with a safe or tool box located under the On seats equipped with air lumbar support, press the
seat. control valve upward to increase lumbar support.
Press the control valve downward to decrease lum-
No adjustments are possible on the two-person bar support.
bench seat or the non-suspended passenger seat.
Seat Cushion Tilt
Bostrom Seat
Rotate the seat cushion tilt knob to increase or de-
Seat Slide Adjustment crease seat cushion tilt.
Move the seat slide and isolator lever (Fig. 5.11) to
the left and hold it there to slide the seat forward or
Backrest Tilt
backward to the desired position. To tilt the backrest, lean forward slightly to remove
pressure from the cushion and hold the backrest tilt
Isolator lever rearward. Lean backward slowly to the desired
To engage the isolator, put the seat slide and isolator position and release the lever to lock the backrest in
lever in the center position. Lock out the isolator by place.
moving the lever to the right.
5.4
Cab Features
Ride Height and Damper Adjustment Lumbar Support

To raise the seat, press the upper portion of the To adjust the lumbar support, use the lumbar support
height adjustment switch. To lower the seat, press switch on the side of the seat to give more or less
the lower portion of the switch. support to your lower back.
Press the damper adjustment switch to adjust the Backrest Tilt
damper.
To tilt the backrest, turn the backrest tilt knob until
National 2000 Series Seat the desired position is reached.
Seat Slide Adjustment Seat Cushion Adjustment
Move the seat slide lever (Fig. 5.12) to the left and To adjust the height of the front of the seat cushion,
hold it there to slide the seat forward or backward to lift the front cushion height adjustment handle, and
the desired position. Move the lever back to its origi- pull forward or push back to the desired setting.
nal position to lock the seat in place.
To adjust the height of the rear of the seat cushion,
remove your weight from the seat and turn the rear
cushion adjustment knob to one of three positions.
Ride Height Adjustment

To raise or lower the height of the seat, use the
height adjustment switch on the side of the seat.
7
Sears Seat
Seat Slide Adjustment
6
Push the seat slide (fore-and-aft adjustment) lever
(Fig. 5.13) all the way to the left and slide the seat
1 forward or backward, as desired. Release the lever
5 to lock the seat in the desired position.
2 4
4 3 3
11/14/2000 f910445
1. Backrest Tilt Knob 5

2. Lumbar Support Switch 2
3. Height Adjustment Switch
4. Seat Slide Lever
5. Front Cushion Height Adjustment Handle 1
6. Isolator Handle
7. Rear Cushion Adjustment Knob
Fig. 5.12, National 2000 Series Seat

10/08/2001 f910487
Isolator 1. Seat Slide Lever
2. Seat Cushion Tilt Adjustment
To use the isolator feature, turn the isolator handle to 3. Ride Height Knob
the horizontal position. Turn the isolator handle down 4. Lumbar Support Lever
to lock out the isolator. 5. Backrest Lever
Fig. 5.13, Sears Low Profile Seat
5.5
Cab Features
Isolator
To engage the isolator (if installed), move the seat
slide and isolator lever (Fig. 5.14) all the way to the
right. To lock out the isolator, move the isolator lever
to the center position.
10/08/2001 1 2 f910488
1. Ride Height Switch

2. Air Lumbar Support Switch
2 Fig. 5.15, Air Controls, Sears Seat
4 Seat Cushion Tilt

5 To raise the seat cushion, lift upward on the front of
6 the seat cushion, and then push it rearwards. To
3 lower the seat cushion, pull forward on the front of
8
the seat cushion, and then push downwards.
Backrest Adjustment
7
10/09/2001 f910486 To adjust the backrest, push downwards on the back-
NOTE: Armrests are optional. rest lever just below the bottom of the backrest cush-
1. Lumbar Support Lever ion. With the lever down, lean forward or backward
2. Backrest Lever to the desired position. Release the lever to lock the
3. Ride Height Knob backrest in place.
4. Shock Absorber Bracket (ride firmness)
5. Pin (ride firmness) Ride Height Adjustment
6. Snap Ring (ride firmness)
7. Seat Slide and Isolator Lever Push the ride height knob inwards to inflate the air
8. Seat Cushion Adjustment cylinder, raising the height of the seat. Pull the ride
height knob outwards to deflate the air cylinder, low-
Fig. 5.14, Sears Fleetmaster Seat (with isolator) ering the height of the seat.
Lumbar Support For seats with air support, use the forward rocker
switch on the control panel on the left-hand side of
Move the three-position lumbar support lever upward the seat (Fig. 5.15). Press up to raise the seat; press
to increase lumbar support (firmer). Move the lever down to lower the seat.
downward to decrease lumbar support (less firm).
NOTE: This three-position lever (see inset) does Ride Firmness Adjustment
not rotate a full 360 degrees. For a softer ride, remove the snap ring and pin from
the shock absorber bracket (see inset). Relocate the
For seats with air support, use the aft rocker switch
pin in the other set of holes in the bracket and se-
on the control panel on the left-hand side of the seat
cure it with the snap ring.
(Fig. 5.15). Press up to make the seat firmer; press
down to make the seat less firm.
5.6
Cab Features
Seat Belts and Tether Belts Seat Belt Inspection

General Information WARNING
Seat belt assemblies are designed to secure persons
in the vehicle to help reduce the chance of injury or Inspect and maintain seat belts. When any part of
the amount of injury resulting from accidents or sud- a seat belt system needs replacement, the entire
den stops. For this reason, Daimler Trucks North seat belt must be replaced, both retractor and
America LLC urges that the driver and all passen- buckle side. Any time a vehicle is involved in an
gers, regardless of age or physical condition, use accident, and the seat belt system was in use,
seat belts when riding in the vehicle. the entire vehicle seat belt system must be re-
placed before operating the vehicle. Do not at-
tempt to modify the seat belt system; doing so
WARNING could change the effectiveness of the system.
Always use the vehicle’s seat belt system when Failure to replace worn or damaged seat belts, or
operating the vehicle. Failure to do so can result making any modifications to the system, may re-
in severe personal injury or death. sult in personal injury or death.
Seat belt assemblies in Daimler Trucks North Inspect the seat belts and tether belts (if so
America (DTNA) vehicles meet Federal Motor Ve- equipped).
hicle Safety Standard 209, "Type 1" and "Type 2" re- 1. Check the web for fraying, cuts, extreme dirt and
quirements. dust, or for severe fading from exposure to sun-
When transporting a child, always use a child re- light, especially near the buckle latch plate and in
straint system or the vehicle seat belts as appropri- the D-loop guide area.
ate. To determine whether a child restraint system is 2. Check operation of the buckle, latch, Komfort
required, review and comply with applicable state Latch or Sliding Komfort Latch (if equipped), web
and local laws. Any child restraint used must comply retractor, and upper seat belt mount on the door
with Federal Motor Vehicle Safety Standard 213, pillar. Check all visible components for wear or
"Child Restraint Systems." When providing a child damage.
restraint system, always carefully read and follow all
instructions pertaining to installation and usage for 3. Check the seat belt and tether belt connection
the child. Make certain the child remains in the re- points and tighten any that are loose.
straint system at all times when the vehicle is in mo-
tion. Seat Belt Operation
In addition to seat belt assemblies, tether belts are Three-Point Seat Belt With Komfort Latch
installed on suspension-type seats. Tether belts help or Sliding Komfort Latch
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.
WARNING
IMPORTANT: Seat belts have a finite life which Wear three-point seat belts only as described
may be much shorter than the life of the vehicle. below. Three-point seat belts are designed to be
Regular inspections and replacement as needed worn by one person at a time. In case of an acci-
are the only assurance of adequate seat belt dent or sudden stop, personal injury or death
could result from misuse.
security over the life of the vehicle.
Fasten the seat belts before driving. Fastening a
three-point seat belt while driving creates a haz-
ard.
When engaged and used properly, the Komfort Latch
(Fig. 5.16) and the Sliding Komfort Latch (Fig. 5.17)
5.7
Cab Features
introduce a small amount of slack into the seat belt, lap (from outboard to inboard) far enough to en-
resulting in a more comfortable ride. gage the buckle. If the retractor locks too soon,
allow the belt to retract slightly, then slowly pull it
out again.
2. Fasten the three-point seat belt by pushing the
latch into the buckle. Listen for an audible click.
See Fig. 5.18.
A B
03/11/2010 f910620
A. Disengaged B. Engaged 01/18/95 f910004a
Fig. 5.16, Komfort Latch

Fig. 5.18, Fastening the Three-Point Belt
3. Tug on the seat belt to make sure it is securely

fastened. If the buckle unlatches, repeat this
step. If the problem continues, replace the three-
point seat belt.
4. Snug the seat belt to your waist.
5. Position the shoulder strap diagonally across
your chest with the adjustable D-loop bracket (if
equipped). If desired, engage the Komfort Latch
or Sliding Komfort Latch as follows.
If equipped with a Sliding Komfort Latch, make
sure that the shoulder strap is snug against your
chest. Without loosening the shoulder strap,
push the Sliding Komfort Latch switch to the
"ON" position. See Fig. 5.17. To activate the
latch lean forward until you hear a click. This will
allow for approximately 1 inch (2.5 cm) of slack
11/18/2010 f910621a
between your chest and the shoulder harness.
Once engaged, the latch will allow you to lean
Fig. 5.17, Sliding Komfort Latch forward about 5 inches (13 cm) without having to
reset the latch. Leaning forward more than 5
1. Slowly pull the latch end of the three-point seat inches (13 cm) will disengage the Sliding Kom-
belt out of the retractor and pull it across your fort Latch, requiring it to be reset.
5.8
Cab Features
If equipped with a Komfort Latch, pull on the belt to release the Sliding Komfort Latch, or
shoulder strap to lessen the pressure of the strap press the Sliding Komfort latch to the "OFF" po-
on your shoulder and chest. Allow no more than sition, then unbuckle the seat belt.
1 inch (2.5 cm) of slack between your chest and If equipped with a Komfort Latch, unbuckle the
the shoulder harness. More slack can signifi- seat belt, then release the Komfort Latch by giv-
cantly reduce the seat belt effectiveness in an ing the shoulder belt a quick tug. If you lean for-
accident or a sudden stop. While holding the belt ward against the shoulder belt, the Komfort Latch
slack, press the Komfort Latch lever up, clamp- will automatically release, and will need to be
ing the seat belt webbing (Fig. 5.19 and reset.
Fig. 5.20).
NOTE: Neither the Komfort Latch nor the Sliding
Komfort Latch need to be manually released in
an emergency situation. Each will release by
itself under rough road or other abnormal condi-
tions. Make sure the three-point seat belt is
A completely retracted when it is not in use.
Air Bag, Optional

Your vehicle may or may not be equipped with a
driver’s air bag supplemental restraint system.
The air bag, when used with seat belts, provides ad-
ditional protection to the driver in severe frontal colli-
sions. The operational readiness of the air bag sys-
01/06/95 f910048a tem is indicated by the supplemental restraint system
A. 1 Inch (2.5 cm) Maximum (SRS) indicator on the dash. The SRS indicator
comes on when the engine is started and then goes
Fig. 5.19, Adjusting Shoulder Harness Clearance,
Komfort Latch
off. The indicator will remain on if there is a problem
with the air bag system. The vehicle should be ser-
viced if the SRS indicator does not come on when
the engine is started or if the SRS indicator remains
on.
WARNING
Air bags are designed to inflate only in severe
frontal collisions. The driver and the passenger
should always wear seat belts. For maximum pro-
tection in a collision or rollover, always be in a
normal seated position with your back against
the seat back and your head upright. Fasten your
seat belt and ensure that it is properly positioned
11/02/95 f910144 on your body as described under the "Seat Belt
Operation" heading. Since the air bag inflates
Fig. 5.20, Locking the Komfort Latch with considerable speed and force, a proper seat
position will keep you a safe distance from the
6. Unbuckle the three-point seat belt and release inflating air bag.
the Komfort Latch or the Sliding Komfort Latch
as follows. Do not place objects on the steering wheel or be-
tween you and the steering wheel. Keep your
If equipped with a Sliding Komfort Latch, un- hands on the sides and lower portion of the
buckle the seat belt, then tug on the shoulder
5.9
Cab Features
steering wheel. Any objects may cause harm dur- • Do not cut, drill, braze, solder, weld, strike,
ing an accident. or probe any part of the air bag system.
Failure to follow these instructions may result in • Do not expose the air bag module to elec-
death or personal injury. tricity. Never probe a circuit.
• Do not attempt to adapt, reuse, or install an
Air Bag Safety Guidelines air bag system in any vehicle other than the
The air bag system contains components that use specific vehicle for which it is designed.
combustible chemicals. Because these chemicals are • Do not cut wires or tamper with the connec-
combustible, care must be taken when replacing or tor between the vehicle wiring harness and
handling system components. the air bag module. Cutting or removing the
connector from the system will disable the
WARNING safety shunt and could cause unintentional
deployment.
Consider undeployed air bags to be dangerous
• Allow deployed air bag systems to cool
and capable of deploying at any time. Do not at-
tempt to service the air bag system unless after deployment.
trained to do so. Damaged air bag systems • Wear rubber gloves and safety glasses
should be examined by qualified personnel be- when handling a deployed air bag.
fore any attempt is made to remove or to deploy
the air bag. All intentional deployments and test- • Wash your hands and exposed skin surface
ing of the system should be performed by trained areas immediately after handling a de-
personnel. Unintentional or improper air bag deployed system.
ployment could cause severe bodily injury or • Store, transport, dispose of, and recycle
death. deployed air bag system components in
Do not attempt to disassemble the air bag inflator accordance with all applicable federal,
unit or breach the integrity of the sealed metallic state, and local regulations.
inflator case. Doing so could cause severe bodily • The air bag module may contain perchlor-
injury or death. ate material: special handling may apply,
Do not allow system chemicals to contact other see www.dtsc.ca.gov/hazardouswaste/
liquids, combustibles, and flammable materials. perchlorate.
Doing so could cause chemical burns or per- • Keep all heavy objects in the cab secured.
sonal injury.
The surface of the deployed air bag may contain Cab Amenities
small amounts of sodium hydroxide (which is a
by-product of the gas generant combustion) and Cup Holders
metallic sodium. Sodium hydroxide may be irri-
There are two cup holders molded into the lower part
tating to the skin and eyes. Always wear rubber
of the auxiliary dash panel, one on either side of the
gloves and safety glasses when handling a de-
HVAC control head.
ployed air bag. Immediately wash your hands and
exposed skin areas with a mild soap and water.
Flush your eyes immediately if exposed to so- Cab Storage
dium hydroxide. There are storage bins in the dash and the overhead
Review and comply with the following list of console. On vehicles with optional individual driver’s
warnings. Failure to do so could result in severe and passenger seats, there is a center storage con-
injury or death. sole between the seats.
• Keep all liquids, acids, halogens, heavy There is a dash storage bin located under the cup
metals, and heavy salts away from the air holders on the center panel. The bin has a hinged
bag system.
5.10
Cab Features
cover and can be used to store sunglasses. There is

also a small storage pocket above the radio.
Overhead Storage
Vehicles without an overhead console have two stor-
age bins located above the windshield.
On vehicles equipped with an overhead console,
most vehicles have a storage bin located in the over-
head console. See Fig. 5.21. The overhead storage
bin is often removed and replaced with a CB radio.
Two map holders with netted openings are located
overhead, one on either side of the overhead
console.
1 2
10/08/2001 f680027
1. Overhead Storage Bin 2. Overhead Console 3. Map Holder Netting
Fig. 5.21, Overhead Storage
Center Storage Console (optional)

On vehicles with individual driver’s and passenger’s
seats, a center storage console can be installed be-
tween the seats.
The center storage console has a table top that can
be lifted up to deploy a writing surface. See
Fig. 5.22.
In another version, the center storage console has a
printer top with a paper slot in it. See Fig. 5.23.
Windshield Washer Reservoir

The standard location for the windshield washer res-
ervoir is on the right-hand side of the cab underneath
the door, just above the trailing edge of the top cab
step. See Fig. 5.24.
5.11
Cab Features
1 3
2 1
2
4 10/08/2001 f820378a
1. Cab
2. Washer Reservoir Fill Cap
3. Top Step
Fig. 5.24, Windshield Washer Reservoir

10/08/2001 f680026
1. Table Top
2. Storage Console Cover
3. Storage Area
4. Storage Console Base
Fig. 5.22, Center Storage Console (with writing surface)
10/08/2001 f680025
1. Printer Top 3. Storage Console Base
2. Printer/Paper Area
Fig. 5.23, Center Storage Console (printer option)
5.12
6
Heater, Ventilator and Air
Conditioner
Climate Control Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.1
Heater, Ventilator and Air Conditioner
Climate Control Panel To increase airflow, turn the fan switch to the right or
to a higher number. To decrease the airflow, turn the
The climate control panel allows you to control the switch to the left or to a lower number.
heating, ventilating, defrosting, and air conditioning
functions. The climate control panel without air condi- Air Selection Switch
tioning is shown in Fig. 6.1. The climate control
panel with air conditioning is shown in Fig. 6.2. The air selection switch allows you to control the flow
of air through the face outlets, the floor outlets, the
Fan Switch defrost (windshield) outlets, or a combination of
these outlets to give you nine air selection modes on
The fan switch controls the fan speed and forces a system without air conditioning. See Fig. 6.3. A
fresh or recirculated air through the air outlets. The system with air conditioning has 11 air selection
fan switch has eight fan speeds and an off position.
1 2 3
2
1 3
0 4
06/17/2003 f831452a
1. Fan Switch 2. Air Selection Switch 3. Temperature Control Switch
Fig. 6.1, Climate Control Panel Without Air Conditioning
1 2 3
2
1 3
0 4
06/18/2003 5 4 f831453a
1. Fan Switch 3. Temperature Control Switch 5. Recirculation Indicator
2. Air Selection Switch 4. Recirculation Button
Fig. 6.2, Climate Control Panel With Air Conditioning
6.1
modes, four of which are air conditioning modes. See

6
Fig. 6.4. 5 7
4
3 5 4 8
2 6 3 9
A
1 7 2 10
8 1 11
06/18/2003 f831462
9 A. Air Conditioning Modes
1. Air Conditioning Face Mode
06/17/2003 f831455 2. Selection Between Air Conditioning Face Mode and
1. Face Mode Air Conditioning Bi-Level Mode
2. Selection Between Face Mode and Bi-Level Mode 3. Air Conditioning Bi-Level Mode
3. Bi-Level Mode 4. Selection Between Air Conditioning Bi-Level Mode
4. Selection Between Bi-Level Mode and Floor Mode and Face Mode
5. Floor Mode 5. Face Mode
6. Selection Between Floor Mode and Floor/Defrost 6. Selection Between Face Mode and Floor Mode
Mode 7. Floor Mode
7. Floor/Defrost Mode 8. Selection between Floor Mode and Floor/Defrost
8. Selection Between Floor/Defrost Mode and Defrost Mode
Mode 9. Floor/Defrost Mode
9. Defrost Mode 10. Selection between Floor/Defrost Mode and Defrost
Mode
Fig. 6.3, Air Selection Switch Without Air Conditioning 11. Defrost Mode
Fig. 6.4, Air Selection Switch With Air Conditioning

Air Selection Switch Without Air
Conditioning through the floor outlets and 25 percent through
1. Face Mode: Directs all airflow through the face the defrost outlets.
or instrument panel outlets. 7. Floor/Defrost Mode: Directs the airflow equally
2. Selection between Face Mode and Bi-Level to the floor outlets and the defrost outlets.
Mode: Directs 75 percent of the airflow through 8. Selection between Floor/Defrost Mode and
the face outlets and 25 percent through the floor Defrost Mode: Directs 75 percent of the airflow
outlets. through the defrost outlets and 25 percent
3. Bi-Level Mode: Directs the airflow equally to the through the floor outlets.
face outlets and the floor outlets. 9. Defrost Mode: Directs all airflow through the
4. Selection between Bi-Level Mode and Floor defrost outlets.
Mode: Directs 25 percent of the airflow through
the face outlets and 75 percent through the floor
Air Selection Switch With Air
outlets. Conditioning
5. Floor Mode: Directs all airflow through the floor 1. Air Conditioning Face Mode: Directs all airflow
outlets. through the face or instrument panel outlets.
6. Selection between Floor Mode and Floor/ 2. Selection between the Air Conditioning Face
Defrost Mode: Directs 75 percent of the airflow Mode and the Air Conditioning Bi-Level
6.2
Mode: Directs 75 percent of the airflow to the Recirculation Mode

face outlets and 25 percent to the floor outlets.
The recirculation mode is only available on vehicles
3. Air Conditioning Bi-Level Mode: Directs the with air conditioning.
airflow equally to the face outlets and the floor
outlets. The recirculation mode limits the amount of outside
air entering the cab. Press the recirculation button to
4. Selection between the Air Conditioning Bi- prevent dusty or smoky air from entering the cab.
Level Mode and the Face Mode: Directs 25 The recirculation mode can also be used to decrease
percent of the airflow to the face outlets and 75 the time required to cool or heat the cab interior dur-
percent to the floor outlets. ing extreme outside temperature conditions. When
5. Face Mode: Directs all airflow through the face the recirculation mode is on, the recirculation indica-
outlets. tor will be on. See Fig. 6.2.
6. Selection between Face Mode and Floor The recirculation mode is not available when the air
Mode: Directs the airflow equally through the selection switch is in one of the following modes:
face outlets and the floor outlets. • floor/defrost mode
7. Floor Mode: Directs all airflow through the floor • selection between floor/defrost mode and de-
outlets. frost mode
8. Selection between Floor Mode and Floor/ • defrost mode
Defrost Mode: Directs 75 percent of the airflow
through the floor outlets and 25 percent through When the recirculation mode is turned on, it will stay
the defrost outlets. on for 20 minutes, or until the recirculation button is
pressed again, or the air selection switch is turned to
9. Floor/Defrost Mode: Directs the airflow equally a defrost mode.
to the floor outlets and the defrost outlets. The
recirculation button will not work in this mode. IMPORTANT: On vehicles built before May 2,
2003, the recirculation mode turns off after
10. Selection between Floor/Defrost Mode and twenty minutes and can be turned back on
Defrost Mode: Directs 75 percent of the airflow when the recirculation button is pressed again.
through the defrost outlets and 25 percent
through the floor outlets. The recirculation button
On vehicles built from May 2, 2003, the system
will not work in this mode. enters a partial recirculation mode for five min-
utes after being in full recirculation mode for 20
11. Defrost Mode: Directs all airflow through the minutes. This cycle repeats as long as the sys-
defrost outlets. The recirculation button will not tem is in recirculation mode.
work in this mode.
NOTE: To prevent the buildup of fumes or odors
Temperature Control Switch inside the cab on a vehicle built before May 2,
2003, do not use the recirculation mode for
The temperature control switch is used to select the
desired temperature. Turn the switch to the left
more than 20 minutes. It is recommended that
(counterclockwise) for cool air, or to the right (clock- the recirculation mode remains off for five min-
wise) for hot air. There are 21 positions on the tem- utes before it is turned back on.
perature control switch ranging from full cool air to
full hot air. Defrosting
Before using any of the defrost modes, clear the
Fresh Air Mode screen at the base of the windshield if snow or ice is
Fresh air, or outside air, is circulated through the present.
heating and air conditioning system unless the recir-
culation mode, if equipped, is turned on.
6.3
Air Conditioning, Optional

There are four air conditioning modes on the air se-
lection switch. The air conditioning settings on the air
selection switch are blue, in addition to the selection
between the air conditioning bi-level mode and the
face mode.
IMPORTANT: Operate the air conditioner at
least five minutes each month, even during cool
weather. This helps prevent drying and cracking
of the refrigerant compressor seals and reduces
the chance of refrigerant leaks in the system.
NOTE: The heating and air conditioning system
has a brushless blower motor with a protection
or shutdown mode to prevent damage due to
overheating and overcurrent conditions. If the
brushless blower motor goes into a protection
mode, the motor will operate at a slower speed.
If the overheating or overcurrent condition con-
tinues, the motor will shut down and stop com-
pletely.
The motor will resume proper operation after the
motor has cooled or the overcurrent condition
has been resolved. It will be necessary to cycle
the fan switch off, and then on, to reset the
motor. If the problem appears repeatedly, take
the vehicle to an Freightliner dealer or autho-
rized service outlet for repairs.
6.4
7
Engines
Aftertreatment System (ATS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.1
Engine Starting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.9
Cold-Weather Starting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.10
Starting After Extended Shutdown or Oil Change . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.10
Engine Break-In . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.10
Engine Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.10
Cruise Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.11
Power Takeoff (PTO) Governor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.13
Cold-Weather Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.13
High-Altitude Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.13
Engine Shutdown . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.14
Engine Braking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.14
Exhaust Braking Systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.15
Engines
Aftertreatment System (ATS) IMPORTANT: See your engine operation manual

for complete details and operation of the after-
IMPORTANT: EPA07 and EPA10 emissions treatment system.
regulations apply to vehicles domiciled in
Canada and the USA at the time of printing this Inside the ATD on Mercedes-Benz, Detroit Diesel,
and Cummins engines, the exhaust first passes over
manual. Vehicles that are domiciled outside of the diesel oxidation catalyst (DOC), then it passes
the USA and Canada may not have EPA07- or through the DPF, which traps soot particles. If ex-
EPA10-compliant engines with an emission af- haust temperature is high enough, the trapped soot
tertreatment system, depending upon local is reduced to ash, in a process called passive regen-
statutory emissions guidelines. eration (regen). Passive regeneration occurs as the
vehicle is driven normally under load; the driver is
EPA07 Aftertreatment System (ATS) not even aware that it is happening. The harder an
EPA07 engine works, the better it disposes of soot,
On-road diesel engines built after December 31, as the exhaust heat alone is enough to burn the soot
2006 are required to meet EPA07 guidelines for re- to ash. Over the course of a workday, however, pas-
duced exhaust emissions of particulate matter and sive regeneration cannot always keep the ATD filter
nitrogen oxides (NOx). NOx is limited to just over 1 clean, so the filter must undergo active regenera-
gram per brake horsepower hour (g/bhp-hr), and par- tion.
ticulate matter cannot exceed 0.01 g/bhp-hr.
In active regeneration, extra fuel is injected into the
EPA07-compliant engines require ultralow-sulfur die- exhaust stream to superheat the soot trapped in the
sel (ULSD) fuel, and they should never be run on DPF and turn it to ash. Active regeneration happens
fuel with sulfur content higher than 15 ppm. In addi- only when the vehicle is moving above a certain
tion, they require low-ash engine oil. The following speed, determined by the engine manufacturer. Con-
guidelines must be followed, or the warranty may be sult manufacturers’ documentation for details. Both
compromised. active and passive regeneration happen automati-
• Use ultralow-sulfur diesel (ULSD) with 15 ppm cally, without driver input.
sulfur content or less, based on ASTM D2622 If conditions do not provide for at-speed active re-
test procedure. generation, the vehicle will need a driver-activated
• Do not use fuel blended with used engine lube parked regeneration. The vehicle must be standing
oil or kerosene. still, and the driver must initiate parked regen. Com-
pleting a parked regen takes 20 minutes to an hour,
• Engine lube oil must have a sulfated ash level depending on ambient conditions.
less than 1.0 wt %, meeting the API CJ-4 index
specifications.
DANGER
IMPORTANT: Using non-specification fuels or
oils can lead to shortened diesel particulate filter During parked regeneration, exhaust tempera-
(DPF) cleaning or exchange intervals. For ex- tures are very high, and could cause a fire, heat
ample, using CI-4+ oil with 1.3% sulfated ash damage to objects or materials, or personal in-
jury to persons near the exhaust outlet.
(30% more ash content) may result in the need
for DPF cleaning or exchange 20 to 30% sooner Before initiating a parked regeneration, make cer-
than would normally be required. tain the exhaust outlets are directed away from
structures, trees, vegetation, flammable materi-
The "exhaust system" in EPA07-compliant vehicles is als, and anything else that may be damaged or
called the aftertreatment system (ATS). The ATS var- injured by prolonged exposure to high heat.
ies according to engine manufacturer and vehicle
configuration, but instead of a muffler, an aftertreat- There are three warning lamps in the driver message
ment system has a device that outwardly resembles center that alert the driver of the need to perform a
a muffler, called the aftertreatment device (ATD). parked regen, clean the filter, or of an engine fault
that affects the emissions.
7.1
Engines
A slow (10-second) flash of the high exhaust system

temperature (HEST) lamp, indicates a regeneration is
in progress, and the driver is not controlling the en-
gine idle speed.
A solid illuminated high exhaust system temperature
(HEST) lamp, alerts the operator of high exhaust
temperature during the regeneration process, when
the speed is below 5 mph (8 km/h). See Fig. 7.1.
The HEST lamp does not indicate the need for any
kind of vehicle or engine service; it only alerts the
vehicle operator of high exhaust temperatures. The
09/25/2006 f610815a
driver must be careful that the exhaust pipe outlet is
not directed at any person, or at any object or mate- Fig. 7.2, Diesel Particulate Filter (DPF) Status Lamp
rial that can be damaged or ignited by the heat.
yellow DPF lamp indicates that a parked regen is
required immediately, or an engine derate may occur.
A solid yellow malfunction indicator lamp (MIL) indi-
cates an engine fault that affects the emissions. See
Fig. 7.3.
Diesel particulate filter servicing must be performed
by an authorized service facility, and a record must
be maintained for warranty purposes. The record
must include:
• date of cleaning or replacement;
09/25/2006 f610816a
• vehicle mileage;
Fig. 7.1, High Exhaust System Temperature (HEST) • particulate filter part number and serial number.
Lamp
WARNING
Active regeneration can occur automatically any-
time the vehicle is moving. The exhaust gas tem-
perature could reach 1500°F (800°C), which is hot
enough to cause a fire, heat damage to objects
or materials, or personal injury to persons near
the exhaust outlet. See Regen-Inhibit Switch later
in this chapter for instructions on preventing au-
tomatic regen if necessary.
09/25/2006 f610814a
The exhaust temperature can remain high even
after the vehicle has stopped. When stopping the Fig. 7.3, Malfunction Indicator Lamp (MIL)
vehicle shortly after an automatic regen, ensure
The request regen switch is located on the dash.
the exhaust outlets are directed away from struc-
See Fig. 7.4 . The function of the switch varies by
tures, trees, vegetation, flammable materials, and
the engine make and model in the vehicle. See the
anything else that may be damaged or injured by
engine operation manual for switch operation details.
exposure to high heat.
A steady yellow DPF lamp indicates that a parked NOTE: The regen switch can start an active
regen is required soon, and should be scheduled for regen only when the DPF light is illuminated
the earliest convenient time. See Fig. 7.2. A blinking
7.2
Engines
because the engine software calls for a manual To meet EPA guidelines, diesel engines installed in
regen. Daimler Trucks North America (DTNA) chassis for
domicile in Canada and the USA use an aftertreat-
The regen-inhibit switch provides additional control ment system (ATS) with an aftertreatment device
over the aftertreatment regeneration process. A driver (ATD) and Selective Catalytic Reduction (SCR) tech-
may decide to use this feature if they are hauling nology to reduce NOx downstream of the engine.
cargo that should not be exposed to possible high
exhaust temperatures from an automatic regen.
When activated, the inhibit switch will stop a regen- NOTICE
eration cycle in progress, and prevent the start of a
regeneration cycle until the switch is no longer ac- Using non-specification fluids can result in seri-
tive. See Fig. 7.5. ous damage to the ATS. It is extremely important
that the following guidelines be followed for ve-
hicles with EPA10-compliant engines, or damage
may occur to the ATD, and the warranty may be
compromised.
• Use ultralow-sulfur diesel with 15 ppm sulfur
content or less.
• Do not use fuel blended with used engine lube
oil or kerosene.
• Engine lube oil must have a sulfated ash level
less than 1.0 wt %; currently referred to as
CJ-4 oil.
10/02/2006 f610848
• Use only certified diesel exhaust fluid (DEF) in
Fig. 7.4, Request Regen Switch the DEF tank.
After exhaust gasses leave the engine, they flow into
the ATS. First they flow into a two-part ATD, com-
prised of a diesel oxidation catalyst (DOC), and a
diesel particulate filter (DPF). The DPF traps soot
particles, then exhaust heat converts the soot to ash
in the DPF, in a process called regeneration (regen).
The harder an engine works, the better it disposes of
soot. When the engine is running under load and
regen occurs without input, it is called passive regen.
If the engine isn’t running hot enough, the electronic
controls may initiate an active regen, whereby extra
fuel is injected into the exhaust stream before the
07/30/2009 f610944 diesel particulate filter, to superheat the soot trapped
in the filter and burn it to ash. Both types of regen
Fig. 7.5, Regen-Inhibit Switch occur without driver input.
EPA10 Aftertreatment System (ATS) WARNING

The EPA mandates that all engines built after De-
cember 31, 2009 must reduce the level of emissions Active regeneration can occur automatically any-
exhausted by the engine to the following levels: time the vehicle is moving. The exhaust gas tem-
perature could reach 1500°F (800°C), which is hot
• Nitrogen Oxides (NOx) – 0.2 g/bhp-hr enough to cause a fire, heat damage to objects
• Particulate Matter (PM) – .01 g/bhp-hr or materials, or personal injury to persons near
the exhaust outlet. See Regen-Inhibit Switch later
7.3
Engines
in this chapter for instructions on preventing au- • An illuminated DEF warning lamp in the gauge,
tomatic regen if necessary. indicates that the DEF tank should be refilled
at the next opportunity.
The exhaust temperature can remain high even
after the vehicle has stopped. When stopping the Parked Regen
vehicle shortly after an automatic regen, ensure
the exhaust outlets are directed away from struc-
tures, trees, vegetation, flammable materials, and DANGER
anything else that may be damaged or injured by
exposure to high heat. During parked regeneration, exhaust tempera-
tures are very high, and could cause a fire, heat
Operating at reduced engine load will allow soot to damage to objects or materials, or personal in-
accumulate in the DPF. When this occurs, the DPF jury to persons near the exhaust outlet.
lamp illuminates, indicating that a regen must be per-
formed, and the driver must either bring the vehicle Before initiating a parked regeneration, make cer-
up to highway speed to increase the load, or park tain the exhaust outlets are directed away from
the vehicle and initiate a parked regen. See Parked structures, trees, vegetation, flammable materi-
Regen, later in this chapter for instructions. als, and anything else that may be damaged or
injured by prolonged exposure to high heat.
After the exhaust stream passes through the ATD, it
flows through another canister housing the SCR de- See Fig. 7.7 for an explanation the ATS warnings,
vice. A controlled quantity of diesel exhaust fluid and actions required to avoid further engine protec-
(DEF) is injected into the exhaust stream, where heat tion sequences.
converts it to ammonia (NH3) gas. This mixture flows
The regen switch, located on the dash, is used to
through the SCR device, where the ammonia gas
initiate a parked regen of the aftertreatment device. It
reacts with the NOx in the exhaust, to produce harm-
is a momentary switch, that you press and hold for 4
less nitrogen (N2) and water vapor (H2O), which then
seconds to activate. See Fig. 7.4.
exits out of the tailpipe.
NOTE: The regen switch can initiate a parked
ATS Warning Lamps regen only when the DPF lamp is illuminated
The malfunction indicator lamp (MIL) illuminates to (because the engine software is signaling for a
indicate a fault that affects the emissions. See parked regen.)
Fig. 7.3. The regen-inhibit switch provides additional control
Warning lamps in the driver’s message center alert over the aftertreatment regeneration process. A driver
the driver of situations with the aftertreatment sys- may decide to use this feature if they are hauling
tem. A decal attached to the driver’s sun visor ex- cargo that should not be exposed to possible high
plains the aftertreatment system DPF, HEST, and exhaust temperatures from an automatic regen.
DEF warning lamps. See Fig. 7.6. When activated, the inhibit switch will stop a regen-
eration cycle in progress, and prevent the start of a
• An illuminated DPF lamp indicates a regen is regeneration cycle until the switch is no longer ac-
needed. tive. See Fig. 7.5.
• A slow, 10-second flashing of the HEST lamp To initiate a parked regeneration, perform the follow-
alerts the driver that a parked regen is in ing steps.
progress, but the exhaust temperatures are still
relatively cool. It also indicates that the high- 1. Park the vehicle away from all combustible and
idle speed is being controlled by the engine flammable materials. Chock the tires. Start and
software, not the driver. warm the engine until the coolant temperature is
at least 150°F (66°C).
• A steadily illuminated HEST lamp alerts the
operator of high exhaust temperatures when 2. Set the parking brake. If the parking brake was
vehicle speed is below 5 mph (8 km/h) while it already set, you must release it, then set it
is performing an automatic regen, and during a again.
parked regen.
7.4
Engines
IMPORTANT
DPF Regen Needed Diesel Particulate Filter (DPF)
1
regeneration is needed.
If flashing, regenerate as soon as
possible. Engine derate possible.
2
Hot Exhaust Hot exhaust can cause fire.
Keep flammables and people away
from exhaust.
3
DEF Refill Needed Diesel Exhaust Fluid (DEF) level is
low. Engine derate likely.
DEF
Refill tank with certified DEF.
See operator’s manual for complete instructions. 24−01656−000
11/30/2010 f080161
1. DPF Warning Lamp 2. HEST Warning Lamp 3. DEF Warning Lamp
Fig. 7.6, Warning-Lamp Decal, Sunvisor
For manual transmissions, fully depress the 5. To stop a parked regen at any time during the
clutch pedal, put the transmission in neutral, then process, engage the clutch, brake, or throttle
release the pedal. pedal, or turn off the engine.
If the vehicle has a two-pedal automated trans-
mission, shift it into gear, then back to neutral.
DPF Maintenance
Eventually ash will accumulate in the DPF and the
IMPORTANT: The driver must remain with the filter will require servicing. DPF servicing must be
vehicle during the entire regen cycle. performed by an authorized technician, following the
3. Press and hold the regen switch for 4 seconds. engine manufacturer’s instructions. A record must be
The engine will increase rpm and initiate the maintained for warranty purposes, that includes:
regen process. • date of cleaning or replacement;
4. After the parked regen has run for 20 to 40 min- • vehicle mileage;
utes, the regen cycle is completed. The engine
idle speed will drop to normal, and the vehicle • particulate filter part number and serial number.
may be driven normally. The HEST lamp may be
illuminated, but will go out when the vehicle DEF
speed exceeds 5 mph (8 km/h), or the system
DEF is used in the aftertreatment system to lower
has cooled to normal operating temperature. NOx in the exhaust stream. DEF is colorless and
7.5
Engines
EXHAUST AFTERTREATMENT SYSTEM INFORMATION

INDICATOR WARNING
CHECK CHECK STOP
LAMP(S)
(Solid) (Flashing) (Flashing) (Flashing)
Level 1 Level 2 Level 3 Level 4
Indicator Lamp Filter Regeneration Filter Regeneration Parked Regeneration Parked Regeneration Required − HEST (High Exhaust
Message(s) Recommended Necessary Required − Engine Engine Shut Down System Temperature)
Derate
Diesel Particulate Filter is reaching Filter is now Filter has reached Filter has exceeded Flashing
Filter Condition capacity. reaching maximum maximum capacity. maximum capacity. A regeneration is in
Switch.
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. 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. 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 f080147
Fig. 7.7, Exhaust-Aftertreatment Warnings
close to odorless. (It may have a slightly pungent diesel outlet from being inserted, and has a blue cap
odor similar to ammonia.) It is nontoxic, nonflam- for easy identification.
mable and biodegradable. It is mildly corrosive to
DEF consumption will vary depending on ambient
aluminum, but it will not affect the strength or struc-
conditions and vehicle application.
ture of the aluminum. A white powder may be notice-
able around components that the DEF comes in con-
tact with. Around 12°F (-11°C) DEF freezes to slush,
but is not damaged or destroyed if frozen, and is fully
usable when thawed. The DEF supply lines are elec-
trically heated and are purged when the engine is
shut down. The DEF in the tank is allowed to freeze
while the vehicle is non-operational. At start up, nor-
mal operation of the vehicle is not inhibited if the
DEF is frozen; an immersion heater with engine cool-
ant flowing through it will warm the DEF once the
engine is running, to allow the SCR system to oper-
ate.
DEF Tank 1
EPA10-compliant vehicles are equipped with a DEF 2
tank located on the driver’s side of the vehicle, usu- 07/24/2009 f470542
ally behind the battery box, or an optional location
1. Batteries 2. DEF Tank
forward of the fuel tank for day cab configurations.
See Fig. 7.8, and Fig. 7.9. The DEF tank has a 19 Fig. 7.8, DEF Tank Located Behind the Battery Box
mm filler neck inlet that prevents the hose from a
7.6
Engines
DEF Warnings and Engine Derates

IMPORTANT: Ignoring the DEF warning lights
will result in limited engine power, with a speed
limit of 5 mph (8 km/h) eventually being applied.
DEF Level Low—Initial Warning
When the DEF level reads low the following warnings
strongly encourage the driver to refill the DEF tank:
• One bar of the DEF level indicator illuminates
amber—DEF very low, refill DEF
• DEF warning lamp illuminates solid amber
1 See Fig. 7.11.
2
07/24/2009 f470541 The DEF tank must be filled to cancel the warning
1. DEF Tank 2. Fuel Tank sequence.
Fig. 7.9, DEF Tank Located Forward of the Fuel Tank DEF Empty
When the DEF level reads empty, the following warn-
Fuel/DEF Gauge ings are activated:
The diesel fuel and DEF levels are measured in a • One bar of the DEF level indicator flashes
dual purpose gauge. See Fig. 7.10. red—DEF empty, refill DEF
The diesel-fuel level is indicated at the top of the • DEF warning lamp flashes amber
gauge. Below the fuel level, a diesel-fuel warning
lamp illuminates amber when the diesel fuel level • MIL lamp illuminates
drops below 1/8th of the capacity.
• CHECK engine lamp illuminates for Cummins
The lower portion of the gauge has a DEF warning ISB and ISC/L engines
lamp that illuminates amber when the DEF tank is
Detroit Diesel engines: Power is limited, with a 55
near empty, and a lightbar that indicates the level of
mph (90 km/h) speed limit.
DEF in the tank. The DEF light bar illuminates as
follows. Cummins engines: Power is limited with progres-
• Four bars illuminated green—Between 75% sively harsher engine power limits applied.
and 100% full. See Fig. 7.12.
• Three bars illuminated green—Between 50% The DEF tank must be filled to cancel the warning
and 75% full. sequence.
• Two bars illuminated green—Between 25%
and 50% full.
DEF Level Empty and Ignored
If the empty warning is ignored and the DEF is not
• One bar illuminated green—Between approxi- refilled, the red STOP engine lamp illuminates in ad-
mately 10% and 25% full. dition to the DEF warning lamp, MIL, (and CHECK
• One bar illuminated amber—DEF very low, re- engine lamp if Cummins ISB or ISC/L engine.) See
fill DEF. Fig. 7.13.
• One bar flashing red—DEF empty, refill DEF. If the DEF is not refilled, a 5 mph (8 km/h) speed
limit will be applied after the next engine shut down
or while parked and idling.
7.7
Engines
1/2 1/2 1/2

ULTRA LOW SULFUR ULTRA LOW SULFUR ULTRA LOW SULFUR
DIESEL FUEL ONLY DIESEL FUEL ONLY DIESEL FUEL ONLY
E F E F E F
DEF DEF DEF
1 E F E F E F
2
A B C
11/08/2010 f611037
A. Green bars—DEF level indicators C. One bar flashing red—DEF empty, refill DEF
B. One bar illuminated amber—DEF very low, refill DEF
1. Diesel Fuel Warning Lamp 2. DEF Warning Lamp
Fig. 7.10, Fuel/DEF Gauge
A A
B B
07/09/2009 f470537 11/08/2010 f470539a

A. DEF Warning Lamp (illuminated) NOTE: MIL illuminates. CHECK engine lamp illuminates
B. DEF Lightbar (one bar amber) if Cummins ISB or ISC/L engine. Engine power is lim-
ited.
Fig. 7.11, DEF Level Low Initial Warning A. DEF Warning Lamp (flashing)
B. DEF Lightbar (one bar flashing red)
DEF Quality or SCR Tampering
Fig. 7.12, DEF Empty Warning
NOTICE Detroit Diesel engines: Power is limited, with a 55
mph (90 km/h) speed limit. If the fault is not cor-
Once contaminated DEF or tampering has been rected the STOP engine light illuminates, and a 5
detected in the SCR system, the vehicle must be mph (8 km/h) speed limit will be applied after the
taken to an authorized service center to check next engine shut down, or while parked and idling.
the SCR system for damage, and to deactivate
the warning lights and engine limits. Cummins engines: Power is limited with progres-
sively harsher engine power limits applied. If the fault
If contaminated DEF or tampering is detected the is not corrected the STOP engine light illuminates,
DEF warning light flashes, and the MIL illuminates to and a 5 mph (8 km/h) speed limit will be applied after
warn the driver. The CHECK engine lamp also illumi- the next engine shut down, or while parked and
nates if the vehicle has a Cummins ISB or ISC/L en- idling.
gine. See Fig. 7.13.
7.8
Engines
Ring gear and starter pinion damage caused by

improper starting procedures is not warrantable.
A
Pre-Start
NOTE: These pre-start steps apply to all en-
gines.
B
1. Perform the engine pretrip inspection and daily
maintenance checks in Chapter 11.
11/08/2010 f470540a
2. Set the parking brake.
NOTE: STOP engine light illuminates. Engine power
limited, speed limit of 5 mph (8 km/h) 3. For manual transmissions, place the transmis-
A. DEF Warning Lamp (flashing) sion in neutral and disengage the clutch.
B. DEF Lightbar (one bar flashing red)
For automatic transmissions, make sure the
Fig. 7.13, DEF Empty and Ignored Warning transmission shift control is in neutral or park.
NOTE: On vehicles equipped with a neutral start
Engine Starting switch, the transmission must be in neutral be-
For cold-weather starting, refer to "Cold Weather fore the engine can be started. For air start sys-
Starting" later in this chapter. tems, check the air supply before starting the
engine. There must be 100 psi (689 kPa) of air
Whenever you start an engine, watch for any signs pressure available.
of engine problems. If the engine vibrates, misfires,
or makes unusual noises, turn the engine off as soon 4. Turn the ignition switch to the ON position
as possible and determine the cause of the problem. (Fig. 7.14). All the electronic gauges on the ICU
Frequently, engine damage may be avoided by a (instrumentation control unit) complete a full
quick response to early indications of problems. sweep of their dials, the warning and indicator
lights light up, and the buzzer sounds for three
NOTICE seconds.
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.
09/12/2001 f610509
Moving a vehicle with the starter and/or using the
starter to bump the engine for maintenance pro- Fig. 7.14, Ignition Switch Positions
cedures is strictly prohibited. Use of these meth-
ods to bump the engine over or move the vehicle
can cause the pinion to release and re-engage,
which could cause ring gear and starter pinion
damage.
7.9
Engines
Starting Precautions, All Engines NOTICE

WARNING Failure to eliminate water-diluted lubricating oil
may lead to serious engine damage at startup.
Never pour fuel or other flammable liquid into the
air inlet opening in the air intake in an attempt to Before engine start-up, complete the engine pretrip
start the vehicle. This could result in a flash fire and post-trip inspections and maintenance proce-
causing serious personal injury or property dam- dures in Chapter 11.
age.
Engine Break-In
NOTICE Every engine is tested on a dynamometer before
shipment, eliminating the need for a break-in period.
Do not crank the engine for more than 30 sec- Before running the engine for the first time, follow the
onds at a time. Wait two minutes after each try to instructions in the engine manufacturer’s operation
allow the starter to cool. Failure to do so could manual.
cause starter damage.
NOTE: Some starters are equipped with op- Engine Operation
tional overcrank protection. If overcranking oc-
curs, a thermostat breaks the electrical circuit to
the starter motor until the motor has cooled.
DANGER
Do not operate the engine in an area where flam-
NOTICE mable vapors such as gasoline or diesel fumes
are present. Shut down the engine when in an
Protect the turbocharger during the start-up by area where flammable liquids or gases are being
not opening the throttle or accelerating the en- handled. Failure to observe these precautions
gine above 1000 rpm until minimum engine idle could result in serious injury or death.
oil pressure registers on the gauge. Failure to do
so could damage the turbocharger. All Freightliner diesel engines comply with the re-
quirements of the Federal (U.S.) Clean Air Act. Once
an engine is placed in service, the responsibility for
Cold-Weather Starting meeting both state and local regulations is with the
owner/operator.
Electronic engines do not normally require special
starting aids. At low temperatures, oil pan heaters or IMPORTANT: EPA07 and EPA10 emissions
water jacket heaters are sometimes used to assist in regulations apply to vehicles domiciled in
starting. See the engine manufacturer’s operation Canada and the USA at the time of printing this
manual for starting aids that are approved for specific manual. Vehicles that are domiciled outside of
engines.
the USA and Canada may not have EPA07- or
EPA10-compliant engines with an emission af-
Starting After Extended tertreatment system, depending upon local
Shutdown or Oil Change statutory emissions guidelines.
An engine in storage for an extended period of time
(over winter, for example) may accumulate water in
NOTICE
the oil pan through normal condensation of moisture It is extremely important that the following points
on the internal surfaces of the engine. Oil diluted by be followed for vehicles with EPA07- or EPA10-
water cannot provide adequate bearing protection at compliant engines, or damage may occur to the
start-up. For this reason, change the engine oil and aftertreatment device, and the warranty may be
filters after extended storage. compromised.
7.10
Engines
• Use ultralow-sulfur diesel with 15 ppm sulfur Cruise Control

content or less.
• Do not use fuel blended with used engine lube WARNING
oil or kerosene.
• Engine lube oil must have a sulfated ash level Do not use the cruise control system when driv-
less than 1.0 wt %; currently referred to as ing conditions do not permit maintaining a con-
CJ-4 oil. stant speed, such as in heavy traffic or on roads
that are winding, icy, snow-covered, slippery, or
• Adequate maintenance of the engine and the roads with a loose driving surface. Failure to fol-
diesel-particulate filter are the responsibility of low this precaution could cause a collision or
the owner/operator, and are essential to keep loss of vehicle control, possibly resulting in per-
the emission levels low. Good operating prac- sonal injury or property damage.
tices, regular maintenance, and correct adjust-
ments are factors that will help to stay within Dash-Mounted Switches
the regulations.
The driver should be familiar with the vehicle warning NOTICE
system in order to bring the vehicle to a safe stop if
the engine malfunctions. If the driver doesn’t under- Do not attempt to shift gears without using the
stand how the warning system works, an engine clutch pedal when the cruise control is engaged.
shutdown could occur, causing a safety hazard. See Failure to follow this precaution will result in a
Chapter 3 for information. temporarily uncontrolled increase in engine
All engines have an operating range specific to that speed; transmission damage and gear stripping
engine in which the engine performs most efficiently. could result.
The operating range extends from maximum torque On standard models, cruise control is activated by
rpm at the low end to engine rated speed at the high two dash switches (Fig. 7.15).
end. Most engines deliver best fuel economy when
• The On/Off Switch—this two-position rocker
operated in the low- and mid-speed segments of the
efficiency range and produce maximum horsepower switch bears the legend SPD CNTL on the
at rated speed, which is also the recommended lower half of the switch. When cruise control is
maximum speed of the engine. For specifics for any on, an amber light illuminates in the top part of
engine refer to the engine manufacturer’s operation the switch.
manual. • The Set/Resume Switch—this three-position
Prolonged idling of engines is not recommended, and paddle switch bears the legend RES/ACC
is illegal in some states. The belief that idling a die- above the paddle and SET/CST below the
sel engine causes no engine damage is wrong. Idling paddle.
produces sulfuric acid, that is absorbed by the lubri- 1. To cruise at a particular speed, do these steps:
cating oil, and eats into bearings, rings, valve stems,
and engine surfaces. If you must idle the engine for 1.1 Press the upper half of the On/Off (rocker)
cab heat or cooling, the high idle function of the switch on the instrument panel.
cruise control switches should be used. An idle 1.2 Hold the accelerator pedal down until the
speed of 900 rpm should be enough to provide cab speedometer reaches the desired speed.
heat in above freezing ambient temperatures.
1.3 Momentarily lower the paddle of the Set/
If the engine is programmed with the idle shutdown Resume switch to SET/CST.
timer, ninety seconds before the preset shutdown
time, the CHECK ENGINE light will begin to flash at 2. To disengage the cruise control, do these steps:
a rapid rate. If the position of the clutch pedal or ser- 2.1 Press down the brake pedal (on automatic
vice brake changes during this final ninety seconds or manual transmission) or
(CHECK ENGINE lamp flashing) the idle shutdown
timer will be disabled until reset. Press down the clutch pedal (on manual
transmission only)
7.11
Engines
Shift Knob Controls, Optional

Cruise control can also be activated by the optional
PAUSE, RESUME, and SET buttons on the transmis-
sion shift knob (Fig. 7.16).
1
09/13/2001 f610510
05/23/95 f260316
To turn cruise control on, press the upper half of the On/
Off (rocker) switch. To turn cruise control off, press the Fig. 7.16, Cruise Control Buttons on the Transmission
lower half of the On/Off (rocker) switch. Shift Knob
1. Cruise Control On/Off (rocker) Switch
2. Cruise Control Set/Resume (paddle) Switch 1. To cruise at a particular speed, do these steps:
Fig. 7.15, Cruise Control Switches, Dash-Mounted 1.1 Hold the accelerator pedal down until the
speedometer reaches the desired speed.
2.2 Press the lower half of the On/Off (rocker)
1.2 Push the SET button on the transmission
switch on the instrument panel.
shift knob.
3. To resume a preselected cruise speed, do these
2. To disengage the cruise control, do these steps:
steps:
3.1 If the On/Off (rocker) switch on the instru- 2.1 Press down the brake pedal (on automatic
ment panel is off, turn it on. and manual transmission) or
3.2
Press down the clutch pedal (on manual
Momentarily raise the paddle of the Set/
transmission only)
Resume switch to RES/ACC. Cruise will
return to the last speed selected. 2.2 Push the PAUSE button on the transmis-
sion shift knob.
NOTE: If the ignition is shut off, the speed
memory will be lost. 3. To resume a preselected cruise speed, push the
RESUME button on the transmission shift knob.
4. To adjust cruise speed up, raise the paddle of Cruise will return to the last speed selected.
the Set/Resume switch to RES/ACC and hold it
there until the vehicle accelerates to the new NOTE: If the ignition is shut off, the speed
speed, as desired. memory will be lost.
5. To adjust cruise speed down, lower the paddle of 4. To adjust cruise speed up, push the SET button
the Set/Resume switch to SET/CST and hold it and hold it in until the vehicle accelerates to the
there until the vehicle decelerates to the new new speed, as desired.
speed, as desired.
7.12
Engines
5. To adjust cruise speed down, push the RESUME cold weather for your engine, see the engine manu-
button and hold it in until the vehicle decelerates facturer’s engine operation manual, supplied in the
to the new speed, as desired. vehicle documentation package.
If satisfactory engine temperature is not maintained,
Power Takeoff (PTO) Governor maintenance costs will increase due to greater en-
gine wear. If the engine coolant temperature be-
Front Engine Power Take Offs (PTO) are devices comes too low, raw fuel will wash the lubricating oil
used to tap into engine power to run auxiliary de- off the cylinder walls and dilute the crankcase oil,
vices. Common uses are vehicles with hydraulic causing all moving parts of the engine to suffer from
pumps which power additional equipment. The fol- poor lubrication.
lowing instructions are general guidelines for operat-
ing a PTO. If the engine is in good mechanical condition and the
precautions necessary for cold-weather operation are
1. Set the parking brake. Shift the transmission to taken, ordinary cold weather will not cause difficulty
neutral. in starting, or loss of efficiency.
2. Press the dash PTO switch. Release the switch The following points are important to observe when
when the light begins to blink. operating in cold weather:
When the light comes on steadily, the PTO is
• Check for cracks in the batteries, for corrosion
engaged and ready to operate. In stationary
of the terminals, and for tightness of the cable
mode, the vehicle must remain in neutral with the
clamps at the terminals.
parking brake set.
• Charge the batteries to full capacity. Replace
3. To activate the mobile mode, shift from neutral to
any battery that is damaged.
reverse, 1st, or 2nd gear. The clutch will open
and the PTO will disengage for a moment. • If so equipped, turn off the load disconnect
4. Touch the throttle pedal to close the clutch and switch after the engine is shut down, to prevent
engage the PTO in mobile mode. The PTO may battery discharge.
be operated with the transmission in the follow- • Have the alternator output checked at an au-
ing gears only: R-N-1-2. thorized service provider.
NOTE: Do not attempt to change gears while • Check the condition and tension of the drive
the vehicle is moving. The transmission will ig- belts.
nore the request. • Refer to the engine manufacturer’s engine op-
5. To end the mobile mode, bring the vehicle to a eration manual for recommended heaters, low-
stop. The clutch will open and shut off power to viscosity lubricating oils, wintergrade fuels, and
the PTO. approved coolants.
6. To resume stationary mode, shift to neutral. The A winterfront may be used to improve cab heating
PTO will engage. while idling. If a winterfront is used, at least 25% of
the grille opening should remain open in sectioned
7. To end stationary mode, press the dash switch. stripes that run perpendicular to the charge-air-cooler
When the light in the switch goes out, power to tube-flow dirrection. This assures even cooling
the PTO is shut off. Shut down the engine. across each tube, and reduces header to tube
stress, and possible failure. Winterfronts should only
Cold-Weather Operation be used when the ambient temperature remains
below 10°F (-12°C).
Satisfactory performance of a diesel engine operating
in low ambient temperatures requires modification of
the engine, surrounding equipment, operating prac- High-Altitude Operation
tices, and maintenance procedures. The lower the Engines lose horsepower when operated at high alti-
temperature, the greater the amount of modification tude because the air is too thin to burn as much fuel
required. For service products approved for use in as at sea level. This loss is about three percent for
7.13
Engines
each 1000 feet (300 m) altitude above sea level for a To turn the two-position On/Off Switch on, raise the
naturally aspirated engine. paddle. When the two-position switch is on, an
amber LED (light-emitting diode) illuminates inside
All engines used on M2 vehicles are altitude- the switch.
compensated by the use of a turbocharger. This re-
duces smoky exhaust at high altitudes, requires less To turn the two-position HI-LO Switch on high, raise
downshifting, and allows the engine to make better the paddle (at the HI-LO legend). To turn the two-
use of its fuel. Nevertheless, shift gears as needed to position HI-LO Switch on low, lower the paddle (at
avoid excessive exhaust smoke. the ENG BRK legend). See Fig. 7.17.
Engine Shutdown
1 2
1. With the vehicle stopped, apply the parking
brakes and place the transmission in neutral.
NOTICE
Idle the engine one to two minutes before shut-
ting it down. After hard operation, shutting down
the engine without idling may cause damage to
the turbocharger.
10/17/2001 f610588
2. Allow the engine to idle one to two minutes be-
fore shutting it down. This allows the lubricating 1. On/Off Switch 2. Hi-Lo Switch
oil and the coolant to carry heat away from the Fig. 7.17, Engine Brake Switches
combustion chambers, bearings, shafts, and
seals. The extreme heat may cause bearings to When the panel lights are on, the Hi-Lo legend is
seize or oil seals to leak. backlit in amber on the three-position switch. On both
the three-position switch and the two-position switch,
IMPORTANT: Bearings and seals in the turbo- the ENG BRK legend is backlit in green when the
charger are subjected to the high heat of com- panel lights are on.
bustion exhaust gases. While the engine is run-
ning, this heat is carried away by oil circulation, Whenever vehicle braking is required on good road
but if the engine is stopped suddenly, the turbo- conditions, the engine brake may be used in con-
junction with the service brakes. There is no time
charger temperature may rise as much as 115°F
limit for operation of the engine brake. However, an
(46°C). engine brake does not provide the precise control
available from the service brakes, and is not a sub-
NOTICE stitute for a service braking system.
Except in an emergency, do not shut down the

engine when the coolant temperature is above
WARNING
194°F (90°C). To do so could damage the engine. Usage of the engine brake as the primary braking
3. Turn off the ignition switch and shut down the system can cause unpredictable stopping dis-
engine. tances, that could result in personal injury or
property damage. Service brakes are the primary
vehicle braking system.
Engine Braking
Since the engine brake is most effective at rated en-
The engine brake switch controls the degree of engine speed, gear selection is very important. Gearing
gine braking. Normally there are two paddle down the vehicle, within the limits of the rated engine
switches, a two-position On/Off Switch to activate the
engine brake, and a two-position HI-LO Switch to
control the amount of engine braking.
7.14
Engines
speed, makes the engine brake more effective. Rec- Use the dash-mounted switch set at the LO
ommended engine braking speed is above 1800 rpm position when driving on flat, open stretches of
and below the rated speed. road. If the service brakes are still required to
slow down on a grade, switch to a higher set-
WARNING ting on the dash switch, until there is no need
for the service brakes. Grade descent speed
The engine brake must be disengaged when should be such that the service brakes are
shifting gears using the clutch pedal. If the en- used infrequently and that they remain cool,
gine brake is engaged when the transmission is thus retaining their effectiveness.
in neutral, the braking power of the engine brake • For maximum retarding, maintain the top gov-
can stall the engine, which could result in loss of erned speed of the engine through the appro-
vehicle control, possibly causing personal injury priate selection of gears. When shifting gears,
and property damage. the engine brake will disengage when the
clutch pedal is depressed, then engage when
NOTICE the clutch pedal is released.
• To cancel the engine brake application, toggle
Do not allow the engine to exceed 2500 rpm. Se-
the ENG BRK switch OFF.
rious engine damage could result.
If the engine is equipped with both cruise control and
"Control speed" is the speed at which the engine
an engine brake, the engine brake can operate auto-
brake performs 100 percent of the required downhill
matically while in cruise control mode. If the cruise
braking, resulting in a constant speed of descent.
control/engine brake function is turned on in the
The control speed varies, depending on vehicle
DDEC VI system programming, the engine brake will
weight and the downhill grade.
come on "low" when the set road speed increases a
For faster descent, select a higher gear than that few miles-per-hour (kilometers-per-hour) above the
used for control speed. Service brakes must then be cruise set speed. The maximum amount of braking
used intermittently to prevent engine overspeed and (low, medium, high) is selected with the dash
to maintain desired vehicle speed. switches. When the vehicle returns to the set cruise
speed, the engine brake will turn off.
A driver may descend slower than control speed by
selecting a lower gear, being careful not to over- The engine brake will only operate when the accel-
speed the engine. Occasional deactivation of the en- erator pedal is fully released. Disengaging the clutch
gine brake may be necessary to maintain the desig- will prevent the engine brake from operating.
nated road speed under these conditions.
Vehicles equipped with antilock braking systems
Below a set engine temperature when the engine is (ABS) have the ability to turn the engine brake off if
cold, the brake may be disabled depending on the a wheel-slip condition is detected. The engine brake
brake type. will automatically turn itself back on once the wheel
slip is no longer detected. The DDEC VI system will
To activate the engine brake after the engine is deactivate the engine brake system when the engine
warmed up and the vehicle is in motion: speed falls below 1000 rpm or when the vehicle
• Remove your feet from both the clutch and slows down to a preset speed, depending on DDEC
throttle pedals. Press the dash-mounted ENG programming. This prevents stalling the engine.
BRK switch to toggle the engine brake ON.
The engine brake will engage at the rate last Exhaust Braking Systems
set on the brake intensity switch.
Exhaust Brake Switch
• Move the intensity switch to the desired inten-
sity. Depending on engine model, LO will pro- The optional exhaust brake is controlled by a dash-
vide 1/3 or 1/2 of the full braking capacity of mounted rocker switch to help slow the vehicle when
the engine. HI will provide maximum engine the accelerator is released.
braking.
7.15
Engines
To turn the exhaust brake on, press on the upper When only the exhaust brake is installed, a two-
part of the rocker (at the light inside the switch). The position switch on the dash controls the engine brak-
exhaust brake turns off automatically. See Fig. 7.18 ing system. The exhaust brake is only active when
or Fig. 7.19. the engine speed is between 1100 and 2700 rpm.
Depressing the accelerator or clutch pedal deacti-
vates the exhaust brake. The ABS system, when ac-
tive, also deactivates the exhaust brake.
The exhaust brake is a butterfly valve mounted in the
exhaust pipe. When the driver’s foot is not on the
accelerator pedal and the upper half of the exhaust
brake switch is pressed in, with the amber light on
the switch illuminated, an air cylinder shuts the but-
terfly valve, which restricts the flow of exhaust gases
and retards the engine. This retarding action is car-
ried through the engine and drivetrain, slowing the
vehicle and reducing the need for frequent service
11/28/2001 f610589 brake applications.
Fig. 7.18, Exhaust Brake Switch Exhaust brakes are not intended for use as the pri-
mary braking system during vehicle operation.
Operating Characteristics
WARNING
Do not use the exhaust brake when driving on
slippery or low-traction road surfaces. Failure to
follow this precaution could result in a loss of
vehicle control and possible personal injury or
property damage.
Before starting the engine, make sure that the lower
03/31/2009 f610589a
half of the exhaust brake switch is pressed in and
Fig. 7.19, Exhaust Brake Switch
the amber light is not illuminated. Do not turn the ex-
haust brake on until the engine has reached normal
When the exhaust brake switch is on, an amber LED operating temperatures.
illuminates inside the switch. When the panel lights When you remove your feet from both the accelera-
are on, the EXHST BRK legend is backlit in green. tor and clutch pedals and the upper half of the ex-
haust brake switch is pressed in with the amber light
Mercedes-Benz Exhaust Brake illuminated, the exhaust brake is applied. The follow-
An exhaust brake is an optional auxiliary braking sys- ing conditions should exist if the brake is operating
tem that assists but does not replace the service properly:
brake system. The exhaust brake can be used alone • A slight change in the sound of the engine may
or together with the constant-throttle valves for steep be noticed when the exhaust brake is applied.
or long grades. The exhaust brake switch located on
the control panel, in combination with the accelerator • Exhaust smoke should appear normal.
and clutch pedals, allows the driver to make maxi- • Engine temperature should remain in the nor-
mum use of the exhaust brake in off-highway and mal operating range.
mountain driving as well as in traffic or high-speed
highway driving. • Road speed usually decreases when the ex-
haust brake is applied during a descent. When
the vehicle is carrying a heavy load or the
7.16
Engines
grade is extremely steep, you may need to Pacbrake Operation (Caterpillar)

apply the service brakes occasionally.
The Pacbrake is controlled by the exhaust brake
• Do not expect a retarding effect similar to sud- switch and the throttle pedal. All applications are ad-
den hard application of the service brakes. The ditionally affected, controlled, or governed by engine
exhaust brake retards the vehicle with a speed through transmission gear selection. The Alli-
smooth braking effect. son MD3060 transmission has automatic downshift-
• During a descent, the tachometer usually ing when the exhaust brake is requested. See the
shows a drop in rpm, depending on the grade information on the "Allison World Transmission" later
and the vehicle load. in this chapter.
• Depending on the grade and vehicle load, you On some applications, when the Pacbrake is in use,
may or may not feel the retarding force acting it may be necessary to check that the cruise control
against your body when the brake is applied. is not set and that the throttle is in the idle position.
The retarding force of the brake may not al- On some applications, the engine, transmission,
ways be noticed, but it is actually preventing cruise control, and the Pacbrake exhaust brake may
the vehicle from going much faster. electronically interact with each other, which auto-
Make sure the exhaust brake is turned off before matically operates their functions. Following are
shutting down the engine. some examples of the programmed options that may
be available with the cruise control in the on position:
Driving Downhill • The coast mode engages the Pacbrake when
While approaching a steep grade, make sure that the the service brake is applied and disengages
upper half of the exhaust brake switch is pressed in, when the service brake is released.
with the amber light illuminated. The exhaust brake • The latch mode engages the Pacbrake when
comes on as soon as you remove your foot from the the service brake is applied and the Pacbrake
accelerator pedal. While going down the grade, use remains on after the service brake is released.
a low enough gear to safely descend with a minimum The Pacbrake is disengaged when another
application of the service brakes. As a general guide- input (depressing the throttle or clutch, engine
line, use the same gear as you would to ascend the speed drops below 800 rpm, or the exhaust
hill. brake switch is turned off) is supplied.
• The manual mode does not require the cruise
NOTICE control switch to be on, and operates the
Pacbrake manually at the driver’s discretion.
Do not allow the engine to exceed its governed
speed, or serious engine damage could result. The amount of braking power the engine will develop
is related to the speed (rpm) of the engine. The
Apply the service brakes to reduce the engine rpm or higher the engine rpm, the greater the retarding
make a slower descent by using a lower gear. power.
Pacbrake® Exhaust Brake Certain conditions may require that the transmission
be downshifted in order to generate adequate rpm
The Pacbrake exhaust brake is intended as a for the amount of retarding power required. Pacbrake
supplement to the service brakes and will not bring exhaust brakes are designed and approved for safe
the vehicle to a complete stop. The Pacbrake will use at 300 rpm above the engine’s maximum gov-
assist in the control or reduction of road speed in erned rpm. Refer to individual engine manufacturer’s
conjunction with, or independent of, the service specifications.
brakes. The amount of retarding or braking force is
controlled by the driver. The Pacbrake will function best if it is used all of the
time. However, if the vehicle is used inconsistently or
seasonally, it may be necessary to perform a preven-
tive maintenance procedure.
7.17
Engines
1. With the engine shut down, use any oil-free or and/or slow the vehicle sufficiently that the transmis-
nonpetroleum-based high-heat lubricant, and sion will automatically downshift, if necessary, to Alli-
spray or coat a sufficient amount on the restricter son’s preselect mode.
valve shaft and the attaching locations at each
The preselect mode is normally assigned to second
end of the actuation cylinder. See Fig. 7.20.
gear; however, the transmission can be repro-
grammed by an Allison Transmission Distributor to
A third or fourth gear, should the operator desire. If ad-
A
ditional retarding power is required before the auto-
A matic downshifting occurs, you can select a lower
transmission gear on the Allison shift selector.
03/06/2000 f490228
A. Lubrication Point
Fig. 7.20, Pacbrake Exhaust Brake and Air Cylinder
2. With your hands or a pair of pliers, motion the

valve several times to distribute the lubricant
down the shaft and the attaching locations.
NOTE: Starting the engine and idling for short
periods of time is not recommended. During a
cold engine start-up, enough moisture is devel-
oped within the engine and the exhaust system
to create a corrosion hazard that could affect
the future operation of the Pacbrake. The brake
housing may trap water in the valve shaft bore
causing corrosion in an improperly functioning
or nonfunctioning brake. If it is necessary to pe-
riodically start the engine, it is recommended
that normal operating temperatures be attained
before shutting down the engine.
Allison World Transmission
Pacbrake exhaust brakes on engines that are used
with the Allison World Transmission MD series, are
interfaced with the transmission electronic control
module (ECM). An exhaust-brake-enabled transmis-
sion ECM will usually provide converter lockup in
gears two through six. Effective exhaust braking be-
gins when the transmission automatically downshifts
into fifth gear (62 mph or less). Once on, the
Pacbrake exhaust brake will control road speed
7.18
8
Drivetrain
Clutches . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.1
Allison On-Highway Transmissions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.3
Allison MD Series . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.5
Eaton® Fuller® Straight-Shift Transmissions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.8
Eaton Fuller Range-Shift Transmissions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.9
Eaton Fuller AutoShift™ . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.12
Freightliner SmartShift Shift Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.15
Eaton Fuller UltraShift . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.15
Mercedes-Benz Manual Transmissions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.22
Mercedes-Benz Automated Transmissions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.22
Meritor™ Drive Axles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.26
Drivetrain
Clutches Holding the Vehicle on an Incline With a

Slipping Clutch
Clutch Operation
A slipping clutch accumulates heat faster than it can
Applying the Clutch Brake be dissipated, resulting in early clutch failures. Never
The purpose of the clutch brake is to stop the trans- use the clutch to hold a vehicle on a hill.
mission gears from rotating in order to engage the
transmission gears quickly in making an initial start.
Coasting With the Clutch Released
To apply the clutch brake, put the transmission in (pedal down) and the Transmission in
neutral and press the clutch pedal to the floor. Gear
CAUTION WARNING
Never apply the clutch brake while the vehicle is Do not coast with the clutch released (pedal de-
moving. The clutch pedal should never be pressed) and the transmission in gear. High
pressed down fully before putting the transmis- driven-disc rpm could cause the clutch facing to
sion in neutral. Considerable heat will be gener- be thrown off the disc. Flying debris could cause
ated, which will be detrimental to the friction injury to persons in the cab.
discs, release bearings, and transmission front If the transmission remains in a low gear and the ve-
bearings. hicle gains speed, as may occur on a downgrade,
Applying the clutch brake with the transmission still in the input shaft and clutch driven disc will turn at
gear puts a reverse load on the gear. At the same speeds that are higher than normal. This occurs be-
time, it will have the effect of trying to stop or decel- cause the rear wheels and the driveline become the
erate the vehicle with the clutch brake. Rapid wear of input for the transmission, and a higher-than-normal
friction discs will take place necessitating frequent re- speed for a given transmission gear translates to a
placement. higher rpm value for the clutch driven disc.
Clutch driven discs are designed to allow for some
Vehicle Overload, or Overloading the amount of excess rotational speed, but the facing
Clutch has a limited burst strength. If the clutch driven disc
rpm increases too much, the clutch facing can be
CAUTION thrown off the disc(s).
Overloading will not only result in damage to the Engaging the Clutch While Coasting
clutch, but also to the entire powertrain.
Engaging the clutch while coasting can result in tre-
Clutches are designed for specific vehicle applica- mendous shock loads and possible damage to the
tions and loads. These limitations should not be ex- clutch as well as to the entire drivetrain.
ceeded.
Report Erratic Clutch Operation Promptly
Riding the Clutch Pedal
Reporting erratic clutch operation as soon as pos-
Riding the clutch pedal is destructive to the clutch. sible will give maintenance personnel a chance to
Partial clutch engagement permits slippage, and gen- inspect the clutch components.
erates excessive heat. Riding the clutch pedal will
also put a constant thrust load on the release bear- CAUTION
ing, which can thin out the lubricant. Release bearing
failures can be attributed to this type of misuse. Operating the vehicle with incorrect clutch pedal
free-travel could result in clutch damage. See
Group 25 of the Business Class® M2 Workshop
Manual for free-pedal adjustment procedures and
specifications.
8.1
Drivetrain
On mechanical clutch linkages, free-pedal travel Clutch Lubrication

should be included and commented on daily in the
driver’s report, since clutch free-pedal travel is the The release bearing should be lubricated at frequent
best guide to the condition of the clutch and the re- intervals. See Group 25 of the Business Class® M2
lease mechanism. Maintenance Manual for intervals and procedures.
Clutch Wear CAUTION

The major reason clutches wear out too soon is ex-
Failure to lubricate the release bearing as recom-
cessive heat. Clutches are designed to absorb and
mended could result in release bearing damage
dissipate more heat than encountered in typical op-
and damage to the clutch.
eration. The temperatures developed in typical op-
eration will not break down the clutch friction sur- NOTE: The Sachs hydraulic clutch does not re-
faces. However, if a clutch is slipped excessively or quire lubrication of the release bearing.
required to do the job of a fluid coupling, high tem-
peratures develop quickly and destroy the clutch. Sachs Hydraulic Clutch
Temperatures generated between the flywheel,
driven discs, and pressure plates can be high The Sachs hydraulic clutch is a 14.5-inch (365 mm)
enough to cause the metal to flow and the friction push-type clutch that is used with the Mercedes-
facing material to char and burn. Benz medium-duty transmissions, models MBT520
and MBT660.
CAUTION NOTE: All Mercedes-Benz transmission models
require a hydraulic clutch system. For more in-
Do not allow sustained slippage of the clutch; formation on the Mercedes-Benz transmissions,
this could severely damage the clutch disc, pres-
sure plate, or flywheel. Damage caused by clutch
see under the heading "Mercedes-Benz Manual
slippage due to improper break-in is not warrant- Transmissions."
able. The clutch hydraulic system consists of three main
Slipping and excessive heat are practically nonexist- components:
ent when a clutch is fully engaged. But during the • A pedal unit, including the pedal, master cylin-
moment of engagement, when the clutch is picking der and fluid reservoir,
up the load, it generates considerable heat. An incor-
rectly adjusted or slipping clutch will rapidly generate • A slave cylinder at the clutch,
sufficient heat to destroy itself. • A hydraulic hose that connects the master and
The most important items that a driver should be slave cylinders.
aware of to ensure long service life of the clutch in- Keep the clutch fluid reservoir full to the MAX mark.
clude: starting in the right gear, recognizing clutch If fluid level falls below the MIN mark, have the hy-
malfunctions, and knowing when to adjust a clutch. draulic system checked for leaks at an authorized
Freightliner service facility. Use only DOT 4 brake
Clutch Adjustments fluid to fill the reservoir.
Some clutches have an internal adjustment. See the The hydraulic clutch provides smooth, quiet, and reli-
applicable section in Group 25 of the Business able clutch actuation with a minimum of mainte-
Class® M2 Workshop Manual for clutch adjustment nance.
procedures and specifications.
Pressure builds up in the master cylinder when the
clutch pedal is pressed. This pressure is transmitted
CAUTION through the brake fluid in the hose to the slave cylin-
der, where it acts directly on the clutch release fork.
Operating the vehicle with the clutch incorrectly
adjusted could result in clutch or clutch brake
failure.
8.2
Drivetrain
Allison On-Highway 6. Chock the rear tires and take any other steps
necessary to keep the vehicle from moving.
Transmissions
2000 Series
The Allison on-highway transmissions are fully auto-
matic and include the 1000 Series™, 2000 Series™, On vehicles with Allison 2000 series transmissions,
and 2400 Series™. Refer to the Allison website for do the following steps if you have to leave the cab
additional information, www.allisontransmission- with the engine running (for example, when checking
.com. the transmission fluid):
Safety Precautions Without Auto-Apply Parking Brake

Follow the instructions for vehicles with 1000 series
WARNING transmissions, under the heading "Without Park Posi-
tion."
Do not leave the vehicle unattended with the en-
gine running. If you leave the vehicle and the en- With Auto-Apply Parking Brake
gine is running, the vehicle can move suddenly, 1. Bring the vehicle to a complete stop using the
which could result in personal injury or property service brake.
damage.
2. Ensure that the engine is at low idle rpm.
1000 Series 3. Put the transmission in PB (auto-apply parking
On vehicles with Allison 1000 series transmissions, brake).
do the following steps if you have to leave the cab 4. Apply the parking brake (if equipped), and make
with the engine running (for example, when checking sure it is properly engaged.
the transmission fluid):
5. Chock the rear tires and take any other steps
Without Park Position necessary to keep the vehicle from moving.
1. Bring the vehicle to a complete stop using the 2400 Series
service brake.
On vehicles with 2400 series transmissions, follow
2. Ensure that the engine is at low idle rpm. the instructions for vehicles with 1000 series trans-
3. Put the transmission in neutral. missions.
4. Apply the parking brake, and make sure it is
properly engaged.
Range Inhibit Indicator, 2000 and
2400 Series
5. Chock the rear tires and take any other steps
necessary to keep the vehicle from moving. A RANGE INHIBIT indicator is a standard feature of
the 2000 series and 2400 series transmissions. The
With Park Position RANGE INHIBIT indicator comes on to alert the
driver that transmission operation is being inhibited
1. Bring the vehicle to a complete stop using the and that the range shifts being requested by the
service brake. driver may not occur. When certain operating condi-
2. Ensure that the engine is at low idle rpm. tions are detected by the TCM (transmission control
module), the controls will lock the transmission in the
3. Put the transmission in P (park). current operating range.
4. Apply the parking brake (if equipped), and make Shift inhibits occur under the following conditions:
sure it is properly engaged.
• Shifts from neutral to reverse or from neutral to
5. Engage the park range by slowly releasing the a forward range when the engine is above idle,
service brake. greater than 900 rpm.
8.3
Drivetrain
• Forward/reverse directional shifts are typically Do not idle in reverse for more than 5 minutes. Se-
not permitted if appreciable output shaft speed lect P (park), PB (auto-apply parking brake), or N
is detected. (neutral) when time at idle exceeds 5 minutes.
• When some types of unusual transmission op- NOTE: The shift into reverse may not succeed if
erating conditions are detected by the TCM, a range inhibitor is active. Check for illumination
the TCM temporarily limits transmission opera- of the RANGE INHIBIT indicator.
tion until the vehicle can be driven to a service
location. When this type of situation is de- N (Neutral)
tected, the TCM will lock the transmission in a
safe gear range. The neutral position places the transmission in neu-
tral. This position is used when starting the engine
• The TCM will prevent shifts from park or neu- and for stationary operation.
tral to range when auxiliary equipment, such as
a power takeoff unit (PTO), is in operation.
WARNING
Operating Instructions, On-Highway Failure to apply the vehicle parking brakes when
Transmissions the transmission is in neutral may allow the ve-
hicle to move unexpectedly, possibly causing
Allison automatic transmissions are electronically
property damage or personal injury.
controlled. The shift selector provides five or six for-
ward ranges and one reverse range. When neutral is selected, the vehicle service brakes,
parking brake, or emergency brake must be applied.
P (Park, optional on 1000 and 2400 Selecting neutral does not apply vehicle brakes un-
Series) less an auxiliary system to apply the parking brake is
installed.
Use park when turning the engine on or off, to check
vehicle accessories, to operate the engine in idle for
longer than 5 minutes, and for stationary operation of WARNING
the power takeoff, if equipped. This position places
the transmission in neutral and engages the park Do not coast in neutral. Coasting in neutral can
pawl of the transmission. cause an accident, possibly resulting in severe
personal injury or death.
NOTE: This does not apply the parking brake.
Do not let the vehicle coast in neutral. If the vehicle
PB (Auto-Apply Parking Brake, optional is allowed to coast in neutral, the engine brake will
not work and you could lose control of the vehicle.
on 2000 Series)
The auto-apply parking brake places the transmis- CAUTION
sion in neutral and applies the parking brake.
Coasting in neutral can cause severe transmis-
R (Reverse) sion damage.
Reverse is used to back the vehicle. When the selec-
tor is in reverse, the reverse warning signal will
D (Drive)
sound. Always bring the vehicle to a complete stop
before shifting from a forward range to reverse, or WARNING
from reverse to a forward range.
When going downhill, use a combination of
downshifting, braking, and other retarding de-
CAUTION vices to control vehicle speed and the engine’s
rated governed speed. Failure to do so could re-
Extended idling in reverse may cause transmis-
duce vehicle braking, possibly causing loss of
sion overheating and damage.
vehicle control and resulting in personal injury or
property damage.
8.4
Drivetrain
In the drive position, the transmission will initially go

into first range when drive is selected. As vehicle
Allison MD Series
speed increases, the transmission will upshift auto- Refer to the Allison website for additional information,
matically through each available range up to fourth www.allisontransmission.com.
range or fifth range. As the vehicle slows, the trans-
mission will downshift automatically. Safety Precautions
When going downhill, downshift to a lower transmis-
sion range to increase engine braking and to help WARNING
maintain control. The transmission has a feature to
prevent automatic upshifting above the lower range Do not leave the vehicle unattended with the en-
selected. However, during downhill operation, the gine running. If you leave the vehicle and the en-
transmission may upshift to the next higher range, if gine is running, the vehicle can move suddenly,
the engine is exceeding its governed speed in the which could result in personal injury or property
lower range. damage.
On vehicles with MD series transmissions, do the
CAUTION following steps if you have to leave the cab with the
engine running (for example, when checking the
Do not idle in drive for more than 5 minutes. Ex- transmission fluid):
tended idling in drive may cause transmission
overheating and damage. Always select PB (auto- 1. Bring the vehicle to a complete stop using the
apply parking brake) or P (park) if time at idle is service brake.
longer than 5 minutes. 2. Put the transmission in N (neutral).
NOTE: The shift into drive may not succeed if a 3. Ensure that the engine is at low idle (500 to 800
range inhibitor is active. Check for illumination rpm).
of the RANGE INHIBIT indicator.
4. Apply the parking brake and emergency brakes,
4 and 3 (Fourth and Third Ranges, and make sure they are properly engaged.
optional) 5. Chock the rear tires and take any other steps
necessary to keep the vehicle from moving.
Use the fourth or third range for city traffic and for
braking on steep downgrades. Operating Instructions, MD Series
3 and 2 (Third and Second Ranges, The Allison MD transmission is electronically con-
standard) trolled and comes with a push-button shift control
that provides five or six forward ranges and one re-
Use the third or second range for heavy city traffic verse range. The push-button shift selector has an R
and for braking on steeper downgrades. (reverse), an N (neutral), a D (drive), an up arrow, a
down arrow, a mode button, and a digital display.
1 (First Range)
New shift controls — known as "fourth generation" —
Use first range when pulling through mud or deep were introduced in mid-2006. They replaced the pre-
snow, when maneuvering in tight spaces, or when vious units that are commonly referred to as "WTEC
driving up or down very steep grades. First range III". See Fig. 8.1 and Fig. 8.2.
provides the vehicle with its maximum driving torque
and maximum engine braking effect. R (Reverse)
NOTE: To have the transmission select these Press the R button to select reverse. The digital dis-
ranges automatically, leave the selector lever in play will show R when reverse is selected. Always
D (drive). bring the vehicle to a complete stop and let the en-
gine return to idle before shifting from a forward
range to reverse, or from reverse to a forward range.
8.5
Drivetrain
NOTE: The shift into reverse may not succeed if

1
a range inhibitor is active. When reverse is se-
2 lected, always be sure that R is not flashing.
3
N (Neutral)
R WARNING
4
N
When starting the engine, make sure that the ser-
D vice brakes are applied. Failure to apply the ser-
vice brakes may result in unexpected vehicle
movement, which could cause severe personal
injury or death. Failure to apply the vehicle park-
07/27/2006 f270113
ing brakes when the transmission is in neutral
1. Digital Display 3. Mode Indicator LED may allow the vehicle to move unexpectedly, pos-
2. Mode Identification 4. Mode Button sibly causing property damage or personal injury.
Label
Press the N button to select neutral. The digital dis-
play will display N when neutral is selected. It is not
Fig. 8.1, WTEC III Push-Button Shift Selector
necessary to press neutral before starting the ve-
hicle. The ECU (electronic control unit) or TCM
(transmission control module) automatically places
the transmission in neutral at start-up.
1
2 WARNING
3 Failure to apply the vehicle parking brakes when
4 the transmission is in neutral may allow the ve-
hicle to move unexpectedly, possibly causing
property damage or personal injury.
When neutral is selected, the vehicle service brakes,
parking brake, or emergency brake must be applied.
Selecting neutral does not apply vehicle brakes un-
less an auxiliary system to apply the parking brake is
installed.
07/27/2006 f610804
1. Digital Display 3. Mode Indicator LED WARNING
2. Mode Identification 4. Mode Button
Label Do not coast in neutral. Coasting in neutral can
cause an accident, possibly resulting in severe
personal injury or death.
Fig. 8.2, Fourth Generation Push-Button Shift Selector
Do not let the vehicle coast in neutral. If the vehicle
is allowed to coast in neutral, the engine brake will
CAUTION not work and you could lose control of the vehicle.
Extended idling in reverse may cause transmis- Always select neutral before turning off the engine.
sion overheating and damage. Neutral is also used during stationary operation of
the power takeoff if your vehicle is equipped with a
Do not idle in reverse for more than 5 minutes. Se-
PTO.
lect neutral when time at idle exceeds 5 minutes.
8.6
Drivetrain
D (Drive) engine governed speed is exceeded in the lower

range, the transmission may upshift to the next
When the D button is pushed, the highest forward higher range.
range will appear in the display. The transmission will
normally go into first range when drive is selected 1 (First Range)
(except for those units programmed to start in sec-
ond range). As vehicle speed increases, the trans- Use the first range when pulling through mud or
mission will upshift automatically through each range. deep snow, when maneuvering in tight spaces, or
As the vehicle slows, the transmission will downshift when driving up or down steep grades. First range
automatically. provides the vehicle with its maximum driving torque
and maximum engine braking effect. Push the down
arrow until the first range appears on the display.
CAUTION
Do not idle in drive for more than 5 minutes. Ex-
Up and Down Arrows
tended idling in drive may cause transmission When a lower range is desired, after D has been
overheating and damage. Always select neutral if pressed, press the down arrow until the desired
time at idle is longer than 5 minutes. range is shown on the display. Pressing the down
arrow continuously causes the range position to con-
NOTE: The shift into drive may not succeed if a tinue to go down until the button is released or the
range inhibitor is active. When drive is selected, lowest range is attained.
always be sure that D is not flashing.
When the transmission is in drive and the down
5, 4, 3, and 2 (Fifth, Fourth, Third, and arrow has the transmission in a lower range position,
Second Ranges) press the up arrow to shift to a higher selector posi-
tion. Pressing the up arrow continuously causes the
Occasionally, road conditions, load, or traffic condi- range position to continue to rise until the button is
tions will make it desirable to restrict automatic shift- released or the highest available position is attained.
ing to a lower range. Lower ranges provide greater
braking for going down grades. The lower the range, Pressing the up or down arrows does not override
the greater the braking effect. the transmission automatic shifting operation. If a
higher or lower position is selected, the transmission
Push the up or down arrows on the push-button shift continues shifting through the ranges according to
selector to select individual forward ranges. The digi- the vehicle operating characteristics until the highest
tal display will display your choice of range. When a or lowest selected position is reached.
lower range is selected, the transmission may not
downshift until the vehicle speed or engine RPM (en- Mode Button
gine governed speed) is reduced.
The MODE button starts a specialized input or output
function that has been previously programmed into
WARNING the ECU or TCM. Pressing the MODE button
changes transmission operation for a specific func-
When going downhill, use a combination of tion.
downshifting, braking, and other retarding de-
vices to control vehicle speed and the engine’s Mode Indicator LED
rated governed speed. Failure to do so could re-
duce vehicle braking, possibly causing loss of When the MODE button is pressed, the mode indica-
vehicle control and resulting in personal injury or tor LED illuminates. A mode identification label, lo-
property damage. cated above the MODE button, identifies the function
associated with a mode change.
When going downhill, downshift to a lower transmis-
sion range to increase engine braking and to help
maintain control. The transmission has a feature to
prevent automatic upshifting above the lower range
selected. However, during downhill operation, if the
8.7
Drivetrain
Digital Display General Information, Straight-Shift

The dual digital display shows both the selected Eaton Fuller 5-speed FS models are fully synchro-
range (SELECT) and actual range attained (MONI- nized. They have five forward speeds and one re-
TOR). The single digital display shows the selected verse. See Fig. 8.3 for the shift pattern.
range.
Oil Level Sensor

Allison MD Series transmissions have an electronic R 2 4
oil level sensor to read fluid level information. The
fluid level diagnostic will display whether the oil level N
is OK, too low, or too high. It will also display a de-
fault code and indicate if the preconditions (of receiv-
ing the fluid level information) are not met. 1 3 5
IMPORTANT: Maintain the the proper fluid level
05/21/2008 f261049
at all times. If the fluid level is too low, the con-
verter and clutch do not receive an adequate Fig. 8.3, Shift Pattern, 5-Speed FS Models
supply of fluid. If the level is too high, the trans-
mission may shift erratically or overheat. Eaton Fuller 6-speed FS and FSO models are fully
synchronized. They have six forward speeds and one
To access the oil level display mode, park the vehicle reverse. See Fig. 8.4 for the shift pattern.
on a level surface, shift to N (Neutral), apply the
parking brake, and idle the engine. Then simulta-
neously press both the up and down arrows once.
The oil level will display at the end of a two-minute
countdown.
R 1 3 5
Diagnostic Codes N
Diagnostic codes are numerical indications relating to
a malfunction in transmission operation. These codes 2 4 6
are logged in the TCM/ECU memory. The most se-
vere or most recent code is listed first. A maximum of 05/21/2008 f261048
five codes (numbered d1-d5) may be listed in
memory at one time. If the mode indicator LED is Fig. 8.4, Shift Pattern, 6-Speed FS and FSO Models
illuminated, the displayed code is active. If it is not
illuminated, the displayed code is not active. Eaton Fuller 7-speed T models are not synchronized.
They have seven forward speeds and one reverse.
NOTE: During normal operation, an illuminated See Fig. 8.5 for the shift pattern.
mode indicator LED signifies the specialized
mode operation is in use. These transmissions are designed for use with on-
highway, fuel economy engines where a minimum of
To enter diagnostics mode, first park the vehicle and shifting is desired and less gear reduction is accept-
apply the parking brake. Then simultaneously press able.
both the up and down arrows twice.
Operation, Straight-Shift
Eaton® Fuller® Straight-Shift 1. Always use first gear when starting to move the
Transmissions vehicle forward.
Refer to the Eaton website for additional information, IMPORTANT: Do not rest your foot on the clutch
www.roadranger.com. pedal while driving. This causes partial clutch
8.8
Drivetrain
4.2 On synchronized models, disengage the

clutch and move the shift lever to the next
6 lower gear.
R 2 4
On unsynchronized models, disengage the
clutch and move the shift lever to neutral.
N Engage the clutch again. With the shift
lever in neutral, disengage the clutch and
1 3 5 move the shift lever to the next lowest
7 gear.
05/21/2008 f261051 4.3 Engage the clutch smoothly.
Fig. 8.5, Shift Pattern, 7-Speed T Models 4.4 Use the sequence described above to
shift progressively down through each
disengagement which could cause premature successive lower gear, as driving condi-
clutch wear. tions require.
2. On synchronized models, press the clutch pedal
to the floor when shifting gears. Double-clutching Eaton Fuller Range-Shift
is unnecessary. Transmissions
On unsynchronized models, press the clutch Refer to the Eaton website for additional information,
pedal to the floor to contact the clutch brake only www.roadranger.com.
when engaging the first or reverse gears.
NOTE: If the vehicle is moving when shifting, General Information, Range-Shift
press the clutch pedal just far enough to disen- Eaton Fuller 9-Speed Models
gage the clutch. Pressing it to the floor will en-
gage the clutch brake, if so equipped, causing Eaton Fuller 9-speed range-shift models are not syn-
premature clutch brake wear. chronized. They have nine forward speeds and two
reverse speeds. The shift lever controls five forward
3. To upshift, do the following steps: gears and one reverse gear in the transmission front
3.1 Accelerate to engine governed speed. section, and the range lever controls a LO and HI
range in the two-speed auxiliary section. The first
3.2 On synchronized models, disengage the position in the front section is used only as a starting
clutch and move the shift lever to second gear. The other four ratios are used once in LO
gear. range and once again in HI range. See Fig. 8.6 for
On unsynchronized models, disengage the the shift patterns.
clutch and move the shift lever to neutral. After shifting out of the first gear position, use the
Engage the clutch again. With the shift Roadranger® "repeat H" shift pattern. Select both LO
lever in neutral, disengage the clutch and range and HI range with the range lever (range
move the shift lever to second gear. knob). It is used once during the upshift sequence
3.3 Engage the clutch and note the drop in and once during the downshift sequence.
engine rpm before accelerating up to en- Always preselect the range shift. After preselection,
gine governed speed again. the transmission will automatically make the synchro-
3.4 Continue upshifting using the same se- nizer range shift as the shift lever passes through
quence described in the previous step. neutral.
Follow the pattern on the shift lever.
Eaton Fuller 10-Speed Models
4. To downshift, do the following steps:
Eaton Fuller 10-speed range-shift models are not
4.1 Wait until the engine speed drops to the synchronized. They have ten forward speeds and
rpm noted immediately after the upshift.
8.9
Drivetrain
HI
Eaton Fuller Shift Progressions
5 7
1 3 LO Range
LO Model HI Range
Off-Highway On-Highway
R R 5 7
A 1 3 1 3 R
N 9-Speed
Direct or
LOW 6 8
Overdrive 2 4 2 4
6 8 B f260322 f260323 f260324
LO
2 4 R R R
7 9
10-Speed 2 4 2 4
11/23/99 f261047 Direct or 6 8 10
Move the range lever up for HI range, down for LO Overdrive 1 3 5 1 3 5
f260329 f260329 f260330
range.
A. HI Range B. LO Range Table 8.1, Eaton Fuller Shift Progressions
Fig. 8.6, Shift Pattern, 9-Speed Models

When downshifting, the driver preselects the range
two reverse speeds. The shift lever controls five for- lever for LO range and the range shift occurs auto-
ward gears and one reverse gear in the transmission matically during the shift lever movement to the next
front section, and the range lever controls a LO and gear position.
HI range in the two-speed auxiliary section. The five
forward gears selected in LO range are used again Eaton Fuller Deep-Reduction Models
in HI range to provide the 10 progressive forward Eaton Fuller deep-reduction models are not synchro-
gears. See Fig. 8.7 for the shift patterns. See nized. They have a five-speed front section and a
Table 8.1 for the shift progressions. two-speed auxiliary section which has an extra deep
reduction gear. The LO gear in the front section is
HI 7 9 used only as a starting gear. The other four ratios
R are used once in LOW RANGE and once in HIGH
LO 2 4
RANGE giving eight highway ratios. LO-LO is se-
lected by the DEEP REDUCTION lever on the dash-
A board. See Fig. 8.8 for the shift pattern.
N
B R R 5 7
6 8 10
1 3 5 R 1 3
12/15/1999 f261053
N
A. HI Range B. LO Range
Fig. 8.7, Shift Pattern, 10-Speed Models LO 6 8

LO−LO 2 4
Once the highest shift lever position (fifth gear) is
03/12/96 f260123a
reached in LO range, the driver preselects the range
shift lever for HI range. The range shift occurs auto-
Fig. 8.8, Shift Pattern, Deep Reduction
matically as the shift lever is moved from fifth gear
position to the sixth gear position.
Operation, Range-Shift
1. When operating off-highway or under adverse
conditions, always use low gear when starting to
move the vehicle.
8.10
Drivetrain
When operating on-highway, with no load or 5. While in the top gear of the low-range shift pat-
under ideal conditions, use first gear when start- tern and ready for the next upshift, flip the range
ing to move the vehicle. preselection lever up into high range. Double-
For all conditions, use the highest gear that is clutch through neutral and shift into the bottom
gear in high range. As the shift lever passes
still low enough to start the vehicle moving with
through neutral, the transmission will automati-
the engine idling and without excessively slipping
cally shift from low range to high range.
the clutch.
6. With the transmission in high range, shift pro-
2. Use the clutch brake to stop gear rotation when
shifting into low (or first) or reverse when the ve- gressively up through each of the high range
hicle is stationary. The clutch brake is applied by gears, double-clutching between shifts.
pressing the clutch pedal all the way to the floor.
Downshifting
For normal upshifts and downshifts, only a partial
disengagement of the clutch is necessary to 1. With the transmission in high range, shift pro-
break engine torque. gressively down to the bottom gear in high
range, double-clutching between shifts.
3. Do not make range shifts with the vehicle moving
in reverse gear. 2. When in the bottom gear of the high-range shift
pattern and ready for the next downshift, push
4. Never attempt to move the range preselection the range preselection lever down into low range.
lever with the gear shift lever in neutral while the Double-clutch through neutral and shift into the
vehicle is moving. Preselection with the range top gear of the low-range shift pattern. As the
preselection lever must be made prior to moving shift lever passes through neutral, the transmis-
the shift lever out of gear into neutral. sion will automatically shift from high range to
5. Do not shift from high range to low range at high low range.
vehicle speeds. 3. With the transmission in low range, downshift
6. through the low range gears as conditions re-
Use double-clutching between all upshifts and
quire.
downshifts.
Never use the clutch brake when downshifting or
7. After your shifting ability improves, you may want
as a brake to slow the vehicle.
to skip some of the ratios. This may be done
only when operating conditions such as load,
grade, and road speed permit.
Operation, Deep-Reduction Models
Upshifting
Upshifting
1. Position the gear shift lever in neutral. See
1. Position the gear shift lever in neutral. Start the Fig. 8.8 for the shift pattern. Start the engine,
engine and bring the air system pressure up to and bring the air system pressure up to 95 to
100 to 120 psi (689 to 827 kPa). 125 psi (655 to 862 kPa).
2. Position the range preselection lever down into 2. Position the range preselection lever down, into
low range. low range.
3. Press the clutch pedal to the floor. Shift into low NOTE: If conditions are difficult, start out in LO-
or first gear, then engage the clutch with the en- LO. Move the DEEP REDUCTION lever on the
gine at or near idle speed to start the vehicle dashboard to the IN position. Otherwise start
moving. Accelerate to 80 percent of engine gov-
erned speed.
out in LO with the DEEP REDUCTION lever in
the OUT position.
4. Shift progressively up from low or 1st gear to the
top gear in low range, double-clutching between
shifts and accelerating to 80 percent of engine
governed speed.
8.11
Drivetrain
3. Depress the clutch pedal to the floor. Shift into gear position and the auxiliary section is in the
LO gear; then, engage the clutch, with the en- low range. Then, move the DEEP REDUCTION
gine at or near idle rpm to start the vehicle mov- lever on the dashboard to the IN position. Imme-
ing. The vehicle will start in LO or LO-LO de- diately release the accelerator, depress the
pending on the DEEP REDUCTION lever clutch pedal once to break torque, engage the
position. clutch, and accelerate. The auxiliary section will
automatically shift from LO to LO-LO when the
4. To upshift if in LO-LO, move the DEEP REDUC-
gears reach the same speed.
TION lever to the OUT position and immediately
release the accelerator, depress the clutch pedal
once to break torque, and reengage the clutch. CAUTION
The auxiliary section will shift from LO-LO to LO
when the gears reach the same speed. Never use the clutch brake when downshifting, or
as a brake to slow the vehicle. This will cause
5. Shift progressively upward from LO through 1st, premature clutch brake wear.
2nd, 3rd, and 4th gears while the range prese-
lection lever is in LO. Always double-clutch be-
tween gears. Eaton Fuller AutoShift™
6. When in 4th gear and ready for the next upshift, Refer to the Eaton website for additional information,
pull up the range preselection lever and move www.roadranger.com.
the shift lever, double-clutching, to the 5th gear IMPORTANT: Before starting the vehicle, always
position. As the shift lever passes through neu- do the following:
tral, the auxiliary section will automatically shift
from low to high range. • Be seated in the driver’s seat.
• Place the transmission in neutral.
CAUTION
• Set the parking brakes.
Never move the shift lever into the LO gear posi- • Press the clutch pedal (if equipped) down to
tion after high range preselection or anytime the the floor.
auxiliary section is in high range. Transmission
damage could result. The AutoShift ASW is an automated 6-speed Eaton
Fuller transmission. No clutch is necessary to oper-
7. Continue upshifting from 5th gear through 8th ate the vehicle.
gear, always double-clutching between gears.
The AutoShift AS2 is a partially automated 10-speed
Downshifting Eaton Fuller transmission. The driver must use the
clutch and put the transmission in neutral to start and
1. While in high range, move the gear shift lever stop the vehicle. A push-button shift selector
from 8th gear through 5th gear as conditions re- (Fig. 8.9) is used with AutoShift AS2 and ASW
quire, always double-clutching between gears. transmissions.
2. When in 5th gear and ready for the next down- IMPORTANT: If you have to leave the cab with
shift, push down the range preselection lever and
move the shift lever to the 4th gear position,
the engine running:
being sure to double-clutch. As the shift lever • Place the transmission in neutral.
passes through neutral, the auxiliary section will
automatically shift from high to low range. • Set the parking brakes.
3. While in the low range, continue downshifting • Chock the tires.

from 4th through LO as conditions require, al-
ways double-clutching between gears. Push-Button Shift Selector
4. Do not downshift into LO-LO from LO unless op- Gear information is presented to the driver on the
erating conditions make it necessary. If it is nec- push-button shift selector, usually mounted on the
essary, make sure that the shift lever is in the LO
8.12
Drivetrain
• To select low gear, press the LOW button.

When low is engaged, the telltale LED will light
up next to the LOW button.
10 1 • To change gears manually, press the MANUAL
button. When the manual mode is engaged,
the telltale LED will light up next to the
9
MANUAL button.
2
• Use the shift buttons (upshift/downshift) to
change the current starting gear selection in R,
D, and LOW. In MANUAL, the shift buttons can
3 be used to select gears.
• In automatic mode, the number of the forward
gear currently engaged appears continually on
8
4 the mode indicator when in drive. In MANUAL,
the last gear selected appears on the mode
indicator.
• If the SERVICE indicator illuminates, take the
5
vehicle as soon as possible to an authorized
7 Freightliner service facility.
• The mode button is reserved for future use.
6
IMPORTANT: To prevent engine overspeed, the
transmission software will override both
MANUAL and LOW if necessary. The system
will not respond to gear selection requests that
will either overspeed or excessively lug the
engine.
11/14/2001 f261145
1. Not Used 7. Upshift/Downshift Automatic Mode
2. R (reverse) Arrows
3. N (neutral) 8. SERVICE Light The AutoShift AS2 transmission is normally operated
4. D (drive) 9. Mode Indicator in an automatic mode. To select MANUAL mode,
5. MANUAL Mode 10. Mode Button press the MANUAL button on the push-button shift
6. Low Gear Hold selector.
Fig. 8.9, Eaton Push-Button Shift Selector When the transmission is in automatic mode, the
transmission automatically selects and engages the
right-hand control panel. On this display, the informa- gears, although the transmission will respond to up-
tion is presented as follows: shift and downshift requests as though in manual
mode. See the instructions for shifting under heading
• To select neutral, press the N button. When
"Manual Mode" below.
neutral is engaged, the telltale LED will light up
next to the N button.
Manual Mode
• To select reverse, press the R button. When
reverse is engaged, the telltale LED will light When the transmission is in manual mode, the driver
up next to the R button. must select the appropriate gear, using the shift but-
tons on the push-button shift selector.
• To select drive, press the D button. When drive
is engaged, the telltale LED will light up next to
the D button.
8.13
Drivetrain
To upshift in MANUAL, press the upshift button (up NOTE: Neutral is always available during ve-
arrow), and release. The number of the gear will ap- hicle operation. When in neutral, requests to
pear on the mode indicator. If the requested gear is upshift or to downshift are ignored.
available, the transmission will shift up.
D (Drive)
CAUTION Drive (D) is used for normal highway driving. In drive,
the transmission shifts into the proper gear for start-
Do not attempt to upshift until the vehicle has
ing, and then automatically selects additional gears
reached a sufficient speed. The clutch absorbs
as needed, in a range between the starting gear and
the speed difference by generating heat, which
the highest gear.
causes the clutch to wear out too soon.
Many drivers upshift into the next gear or even skip- To select drive, press the clutch pedal to the floor.
shift into a higher gear before the vehicle has Then press the D button. Slowly release the clutch
reached the correct speed. This type of shifting is pedal and drive the vehicle.
almost as bad as starting off in a gear that is too To start up in a gear other than the normal starting
high. When the engine speed (rpm) and the vehicle gear, push the upshift arrow with D selected, and
speed (mph or km/h) are too far apart, the clutch while the vehicle is stopped.
must absorb the difference in speed by generating
heat. IMPORTANT: AutoShift will not start up in any
gear higher than third gear.
To downshift in MANUAL, press the downshift button
(down arrow), and release. The number of the gear The number of the gear selected will flash on the
will appear on the mode indicator. If the requested auxiliary display until the driver presses the clutch
gear is available, the transmission will shift down. pedal. This gear will be stored in memory as the de-
fault starting gear until a different starting gear is se-
If any requested gear is not available, an audible
lected by the driver, or until the engine is shut down.
warning will sound and the digital display will indicate
that the gear is not available. NOTE: The transmission may be programmed
so that it is not possible to select a starting gear
Selecting Gears other than the preprogrammed starting gear.
R (Reverse)
L (Low)
Reverse (R) is used to back the vehicle. Make sure
the vehicle comes to a full stop and the clutch pedal LOW is used to hold the transmission in low gear
has been pressed before shifting into reverse. when descending steep hills. If LOW is selected
when the vehicle is stopped, the transmission re-
To select reverse, press the clutch pedal to the floor. mains in low gear until drive is selected. If LOW is
Then press the R button. selected while the vehicle is moving, the transmis-
sion downshifts at a higher engine speed than nor-
N (Neutral) mal, in order to maximize the engine braking effect.
Neutral (N) is used for starting, parking, or any sta- To select LOW, press the clutch pedal to the floor.
tionary operation. No gear is selected. The transmis- Then press the LOW button. Slowly release the
sion must be in neutral to start the engine. clutch pedal and drive the vehicle.
IMPORTANT: If the vehicle starts up in any gear IMPORTANT: Before parking the vehicle, always
but neutral, bring the vehicle to an authorized do the following:
Freightliner service facility as soon as possible.
• Place the transmission in neutral.
To select neutral, press the clutch pedal to the floor.
• Set the parking brakes.
Then press the N button. Set the parking brakes and
slowly release the clutch pedal. • Chock the tires, if parking on an incline.
8.14
Drivetrain
Freightliner SmartShift Shift 5 6 7

Control 4 8
3
General Information, SmartShift
The SmartShift transmission control is an electronic
transmission control device. It is installed with the
9
following transmissions: 1
2
• Eaton Fuller UltraShift™ 10
11
• Mercedes-Benz Automated Gear Shift (AGS) 12
01/24/2003 f270120
It replaces the typical floor-mounted shift lever or
To upshift manually, pull the lever up (towards you). To
dash-mounted push button control.
downshift manually, push the lever down (away from
SmartShift accepts driver requests for transmission you).
functions and transmits them through hard wiring to 1. SmartShift Control Lever
the transmission control unit (TCU). SmartShift is a 2. Slide Switch (forward driving mode switch)
true shift-by-wire system. 3. MAN Mode (of slide switch)
4. AUTO Mode (of slide switch)
SmartShift offers two main advantages over conven- 5. Upshift Direction
tional transmission control devices. Without a floor- 6. Reverse Position (of selector switch)
mounted shift control, usable cab space is increased. 7. Selector Switch
The SmartShift control mounts to the right-hand side 8. Neutral Lock Button
of the steering column and is operated by the fingers 9. Neutral Position (of selector switch)
of the driver’s right hand, allowing both hands to re- 10. Drive Position (of selector switch)
main on the steering wheel. 11. Low Position (of selector switch)
12. Downshift Direction
A two-position slide switch (Fig. 8.10) is mounted on
the body of the control lever just before the paddle Fig. 8.10, SmartShift Control (with Eaton Fuller
widens out. The slide switch allows the driver to UltraShift)
choose automatic (AUTO) or manual (MAN) mode.
In AUTO mode, gears shift automatically, without
Eaton Fuller UltraShift
driver interaction. Manual gearshifts are accom- The Eaton® Fuller® UltraShift™ transmission uses the
plished by a momentary pull or push on the control in four-position SmartShift control lever on the steering
the plane perpendicular to the steering wheel. Pull column to change gears, combined with a gear indi-
upward (toward you) on the control to upshift and cator on the right-hand control panel as shown in
push downward (away from you) to downshift. The Fig. 8.12. All forward shifts can be made either
control is spring-loaded and returns to mid-position manually or automatically, at the driver’s choice. No
when released after an upshift or downshift. clutch pedal is required to operate the vehicle.
For Eaton Fuller UltraShift (Fig. 8.10), a four-position
(R, N, D, L) selector switch is located at the end of General Information, UltraShift ASW
the lever. For the Mercedes-Benz AGS (Fig. 8.11), a UltraShift ASW is a six-speed medium-duty fully au-
three-position (R, N, D) selector switch is located at tomated transmission used on the M106 only. Six-
the end of the lever. speed UltraShift ASW uses a "wet" clutch system in
Embedded in the selector switch is a small neutral which the drive and driven discs rotate in a bath of
lock button to prevent accidental shifts into gear from transmission fluid (Dexron III).
neutral. Any time you shift through N, press down on
the neutral lock button to move the switch from neu- General Information, UltraShift DM
tral (N) to another gear, such as drive (D), low (L), or
reverse (R). When shifting to N, it is not necessary to UltraShift DM is a ten-speed heavy-duty fully-
press the neutral lock button. automated transmission used on the M112 only. Ten-
speed UltraShift DM uses a dry clutch system which
8.15
Drivetrain
5
is offered only on this automated transmission sys-
6 tem.
7
4
3 8 Operation, UltraShift
Power Up
NOTE: These operating instructions apply
9
1 equally to six-speed UltraShift ASW and ten-
2
10 speed UltraShift DM, with the exceptions ex-
plained below.
11
11/11/2002 f270080 1. With the parking brake set, select neutral (N) by
To upshift manually, pull the lever up (towards you). To moving the selector switch to the N position.
downshift manually, push the lever down (away from 2. With the transmission in neutral, turn on the igni-
you).
tion switch. The "CHECK TRANS" and "TRANS
1. SmartShift Control Lever TEMP" telltale lights come on and go out again
2. Slide Switch
(bulb check). See Fig. 8.13.
3. MAN Position (of slide switch)
4. AUTO Position (of slide switch)
5. Upshift Direction 1 2
6. Reverse Position (of selector switch)
7. Selector Switch CHECK
8. Neutral Lock Button TRANS
9. Neutral Position (of selector switch) TRANS
10. Drive Position (of selector switch) TEMP
11. Downshift Direction
BRAKE
Fig. 8.11, SmartShift Control (with Mercedes-Benz AGS)
10/27/2003 f610677
2 1. "CHECK TRANS" Light
2. "TRANS TEMP" Light
Fig. 8.13, Telltale Lights, UltraShift Transmission
3. After the ignition is turned on, the current gear

indicator shows the dot display, arranged in a
square pattern. All dots in the pattern should light
up, without gaps or spaces. See Fig. 8.14.
4. Wait for the current gear indicator to show a solid
"N." When the "N" is solid, rather than flashing,
the UltraShift transmission control unit (TCU) is
10/13/2003 f270079
powered up. Apply the service brake and start
the engine.
To know what gear the transmission is in, look at the
current gear indicator. 5. Select drive (D) by pressing in the neutral lock
1. Gear Indicator button and moving the selector switch downward
2. SmartShift Control to the position below neutral. Release the park-
ing brake. The gear is displayed on the current
Fig. 8.12, Shift Controls and Indicators, UltraShift gear indicator.
Transmissions
8.16
Drivetrain
On steep hills, set the parking brake.

When parking, chock the tires, front and/or
rear. Never hold a hill with the throttle
pedal. This will cause the clutch to over-
heat.
Power Down
1. Apply the service brake.
2. Select neutral (N) by moving the selector switch
to the N position. When the "N" on the gear indi-
cator is solid, rather than flashing, the UltraShift
TCU is ready to power down. See Fig. 8.13.
10/13/2003 f610678 3. With the transmission in neutral, set the parking
brake.
Fig. 8.14, Power-Up Dot Display
4. Turn off the ignition key and shut down the en-
NOTE: When D is selected, the transmission gine.
controller starts up in second gear. On both six-
speed Ultrashift ASW and ten-speed Ultrashift Automatic and Manual Modes
DM, the driver can select to start up in first. No The SmartShift control has a slide switch located on
other start gear is available. the body of the control lever just before the paddle
widens out. See Fig. 8.15. The slide switch controls
6. On a level grade, release the service brake and the forward driving mode, automatic or manual.
press down on the throttle pedal to allow the ve-
hicle to move forward.
WARNING
When starting or stopping on hills and grades,
use extra care to prevent the vehicle from rolling
back. A rollback accident could cause death, seri-
ous personal injury, or property damage.
1 2
7. Prevent the vehicle from rolling backward when
stopped on a hill or grade, or when the vehicle is 3
starting from a stop on a hill or grade.
7.1 To start from a full stop on a hill or grade,
quickly move your foot from the brake
pedal and press firmly on the throttle
pedal.
01/21/2004 f270079c
On steep hills, set the parking brake and
release it only when there is enough en- 1. Slide Switch (controls forward driving mode)
2. Selector Switch (controls gear selection)
gine power to prevent rollback. 3. Neutral Lock Button (prevents accidental shift into
7.2 To stop on a hill or grade, press and hold gear)
the brake pedal to keep the vehicle from Fig. 8.15, Switches, Ultrashift Transmission
moving.
8.17
Drivetrain
To change mode at any time, move the slide switch shift if the engine speed is within 75 rpm of the load-
in the desired direction. This allows the driver to re- based shift point for that gear.
spond to a wide range of driving conditions, such as
If the driver presses down on the throttle pedal after
blind corners, tight curves, and steep hills.
a manual downshift in automatic mode, the transmis-
IMPORTANT: Whatever the mode, it is always sion will upshift again if the UltraShift TCU requires
possible to shift manually by moving the lever it.
up or down as needed. When the engine speed
is within 75 revolutions per minute (rpm) of the Manual Mode (MAN)
load-based shift point for an automatic shift, the In manual drive mode (MAN), upshifts and down-
UltraShift TCU will advance the shift. shifts are made by the driver:
In either mode, the gear indicator displays the cur- • To shift up, pull the lever up (towards you).
rent gear. See Fig. 8.16. • To shift down, push the lever down (away from
you).
The system will hold the current gear until the driver
requests a shift. In downhill situations in particular,
the driver must be alert to vehicle speed by down-
shifting and/or using the service brake.
A shift request will still be refused if the selected gear
would cause engine overspeed or excessive lugging.
Selecting Gears
Reverse
Reverse (R) is at the upper end of the four-position
selector switch located at the end of the SmartShift
10/13/2003 f610680 control lever. To select R, press in the neutral lock
NOTE: The gear indicator displays the current gear. In
button and move the selector switch upward to the
this example, it displays first gear. position above neutral.
Fig. 8.16, Current Gear Display Six-speed UltraShift ASW has one reverse gear.
When reverse is selected, the letter "R" displays on
At the start of a shift, the current gear continues to the gear indicator. See Fig. 8.17.
display until the transmission has been pulled into
neutral. At this point, as the transmission is synchro-
nizing for the new (target) gear, the gear indicator
flashes the number of the new gear.
When the shift is complete, the new gear displays
solid, without flashing.
Automatic Mode (AUTO)

In automatic drive mode (AUTO), upshifts and down-
shifts are made by the transmission without driver
intervention. Press in the neutral lock button, move
the selector switch to drive (D), and press down on
the throttle pedal. The transmission will shift auto-
matically.
10/14/2003 f610681
If driving conditions require, it is still possible to re-
quest a manual shift. The transmission will make the Fig. 8.17, Reverse Gear Display
8.18
Drivetrain
Ten-speed UltraShift DM has two reverse gears, re-

verse low and reverse high. To shift manually be- WARNING
tween them, use the shift lever as described for MAN
mode. There is no AUTO mode for reverse. Do not coast in neutral. Coasting in neutral can
When reverse low is selected, the letter "R" displays personal injury or death.
on the current gear indicator. When reverse high is
selected, the letter "H" displays on the current gear Neutral is always available during operation, what-
indicator. ever the vehicle speed. When in neutral, requests to
upshift or downshift are ignored. If the selector switch
IMPORTANT: Under normal conditions, do not is moved from neutral to drive while the vehicle is
select reverse with the vehicle moving forward. moving, the transmission will shift into a gear within
the engine’s operating speed range.
The vehicle must be moving at less than two miles
per hour (3 km/h) before selecting reverse. If reverse When shifting from neutral, always press on the
is selected when the vehicle is moving faster, an au- brake pedal. If the brake pedal is not pressed, the
dible alert will sound and continue sounding at three- transmission will not shift, the current gear display
second intervals until the control lever is returned to will flash "N," and an audible alert will sound.
the D position. When the vehicle is moving at the
proper speed, reverse can be engaged. NOTE: To reset the transmission, return the se-
lector switch on the SmartShift lever to N and
On ten-speed UltraShift DM only, if necessary to rock attempt the shift again, this time with the brake
the vehicle, use the selector switch to shift back and pedal pressed.
forth at low speed between reverse and drive.
Before shutting down the engine, return the selector
Neutral switch to "N." When the ignition is turned off, the
transmission will reset to neutral in a few minutes
IMPORTANT: Always start the engine with the regardless of the position of the shift lever.
transmission in neutral, the parking brake set,
and the service brakes applied. Drive
Neutral (N) is directly below R on the four-position Drive (D) is directly below N on the four-position se-
selector switch located at the end of the SmartShift lector switch located at the end of the SmartShift
control lever. To select N, move the selector switch to control lever. To select D, press in the neutral lock
the position below R. When neutral is selected, the button and move the selector switch to the position
letter "N" displays on the gear indicator. See below N. When drive is selected, the number of the
Fig. 8.18. currently selected forward gear (1 through 6 on six-
speed UltraShift ASW; 1 through 10 on ten-speed
UltraShift DM) displays on the gear indicator. See
Fig. 8.16.
When in drive, requests to upshift or downshift are
enabled. Either manual or automatic mode can be
selected on the slide switch.
Two starting gears are available, first and second.
The default starting gear is second, but first can be
selected by the driver, if desired. To change the start-
ing gear, press the brake pedal and select D with the
vehicle stopped. The current gear indicator will dis-
play the starting gear. Move the shift lever up or
down until the desired starting gear is displayed.
10/13/2003 f610679 The UltraShift TCU adapts to the working conditions
of each vehicle and its driver. After power-up or a
Fig. 8.18, Neutral Display load change, it needs to learn the new conditions.
8.19
Drivetrain
While learning, it may hold a gear too long before If the gear is available, the transmission downshifts
upshifting. Start the upshift manually. It may take and the new gear displays on the gear indicator. Skip
three or four shifts before UltraShift succeeds in shifts are available while downshifting.
learning the new load-based shift points, but after
For best engine braking, select low while moving. In
that it will handle the shifting automatically.
low, downshifts are performed at higher rpm than in
Low drive.
Low (L) is located at the lower end of the four- IMPORTANT: If the engine is approaching over-
position selector switch located at the end of the speed, the UltraShift TCU will override the cur-
SmartShift control lever. To select L, press in the rent gear setting and upshift to prevent engine
neutral lock button and move the selector switch to damage.
the position below D.
If the gear requested is unavailable, a tone will
When in low, the current gear is maintained. Re- sound. An unavailable request to downshift is not
quests to upshift are not enabled. stored in memory. The downshift must be requested
again.
IMPORTANT: If the engine is approaching over-
speed, the UltraShift TCU will override the cur- When coasting to a stop, the UltraShift TCU may not
rent gear setting and upshift to prevent engine finish the downshift until the driver presses down on
damage. the throttle pedal again.
To enhance engine braking, downshifts are per- IMPORTANT: A downshift request can never
formed at higher rpm than normal. result in a shift into neutral, even if the vehicle is
in the drive position in the lowest possible gear.
If L is selected from neutral while stopped, the ve-
hicle starts up in first gear and stays there until the Before starting down a hill, slow down. Downshift to
engine approaches overspeed. a speed that you can control without hard pressure
on the service brakes.
Upshifting
Before entering a curve, slow down to a safe speed.
To request an upshift with the transmission in drive, Downshift if necessary. This lets you use some
pull the control lever up (towards you). If the gear is power through the curve to help the vehicle be more
available, the transmission upshifts and the new gear stable on the turn. It also allows you to regain speed
displays on the gear indicator. No skip shifts are faster as you come out of the curve.
available while upshifting.
No upshifts are available in low, except to prevent
UltraShift Diagnostics
engine overspeed. Clutch Calibration
If the transmission does not upshift quickly enough NOTE: Clutch calibration only occurs on six-
after power-up or a load change, begin the shift speed UltraShift ASW.
manually. The UltraShift TCU will learn the new load-
based shift conditions after three or four shifts. The UltraShift TCU automatically adjusts for clutch
wear. The calibration takes place whenever the fol-
If the gear requested is unavailable, a tone will lowing conditions are met:
sound. An unavailable request to upshift is not stored
in memory. The upshift must be requested again. • The engine is at normal operating temperature
• The vehicle is stopped
Downshifting
• The engine is at idle speed
NOTE: The driver can manually downshift at
any time, even when the slide switch is set to • The selector switch on the control lever is in
AUTO mode. neutral
To request a downshift with the transmission in drive

or low, push the control lever down (away from you).
8.20
Drivetrain
Calibration may take up to two minutes to complete. 4. Wait at least two minutes with the engine shut
The engine may slow and return to normal idle sev- down.
eral times during calibration.
5. Restart the engine.
To stop calibration at any time, select one of the
If the problem continues, contact an authorized
drive positions on the selector switch (R, D, or L).
Freightliner or Eaton service facility.
Clutch Protection Fault Locked In Gear
Excessive clutch slippage creates heat and reduces If the transmission becomes locked in gear, a dash
the life of the clutch. These are some conditions (–) will appear on the gear indicator when the vehicle
which lead to clutch abuse: is restarted during the reset procedure.
• Using the throttle to hold the vehicle on a
NOTE: If the transmission becomes locked in
grade
gear while the vehicle is moving, increased
• Starting the vehicle in too high a gear braking effort may be required to stop the ve-
• Overloading the vehicle hicle.
• Using high idle with the vehicle in gear If the current gear indicator displays a dash during
power-up with the selector switch in neutral, do the
The UltraShift TCU is programmed to prevent clutch following steps:
abuse. When the clutch overheats, the following
alerts take place: 1. Make sure the parking brake is set.
• The "TRANS TEMP" light comes on 2. Turn off the ignition and wait at least two min-
utes.
• The gear indicator displays "CA"
3. Apply the service brakes.
• A warning tone sounds at one second intervals
4. With the service brakes applied, release the
The alerts continue until the clutch cools, the throttle parking brake.
is released, or the clutch is fully engaged.
5. Make sure the selector switch is in neutral and
System Problem turn on the ignition key. Do not attempt to start
the engine at this time.
In the event of a problem, do the following steps:
6. If necessary to get the transmission to shift into
1. Note the driving conditions at the time the prob- neutral, release the pressure on the brake pedal
lem occurred. slightly.
2. Record the status of the transmission at the time 7. Once the UltraShift TCU reaches neutral, a solid
of the problem (AUTO or MAN mode, gear set- "N" will appear on the current gear indicator and
ting R, N, D, or L, current gear, engine speed, the vehicle will start. Make sure the service
etc.) brakes are applied and the parking brake is set.
3. Reset the system, using the procedure below. If the gear indicator continues to display a dash, con-
tact an authorized Freightliner or Eaton service facil-
Reset Procedure ity.
Transmission operation can sometimes be restored
by doing the following reset procedure:
1. Stop the vehicle when it is safe to do so.
2. Place the selector switch in neutral and turn off
the ignition.
3. Check all harness connectors as described in
Chapter 11.
8.21
Drivetrain
Mercedes-Benz Manual When shifting, always press the clutch pedal all the
way down. Do not force the gear lever.
Transmissions Before shifting into reverse, be sure the engine is
idling and the vehicle is not moving.
CAUTION
Operating a manual transmission with the fluid
CAUTION
level higher or lower than recommended can re-
If the transmission locks up while driving, mak-
sult in transmission damage.
ing further shifting impossible, continue driving
Mercedes-Benz transmissions use a simple 6-speed in the gear already selected to reach service as-
gear pattern as shown in Fig. 8.19. sistance, as circumstances allow. Or, safely park
the vehicle off the roadway and contact your
nearest Freightliner dealer or other qualified ser-
vice provider for roadside assistance. To prevent
1 3 5 further transmission damage, do not move the
vehicle from a standing start unless this can be
N accomplished safely, taking into account the gear
that is engaged and the load on the vehicle.
R 2 4 6
05/03/2001 f261098 Mercedes-Benz Automated
Fig. 8.19, Shift Pattern, M-B Transmissions
Transmissions
Always use first gear when starting to move the ve-
General Information, AGS
hicle forward. The AGS Automated Gear Shift is a fully automated
IMPORTANT: Do not rest your foot on the clutch 6-speed medium-duty transmission. The clutch is ac-
tivated by a hydraulic system that is integral to the
pedal while driving. This causes partial clutch
transmission. No clutch pedal is needed to operate
disengagement which could cause premature the vehicle.
clutch wear.
AGS transmissions use the SmartShift control lever
While traveling, check the tachometer regularly to be on the steering column to select gears. A manual
sure the engine speed is within the most economical shift is possible at any time by moving the SmartShift
range (1400 to 2000 rpm). lever up or down as needed.
On level roads, drive in the highest usable gear, The transmission control unit (TCU) can direct all
keeping engine speed down. forward shifts in response to driving conditions and
the driver’s pressure on the brake and throttle ped-
CAUTION als. To know which gear the transmission is in, look
at the round current gear indicator on the right-hand
Do not rest your hand on the gear shift lever control panel as shown in Fig. 8.12.
while driving. This can cause synchronizer dam- The TCU always selects first gear to start the vehicle
age. in motion. It is possible, in manual mode, to start an
When approaching an uphill grade, shift down ahead unloaded or lightly loaded vehicle in second gear. In
of time to prevent loss of engine rpm. When ap- most cases, second gear is acceptable for downhill
proaching a downhill grade, shift down ahead of time starts. In other situations, for best results always start
to prevent runaway speed. For information about moving in first gear. Loaded vehicles, or vehicles on
shift points and "progressive shifting," see Chap- substantial grades, must start moving only in first
ter 7. gear.
Change gears only when absolutely necessary. Skip
gears if needed.
8.22
Drivetrain
CAUTION WARNING
At the first sign of a transmission malfunction, When starting or stopping on hills and grades,
take the vehicle out of service immediately. De- use extra care to prevent the vehicle from rolling
pending on the type of problem, further shifting back. A rollback accident could cause death, seri-
may not be possible, and driveline torque may be ous personal injury, or property damage.
interrupted.
7. Prevent the vehicle from rolling backwards when
stopped on a hill or grade, or when the vehicle is
Operation, AGS starting from a stop on a hill or grade.
Power Up 7.1 To start from a full stop on a hill or grade,
1. With the parking brake set and/or the brake quickly move your foot from the brake
pedal pressed down, select neutral (N) by mov- pedal and press firmly on the throttle
ing the selector switch to the center position. pedal.
2. With the transmission in neutral, turn on the igni- On steep hills, set the parking brake and
tion switch. The "CHECK TRANS" and "TRANS release it only when there is enough en-
TEMP" telltale lights come on and go out again gine power to prevent rollback.
(bulb check). See Fig. 8.13. 7.2 To stop on a hill or grade, press and hold
3. On power up, the current gear indicator shows the brake pedal to keep the vehicle from
the dot display, arranged in a square pattern. All moving.
dots in the pattern should light up, without gaps On steep hills, set the parking brake.
or spaces. See Fig. 8.14. Never hold a hill with the throttle pedal.
4. When the current gear indicator shows "N," start This will cause the clutch to overheat.
the engine.
Power Down
NOTE: No matter what the circumstances, do
1. Bring the vehicle to a complete stop.
not start the engine unless the current gear indi-
cator shows "N." See Chapter 13 for jump start- 2. Set the parking brake.
ing information. 3. Move the selector switch to N. Wait until "N" ap-
5. Select drive (D) by pressing in the neutral lock pears on the current gear indicator.
button and moving the selector switch downward
to the position below neutral. Release the park- WARNING
ing brake and/or service brake pedal. The gear is
displayed on the current gear indicator. Always apply the parking brake before shutting
down the engine. AGS will shift into neutral after
NOTE: When D is selected, the transmission
shutdown, regardless of the position of the shift
starts up in first gear. To start up in second gear lever. If you do not set the parking brake, the ve-
(downhill start, vehicle unloaded or lightly hicle could roll and cause an accident resulting
loaded), pull up on the SmartShift lever when in death, serious personal injury, or property
the current gear indicator displays "1." damage.
6. On a level grade, press down on the throttle 4. Turn the ignition switch off and shut down the
pedal to allow the vehicle to move forward. The engine.
vehicle will not move until the pedal is de-
pressed. 5. If the current gear indicator flashes "PB" when
the engine is shut down, set the parking brake
and move the selector switch to "N."
8.23
Drivetrain
Automatic and Manual Modes If driving conditions require, it is still possible to re-
quest a manual shift. The transmission will make the
The SmartShift control has a slide switch located on shift unless the selected gear would cause engine
the body of the lever just before the paddle widens overspeed.
out. See Fig. 8.20. The slide switch controls the for-
ward driving mode, automatic or manual. If the driver presses down on the throttle pedal after
a manual downshift in automatic mode, the transmis-
sion will upshift again if the TCU requires it.
On downgrades, the transmission holds the current
gear until the driver requests a shift, or presses the
throttle pedal.
WARNING
1 2 While driving off-road or with locked differential
in AUTO mode, use extra caution. Shifts of the
3 AGS could interrupt power to the drive wheels,
causing a rollback accident while climbing steep
grades at low speeds. A rollback accident could
cause death, serious personal injury, or property
damage.
01/19/2004 f270079b Manual Mode (MAN)

1. Slide Switch (controls forward driving mode) Manual mode may be required under certain condi-
2. Selector Switch (controls gear selection) tions, such as:
3. Neutral Lock Button (prevents accidental shift into
gear) • In difficult or slippery conditions
Fig. 8.20, Switches, AGS Transmissions • On hills, steep grades, or other situations
where driveline torque interruption is not desir-
To change mode at any time, move the slide switch able
in the desired direction. This allows the driver to re- • During off-road driving or driving with a locked
spond to a wide range of driving conditions, such as differential
blind corners, tight curves, and steep hills.
• In downhill driving where control of engine
IMPORTANT: Whatever the mode, it is always braking is needed
possible to shift manually by moving the lever
up or down as needed. • If necessary to hold a specific gear on a down-
grade
In either mode, the gear indicator displays the cur-
rent gear. See Fig. 8.16. In manual drive mode (MAN), upshifts and down-
shifts are made by the driver:
Automatic Mode (AUTO) • To shift up, pull the lever up (towards you).
Automatic drive mode (AUTO) is recommended for • To shift down, push the lever down (away from
most driving conditions. For the best fuel economy, you).
always use AUTO mode.
The system will hold the current gear until the driver
In AUTO mode, upshifts and downshifts are made by requests a shift. In downhill situations in particular,
the transmission without driver intervention. Press in the driver must be alert to vehicle speed and main-
the neutral lock button, move the selector switch to tain vehicle control by downshifting and/or using the
drive (D), and press down on the throttle pedal. The service brakes as needed.
transmission will shift automatically through the for-
ward gears.
8.24
Drivetrain
When braking or slowing in MAN, downshift as nec-

essary to prevent lugging the engine when speed is WARNING
resumed. If the vehicle comes to a complete stop,
the TCU resets the transmission to neutral. Do not coast in neutral. Coasting in neutral can
NOTE: A downshift request will be refused if the personal injury or death.
selected gear would cause engine overspeed.
Neutral is always available during operation, what-
Cruise Control ever the vehicle speed. When in neutral, requests to
upshift or downshift are ignored. If the selector switch
Cruise control is fully functional with AGS transmis- is moved from neutral to drive while the vehicle is
sion in either AUTO or MAN mode. moving, the transmission will shift into a gear within
the operating torque range of the engine.
In AUTO, the TCU will adjust the gear selections to
maintain the speed settings as desired. No driver
action is necessary. WARNING
In MAN, the vehicle speed settings must be within Always apply the parking brake before shutting
the engine speed range for the gear selected. If the down the engine. AGS will shift into neutral after
engine cannot maintain set speed due to changes in shutdown, regardless of the position of the shift
road grade, the driver must downshift or upshift as lever. If you do not set the parking brake, the ve-
necessary. hicle could roll and cause an accident resulting
For vehicles equipped with a power take-off (PTO) in death, serious personal injury, or property
unit, two modes of operation are possible, stationary damage.
and mobile. For PTO operation, see Chapter 7. Before shutting down the engine, return the selector
switch to "N." When the ignition is turned off, the
Selecting Gears transmission will reset to neutral during power down.
Reverse
Drive
Reverse (R) is at the upper end of the three-position
selector switch located at the end of the SmartShift IMPORTANT: The vehicle must come to a com-
control lever. To select reverse (R), press in the neu- plete stop before selecting drive. If drive is se-
tral lock button and move the selector switch upward lected with the vehicle moving in reverse, an
to the position above neutral. When reverse is se- audible alert will sound and continue sounding
lected, the letter "R" displays on the gear indicator. at three-second intervals until the selector
See Fig. 8.17.
switch is returned to N or R.
IMPORTANT: The vehicle must come to a com- Drive (D) is at the lower end of the three-position se-
plete stop before selecting reverse. If reverse is lector switch located at the end of the SmartShift
selected with the vehicle moving forward, an control lever. To select drive, press in the neutral lock
audible alert will sound and continue sounding button and move the selector switch to the position
at three-second intervals until the selector below neutral. When drive is selected, the number of
switch is returned to N or D. the currently selected forward gear (1, 2, 3, 4 , 5, or
6) displays on the gear indicator.
Once the vehicle has come to a complete stop, re-
verse can be engaged. Upshifting
Neutral NOTE: The driver can manually upshift at any
Neutral (N) is in the center of the three-position se- time, even when the slide switch is set to AUTO
lector switch located at the end of the SmartShift mode.
control lever. Always start the engine in neutral. To To request an upshift with the transmission in drive,
select neutral, move the selector switch to the center pull the control lever up (towards you). If the gear is
position. When neutral is selected, the letter "N" dis-
plays on the gear indicator. See Fig. 8.18.
8.25
Drivetrain
available, the transmission upshifts and the new gear System Malfunction
displays on the gear indicator.
If the "CHECK TRANS" telltale light comes on while
As in a manual transmission, upshifting too early driving, the audible alert sounds, and the current
causes engine lugging and uneven operation. gear indicator begins to flash between the current
To achieve smooth operation in MAN mode, upshift gear and "SM" (system malfunction), there is a prob-
when the engine speed reaches approximately 2000 lem which may or may not be apparent to the driver.
revolutions per minute (rpm). Heavy loads or steep Bring the vehicle at once to a safe stopping place
grades require higher rpm; lighter loads require lower and call an authorized Freightliner service facility for
rpm. assistance.
An unavailable request to upshift is not stored in Clutch Overload

memory. The upshift must be requested again.
If the "TRANS TEMP" telltale light comes on while
Downshifting driving and the current gear indicator begins to flash
between the current gear and "CO" (clutch overload),
NOTE: The driver can manually downshift at the clutch has begun to overheat.
any time, even when the slide switch is set to The clutch overload may have been caused by im-
AUTO mode. proper driving practices such as frequent and rapid
To request a downshift with the transmission in drive, start/stop driving, or hillholding with the throttle pedal.
push the control lever down (away from you). If the In this case, allow the clutch to cool, and continue
gear is available, the transmission downshifts and on, but cease the improper driving practices.
the new gear displays on the gear indicator. If the clutch overload message returns or continues,
Downshifts are not available if the engine speed after the clutch is worn or damaged. Bring the vehicle at
the shift would exceed 2700 rpm. If the gear re- once to a safe stopping place and call an authorized
quested is unavailable, an audible alert will sound. Freightliner service facility for assistance.
An unavailable request to downshift is not stored in
memory. The downshift must be requested again. Low Hydraulic Fluid Level
To achieve smooth operation in MAN mode, down- IMPORTANT: The only hydraulic fluid permitted
shift when the engine speed reaches approximately in this system is Pentosin CHF 11S. No other
1200 rpm. fluid can be substituted.
Before starting down a hill, slow down. Downshift to If the "CHECK TRANS" telltale light comes on while
a speed that you can control without hard pressure driving and the current gear indicator begins to flash
on the service brakes. between the current gear and "FL" (fluid level), there
has been an unusual loss of hydraulic fluid. Bring the
Before entering a curve, slow down to a safe speed.
vehicle at once to a safe stopping place and call an
Downshift if necessary. This lets you use some
authorized Freightliner service facility for assistance.
power through the curve to help the vehicle be more
The hydraulic reservoir holds about 1.05 quarts (one
stable when turning. It also allows you to regain
liter) of Pentosin CHF 11S.
speed faster as you come out of the curve.
NOTE: After hydraulic fluid loss, a special pro-
AGS Diagnostics cedure is required to fill the hydraulic reservoir.
This procedure must be carried out by an autho-
CAUTION rized Freightliner service facility.
At the first sign of a transmission malfunction,

take the vehicle out of service immediately. De-
Meritor™ Drive Axles
pending on the type of problem, further shifting Refer to the Meritor website for additional informa-
may not be possible, and driveline torque may be tion, www.arvinmeritor.com.
interrupted.
8.26
Drivetrain
Drive Axles With Differential Lock sible for some vehicles to have differential lock on
only one of the drive axles.
The Meritor driver-controlled differential lock feature
(side-to-side wheel lock, traction control, or traction A two-position guarded rocker switch (Fig. 8.21) con-
equalizer) is available on single-drive or dual-drive trols differential lock, causing the wheels on each
rear axles. It is available on both axles of a dual- axle governed by the switch to rotate together. To
drive vehicle, or on one only. It is only available on lock the wheels together, press the upper half of the
drive axles. Differential lock must only be used under rocker momentarily (at the red LED). To unlock the
adverse road conditions where greater traction is wheels, press the upper half of the rocker again.
needed. With differential lock on, the turning radius is IMPORTANT: The differential lock rocker switch
increased and vehicle handling is affected. The differ- is guarded to prevent unintentional switch acti-
ential lock switch (Fig. 8.21) allows the driver to lock vation. If the LED in the switch begins to blink
the wheels on the same axle together. The red differ-
ential lock warning light illuminates on the dash mes-
during normal operation, when the switch has
sage center when differential lock is engaged. not been activated, this indicates an error condi-
tion. Bring the vehicle to an authorized Freight-
liner service facility as soon as possible.
When the differential lock switch is pressed, three
responses are possible: a normal response, a slow
response, and an abnormal response.
Normal Response: The LED in the switch blinks until
the axle has responded to the request to lock the
wheels. At this point, the LED comes on steady and
stays illuminated. In normal operation, the wheels
may lock so quickly that the blinking of the switch is
10/26/2001 f610596
barely noticeable.
Fig. 8.21, Differential Lock Switch If operation of the switch is not possible for any rea-
son (ignition is turned off, vehicle is moving faster
Differential lock provides maximum traction under than 25 mph, etc.), the LED will stop blinking and
slippery conditions. When the differential lock is en- turn off.
gaged, the clutch collar completely locks the differen-
tial case, gearing, and axle shafts together, maximiz- Slow Response: If operation of the switch is slowed
ing the traction of both wheels and protecting against for any reason (vehicle moving too fast, low air pres-
spinout. sure, etc.), the switch will continue to blink until the
wheels are able to lock. As in the normal response,
Under normal traction conditions, do not use the dif-
the LED comes on steady and stays illuminated once
ferential lock feature.
the wheels have locked.
Differential Lock Switch NOTE: If the vehicle is moving too fast, let up
slightly on the accelerator. As the vehicle slows,
CAUTION the wheels will lock.
Differential lock should only be engaged when

Abnormal Response: If the LED blinks for more than
30 seconds, the lock mechanism may not be fully
the vehicle is stopped or moving slowly at low
engaged/disengaged. Bring the vehicle to an autho-
throttle. This will prevent internal axle damage.
rized Freightliner service facility for testing.
Normally, when differential lock is available on dual-
drive vehicles, one switch activates the lock on both
rear drive axles. As an option, it possible to have two
differential lock switches, one for the forward rear
and one for the rearmost drive axle. It is also pos-
8.27
Drivetrain
Differential Lock Operation

A
WARNING
Locking the wheels when the vehicle is traveling
down steep grades or when the wheels are slip- B
ping could damage the differential and/or lead to
loss of vehicle control, causing personal injury
and property damage.
Lock the wheels only when the vehicle is standing
still or moving at very low speed, less than 5 mph (8 02/09/96 f350079a
km/h). Never lock the wheels when the vehicle is A. Turning Radius When the Differential Lock is
traveling down steep grades or when the wheels are Engaged (understeer condition)
slipping. B. Turning Radius When the Differential Lock is
Disengaged
NOTE: On some vehicles, the differential lock
system is connected through the low speed Fig. 8.22, Turning Radii
range of the transmission. If this system is used,
switch will blink until the wheels unlock, and
the transmission must be in the low speed
then go out.
range for the wheels to fully lock.
Tandem Drive Axles With Interaxle
WARNING Lock
A vehicle with locked wheels can still slip side-
ways, causing possible loss of vehicle control, CAUTION
personal injury, and property damage.
The interaxle lock should not be engaged on a
Be especially careful when driving under slippery vehicle with obviously spinning wheels. Engage-
conditions with the wheels locked. Though forward ment at high speed or power can damage the
traction is improved, the vehicle can still slip side- axle(s).
ways.
Meritor has an interaxle lock (axle lock, interaxle dif-
If the vehicle is moving, maintain a constant vehicle ferential lockout) feature that is standard on all dual-
speed when the differential lock is turned on. Briefly drive (tandem-drive) vehicles. Interaxle lock is recom-
let up on the accelerator to relieve torque on the mended for use under adverse road conditions
gearing, allowing the wheels to lock completely. where greater traction is needed. See the axle manu-
When the wheels are fully locked, the turning radius facturer’s manual provided with the vehicle for more
will increase because the vehicle understeers. See information.
Fig. 8.22. Drive cautiously and do not exceed 25
mph (40 km/h). The interaxle lock switch (Fig. 8.23) allows the driver
to lock both rear axles together. The red interaxle
To disengage differential lock after leaving poor road warning light illuminates on the dash message center
conditions, operate the differential lock switch as dis- when interaxle lock is engaged.
cussed above while maintaining vehicle speed. Let
up momentarily on the accelerator to allow the When the interaxle lock is not engaged, there is dif-
wheels to fully unlock, then resume driving at normal ferential action between the two axles. The differen-
speed. tial compensates for different wheel speeds and
variations in tire size. Keep the interaxle lock disen-
NOTE: If the differential lock system is con- gaged when driving on roads where traction is good.
nected with the transmission in its low speed When the interaxle lock is engaged, the differential
range, shifting out of the low speed range will action between the two axles is locked. Both drive
also disengage the differential lock function. The axles now share the power. Both axles, and both
8.28
Drivetrain
Abnormal Response: If the LED blinks for more than

30 seconds, the lock mechanism may not be fully
engaged/disengaged. Bring the vehicle to an autho-
rized Freightliner service facility for testing.
Interaxle Lock Operation

To engage interaxle lock and achieve maximum pull-
ing power in slippery or hazardous road conditions,
operate the interaxle lock switch as discussed above,
10/26/2001 f610595 while maintaining vehicle speed. Let up momentarily
on the accelerator until the axle lock engages. Pro-
Fig. 8.23, Interaxle Lock Switch ceed over poor road conditions with caution. Do not
wait until traction is lost and the tires are spinning
sets of wheels, turn together at the same speed. The before engaging the interaxle lock.
interaxle lock should be used when the vehicle en-
counters poor traction conditions; however, it also
increases drivetrain and tire wear and should be CAUTION
used only when improved traction is required.
Do not turn on the interaxle lock switch when the
Interaxle Lock Switch tires are slipping. Do not continuously operate
the vehicle with the interaxle lock engaged dur-
A two-position guarded rocker switch (Fig. 8.23) con- ing good road conditions. To do so could result
trols interaxle lock, causing both axle shafts to rotate in damage to the axle gearing and excessive tire
together. To lock the axles together, press the upper wear.
half of the rocker momentarily (at the red LED). To
To disengage the interaxle lock after leaving poor
turn off interaxle lock, press the lower half of the
road conditions, operate the interaxle lock switch as
rocker (at the double-axle icon).
discussed above while maintaining vehicle speed.
IMPORTANT: The interaxle lock rocker switch is Let up momentarily on the accelerator to allow the
guarded to prevent unintentional switch activa- axles to fully unlock, then resume driving at normal
tion. This switch does not have a diagnostic speed.
blink function when inactive.
Axle Shift
When the interaxle lock switch is pressed, three re-
sponses are possible: a normal response, a slow re-
sponse, and an abnormal response. CAUTION
Normal Response: The LED in the switch blinks until To prevent transmission and axle damage, make
the interaxle lock is engaged. At this point, the LED sure the automatic transmission is in high range
comes on steady and stays illuminated. In normal when performing an axle shift with the vehicle
operation, the interaxle may lock so quickly that the moving.
blinking of the switch is barely noticeable. Axle shift is a function installed on vehicles with two-
If operation of the switch is not possible for any rea- speed axles to allow the use of the low speed range
son (ignition is turned off, vehicle is moving too fast, when greater traction and maximum pulling power is
etc.), the LED will stop blinking and turn off. needed at low engine speed (rpm).
Slow Response: If operation of the switch is slowed Under normal operating conditions, the vehicle is op-
for any reason (by cold weather, low air pressure, erated using the high-speed gear ratios of the axle.
etc.), the switch will continue to blink until the axles Under extreme weather or off-road conditions, at low
lock together, or for a maximum of 10 seconds. As in speed and rpm and/or to pull heavy loads, the ve-
the normal response, the LED comes on steady and hicle must be operated using the low-speed, or re-
stays illuminated. duction, gear ratios of the axle.
8.29
Drivetrain
Axle Shift Switch shifts. As in the normal response, the LED comes on
steady and stays illuminated.
The axle shift switch is a two-position guarded rocker
switch (Fig. 8.24) installed on vehicles with two- Abnormal Response: If the LED blinks for more than
speed axles. 30 seconds, the axle shift function/mechanism may
not be operating correctly. Bring the vehicle to an
authorized Freightliner service facility for testing.
Axle Switch Interlock

NOTE: On vehicles with tandem drive axles,
there is an interlock that prevents an axle from
shifting speed whenever the interaxle lock is on.
If the axle shift switch is pressed when the interaxle
lock is on, the axle shift will not be completed. The
10/26/2001 f610594 LED does the following:
• If the LED is off, the LED comes on briefly and
Fig. 8.24, Axle Shift Switch
turns off again.
To shift the axle from low speed to high speed, press • If the LED is on, it stays on.
the upper half of the rocker momentarily (at the
LED). To turn the axle shift off (switch from high To complete the axle shift, turn off the interaxle lock
speed back to low speed), press the upper half of and press the axle shift switch again. If still needed,
the rocker again. When the axle has shifted speed, the interaxle lock can then be reactivated.
the LED turns off.
When the panel lights are on, the AXLE SHIFT leg-
end is backlit in green.
IMPORTANT: The axle shift rocker switch is
tion. If the LED in the switch begins to blink dur-
ing normal operation, when the switch has not
been activated, this indicates an error condition.
Bring the vehicle to an authorized Freightliner
service facility as soon as possible.
When the axle shift switch is pressed, three re-
sponses are possible: a normal response, a slow re-
sponse, and an abnormal response.
Normal Response: The LED in the switch blinks until
the axle shifts speed. At this point, the LED comes
on steady and stays illuminated. In normal operation,
the axle may shift so quickly that the blinking of the
switch is barely noticeable.
If operation of the switch is not possible for any rea-
son (interaxle lock is on, ignition is turned off, etc.),
the LED will stop blinking and turn off.
Slow Response: If operation of the switch is slowed
for any reason (by cold weather, low air pressure,
etc.), the switch will continue to blink until the axle
8.30
9
Steering and Brake Systems
Steering System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.1
Air Brake System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.1
Hydraulic Brake System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.6
Steering System If the power-assist feature does not work due to hy-
draulic fluid loss, steering pump damage, or some
Steering Wheel Adjustment other cause, bring the vehicle to a safe stop. Do not
drive the vehicle until the cause of the problem is
Two steering wheels are available: a standard 18- corrected.
inch (450-mm) steering wheel and an optional 20-
inch (500-mm) steering wheel.
WARNING
When there is no load on the vehicle and the front
tires are pointed straight ahead, the standard steer- Driving the vehicle without the power-assist fea-
ing wheel spokes should be at the 3 o’clock and 9 ture of the steering system requires much greater
o’clock positions or within 10 degrees of these posi- effort, especially in sharp turns or at low speeds,
tions. See Fig. 9.1. which could result in an accident and possible
injury.
Drivers should use the power available with a power
steering system carefully. If the front tires become
lodged in a deep chuckhole or rut, drive the vehicle
out instead of using the steering system to lift the
10° 10°
tires from the hole. Avoid turning the tires when they
are against a curb as this places a heavy load on
steering components and could damage them.
1 2
Air Brake System

10° 10°
A dual air brake system consists of two independent
air brake systems that use a single set of brake con-
11/14/2001 f461923
trols. Each system has its own reservoir, plumbing,
and brake chambers. The primary air system oper-
NOTE: The standard steering wheel is shown. ates the service brakes on the rear axle; the second-
1. 9 o’Clock 2. 3 o’Clock ary air system operates the service brakes on the
front axle. Service brake signals from both systems
Fig. 9.1, Steering Wheel Centered
are sent to the trailer.
On the optional 20-inch (500-mm) wheel, the steering
wheel spokes should be at the 4 o’clock and 8 Primary Air Brake System
o’clock positions or within 10 degrees of these posi- Loss of air pressure in the primary air system causes
tions. For steering wheel adjustment procedures, see the rear service brakes to become inoperative. The
Group 46 of the Business Class® M2 Workshop front brakes will continue to be operated by the sec-
Manual. ondary air system. In addition, the trailer brakes (if
equipped) will be operated by the secondary air
Power Steering System system.
The power steering system consists of a steering
gear (which includes a manual steering mechanism, Secondary Air Brake System
a hydraulic control valve, and a hydraulic power cyl- Loss of air pressure in the secondary air system
inder), hydraulic hoses, power steering pump, power causes the front axle brakes to become inoperative.
steering reservoir, and other components. Some The rear service brakes will continue to be operated
models are also equipped with a separate hydraulic by the primary air system. In addition, the trailer
power cylinder on the right side of the front axle. brakes (if equipped) will be operated by the primary
The power steering pump, driven by the engine, pro- air system.
vides the power assist for the steering system. If the
engine is not running, there is no power assist.
9.1
Emergency Braking System ing brakes and the trailer service brakes. When the
tractor and trailer parking brakes (or trailer service
When air pressure is lost in either the primary or sec- brakes) are both applied, the trailer brakes can be
ondary air system, the air compressor will operate, released by pushing in the red knob, leaving the trac-
but the air supply in the other system, the one that is tor parking brakes applied.
not leaking, will not be replenished. There will be
The trailer brake lever (hand control valve) is used
enough air in the other system to stop the vehicle
for applying the trailer brakes without applying the
safely. The dual air brake system thus provides
truck or tractor service brakes. It is usually mounted
emergency braking capability. When the low air pres-
on the right-hand control panel. See Fig. 9.3.
sure warning light and emergency buzzer first come
on, stop the vehicle immediately. Do not drive the
vehicle until the cause of the problem is corrected.
Parking Brakes, Tractor and Trailer

The yellow diamond-shaped knob (parking brake
control valve) on the auxiliary dash panel applies the
parking brakes (spring brakes). Pulling out the knob
applies both the tractor and the trailer parking brakes
and automatically causes the red octagonal knob
(trailer air supply valve) to pop out. See Fig. 9.2.
1 10/17/2001 f610591
2
Fig. 9.3, Trailer Brake Lever
The valve can be partially or fully applied, but in any

partially on position it will be overridden by a full ap-
plication of the service brake pedal. Moving the lever
down applies the trailer brakes, while moving it up
03/10/99 f610291 releases the trailer brakes. The lever will automati-
1. Trailer Air Supply Valve (red knob) cally return to the up position when it is released.
2. Parking Brake Control Valve (yellow knob)
On Tractor-Trailers
Fig. 9.2, Brake Valve Control Knobs
If both the primary and secondary air systems be-
The red octagonal-shaped knob on the auxiliary dash come inoperative on tractor-trailers, the trailer service
panel operates the trailer air supply valve. After the brakes or parking brakes will automatically apply
vehicle and its air hoses are connected to a trailer, when the air pressure drops below 35 to 45 psi (241
and the pressure in the air system is at least 65 psi to 310 kPa).
(448 kPa), the red knob must be pushed in (and
The tractor parking brakes will automatically apply
should stay in) to charge the trailer air supply system
when the air pressure drops below 20 to 30 psi (138
and release the trailer parking brakes. Before discon-
to 207 kPa).
necting a trailer or when operating a vehicle without
a trailer, the red knob must be pulled out.
On Trucks
If pressure in both air systems drops to 35 to 45 psi
(241 to 310 kPa), the red knob automatically pops Trucks are equipped with spring brake modulation. If
out, exhausting the trailer air supply and applying the an air pressure loss occurs in the primary air system,
trailer parking brakes. the rear parking brakes will be modulated (applied
and released) in proportion to the service brake ap-
If the trailer is not equipped with parking brakes, pull- plication. There will only be enough air in the sec-
ing out the yellow knob applies both the tractor park- ondary system for two to four brake applications, at
9.2
which time the parking brake control valve will pop brake application. Make sure all occupants are wear-
out and fully apply the brakes. ing seat belts.
On trucks, the parking brakes will apply when the air Parking Brake Interlock
pressure drops below 20 to 30 psi (138 to 207 kPa).
Do not wait for the brakes to apply automatically. Be-
fore continuing to operate the vehicle, correct the CAUTION
cause of the air loss.
Do not continually press down on the parking
Automatic Slack Adjusters brake control valve (yellow knob) without press-
ing down on the service brake pedal. This will
Automatic slack adjusters are required on all vehicles damage the safety interlock.
equipped with air brakes manufactured after October
20, 1994. Automatic slack adjusters should never be The service brakes and parking brakes have a safety
manually adjusted except during routine maintenance interlock that prevents the unintentional release of
of the foundation brakes (e.g., replacing shoes), dur- the parking brake. If the yellow knob is pressed in, it
ing slack adjuster installation or in an emergency will pop back out unless the service brake pedal is
situation. being pressed down.
When the brake pushrod stroke exceeds the legal A decal on the dash alerts you to press down on the
brake adjustment limit on a vehicle, there likely is a service brake pedal before releasing the parking
mechanical problem with the foundation brake com- brake. If you do not, the yellow knob will not allow
ponents, or the adjuster is improperly installed. itself to be pressed in, but will return to its old posi-
tion.
Visit a repair facility as soon as possible when
brakes equipped with automatic slack adjusters are Operating the Brakes
determined to be out of adjustment.
To ensure safe operation and minimum brake wear,
do the following steps when operating the brakes.
WARNING
1. Monitor the air pressure system by observing the
Manually adjusting an automatic slack adjuster to low air pressure warning light, the emergency
bring the pushrod stroke within legal limits is buzzer, and both the primary and secondary air
likely masking a mechanical problem. Adjustment pressure gauges.
is not repairing. In fact, continual adjustment of When the ignition switch is turned on, the low air
automatic slack adjusters may result in prema- pressure warning light (pressure circle icon) illu-
ture wear of the adjuster itself. Further, the im- minates and the emergency buzzer sounds.
proper adjustment of some automatic slack ad-
justers may cause internal damage to the The warning light and buzzer shut off when air
adjuster, thereby preventing it from properly pressure in both systems reaches 65 to 75 psi
functioning. (448 to 517 kPa).
2. Before driving your vehicle, continue to monitor
Air Brake Operation the air pressure system until the air compressor
has built up a minimum pressure of 95 psi (655
WARNING kPa) in both the primary and secondary air sys-
tems.
Do not operate the vehicle with the front brakes
3. While driving, the low air pressure warning light
backed off or disconnected. Backing off or dis-
and buzzer come on if air pressure drops below
connecting the front brakes will not improve ve-
65 to 75 psi (448 to 517 kPa) in either system. If
hicle handling and may lead to loss of vehicle
this happens, check the air system pressure
control, resulting in property damage or personal
gauges to determine which system has low air
injury.
pressure.
Before driving the vehicle, secure all loose items in
the cab so that they will not fly forward during a full
9.3
Although vehicle speed can be reduced using the vehicle could roll causing serious personal
the service brake, either the front or rear service injury or property damage.
brakes will not be operating, causing a longer
stopping distance. IMPORTANT: Air pressure in the primary or sec-
ondary reservoir must be at least 65 psi (448
Bring the vehicle to a safe stop and have the air kPa) before the tractor parking brakes and the
system repaired before continuing. trailer service brakes (or parking brakes) can be
4. During normal brake stops, depress the service released.
brake until braking action slows down the ve-
hicle. Increase or decrease the pressure on the On trailers without parking brakes, do the following to
pedal so that the vehicle comes to a smooth, park safely:
safe stop. • To park just the trailer, chock the trailer tires
before disconnecting the tractor.
IMPORTANT: In the event of a total loss of ser-
vice brakes, use the parking brake control valve • To park a tractor with a trailer, apply the tractor
(yellow knob) to bring the vehicle to a complete parking brakes.
stop in the safest location possible.
Caging the Parking Brakes
5. When the forward speed of the vehicle has de-
creased almost to the idling speed of the engine,
press in the clutch pedal (on manual transmis-
WARNING
sions) and shift the transmission to neutral. Apply
Do not drive the vehicle with the parking brakes
the parking brakes, if the vehicle is to be parked.
caged. If the vehicle is driven with the parking
6. If the brakes are wet, drive the vehicle in low brakes caged, there would be no means of stop-
gear and lightly apply the brakes to heat and dry ping the vehicle if a complete loss of air pressure
them. occurred. This could result in serious personal
injury or vehicle damage.
CAUTION To move a vehicle with insufficient system air pres-
sure, it is necessary to release the parking brake
Do not use the spring parking brakes if the ser- springs.
vice brakes are hot, such as after descending a
steep grade. Also, do not use the spring parking There are two ways to do this:
brakes during freezing temperatures if the ser- • Apply an external air source at the gladhands;
vice brakes are wet. To do so could damage the
brakes if hot, or cause them to freeze during cold • Cage (manually release) the parking brakes.
weather. IMPORTANT: Before caging the parking brakes,
If the brakes are wet, drive the vehicle in low make the connection to a towing vehicle or
gear and lightly apply the brakes to heat and dry chock the tires.
them. Allow hot brakes to cool before using the
spring parking brakes. Always chock the tires. After correcting the brake system problem, uncage
the parking brakes before resuming normal vehicle
7. Allow hot brakes to cool before using the parking operation.
brakes. Always chock the tires.
Parking the Vehicle
System (ABS) for Air Brakes
WARNING ABS is an electronic wheel-speed monitoring and
control system that works with the air brake system.
Do not use the trailer service brakes for parking; It passively monitors vehicle wheel speed at all
they are not designed for this purpose. If air times, but controls wheel speed during an emer-
bleeds out of the trailer air tank during parking, gency or reduced-traction stop. In normal braking
9.4
applications, the standard air brake system is in ef- Even if the ABS system is partially or completely in-
fect. operative, normal braking ability is usually main-
tained.
ABS Operation
IMPORTANT: If a solenoid control valve (or
The Meritor WABCO ABS is a four-sensor system. It combination solenoid control valve) is damaged
combines one front-axle control channel with one and inoperative, normal braking may be im-
rear-axle control channel to form one control circuit. paired.
Example: The sensor and solenoid control valve at
the left front wheel form a control circuit with the sen- ABS Indicator Lights
sor and solenoid valve at the right rear wheel. IMPORTANT: If any of the ABS indicator lights
ABS includes signal-generating tone wheels and sen- do not work as described below, or come on
sors located in the wheel hubs of each sensed axle. while driving, repair the ABS system immedi-
The sensors transmit vehicle wheel speed informa- ately to ensure full antilock braking capability.
tion to an electronic control unit.
IMPORTANT: For proper ABS system operation, Tractor ABS Light
do not change tire sizes. The sizes of the tires If equipped only with the tractor ABS system, the
installed during production are programmed into amber TRACTOR ABS indicator light (see Fig. 9.4)
the electronic control unit. Installing different comes on after the ignition switch is turning on. The
sized tires could result in a reduced braking indicator light goes out only if all of the tractor ABS
components are working.
force, leading to longer stopping distances.
During emergency or reduced-traction stops, fully 2
depress the brake pedal until the vehicle comes to a 1 3
safe stop. Do not pump the brake pedal. With the
brake pedal fully depressed, the ABS system will
control all wheels to provide steering control and a
reduced braking distance.
Although the ABS system improves vehicle control
during emergency braking situations, the driver still
has the responsibility to change driving styles de-
pending on the existing traffic and road conditions.
For example, the ABS system cannot prevent an ac-
cident if the driver is speeding or following too close
on slippery road surfaces.
The main circuit of the control unit interprets the 10/12/2000 f610454
speed sensor signals and calculates wheel speed, 1. Tractor ABS Indicator 3. Trailer ABS Indicator
wheel retardation, and a vehicle reference speed. If 2. Wheel Spin Indicator
the calculations indicate wheel lockup, the main cir- (optional)
cuit signals the appropriate solenoid control valve to Fig. 9.4, ABS Indicator Lights
reduce braking pressure.
The electronic control unit also has a safety circuit CAUTION
that constantly monitors the wheel sensors, solenoid
control valves, and the electrical circuitry. During An accumulation of road salt, dirt, or debris on
emergency braking, the solenoid control valve alter- the ABS tone wheels and sensors can cause the
nately reduces, increases, or maintains the supply of ABS warning light to come on. If the ABS light
air pressure in the brake chamber, thereby prevent- does come on, the tone rings and sensors
ing front and/or rear wheel lockup. should be inspected for corrosion and serviced if
necessary. The service should include cleaning
9.5
of the tone rings and sensors. If any tone ring on Wheel Spin Light
a vehicle shows severe corrosion, all tone rings
on that vehicle should be replaced. If equipped with Automatic Traction Control (ATC),
the amber WHEEL SPIN indicator light illuminates if
During winter months in areas where corrosive one of the drive wheels spins during acceleration.
materials are used on the highways, periodically When the light illuminates, partially release the
clean the underside of the vehicle, including the throttle pedal until the light goes out. The light goes
tone rings and sensors, to ensure proper ABS out when the wheel stops spinning.
function and to protect the components from cor-
rosion. Clean more frequently when unusually If slippery road conditions continue, turn on the differ-
corrosive chemicals are being used. ential lock switch (on dual-drive vehicles, turn on the
interaxle lock switch). See Chapter 8 for axle switch
During vehicle operation, if the safety circuit senses instructions.
a failure in any part of the ABS system (a sensor,
solenoid control valve, wiring connection, short cir- CAUTION
cuit, etc.), the TRACTOR ABS indicator light comes
on and the control circuit where the failure occurred Do not turn the differential lock switch on while
is switched to normal braking action. The remaining the WHEEL SPIN indicator light is on. To do so
control circuit will retain the ABS effect. could damage the rear axle.
Trailer ABS Light Automatic Traction Control, Optional
The amber TRAILER ABS indicator light operates as
Automatic Traction Control is an option available on
follows when a compatible trailer is properly con-
ABS-equipped vehicles with air brake systems. It im-
nected to the tractor:
proves traction when vehicles are on slippery sur-
• When the ignition switch is turned to the on faces by reducing drive wheel overspin. ATC works
position, the trailer ABS light will illuminate mo- automatically in two ways.
mentarily, then turn off. • If a drive wheel starts to spin, ATC applies air
• If the light comes on momentarily during ve- pressure to brake the wheel. This transfers en-
hicle operation, then shuts off, a fault was de- gine torque to the wheels with better traction.
tected and cleared. • If all drive wheels spin, ATC reduces engine
• If the light flickers, or comes on and goes off torque to provide improved traction.
repeatedly, it could indicate an intermittent wir-
ATC turns itself on and off. Drivers do not have to
ing problem. Bring the vehicle to an authorized
select this feature. If drive wheels spin during accel-
Freightliner service facility for testing and re-
eration, the WHEEL SPIN indicator comes on, indi-
pairs.
cating ATC is active. It goes out when the drive
• If the light comes on and stays on during ve- wheels stop spinning.
hicle operation, there is a fault with the trailer
ABS. Repair the trailer ABS system immedi-
ately to ensure full antilock braking capability.
Hydraulic Brake System
The Trailer ABS light will not illuminate unless a com-
General Information
patible trailer is connected to the tractor. The hydraulic brake system includes a power
IMPORTANT: If a compatible trailer is con- booster, master cylinder, reservoir, hydraulic lines, a
brake rotor on each wheel hub, and a brake caliper
nected, and the light is not illuminating for three
and pad assembly at each rotor.
seconds when the ignition switch is turned to
the ON position, it is possible that the light is IMPORTANT: Make sure that the fluid level in
burnt out. the master cylinder reservoir is up to the ridge
that surrounds the reservoir. See Fig. 9.5. Use
only heavy-duty brake fluid, DOT 3, in the hy-
draulic brake system.
9.6
push the clutch pedal in, and shift the transmission

A into Neutral. Apply the parking brake if the vehicle is
to be parked.

System (ABS) for Hydraulic Brakes
The Meritor WABCO Antilock Braking System (ABS)
is an electronic wheel-speed monitoring and control
system that works with the hydraulic brake system.
ABS passively monitors vehicle wheel speed at all
times, but controls wheel speed during an emer-
B
gency or reduced-traction stop. In normal braking
applications, the standard hydraulic brake system is
in effect.
IMPORTANT: For proper hydraulic ABS opera-
10/31/94 f460513a tion, Meritor WABCO recommends that front
A. Open caps and check fluid level. and rear tire sizes be within 16% of each other.
B. Fill to this level. Contact the Meritor WABCO Customer Support
Fig. 9.5, Hydraulic Brake Reservoir Center at 800-535-5560 if you plan a tire size
difference greater than ±8%. Installing different
The master cylinder controls braking power to the sized tires could result in inaccurate wheel
front and rear brakes. The Bendix Hydro-Max® power speed signals to the ECU resulting in a reduced
booster is attached to the rear of the master cylinder braking force, which could lead to longer stop-
and is connected to the power steering system ping distances.
(which provides pressurized power steering fluid). An
electrically powered backup pump operates if there is ABS includes signal-generating tone rings and sen-
inadequate fluid flow from the power steering pump sors located in the wheel hubs of each sensed axle.
to the power booster. The brake system warning light The sensors transmit vehicle wheel speed informa-
comes on if there is a problem within the system. tion to the ECU which interprets these signals to cal-
Bring the vehicle to a safe stop and correct the prob- culate wheel speed and a vehicle reference speed. If
lem before continuing operation of the vehicle. See the calculations indicate wheel lockup, the appropri-
Group 42 of the Business Class® M2 Workshop ate control circuit signals the brake pressure modula-
Manual for hydraulic brake system troubleshooting tor to increase or decrease braking pressure.
and adjustment procedures.
CAUTION
Operation
An accumulation of road salt, dirt, or debris on
Before driving the vehicle, secure all loose items in
the ABS tone wheels and sensors can cause the
the cab so that they will not fly forward during a full
ABS warning light to come on. If the ABS light
brake application. Make sure that all occupants are
does come on, the tone rings and sensors
wearing seat belts. Check that the brake system
should be inspected for corrosion and serviced if
warning light is off after releasing the parking brake.
necessary. The service should include cleaning
If the warning light does not go off, correct the prob-
of the tone rings and sensors. If any tone ring on
lem before continuing operation of the vehicle.
a vehicle shows severe corrosion, all tone rings
During normal brake stops, depress the foot brake on that vehicle should be replaced.
control pedal until braking action slows down the ve-
hicle. Increase or decrease the pressure on the During winter months in areas where corrosive
pedal so that the vehicle comes to a smooth, safe materials are used on the highways, periodically
stop. When the forward speed of the vehicle has de- clean the underside of the vehicle, including the
creased to almost the idling speed of the engine, tone rings and sensors, to ensure proper ABS
9.7
function and to protect the components from cor-

rosion. Clean more frequently when unusually
corrosive chemicals are being used.
The ECU also has a safety circuit that constantly
monitors the wheel sensors, brake pressure modula-
tor, and the electrical circuitry. The ABS indicator
lamp comes on after the ignition is switched on and
will go out within three seconds if the system is func-
tioning correctly. If the ABS indicator lamp does not
come on, or does not go out after three seconds,
have the vehicle serviced before operation.
If, during vehicle operation, the safety circuit senses
a failure in any part of the ABS system (a sensor,
brake pressure modulator, wiring connection, short
circuit, etc.), the warning lamp comes on and the
control circuit where the failure occurred is switched
to normal braking action. Even if the ABS system is
partially or completely inoperative, normal braking
ability is maintained. An exception would be if the
brake pressure modulator or a hydraulic fluid line is
damaged. Since these components are an integral
part of the hydraulic brake system, normal braking
may be impaired or inoperative.
IMPORTANT: If any of the ABS warning lights
do not work as described above, or come on
while driving, repair the ABS system immedi-
ately to ensure full antilock braking capability.
During emergency or reduced-traction stops, fully
depress the brake pedal until the vehicle comes to a
safe stop; do not pump the brake pedal. With the
brake pedal fully depressed, the ABS system will
control all wheels to provide steering control and a
reduced braking distance.
Although the ABS system improves vehicle control
during emergency braking situations, the driver still
has the responsibility to change driving styles de-
pending on the existing traffic and road conditions.
For example, the ABS system cannot prevent an ac-
cident if the driver is speeding or following too close
on slippery road surfaces.
9.8
10
Fifth Wheels and Trailer
Couplings
Fifth Wheels, General Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.1
Fifth Wheel Coupling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.1
Fifth Wheel Uncoupling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.4
Fifth Wheel Slide . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.7
Fifth Wheels and Trailer Couplings
Fifth Wheels, General Fifth Wheel Lubrication

Information
WARNING
WARNING Keep the fifth wheel plate lubricated to prevent
binding between the tractor and trailer. A binding
Do not use any fifth wheel that fails to operate fifth wheel could cause erratic steering and loss
properly. Doing so may cause loss of vehicle of vehicle control, possibly resulting in personal
control, possibly resulting in severe personal in- injury or death.
jury or death.
The standard fifth wheel plate must be kept well lu-
Air-Suspension Dump Valve bricated with chassis grease to prevent friction and
binding between the tractor fifth wheel plate and the
The air-suspension dump valve may be used to ad- trailer.
just the tractor height to aid with coupling to or un-
For a low-lube fifth wheel plate, inspect the condition
coupling from a trailer. See Fig. 10.1. When the
of the low-lube pads. There should be no damaged
switch is set to LOWER, the air-suspension dump
or missing pieces. Slight puckering at the outside
valve deflates the air springs to lower the rear of the
edges is normal.
vehicle. In the AUTO position, the automatic ride-
control valves operate for normal driving. For lubrication instructions, see Group 31 of the
Business Class M2 Maintenance Manual.
WARNING
Fifth Wheel Coupling
Never exhaust air from the suspension while
driving. The suspension will not absorb road Fifth wheel coupling is activated with the lock control
shocks, possibly damaging components, and ve- handle located on either the right side or left side of
hicle handling may be compromised. This could the fifth wheel. Coupling has successfully occurred
result in loss of vehicle control, possibly result- when the kingpin has been forced into the jaws and
ing in severe personal injury or death. the lock control handle has moved to the locked
position.
NOTICE
NOTICE
Do not operate the vehicle over uneven ground
such as ramps, speed bumps, curbs, etc. with Some fifth wheels may be mounted on sliding
the air springs deflated. Doing this may lead to rails. Before attempting to couple a trailer to a
air bag separation from the piston, preventing the sliding fifth wheel, the slide feature must be
suspension air springs from inflating. locked to prevent the top plate from sliding rap-
idly forward or rearward, causing damage to the
fifth wheel or kingpin.
Fontaine and Holland Fifth Wheels

Coupling
1. Chock the front and rear of the trailer tires to
prevent the trailer from moving.
2. Ensure the fifth wheel jaw is fully open and the
operating rod is in the unlocked position. See
10/26/2001 f610597 Fig. 10.2 or Fig. 10.3.
Fig. 10.1, Air-Suspension Dump Valve

3. Make sure the fifth wheel top plate is tilted so the
ramps are as low as possible.
10.1
1
1
2
1 1
3
B
2
10/26/2010 f310110a
NOTE: Make sure the safety latch is down when the 11/02/2010 f310447
control handle is locked. 1. Safety Latch
A. Unlocked B. Locked 2. Operating Rod (locked)
3. Operating Rod (unlocked)
1. Safety Latch 2. Lock Control Handle
Fig. 10.3, Holland Simplex SE Locking Mechanism
Fig. 10.2, Fontaine Locking Mechanism
4. Position the tractor so that the center of the fifth D

wheel is in line with the trailer kingpin. The king-
C A
pin should be in a position to enter the throat of
the locking mechanism.
NOTICE
Attempting to couple at the wrong height may B
cause improper coupling, which could result in
damage to the fifth wheel or kingpin.
10/28/2010 f311124
5. Adjust the trailer height if required. A. Fifth wheel must lift C. Ramps tilted down
For a standard fifth wheel plate, the trailer trailer D. 4 to 8 inches
should contact the fifth wheel approximately 4 to B. Adjust trailer height
8 inches (10 to 20 cm) behind the fifth wheel Fig. 10.4, Trailer Connection Point, Standard Fifth
pivot. See Fig. 10.4. Wheel
For a low-lube fifth wheel plate, the fifth wheel
prevent from hitting the kingpin too hard, then
must slide freely under the trailer, and the trailer
resume backing slowly until the fifth wheel locks.
should contact the fifth wheel at the pivot. See
Fig. 10.5. On a standard fifth wheel, the fifth wheel must lift
the trailer.
6. With the fifth wheel lock opening aligned with the
trailer kingpin, back the tractor slowly toward the On a low-lube fifth wheel, do not lift the trailer as
trailer. After sliding under the trailer, STOP to this may damage the fifth wheel plate.
10.2
A B
09/10/2010 f311126
A. No gap between trailer B. Kingpin inside lock
and fifth wheel
A
Fig. 10.6, Coupling Inspection
09/10/2010 f311125
A. Adjust trailer height B. Ramps tilted down NOTICE
Fig. 10.5, Trailer Connection Point, Low-Lube Fifth
Always make sure the connection hanger keeps
Wheel
the trailer air hoses and electrical cables posi-
7. Apply the tractor parking brakes. tioned so that they do not rub on anything. Rub-
bing may wear through hoses or cables, resulting
in air leaks, or exposed or broken wires, poten-
WARNING tially affecting trailer brake or electrical systems.
A visual inspection is required by law. Some im- 11. Charge the air brake system with air, checking
proper couplings can pass a pull test. Sound is that the air connections do not leak.
not reliable. Get out of the cab and look. Incor-
rect coupling could cause the trailer to discon- WARNING
nect, possibly resulting in serious personal injury
or death. Incorrect fifth wheel lock adjustment could cause
8. Perform a coupling inspection, checking that the trailer to disconnect, possibly resulting in se-
there is no gap between the bottom of the trailer rious personal injury or death.
and the fifth wheel, and that the kingpin is se- 12. With the trailer wheels chocked and the brakes
curely locked. See Fig. 10.6 set, check for clearance between the kingpin and
When lockup has occurred, the fifth wheel con- the fifth wheel jaws by moving the tractor forward
trol handle moves to the locked position. Make and backward against the locked kingpin. If slack
sure that the safety latch is down over the lock is present, uncouple the trailer and have the fifth
control handle to hold the control handle in the wheel inspected and adjusted by a certified
locked position. (The safety latch will only rotate technician.
down if the operating rod is fully retracted in the
locked position.) See Fig. 10.2 for Fontaine fifth Jost Fifth Wheel Coupling
wheels. See Fig. 10.3 for Holland fifth wheels.
1. Tilt the ramp down.
9. Release the tractor parking brakes. Test for king-
2. Open the kingpin locks. See Fig. 10.7.
pin lockup slowly inching the tractor forward, pull-
ing on the trailer against the chocks. 3. Back the vehicle close to the trailer, centering the
10. After lockup is completed, connect the tractor-to- kingpin on the fifth wheel.
trailer air system lines and the electrical cable to 4. Chock the trailer wheels.
the trailer. Take care to prevent dirt or foreign
material from entering the air system lines. 5. Connect the air lines and electrical cable.
6. Ensure that the red trailer air supply valve (trailer
brake) is pulled out, and that the trailer parking
10.3
nect, possibly resulting in serious personal injury

or death.
A 10. Apply the tractor parking brake, then perform a
physical check for positive kingpin lockup, and
that there is no gap between the trailer and the
fifth wheel. See Fig. 10.6.
11. Ensure that the release handle is in the locked
position adjacent to the casting. See Fig. 10.8.
12. Release the tractor parking brakes and test for
kingpin lockup by slowly moving the tractor for-
09/10/2010 f311128 ward, pulling on the trailer against the chocks.
A. Lock held open by catch mechanism
Fifth Wheel Uncoupling
Fig. 10.7, Jost Release Handle Unlocked
Manual Uncoupling
brakes are set. See Chapter 5 in this manual for
operation of the dash-mounted brake controls. 1. Apply the tractor and trailer parking brakes.
2. Chock the trailer rear wheels.
NOTICE 3. Lower the trailer landing gear until the weight is
Attempting to couple at the wrong height may removed from the fifth wheel.
cause improper coupling, which could result in 4. Disconnect the tractor-to-trailer air system lines
damage to the fifth wheel or kingpin. and electrical cable. Plug the air lines to prevent
7. Adjust the trailer height (if required). dirt or foreign material from entering the lines.
For a standard fifth wheel plate, the trailer 5. Verify that both the yellow parking-brake and red
should contact the fifth wheel approximately 4 to trailer-air-supply knobs are out, the tractor and
8 inches (10 to 20 cm) behind the pivot. See trailer parking brakes are set, and that the trailer
Fig. 10.4. is prepared for uncoupling.
For a low-lube fifth wheel plate, the fifth wheel 6. Release the kingpin locking mechanism following
must slide freely under the trailer, and the trailer the instructions for each manufacturer below.
should contact the fifth wheel at the pivot. See 6.1 Fontaine: Lift the safety latch and pull the
Fig. 10.5. lock control handle to the unlocked posi-
8. Back the tractor under the trailer. tion.
On a standard fifth wheel, the fifth wheel must lift 6.2 Holland: In the locked position the safety
the trailer. indicator swings freely over the operating
rod. See Fig. 10.9, View A.
On a low-lube fifth wheel, do not lift the trailer as
this may damage the fifth wheel plate. To unlock the mechanism, manually rotate
the safety indicator toward the rear of the
9. After sliding under the trailer, STOP to prevent fifth wheel. See Fig. 10.9, View B.
from hitting the kingpin too hard, then resume
backing slowly until the fifth wheel locks. Pull the operating rod out. When the
upper operating rod shoulder is outside
the slot, raise the handle and place the
WARNING shoulder of the upper rod against the plate
casting, above the slot. See Fig. 10.9,
A visual inspection is required by law. Some im-
View C.
proper couplings can pass a pull test. Sound is
not reliable. Get out of the cab and look. Incor-
rect coupling could cause the trailer to discon-
10.4
OK OK
09/10/2010 f311127
Fig. 10.8, Jost Release Handle Locked
The fifth wheel is now in the lockset posi- been uncoupled and coupled again. Failure to do
tion and is ready for uncoupling. As the so may result in separation of the trailer from the
tractor pulls away from the trailer the king- tractor, possibly causing serious personal injury
pin forces the jaw to rotate, contacting the or death.
lock. Continued rotation of the jaw forces
the lock to move outward, and drops the Preparing the Trailer for Uncoupling
upper rod back into the slot. See Fig. 10.9
View D. The wheel is now ready for Before using the air valve to unlock a fifth wheel
coupling. kingpin, prepare the trailer as follows.
1. Apply the tractor and trailer parking brakes.
6.3 Jost: Pull the retractable handle out, then
secure it in the open position with the 2. Chock the trailer rear wheels.
catch.
3. Lower the trailer landing gear until the weight is
7. Release the tractor parking brake then drive out removed from the fifth wheel.
slowly, allowing the trailer to slide down the fifth
wheel and pick-up ramps. 4. Disconnect the tractor-to-trailer air lines and elec-
trical cable. Plug the air lines to prevent dirt or
Air-Actuated Uncoupling foreign material from entering the lines.
An air-actuated kingpin release valve is optional with Fontaine and Holland Fifth Wheels Air-
all fifth wheels. See Fig. 10.10. Activated Kingpin Unlock
NOTE: In the event of an air system failure, air- 1. Verify that both the yellow parking-brake and red
actuated kingpins can be manually released fol- trailer-air supply knobs are out, the tractor and
lowing the instructions for manual unlocking. trailer parking brakes are set, and that the trailer
is prepared for uncoupling.
WARNING NOTE: On Fontaine and Holland fifth wheels, if
the tractor parking brake is not set, the air-
Once the kingpin release valve has been pulled actuated kingpin-release valve will not activate.
the kingpin lock is released. The vehicle MUST
NOT be driven with the trailer until the trailer has
10.5
1
4
A 2 C
B D
11/02/2010 f311133
A. Locked Position C. Lockset Position (upper rod resting against casting
B. Unlatched Position (safety indicator rotated towards the above slot)
rear of the fifth wheel) D. Open Position (ready for recoupling)
1. Safety Indicator 3. Upper Rod
2. Operating Rod 4. Plate Casting
Fig. 10.9, Holland Kingpin Locking Mechanism
2. Pull and hold the kingpin release valve until the Jost Fifth Wheels Air-Activated Kingpin
kingpin lock mechanism opens and locks in Unlock
place. See Fig. 10.10.
1. Verify that both the yellow parking-brake and red
3. Release the pull valve. trailer-air-supply knobs are out, the tractor and
4. Release the tractor parking brake. trailer parking brakes are set, and that the trailer
is prepared for uncoupling.
5. Drive out from under the trailer.
10.6
The maximum axle weight ratings are shown on the

Federal Motor Vehicle Safety Standard (FMVSS)
label or Canadian Motor Vehicle Safety Standard
(CMVSS) label attached to the left rear door post of
the tractor. The desired load on the axle is no less
than 80 percent of the maximum axle weight rating,
but in no instances should the axle load exceed the
maximum axle weight rating given on the FMVSS or
CMVSS label.
Manual Slide Operation

The manual slide feature is operated from the fifth
wheel plate with a manual release handle using the
10/26/2010 f611102 following procedure. See Fig. 10.11.
Fig. 10.10, Air-Actuated Kingpin Release Valve 1
NOTE: With Jost fifth wheels, if the trailer park-
ing brake is not set the air-actuated valve will
not activate.
2. Release the tractor parking brake.
3. Pull and hold the kingpin release valve, then
drive forward slowly.
4. After the trailer has slid down the fifth wheel and
pick-up ramps, release the pull valve.
Fifth Wheel Slide

WARNING
2
Adjust the fifth wheel slide correctly, and do not 07/25/95 f310190
overload any tractor axle by incorrectly loading 1. Locking Wedge
the trailer. Incorrect slide adjustment or improper 2. Slide Release Pull Handle
axle loading could cause erratic steering and
loss of vehicle control, possibly resulting in seri- Fig. 10.11, Manual Release Sliding Fifth Wheel
ous personal injury or death. (Fontaine shown)
On sliding fifth wheel assemblies, the fifth-wheel 1. Stop the tractor and trailer in a straight line on
plate is attached to rails that allow forward and rear- level ground. Pull the red trailer air supply knob
ward movement of the fifth wheel to optimally distrib- to apply the trailer parking brakes.
ute the load across the axles. Slots are evenly 2. Apply the tractor parking brake, then release the
spaced along the slide rails, and retractable wedges sliding mechanism using the appropriate method
are positioned through the slots to hold the fifth for the fifth wheel manufacturer.
wheel in the desired position.
2.1 Fontaine: Lift the slide release pull handle
The amount of load distribution on the front steering to disengage it from the guide plate. Then,
axle and rear drive axle(s) will have a direct effect on pull out the handle until it is in the un-
the steering control of the vehicle. Determine the locked position and can be positioned
front and rear axle weights by weighing the vehicle against the guide plate to hold it out. The
on scales designed for this purpose.
10.7
handle will stay in the unlocked position 5. Release the tractor parking brakes, then slowly
until it is manually disengaged from the move the tractor forward or backward until the
guide plate. See Fig. 10.12. fifth wheel is in the desired location.
NOTICE
When moving the fifth wheel to the desired posi-
tion, be sure the trailer landing gear will not at
any time come in contact with the tractor frame
or other components. Make sure that the front of
the trailer will not come in contact with the rear
of the cab or with other components if they ex-
tend beyond the rear of the cab.
WARNING
Check that the locking wedges have seated in the
slots. Failure to achieve complete lockup may
10/26/2010 f310050
allow disengagement of the tractor from the
trailer, possibly resulting in serious personal in-
Fig. 10.12, Releasing the Sliding Fifth Wheel, (Fontaine) jury or death.
2.2 6. Apply the tractor parking brakes, then lock the

Holland: Pull the operating rod out. Make
sure both side plungers have released. sliding member in position using one of the fol-
See Fig. 10.13. lowing methods:
6.1 Fontaine: Disengage the slide release
5 pull handle from the guide plate. The slide
4 release pull handle is spring-loaded in the
locked position and will seek the locked
6
position when disengaged from the guide
3 plate. After the slide release pull handle
returns to the fully locked position, visually
8 and physically check the locking wedges
3 to make sure they are fully inserted into
2 the slots in the slide rails. Make sure the
handle is locked in position against the
1 7
guide plate.
6.2 Holland: Raise the operating rod so that it
10/26/2010 f310445 is free to move inward. Make sure that the
lock pins have seated in the base plate
1. Baseplate 5. Slider Saddle Plate
2. Bolted Stop 6. Safety Latch rail holes and the operating rod moves
3. Baseplate Rail 7. Operating Rod into the locked position.
4. Fifth Wheel Mount 8. Operating Lever NOTE: The fifth wheel may need to be moved
Fig. 10.13, Sliding Fifth Wheel Manual Release, slightly to enable the locking wedges to enter
(Holland Simplex) the fully locked position.
3. Lower the trailer landing gear just enough to re-
move the weight from the tractor.
4. Chock the front and rear of the trailer tires to
prevent the trailer from moving.
10.8
Air Slide Operation

The slide feature may be operated with an air switch
mounted in the dash, that operates an air cylinder
that locks and unlocks the slide. See Fig. 10.14.
02/22/2011 f611114
Fig. 10.14, Air-Slide Switch
1. Set the air-slide switch to UNLOCK. See

Fig. 10.14
Ensure the locking plungers have released. See
Fig. 10.15. B
For Jost fifth wheels, the mechanism activates as
09/10/2010 f311131
shown in Fig. 10.16.
A. Unlocked B. Locked
2. Lower the trailer landing gear just enough to re-
move the weight from the tractor. Fig. 10.16, Jost Sliding Fifth Wheel
1 3. Pull the red trailer-air-supply knob to set the

trailer-parking brakes.
4. Slowly move the tractor forward or backward
until the fifth wheel is in the desired location.
NOTICE
Ensure the trailer landing gear does not come in
contact with the tractor frame or other compo-
nents, and that the front of the trailer will not
come in contact with the rear of the cab or other
components if they extend beyond the rear of the
cab.
5. Apply the tractor parking brakes.
2 WARNING
07/25/95 f310189
1. Locking Wedge 2. Air Cylinder Check that the locking wedges have seated in the
slots. Failure to achieve complete lockup may
Fig. 10.15, Air-Operated Sliding Fifth Wheel (Fontaine
allow disengagement of the tractor from the
shown)
10.9
trailer, possibly resulting in serious personal in-

jury or death.
6. Set the air-slide switch to LOCK. Visually inspect
the locking wedges or plungers to make sure
that they are fully inserted in the slide rail slots.
Verify that the plungers have engaged by tugging
the tractor forward while the trailer brakes are
locked and the wheels are chocked.
NOTE: The fifth wheel may need to be moved
slightly to enable the locking wedges to fully
lock.
10.10
11
Pretrip and Post-Trip
Inspections and
Maintenance
Pretrip and Post-Trip Inspection Checklists . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11.1
Pretrip and Post-Trip Maintenance Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11.3
Pretrip and Post-Trip Inspections and Maintenance
Pretrip and Post-Trip See Table 11.2 for a list of procedures that should
be performed weekly, post-trip.
Inspection Checklists See Table 11.3 for a list of procedures that should
Regulations in both Canada and the United States be performed monthly, post-trip.
clearly indicate that it is the driver’s responsibility to
perform an inspection and ensure the complete road-
IMPORTANT: Before performing any checks,
worthiness of a vehicle before placing it into service apply the parking brake and chock the tires.
for the day. Commercial vehicles may be subject to
inspection by authorized inspectors, and an unsafe
vehicle can be put "out of service" until the driver or
owner repairs it.
IMPORTANT: The pre- and post-trip checklists,
and inspections and maintenance procedures
detailed in this chapter, are not all-inclusive.
Also refer to other component and body manu-
facturers’ instructions for specific inspection and
maintenance instructions.
Use the inspection checklists to ensure that vehicle
components are in good working condition before
each trip. A driver that is familiar with the vehicle,
and drives it regularly, can perform the daily inspec-
tions, then add the weekly and monthly post-trip in-
spections as scheduled. If the driver does not oper-
ate the vehicle on a consistant basis, all three of the
inspection procedures should be performed before
the trip.
NOTE: Procedure reference numbers in the
checklists reference the corresponding detailed
instructions found under the pretrip and post-trip
maintenance procedures.
Pre- and post-trip inspections cannot be done
quickly. However, careful inspections save time by
eliminating stops later to adjust items overlooked or
forgotten.
If any system or component does not pass this in-
spection, it must be corrected before operating the
vehicle. Whenever equipment requires adjustment,
replacement, repair, addition of lubricants, or a
change of lubricants, see the Business Class® M2
Workshop Manualfor procedures and specifications,
and see the Business Class® M2 Maintenance Manu-
alfor lubricant recommendations, specifications, and
maintenance intervals.
See Table 11.1 for a list of procedures that should
be perfomed daily, before the first trip.
11.1
Procedure Performed Procedure

Daily Pretrip Inspections/Checks
(check off) Reference
_______ Drain manually drained air reservoirs (not equipped with automatic drain valves) D1
Check _______ windshield washer reservoir fluid D2
Check _______ surge tank coolant; and, if equipped, coolant for hybrid cooling system D3
Inspect _______ radiator and charge air cooler D4
Check _______ engine for fuel, oil, or coolant leaks —
Inspect _______ engine and chassis wiring D5
Inspect _______ air intake system D6
Check _______ intake-air restriction indicator mounted on air intake D6
Check _______ engine oil level D7
Check _______ power steering fluid level —
Inspect _______ fuel tank(s), fuel lines, connections, and fuel level D8
Check _______ fuel/water separator D9
Inspect _______ natural gas fuel system, if equipped D10
Inspect _______ front and rear suspension components D11
Inspect _______ headlights, mirrors, and window glass, and windshield wipers D12
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 D6
Check _______ oil- and air-pressure warning systems D13
Check _______ ICU fault codes D14
Check _______ horn, windshield wipers, and windshield washer D15
Check _______ heater, defroster, and optional mirror heat controls D16
Check _______ backup alarm —
Check _______ panel lights and interior lights D17
Check _______ exterior lights and reflectors D18
Check _______ tire pressure D19
Inspect _______ tire condition D20
Inspect _______ rims and wheels D21
Inspect _______ hub oil seals and lubrication levels D22
Check _______ automatic transmission fluid level —
Inspect _______ air brake chambers and pushrods D23
Inspect _______ air brake lines D24
Inspect _______ slack adjusters D25
Check _______ air brake system operation D26
Check _______ Bendix Hydro-Max® Power Booster, if equipped D27
Inspect _______ frame rails (missing bolts) and crossmembers (bent or loose) —
mud flaps (aren’t damaged, at least 10 inches above the ground, and brackets
Check _______ —
are secure)
exhaust system (mounted securely, connected tightly, no signs of leaks such as
Check _______ —
soot trails)
Inspect _______ seat belts and tether belts D28
_______ Remove chocks and test service brakes D29
Inspector___________________________________________________ Date ________________

Table 11.1, Daily Pretrip Inspection and Maintenance Checklist
11.2

Weekly Post-Trip Inspections/Checks
_______ 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

Monthly Post-Trip Inspections/Checks
_______ clean the battery terminals M1
Inspect _______ radiator hoses and heater hoses M2
fluid level in the hydraulic clutch reservoir (if applicable, and if necessary, fill with
Check _______ —
DOT 4 brake fluid)
Check _______ steering wheel play M3
Check _______ outer surfaces of the hood and body (for visible surface breaks and damage) —
Check _______ hood tilt damper (attached at both ends) —
Inspect _______ brake lining wear M4
Inspect _______ driveshaft —
Inspect _______ natural gas fuel system leak test, if equipped M5
_______ drain the CNG high-pressure fuel filter housing, if equipped M6
Inspector___________________________________________________ Date ________________

Table 11.3, Monthly Post-Trip Inspection and Maintenance Checklist
Pretrip and Post-Trip 1.1 Open the wet tank valve. The drain cock
or pull chain drain is located on the for-
Maintenance Procedures ward end of the supply air reservoir, which
is connected directly to the air compres-
Daily Pretrip Inspection and sor. Block the valve open.
Maintenance
Whenever equipment requires adjustment, replace- WARNING
ment, and/or repair, see the Business Class® M2
Workshop Manual for procedures and specifications. When draining the air reservoir, do not look into
Specific references to the manual will be found the air jets or direct them toward anyone. Dirt or
where appropriate. sludge particles may be in the airstream and
could cause injury.
1. Drain manually drained air reservoirs.
1.2 Exhaust the remaining air and moisture
Water and oil normally enter the air reservoir in from the system by opening the drain
the form of vapor because of the heat generated cocks on the bottoms of the remaining air
during compression. After the water and oil con- reservoirs. Block the valves open.
dense, drain the resulting emulsion as follows:
11.3
1.3 Water and oil emulsion often form pockets

that will not drain while compressed air is
in the reservoirs. Because of these pock-
ets, leave the valves blocked open during
the first part of the pretrip inspection.
1.4 If the drained water is cloudy or oily, it
may indicate a problem with the compres-
sor. If oil is allowed to contaminate the air
dryer, it will not remove the water from the
air brake system, which could adversely
affect braking.
2. Check the fluid level in the windshield washer 11/02/2001 f820382
reservoir.
Add coolant here (arrow).
Add washer fluid as needed. Unscrew the cap to
Fig. 11.1, Coolant Level Checking
add fluid.
4.1 Inspect the radiator and charge air cooler
WARNING for clogged fins. Use compressed air or
water directed from the fan side of the
Washer fluids may be flammable and poisonous. core to backflush any material restricting
Do not expose washer fluid to an open flame or airflow.
any burning material, such as a cigarette. Always
4.2 Inspect the radiator and charge air cooler
comply with the washer fluid manufacturer’s rec-
for damage and accumulated debris.
ommended safety precautions.
Straighten bent or damaged fins to permit
3. Check the engine coolant levels in the radiator airflow across all areas of the cores.
surge tank, and, if equipped, the reservoir for the NOTE: When traveling through areas of high
hybrid cooling system.
insect concentration, it may be necessary to
See Fig. 11.1. If the coolant is low, add a 50/50 clean the exterior of the radiator or the
mixture of water and the type of antifreeze speci- charge air cooler core as often as every 200
fied for your vehicle. Fill the surge tank with cool- miles (320 km).
ant to the MAX line when the tank is cool. If the
surge tank was empty, start the engine after re- 4.3 On vehicles equipped with air condition-
filling and check the level again when the engine ing, also inspect and clean the condenser.
is at operating temperature. If clogged, the condenser can restrict air-
flow through the radiator.
For natural gas vehicles, use only Fleetguard ES
Compleat™ EG Premix 50/50 engine coolant. 4.4 Check the radiator for leaks. If leaks are
found, have the radiator repaired or re-
For vehicles equipped with a hybrid cooling sys-
placed. See Group 20 of the Business
tem, the coolant should be approximately 1.5
Class® M2 Workshop Manual for instruc-
inches (4 cm) below the top of the reservoir for
tions, or take the vehicle to an authorized
this system. If the coolant is low, add a 50/50
Freightliner dealer.
mixture of water and the type of antifreeze speci-
fied for your vehicle. 5. Inspect the engine and chassis wiring.
Check for loose wiring, chafed insulation, and
CAUTION damaged or loose hold-down clamps. Tighten
loose wires or hold-down clamps; replace dam-
Coolant must be filled to the full line of the surge aged wiring or clamps.
tank. Low coolant could result in engine over-
heating, which could cause engine damage. 6. Inspect the air intake system for leaks or dam-
age.
4. Inspect the radiator and charge air cooler.
11.4
clogged or dirty. This element should be

CAUTION replaced with every third primary element
replacement.
Failure to maintain a sealed air intake system
could allow the entry of dirt and contaminants 6.4 Check the engine air intake piping from
into the engine. This could adversely affect en- the air cleaner to the engine intake. In-
gine performance and result in engine damage. spect the piping for loose connections,
cracks, torn or collapsed hoses, punc-
6.1 Check the intake-air restriction indicator (if tures, and other damage. Tighten loose
mounted in the air intake system). connections, and have damaged compo-
6.2 Replace the primary filter element in the nents replaced. Make sure the piping sys-
air cleaner (see Fig. 11.2) if the yellow tem is airtight so that all of the intake air
signal stays locked at 25 inH2O for Cater- passes through the air cleaner.
pillar engines or 20 inH2O for Mercedes- 7. Check the engine oil level.
Benz engines. See Group 09 of the
Business Class® M2 Workshop Manual for If the oil level is at or below the minimum fill (or
filter element replacement instructions. "add") mark on the dipstick, add enough oil to
maintain the level between the minimum fill (or
"add") and the maximum fill (or "full") marks on
the dipstick. See Fig. 11.3. Engine lube oil must
have a sulfated ash level less than 1.0 wt %;
currently referred to as CJ-4 oil. Use the proper
SAE viscosity rating for the temperature and time
of year.
1 For natural gas vehicles, use only Exxon Bus-
gard® Geo 15W-40 natural gas engine oil. Bus-
gard Geo engine oil with an SAE grade of
2 15W-40 has multiple benefits in natural gas ve-
hicles, including improved cold-weather starting
and pumping, and reduced oil consumption.
1 2
01/13/99 f011525
NOTE: The MBE900 dipstick is shown.
1. Maximum Fill Level
2. Minimum Fill Level
09/12/2001 f090363
1. Primary Filter Element Fig. 11.3, Checking Engine Oil Level
2. Secondary or Safety Filter Element
Fig. 11.2, Air Cleaner Filter Elements CAUTION

NOTE: After replacing the filter element, Operating the engine with the oil level below the
reset the restriction indicator by pressing the minimum fill (or "add") mark or above the maxi-
rubber reset button. mum fill (or "full") mark could result in engine
damage.
6.3 Inspect the secondary or safety filter ele-
ment in the air cleaner when replacing the 8. Inspect the fuel tanks, fuel lines, and connections
primary element, and replace it when for leaks, and check the fuel level in the fuel
tank(s).
11.5
8.1 Check that the fuel tanks are secured to 8.7 Before installing the fuel cap, clean the
their mounting brackets and that the area with a rag, or if necessary, clean the
mounting brackets are secured to the cap with solvent.
frame.
8.8 If needed, prime the fuel system. For
8.2 Replace leaking fuel tanks. priming procedures, see the applicable
engine manufacturer’s manual.
8.3 If lines or connections are leaking, have
them repaired or replaced. 9. If equipped with a fuel/water separator, check for
For repair and/or replacement procedures, water. Drain any water found. Check the fuel/
see Group 47 of the Business Class® M2 water separator for leaks and contaminants.
Workshop Manual, or take the vehicle in 9.1 Place a suitable container under the fuel/
to an authorized Freightliner dealer. water separator.
8.4 If equipped with fuel tank shutoff valves, 9.2 Check the water level in the sight bowl, if
be sure the valves are fully open. equipped, and loosen the filter vent at the
top of the separator.
WARNING 9.3 Drain the water by loosening the valve at
the bottom and allowing the water to run
Never operate the engine with the fuel tank shut- out. Close and tighten the valve finger-
off valves partly closed. This could damage the tight.
fuel pump, causing loss of engine power and re-
duced vehicle control. 9.4 Close and tighten the filter vent at the top
of the separator.
8.5 Check the fuel level in the fuel tank(s).
IMPORTANT: When draining fluid from a fuel/
To keep condensation to a minimum, fuel
tanks should be filled at the end of each water separator, drain the fluid into an appropri-
day. Federal regulations prohibit filling a ate container and dispose of it properly. Many
fuel tank to more than 95 percent of its states now issue fines for draining fuel/water
liquid capacity. separators onto the ground. On all types of
separators, stop draining fluid when you see
WARNING fuel come out of the separator drain valve.
10. Inspect all natural gas fuel system components,
Do not mix gasoline or alcohol with diesel fuel. if equipped, for damage or leaks. Replace com-
This mixture could cause an explosion, possibly ponents as necessary.
resulting in serious personal injury or death. Do
not fill the fuel tanks in the presence of sparks, 10.1 Inspect fuel tanks for dents, scratches,
open flames, or intense heat. These could ignite gouges, or other signs of damage. Inspect
the fuel, possibly causing severe burns. the fuel lines and connections for leaks.
IMPORTANT: Use ultralow-sulfur diesel 10.2 Check that the fuel tanks are securely
(ULSD) with 15 ppm sulfur content or less, mounted. Look for signs of abrasion be-
based on ASTM D2622 test procedure. Fail- tween components.
ure to use ultralow-sulfur diesel fuels may CNG Fuel System: Ensure that the CNG
void the warranty on emission components. fuel cylinder storage box is secured to the
frame. Inspect for any signs of looseness.
8.6 Fuel should always be strained or filtered
before being put into the tanks. This will LNG Fuel System: Ensure that the LNG
lengthen the life of the engine fuel filter fuel tank is secured to the mounting
and reduce the chances of dirt getting into brackets and that the mounting brackets
the engine. are secured to the frame. Inspect for any
11.6
signs of looseness. Ensure all rubber iso-

lator straps are secure around the LNG 8 9
7
fuel tank. 6 10
10.3 Check for the presence of all required de- 5
cals. Natural gas decals should be present 11
in the following locations:
• Left front bumper 12
• End-of-frame crossmember
• LNG fuel tank fill port (maximum
psi), if equipped 4
10.4 Check for the presence of all necessary
vent caps on pressure relief valves and 3
devices.
2
CNG Fuel System: Check for the pres-
ence of blue caps on all pressure relief
devices. Each fuel cylinder is equipped 1
with two caps (one on each end), which
are visible on the back of the CNG fuel 05/05/2010 f470533
cylinder storage box. One cap is located 1. Pressure Control 7. Primary Relief Valve
on the pressure relief valve on the inboard Regulator 8. Tank Pressure Gauge
side of the CNG fuel box, next to the fuel 2. Vapor Shutoff Valve 9. Fill Vent Fitting
outlet line. If any blue caps are missing, 3. Fuel Fill Hose 10. Excess Flow Valve
remove the vehicle from service and have 4. Secondary Relief 11. Fuel Shutoff Valve
Valve (red cap) (liquid)
the fuel system inspected by a qualified
5. Fuel Fill Fitting 12. Fill Check Valve
technician. 6. Fuel Level Sender
LNG Fuel System: Check for the presence Box
of a red cap on the secondary relief valve.
Fig. 11.4, LNG Tank Plumbing Components
If the red vinyl cap is missing from the
secondary relief valve (Fig. 11.4, Item 4), 10.7 Inspect all coolant hoses for signs of chaf-
remove the vehicle from service and have ing, kinks, or leaks. The LNG fuel system
the fuel system inspected by a qualified utilizes coolant hoses between the engine
technician. and the vaporizer, while the CNG fuel sys-
10.5 Inspect all plumbing components, includ- tem utilizes coolant hoses between the
ing the fuel shutoff valve(s), primary and engine and the pressure regulator inside
secondary relief valves, and the LNG the fuel panel.
vapor shutoff and excess flow valves, if 10.8 If equipped with an LNG fuel system,
equipped, for signs of damage or leaks. check the LNG fuel tank pressure gauge
See Fig. 11.4 or Fig. 11.5. to ensure that pressure is within the nor-
Inspect the fuel fill fitting for signs of dam- mal range of 120 to 150 psi (827 to 1034
age or leaks. kPa). In the unlikely event that tank pres-
sure exceeds 230 psi (1586 kPa) and the
Inspect all lines for signs of leaks or dam- pressure relief valve does not open auto-
age, and check all threaded connections. matically, vent the tank immediately.
10.6 Inspect all fuel gauge components for 10.9 Inspect the LNG vaporizer, if equipped, for
signs of leaks or damage. Inspect the signs of damage or leaks. See Fig. 11.6.
LNG fuel level sender cable and wiring, if
equipped. Inspect the vaporizer mounting brackets
for signs of looseness.
11.7
components do not have adequate gripping sur-

1 2 faces and handholds.
Check the condition of the windshield wiper arms
and blades.
Be sure the windshield wiper blades are ten-
H IG
H PRESS UR E CYLINDERS LOW PRES S U
RE
sioned against the windshield.
INSPECT CYLINDERS
EVERY 36 MONTHS
OR 36000 MILES
REGULATOR
INSPECT PRESSURE
RELIEF DEVICE
WHICHEVER OCCURS FIRST
NATURAL
Inspect the wiper blades for damage and deterio-
EVERY 2000 MILES
110 PSIG
GAS
VEHICLE
rated rubber.
OPEN VALVE
FILTER ON
SLOWLY
3600 PSIG MAX.
SERVICE PRESSURE
DRAIN HOUSING
EVERY 1500 MILES
REPLACE ELEMENT 4 Replace the wiper arms if the wiper blades are
VA T O AL
LV FF
EVERY 3000 MILES

U U
E
SH AN
3
M
not tensioned against the windshield.

Replace damaged or deteriorated wiper blades.
WARNING
04/30/2010 f470556
1. High Pressure Gauge
When cleaning windshields and windows, always
2. Low Pressure Gauge stand on the ground or on a secure ladder or
3. Manual Fuel Shutoff Valve platform. Use a long-handled window cleaner. Do
4. Fuel Fill Port not use the cab steps, tires, fenders, fuel tanks,
engine, or under-hood components to access the
Fig. 11.5, CNG Fuel Panel windshield or windows. Doing so could cause a
fall and result in an injury.
10.10 Inspect the LNG vaporizer overpressure
regulator, if equipped, for signs of damage 13. After starting the engine, make sure the oil- and
or leaks. air-pressure warning systems are operating and
that the buzzer stops sounding when the preset
11. Inspect the front and rear suspension compo- minimum is reached.
nents, including springs, spring hangers, shocks,
and suspension brackets. If the warning systems do not come on when the
ignition is turned on, have the systems repaired.
11.1 Check for broken spring leaves, loose
U-bolts, cracks in the suspension The air pressure in both the primary and second-
brackets, and loose fasteners in the spring ary air reservoir systems must be above 65 psi
hangers and shackles. (448 kPa) on most vehicles. For vehicles with an
optional Bendix dryer reservoir module (DRM),
11.2 Inspect the shock absorbers for loose fas- the cut-out pressure is 130 psi (896 kPa).
teners and leaks.
NOTE: If the air pressure in both systems is
11.3 Tighten all loose fasteners and have any above the preset minimum when the engine is
component(s) replaced that are worn, started, test the low air pressure warning sys-
cracked, or otherwise damaged.
tem by lowering the pressure to below this
11.4 On vehicles with air suspensions, check range, or until the warning system comes on.
for leaks. Check air suspension compo-
nents for cuts and bulges. 14. Check the instrumentation control unit (ICU) for
fault codes.
12. Clean the windshield, side, and rear windows
with a long-handled or telescoping window clean- During the ignition sequence, if an active fault is
ing device and standard cleaning solutions. detected in any device that is connected to the
Stand only on the ground, on a stepladder, or an ECU, the message display screen will show the
elevated walkway. The cab entry/exit steps and active fault codes, one after the other, until the
handholds are not designed for this purpose. The parking brake is released or the ignition switch is
tires, fenders, engine, and other under-hood turned off. See Chapter 2 for detailed operating
instructions for the ICU.
11.8
9
8
1
12
11
10
4 6
2 3
06/29/2009 f470536
1. Pressure Relief Device 5. Coolant Inlet Line 9. Pressure Gauge

2. Fuel Inlet Line 6. Vaporizer 10. Overpressure Regulator
3. Check Valve 7. Fuel Shutoff Solenoid Valve 11. Pressure Relief Valve
4. CNG Quick-Connect Port 8. Coolant Outlet Line 12. Fuel Outlet Line
Fig. 11.6, LNG Vaporizer Assembly
15. Make sure that the horn, windshield wipers, and 17. Check the operation of all the panel lights and
windshield washers are operating properly. interior lights.
These devices must be in good working order for Turn on the headlights, dash lights, and four-way
safe vehicle operation. flashers and leave them on. If any of the gauge
15.1 Make sure that the horn works. If a horn is bulbs, the dome light bulbs, or the right- and left-
not working, have it repaired before trip turn indicator bulbs are not working, replace
departure. them.
15.2 Check the wiper and washer control on 18. Make sure all the exterior lights are working
the multifunction turn signal switch. If the properly.
wipers and/or washers are not working, Check that all the lights and reflectors are clean.
have them repaired before trip departure. See Fig. 11.7.
16. During cold weather, make sure the heater, de- 18.1 Check that the brake lights, taillights,
froster, and optional mirror heat controls are op- headlights, parking lights, turn signals,
erating properly. If so equipped, turn on the mir- marker lights, identification lights, road
ror heat switch and make sure the system is lights (if so equipped), and front clearance
working. lights are working properly and are clean.
11.9
19.3 If a tire has been run flat or underinflated,

1 check the wheel for proper lockring and
3 2 side-ring seating, and possible wheel, rim,
2 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.
4
WARNING
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
5 tire failure and loss of vehicle control, resulting
in serious personal injury or death.
8 7 6
IMPORTANT: The load and cold inflation pres-
10/31/2001 8 f543920
sure must not exceed the rim or wheel manu-
NOTE: The parking lights, front clearance lights, and facturer’s recommendations, even though the
taillights all function as turn signals.
tire may be approved for a higher load inflation.
1. Utility Light 5. Headlight Low Beam Some rims and wheels are stamped with a
2. Identification Light 6. Headlight High Beam
3. Marker Lights 7. Parking Light
maximum load and maximum cold inflation rat-
4. Front Clearance Light 8. Road Light ing. If they are not stamped, consult the rim or
wheel manufacturer for the correct tire inflation
Fig. 11.7, Exterior Lights pressure for the vehicle load. If the load ex-
18.2 Test the high and low beams of the head-
ceeds the maximum rim or wheel capacity, the
lights. load must be adjusted or reduced.
18.3 Replace light bulbs or sealed beam units
that are not working.
CAUTION
18.4 Be sure all reflectors and lenses are in A weekly pressure loss of 4 psi (28 kPa) or more
good condition and are clean. Replace in a tire may indicate damage. The tire should be
any broken reflectors or lenses. inspected and, if necessary, repaired or replaced.
19. Check tire inflation pressures using an accurate 20. Inspect each tire for wear, bulges, cracks, cuts,
tire pressure gauge. penetrations, and oil contamination.
Tires should be checked when cool. For inflation 20.1 Check the tire tread depth. If tread is less
pressures and maximum loads (per tire) see the than 4/32 inch (3 mm) on any front tire, or
tire manufacturer’s guidelines. less than 2/32 inch (1.5 mm) on any rear
tire, replace the tire.
19.1 Be sure valve stem caps are on every tire
and that they are screwed on finger-tight. 20.2 Inspect each tire for bulges, cracks, cuts,
and penetrations.
19.2 Inflate the tires to the applicable pressures
if needed.
11.10
20.3 Inspect each tire for oil contamination. occur, possibly resulting in serious personal in-
Fuel oil, gasoline, and other petroleum jury or death.
derivatives, if allowed to contact the tires,
21.3 Have broken, cracked, badly worn, bent,
will soften the rubber and destroy the tire.
rusty, or sprung rings and rims replaced.
21. Check the wheel nuts or rim nuts for indications Be sure that the rim base, lockring, and
of looseness. Examine each rim and wheel com- side ring are matched according to size
ponent. and type.
21.1 Remove all dirt and foreign material from 21.4 Make sure all wheel nuts are tightened
the assembly. Dirt or rust streaks from the 450 to 500 lbf·ft (610 to 678 N·m) for Ac-
stud holes, metal buildup around stud curide wheels with unlubricated threads.
holes, or out-of-round or worn stud holes Use the tightening pattern in Fig. 11.10 for
may be caused by loose wheel nuts. See 10-hole wheels and the tightening pattern
Fig. 11.8 and Fig. 11.9. in Fig. 11.11 for 8-hole wheels. See
Group 40 of the Business Class® M2
Workshop Manual for more information.
NOTICE
Insufficient wheel nut torque can cause wheel
shimmy, resulting in wheel damage, stud break-
age, and extreme tire tread wear. Excessive
wheel nut torque can break studs, damage
threads, and crack discs in the stud hole area.
Use the recommended torque values and follow
the proper tightening sequence.
22. Inspect the outboard side of all wheel hubs and
the hub oil seal area on the inboard side of each
02/09/95 f400058 wheel for signs of oil leakage.
Fig. 11.8, Dirt and Rust Streaks from the Stud Holes If any oil is found on wheel and tire or brake
components, remove the vehicle from service
21.2 Examine the rim and wheel assembly until the leak has been repaired.
components (including rims, rings, flanges, If needed, fill the hubs to the level indicated on
studs, and nuts) for cracks, or other dam- the hub cap. See Group 35 of the Business
age. Class® M2 Maintenance Manual for recom-
See Group 33 or Group 35 of the mended lubricants.
Business Class® M2 Workshop Manual for NOTE: Vehicles operating under severe or ad-
service procedures on the studs and hubs,
and see Group 40 in the same manual for verse conditions should be checked more fre-
wheel and tire servicing, or take the ve- quently.
hicle to an authorized Freightliner dealer. 23. Inspect the air brake chamber and the air brake
chamber pushrods.
WARNING
WARNING
Have any worn or damaged wheel components
replaced by a qualified person using the wheel Do not operate the vehicle with the front brakes
manufacturer’s instructions and the wheel indus- backed off or disconnected. Backing off or dis-
try’s standard safety precautions and equipment. connecting the front brakes will not improve ve-
Otherwise a vehicle or workshop accident could hicle handling and may lead to loss of vehicle
11.11
02/09/95 f400001
Fig. 11.9, Worn Stud Holes
control, resulting in property damage or personal

1 injury.
10 8 23.1 Check that the air brake chamber is
mounted securely on its mounting bracket,
and that there are no loose or missing
3 6 bolts.
23.2 Look for worn clevis pins on brake cham-
5 4 ber pushrods and missing or damaged
cotter pins on brake chamber pushrod cle-
vis pins. Replace worn clevis pins and in-
7 9 stall new cotter pins if necessary.
2 23.3 See if the chamber piston rod is in line
08/23/93 f400081a
with the slack adjuster. Misalignment can
Fig. 11.10, Tightening Pattern, 10-Hole Wheels cause the piston rod to rub on the non-
pressure chamber and cause a dragging
brake. See Group 42 of the Business
A Class® M2 Workshop Manual.
1 2
CAUTION
7 4
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
5 6 and debris can cause the internal parts of the
chamber to deteriorate faster.
23.4 Inspect the exterior surfaces of the cham-
ber for damage. Make sure that breather
3 8
08/20/93 f400052a holes in the non-pressure section(s) are
open and free of debris. See Group 42 of
Fig. 11.11, Tightening Pattern, 8-Hole Wheels the Business Class® M2 Workshop
Manual to replace any damaged parts.
11.12
24. Inspect the air brake lines.

DANGER
24.1 Check the clearance between the hoses
Do not loosen or remove the parking brake clamp and the exhaust manifold or other hot
ring for any purpose. The parking/emergency spots. Excessive heat will cause material
brake section of the brake chamber is not in- in the hoses to deteriorate rapidly or be-
tended to be serviced. Serious injury or death come brittle. Provide at least 6 inches
may result from sudden release of the power (150 mm) of clearance. More clearance is
spring. recommended if the hose is located above
the heat source.
Before doing any repairs or adjustments on a
service/parking brake chamber, read the appli- 24.2 Check for kinks, dents, or swelling of the
cable warnings and instructions in Group 42 of hoses. If damaged, have the hose re-
the Business Class® M2 Workshop Manual. placed with the same size and type.
23.5 On all parking brake installations, make NOTE: Do not route the hose on top of any-
sure the end cover cap or dust plug is se- thing likely to be stepped on.
curely snapped into place. See Fig. 11.12.
24.3 Check for damage to hoses located near
moving parts, such as drivelines, kingpins,
suspensions, and axles. If moving parts
are catching or pinching the lines, correct
1 as needed.
24.4 Check for hose damage caused by abra-
sion. If abraded, have the hose replaced.
A
Check for the cause of abrasion, such as
loose or damaged hose clamps. Have the
clamps repaired or replaced as needed.
24.5 Observe the hose cover condition, espe-
cially hoses exposed to water splash and
ice. If dried out or ragged (the wire or liner
is showing through the cover), have the
hose(s) replaced.
24.6 Inspect the air tubing, especially tubing
made of nylon. In cold weather, nylon tub-
ing is sensitive to damage, such as nicks
or cuts. Have nicked or cut tubing re-
02/22/2000 f421352 placed, even if it is not leaking.
A. Do not remove this clamp ring. 24.7 Check for kinked or twisted hoses. A
1. MGM TR–T (TR Series) Brake Chamber shown seven-percent twist in the hose can re-
duce its life by up to 90 percent. A twisted
Fig. 11.12, Parking Brake Chamber Clamp
hose under pressure tends to untwist,
NOTE: On most MGM parking brake cham- which may loosen the fitting. Reconnect
hoses that are twisted.
bers equipped with an integral release bolt,
an end cover cap is installed over the re- NOTE: The front brake lines flex continu-
lease bolt. ously in vehicle operation, so they require
23.6 Check for rusted connections, missing
special examination. Give particular attention
snap rings, and damaged camshaft to the areas near where they connect to the
grease seals. Have damaged or missing front air brake chambers. This inspection
parts repaired or replaced. requires two people, one in the driver seat
11.13
and another to inspect the brake line con-

nections at the wheels.
4
24.8 Both wheel air lines must be inspected 5
with the emergency brake set, engine 6
idling, air pressure at 80 to 90 psi (550 to
620 kPa), and the brake pedal held down. 7
3 8
24.9 Turn the wheels to full lock in one direc-
tion and inspect both air lines where they
connect to the air chambers, then turn the 2 9
wheels to full lock in the other direction
and inspect both lines. If a hose is leak- 1
ing, have it replaced.
10
IMPORTANT: ABS-equipped vehicles operat-
ing in regions where especially corrosive
ice-removal chemicals are used may experi- 06/17/2003 f421398
ence higher than normal rotor corrosion. 1. 7/16-inch Adjusting 6. Clevis
Tone rings should be routinely inspected for Nut 7. 1/2-inch Clevis Pin
corrosion. Severe corrosion of the integral 2. Grease Fitting 8. 1/4-inch Clevis Pin
ABS tone ring may cause the ABS warning 3. Boot 9. Grease Relief
4. Link Opening
lamp in the dash to illuminate due to false 5. Brake Chamber Piston 10. Slack Adjuster Spline
wheel speed readings. If the ABS warning Rod
lamp illuminates at any time other than at
vehicle start-up, have the problem repaired Fig. 11.13, Gunite Automatic Slack Adjuster
immediately. eral times. The air governor should cut in
25. Inspect the slack adjusters. the air compressor at approximately 100
psi (689 kPa). If the air governor does not
25.1 Meritor Slack Adjusters: Check the boot cut in and out as described above, it must
for cuts, tears, or other damage. Have it be adjusted to these specifications. If the
replaced if necessary. air governor cannot be adjusted or re-
25.2 Gunite Slack Adjusters: Inspect the slack paired, replace it before operating the ve-
adjuster for any signs of damage. If dam- hicle.
aged, have the slack adjuster replaced. 26.2 Check the air pressure buildup time as
Inspect the slack adjuster boot for cuts or follows.
tears. If the boot is damaged, have it re- With the air system fully charged to 120
placed. See Fig. 11.13. psi (827 kPa), make one full brake appli-
25.3 Haldex Slack Adjusters: Inspect each cation and note the air pressure reading
slack adjuster and anchor strap for dam- on the gauge. Continue to reduce the air
age. See Fig. 11.14. Have any damaged pressure by moderate brake applications
components replaced. to a maximum of 90 psi (620 kPa), then
run the engine at governed rpm. If the
26. Check the air brake system for proper operation. time required to raise the air pressure to
26.1 Check the air governor cut-in and cut-out 120 psi (827 kPa) (from the pressure
pressures as follows. noted after one brake application) is more
than 30 seconds, eliminate any leaks or
Run the engine at fast idle. The air gover- replace the air compressor before operat-
nor should cut out the air compressor at ing the vehicle.
approximately 120 psi (827 kPa). With the
engine idling, apply the brake pedal sev- 26.3 Check the air pressure reserve as follows.
11.14
vice brake applied, shut down the engine,

wait 1 minute and note the air pressure
1 gauge reading. Observe the air pressure
2 drop in psi (kPa) per minute.
If leakage exceeds the limits shown in
3 Table 11.4, repair all areas of leakage be-
fore driving the vehicle.
Maximum Allowable Service Brake Air Leakage

Air Leakage in psi
4 8 9 Description (kPa) Per Minute
Released Applied
7
Truck or Tractor Only 2 (14) 3 (21)
6 Truck or Tractor w/Single Trailer 3 (21) 4 (28)
Truck or Tractor w/Two Trailers 5 (35) 6 (42)
5 Table 11.4, Maximum Allowable Service Brake Air

10/11/2005 A f421397
Leakage
A. Rotate the control arm toward the brake chamber
until you can feel it contacting the internal stop. 27. Check the operation of the Bendix Hydro-Max®
1. Clevis 6. Control-Arm Washers brake booster, if equipped, as follows.
2. Slack Adjuster and Nut 27.1 With the engine off, depress the brake
3. Clevis Pin 7. Anchor Strap Slot
4. Manual Adjusting Nut 8. Anchor Strap pedal; the warning light and buzzer should
5. Control Arm 9. Brake Chamber come on, and the electric motor should
run.
Fig. 11.14, Haldex Automatic Slack Adjuster
27.2 Start the engine and allow the gauges to
With the air system fully charged to 120 sweep. Depress the brake pedal; no warn-
psi (827 kPa), stop the engine and note ing lights, buzzer, or electric motor should
the air pressure. Then make one full brake come on.
application and observe the pressure 28. Inspect the seat belts and tether belts.
drop. If it drops more than 25 psi (172
kPa), all areas of leakage must be elimi-
nated before operating the vehicle. WARNING
26.4 Check the air leakage in the system as Inspect and maintain seat belts. When any part of
follows. a seat belt system needs replacement, the entire
With the parking brake (spring brake) ap- seat belt must be replaced, both retractor and
plied, the transmission out of gear, and buckle side. Any time a vehicle is involved in an
the tires chocked, charge the air system accident, and the seat belt system was in use,
until cut-out pressure of 120 psi (827 kPa) the entire vehicle seat belt system must be re-
is reached. placed before operating the vehicle. Do not at-
tempt to modify the seat belt system; doing so
With the service brakes released, shut could change the effectiveness of the system.
down the engine, wait 1 minute and note Failure to replace worn or damaged seat belts, or
the air pressure gauge reading. Observe making any modifications to the system, may re-
the air pressure drop in psi (kPa) per sult in personal injury or death.
minute.
Charge the air system until cut-out pres-
sure of 120 psi (827 kPa) is reached. With
the parking brakes released and the ser-
11.15
28.1 Check the web for fraying, cuts, extreme 2. Check the level of the wheel bearing lubricant in
dirt and dust, or for severe fading from the hub cap at each end of the front axle.
exposure to sunlight, especially near the
If needed, fill the hubs to the level indicated on
buckle latch plate and in the D-loop guide
the hub cap. See Group 35 of the Business
area. Class® M2 Maintenance Manual, for recom-
28.2 Check operation of the buckle, latch, Kom- mended lubricants.
fort Latch or Sliding Komfort Latch (if
IMPORTANT: Before removing the fill plug, al-
equipped), web retractor, and upper seat
belt mount on the door pillar. Check all ways clean the hub cap and plug.
visible components for wear or damage. 3. Examine the steering components.
28.3 Check the seat belt and tether belt con- See Fig. 11.15. If repairs are needed, see
nection points and tighten any that are Group 46 of the Business Class® M2 Workshop
loose. Manual for instructions, or take the vehicle to an
29. Test the service brakes. authorized Freightliner dealer.
When starting to move the vehicle and before

picking up speed, test the brakes with the foot
pedal and parking brake control valve (yellow
knob) to be sure they will bring the vehicle to a
safe stop.
Weekly Post-Trip Inspection and 1

Maintenance
1
WARNING
Battery posts, terminals, and related accessories 2 1
contain lead and lead compounds, chemicals
known to the State of California to cause cancer 3
and reproductive harm. To prevent possible per-
3
sonal injury, always wash your hands after han-
dling battery parts and related accessories.
1. Inspect the batteries and battery cables. 10/11/2001 f461916
1.1 Access the batteries. Be sure the battery 1. Steering Gear Mounting Bolt
hold-down is secure. If it is loose, tighten 2. Pitman Arm Pinch Bolt Nut
the hold-down bolts; if it is broken, replace 3. Drag Link Nut
it. Fig. 11.15, Steering Gear Fasteners
1.2 If the battery is equipped with a built-in
hydrometer, examine the hydrometer. If a 3.1 Check the mounting bolts and pitman arm
green dot shows in the sight glass, the nut for tightness.
battery is sufficiently charged. 3.2 Check the drag link nuts for missing cotter
If the sight glass is dark, the charge is low pins.
and the battery must be recharged. 3.3 Inspect the steering drive shaft and steer-
If the sight glass is clear, the battery has a ing linkage for excessive looseness, or
low level of electrolyte and must be re- other damage.
placed. 3.4 Tighten loose nuts and have damaged
parts replaced as needed.
11.16
4. Check the condition of the serpentine drive belt. 1. Clean the batteries.
Look for signs of glazing, wear (frayed edges), 1.1 Remove any corrosion from the hold-down
damage (breaks or cracks), or oil contamination. and the top of the battery.
If a belt is glazed, worn, damaged, or oil soaked,
have the belt replaced, following the instructions
in Group 01 of the Business Class® M2 Work-
NOTICE
shop Manual. Take care to keep the vent plugs tight so that the
neutralizing solution does not enter any of the
NOTICE battery cells and damage the battery.
Do not drive with a serpentine belt that is visibly 1.2 Use a soda solution to neutralize the acid
worn or damaged. If it fails, the lack of coolant present, then rinse off the soda solution
flow could rapidly cause damage to engine com- with clean water.
ponents. 1.3 If the battery posts or cable terminals are
5. Check the drive belt for proper tension. corroded, disconnect the terminals from
the posts. Clean them with a soda solution
Use your index finger to apply force at the center and a wire brush. After cleaning, connect
of the belt free-span. See Fig. 11.16. There is no the terminals to the battery posts, then
adjustment for belt tension on engines with auto- apply a thin coat of petroleum jelly to the
matic belt tensioners. If there is not proper ten- posts and terminals to help retard corro-
sion, have the belt tensioner replaced. See sion.
Group 01 of the Business Class® M2 Workshop
Manual for instructions, or take the vehicle to an 2. Inspect the radiator and heater hoses, including
authorized Freightliner dealer. 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 Make sure the heater hoses are pliable
A and are not cracking or ballooning. Re-
place hoses that show signs of cracking,
B weakening, or ballooning.
2.3 Tighten hose clamps as necessary, but do
10/31/94 f200036a not overtighten, as hose life can be ad-
versely affected.
A. Deflection B. Belt Free-Span
2.4 Be sure the hose support brackets are
Fig. 11.16, Checking Belt Tension securely fastened. Make sure the hoses
are not located near sources of wear,
Monthly Post-Trip Inspection and abrasion, or high heat.
Maintenance IMPORTANT: Replace all hoses, including
heater hoses, at the same time. Service-type
WARNING knitted or braided yarn-reinforced neoprene
hose is acceptable. Silicone hoses having an
Battery posts, terminals, and related accessories
contain lead and lead compounds, chemicals
extended service life can be substituted for the
known to the State of California to cause cancer reinforced neoprene type. See the Freightliner
and reproductive harm. To prevent possible per- Service Parts Catalog or contact your Freight-
sonal injury, always wash your hands after han- liner Dealer.
dling battery parts and related accessories. 3. Check the steering wheel for excessive play.
11.17
3.1 Start the engine. With the front tires 6. Drain the CNG high-pressure fuel filter housing,
straight ahead, turn the steering wheel if equipped.
until motion is observed at the front
6.1 Purge the CNG fuel lines by closing the
wheels.
CNG fuel cylinder shutoff valves. Start the
3.2 Align a reference mark on a ruler, then engine and let it idle until the fuel lines are
slowly turn the steering wheel in the oppo- empty and the engine stops.
site direction until motion is again detected Gauges on the fuel panel should now read
at the wheels. at or near 0 psi (0 kPa).
3.3 Check the lash (free play) at the rim of the 6.2 Close the manual fuel shutoff valve on the
steering wheel. See local/federal regula-
fuel panel.
tions for acceptable ranges of lash.
6.3 Remove the two capscrews that secure
If there is excessive lash, check the steer-
the access cover to the fuel panel, then
ing system for wear or incorrect adjust-
remove the access cover. See Fig. 11.17.
ment of the linkage and steering gear be-
Save the capscrews for installation.
fore operating the vehicle.
4. Check the brake lining wear on all vehicles, in-
cluding those with automatic slack adjusters.
Proper brake operation is dependent on periodic
maintenance and inspection of the brake linings.
4.1 Check that brake linings are free of oil and
grease.
8
4.2 Inspect the thickness of the brake linings.
If the axle assembly is equipped with a
dust shield or backing plate, remove the
inspection plugs. If any brake linings are 7
worn to less than approximately 1/4 inch
(6.4 mm) at the thinnest point, have the
linings replaced on all brake assemblies 2
on that axle. See Group 42 of the 6
Business Class® M2 Workshop Manual for 5
lining replacement instructions and cam- 4
3 2
shaft end-play inspection.
4.3 Check the brake drums for wear and
cracks.
4.4 Check that the inspection plugs in the dust
shields or backing plates, if so equipped,
are installed.
5. Leak test the natural gas fuel system, if 1
equipped. 05/04/2010 f470557
Use a methane detector to test all fuel system 1. Fuel Panel Access 5. Coolant Outlet Line
components, joints, and fittings for leaks. A Cover 6. Coolant Inlet Line
bubble solution can be used to pinpoint the exact 2. Capscrews (qty 2) 7. Fuel Inlet Line (to fuel
location of leaks. 3. Wiring Harness cylinders)
4. Pressure Relief Valve 8. Fuel Outlet Line (to
Replace any leaking or damaged fuel tanks and and Cap engine)
fuel lines; repair or replace leaking or damaged
fittings. Fig. 11.17, CNG Fuel Panel Assembly
11.18
6.4 Slowly open the bleed valve on the mani- 6.8 Use a methane detector to leak test all
fold to relieve remaining fuel pressure fuel system components between the fuel
within the system. See Fig. 11.18. cylinders and the solenoid valve. A bubble
solution can be used to pinpoint the exact
6 location of leaks.
5
Repair or replace any leaking compo-
7 nents.
6.9 Using the two capscrews removed in sub-
step 6.3, install the access cover on the
fuel panel.
4 8
2 10 9
13 12 11
14
1
05/04/2010 f470558
1. Coolant Inlet Port 9. Fuel Fill Port
2. Coolant Outlet Port 10. Filter Housing
3. Pressure Relief Valve 11. Filter Bowl
4. Pressure Regulator 12. Filter Drain Plug
5. Wiring Harness 13. Solenoid Valve
6. Manifold Bleed Valve 14. Fuel Line To Cylinders
7. Manifold
8. Manual Fuel Shutoff
Valve
Fig. 11.18, CNG Fuel Panel Components
IMPORTANT: Some pressure may remain in

the fuel system between the solenoid valve
and the engine. Use caution when loosening
fittings, as a small amount of gas may leak
out.
6.5 Put a clean receptacle under the filter as-
sembly.
6.6 Using an 11/16-inch wrench, remove the
drain plug from the filter bowl.
When all liquid has drained, install and
tighten the drain plug on the filter bowl.
6.7 Close the bleed valve on the manifold and
open the manual fuel shutoff valve on the
fuel panel.
Open the fuel cylinder shutoff valves.
11.19
12
Cab Appearance
Cab Washing and Polishing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12.1
Care of Fiberglass Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12.1
Care of Chrome Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12.1
Care of Exterior Lights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12.1
Dashboard Care . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12.1
Vinyl Upholstery Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12.2
Velour Upholstery Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12.2
Cab Appearance
Cab Washing and Polishing Care of Fiberglass Parts

Wash unpainted fiberglass air fairings and shields
CAUTION monthly with a mild detergent, such as dishwashing
liquid. Avoid strong alkaline cleansers.
When pressure washing the vehicle or leaving
the hood open when parked outdoors and sub- Apply a wax specifically designed for fiberglass.
ject to rain, cover the air cleaner inlet with a plas-
tic bag to prevent water from entering the air in- Care of Chrome Parts
take system and possibly damaging the engine.
To prevent rust, keep chrome parts clean and pro-
To protect the finish of your new vehicle, follow these tected at all times. This is especially important during
guidelines carefully: winter driving and in coastal areas where there is
• During the first 30 days, rinse your vehicle fre- exposure to salt air.
quently with water. If the vehicle is dirty, use a When cleaning chrome parts, use clean water and a
mild liquid soap. Do not use detergent. soft cloth or sponge. A mild detergent may also be
• During the first 30 days, do not use anything used.
abrasive on your vehicle. Brushes, chemicals, Sponge gently, then rinse. If necessary, use a non-
and cleaners may scratch the finish. abrasive chrome cleaner to remove stubborn rust or
• During the first 120 days, do not wax your other material. Do not use steel wool.
vehicle. To help protect the chrome after cleaning, apply a
To extend the life of your vehicle’s finish, follow these coat of polishing wax to the surface. Never use wax
guidelines: on parts that are exposed to high heat, such as ex-
haust pipes.
• Avoid washing your vehicle in the hot sun. Al-
ways use water. After the cab is completely
washed, dry it with a towel or chamois. Care of Exterior Lights
• Do not dust painted surfaces with a dry cloth, Clean the headlight lenses by hand only, using a
as this will scratch the paint. flannel cloth with mild, non-caustic soap or detergent,
and water.
• Do not remove ice or snow from a painted sur-
face with a scraper of any sort.
CAUTION
• To prevent damage to the finish, wax it regu-
larly. If the finish has become dull, before wax- Do not use a power buffer, paper towels, chemi-
ing, remove oxidized paint using a cleaner spe- cal solvents, or abrasive cleaners on the head-
cifically designed for this purpose. Remove all light lens, all of which can remove the UV coating
road tar and tree sap before waxing. Freight- from the surface, and result in yellowing of the
liner recommends that a quality brand of lens.
cleaner or cleaner-polish and polishing wax be
used. Dashboard Care
• Do not let diesel fuel or antifreeze stand on a
painted surface. If either should occur, rinse Periodically wipe the dashboard with a water-
the surface off with water. dampened cloth. A mild detergent can be used, but
avoid using strong detergents.
• To prevent corrosion, have any nicks or other
damage on the finish touched up as soon as CAUTION
possible.
• Park your vehicle in a sheltered area whenever Do not use Armor-All Protectant®, STP Son-of-a-
possible. Gun®, or other equivalent treatments. These
cleaners contain vinyl plasticizers that can cause
12.1
Cab Appearance
stress crazing in the interior plastic panels, pentine may be used. Use care to prevent contact
which can result in cracking of the panels. with parts of the upholstery that are not vinyl.
Vinyl Upholstery Cleaning Sulfide Stains

To prevent soiling, frequent vacuuming or light brush- Sulfide compounds, such as those found in eggs and
ing to remove dust and dirt is recommended. Harsh some canned goods, can stain after prolonged con-
cleaning agents can cause permanent damage to tact with vinyl. These stains can be removed by plac-
vinyl upholstery. To preserve the upholstery and pre- ing a clean, unprinted piece of cloth over the spotted
vent damage, carefully review the following sections area and pouring a liberal amount of 6 percent hy-
for recommended cleaning procedures. Waxing or drogen peroxide onto the cloth. Allow the saturated
refinishing improves soil resistance and cleanability cloth to remain on the spot for 30 to 60 minutes. For
for all vinyls. Any hard wax, such as that used on stubborn spots, allow the hydrogen-peroxide satu-
automobiles, may be used. rated cloth to remain on the area overnight. Use cau-
tion to prevent the solution from seeping into the
Ordinary Dirt seams or it will weaken the cotton thread.
Wash the upholstery with warm water and mild soap, Nail Polish and Nail Polish Remover
such as saddle or oil soap. Apply soapy water to a
large area and allow to soak for a few minutes, then Prolonged contact with these substances causes per-
rub briskly with a cloth to remove the dirt. This can manent damage to vinyl. Careful blotting immediately
be repeated several times as necessary. after contact minimizes damage. Do not spread the
liquid during removal.
If dirt is deeply imbedded, use a soft bristle brush
after applying the soap. Shoe Polish
If dirt is extremely difficult to remove, wall-washing Most shoe polishes contain dyes which penetrate
preparations normally found around the home can be vinyl and stain it permanently. Shoe polish should be
used. Powdered cleaners, such as those used for wiped off as quickly as possible using naphtha or
sinks and tiles, are abrasive and must be used with lighter fluid. If staining occurs, try the procedure used
caution as they can scratch the vinyl or give it a per- for sulfide stains.
manent dull appearance.
Chewing Gum Ball Point Ink

Ball point ink can sometimes be removed if rubbed
Harden the gum with an ice cube wrapped in a plas- immediately with a damp cloth, using water or rub-
tic bag, then scrape it off with a dull knife. Any re- bing alcohol. If this does not work, try the procedure
maining traces of gum can be removed with an all- used for sulfide stains.
purpose light oil (peanut butter will also work) and
wiped off.
Miscellaneous
Tars, Asphalts, and Creosote If stains do not respond to any of the treatments de-
scribed above, it is sometimes helpful to expose the
Tars, asphalts, and creosote stain vinyl after pro-
vinyl to direct sunlight for up to 30 hours. Mustard,
longed contact. They should be wiped off immedi-
ball point ink, certain shoe polishes, and dyes often
ately and the area carefully cleaned, using a cloth
bleach out in direct sunlight leaving the vinyl undam-
dampened with naphtha.
aged.
Paint, Shoe Heel Marks
Velour Upholstery Cleaning
Paint should be removed immediately. Do not use
paint remover or liquid-type brush cleaner on vinyl. To prevent soiling, frequent vacuuming or light brush-
An unprinted cloth, dampened with naphtha or tur- ing to remove dust and dirt is recommended. Spot
clean with a mild solvent or an upholstery shampoo,
12.2
Cab Appearance
or the foam from a mild detergent. When using a sol-

vent or a dry-cleaning product, follow the instructions
carefully and clean only in a well-ventilated area.
Avoid any product that contains carbon tetrachloride
or other toxic materials. With either method, pretest a
small area before proceeding. Use a professional
upholstery cleaning service when extensive cleaning
is needed.
Grease and Oil-Based Stains

Dampen a small absorbent cloth with dry-cleaning
solvent or spot remover. Apply the cloth carefully to
the spot from the outer edge to the center. Pat and
blot the spot with a clean, dry cloth. Repeat several
times, as necessary, turning the cloths so that the
stain does not redeposit on the fabric.
Sugar and Water-Based Stains

Apply water-based detergent or cleaner, working in
circular motions. Pat and blot as dry as possible. Re-
peat if necessary before drying thoroughly.
Chewing Gum or Wax

Harden the gum or wax with an ice cube wrapped in
a plastic bag, then scrape it off with a dull knife. Ex-
cess wax can be absorbed by placing a thick white
blotter over the wax and heating with a warm (not
hot) iron. Remove the remainder by using the proce-
dure for grease and oil-based stains.
Mildew
Brush the dry fabric with a soft brush. Sponge with
detergent, and blot. If the fabric is colorfast, dilute a
teaspoon of bleach in one quart (one liter) of cool
water. Apply with a swab, directly on the mildew
stain. Dab repeatedly with clear, cool water, and blot
dry.
12.3
13
In an Emergency
Hazard Warning Lights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13.1
Fire Extinguisher . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13.1
Emergency Kit, Optional . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13.1
Emergency Filter Replacement, Davco . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13.1
Emergency Starting With Jumper Cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13.2
Towing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13.5
Fire in the Cab . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13.6
In an Emergency
Hazard Warning Lights WARNING

The hazard warning light flasher (Fig. 13.1) is part of
the multifunction turn signal switch. It is a red rocker Use extreme care when placing flares in emer-
switch located on the top of the multifunction switch gency situations that involve exposure to flam-
module. mable substances such as fuel. An explosion or
fire could occur causing serious personal injury.
4
Emergency Filter
Replacement, Davco
5
If the filter cover on the Davco fuel/water separator is
broken, it will not be possible to operate the vehicle.
1 A standard spin-on filter will correct this problem.
2 Refer to the Davco web site for additional informa-
tion, www.davcotec.com.
3
To replace the filter on all Davco fuel/water separa-
tors, follow these procedures:
11/16/2001 f820386
1. Drain the fuel until it is below the level of the fil-
Press down on the upper part of the rocker to activate ter collar. See Fig. 13.2 for the model 232/233
the flashers. fuel/water separator and Fig. 13.3 for the model
1. Washer Button 382 fuel/water separator.
2. Wiper Control Dial
3. Turn Signal Lever 2. Remove the filter vent and vent seal.
4. Hazard Flasher (red)
5. Multifunction Switch Module NOTE: The filter vent and vent seal are not
needed in the emergency replacement. They
Fig. 13.1, Hazard Warning Flashers should be retained for later installation at the
To flash the hazard warning lights, press down on time when the filter cover is replaced.
the upper part of the rocker (towards the dash). To 3. Remove the filter collar using channel-lock pliers.
stop the hazard warning lights, press down on the
lower part of the rocker (towards the steering wheel). 4. Remove the filter cover, filter cover seal and
spring. Retain them for later assembly.
Fire Extinguisher 5. Remove the filter element and dispose of it prop-
erly.
A fire extinguisher is located in the cab by the driv-
er’s door. 6. Install the standard engine spin-on filter (included
in the emergency kit) on the threaded stud.
Emergency Kit, Optional NOTE: Remove the rubber grommet from the
stud.
An optional emergency kit is located in the cab. The
kit includes one or more of the following: a first aid 7. Install the filter cover, filter cover seal, and
kit, a reflective vest, a triangular reflector, a flare kit, spring, as removed.
and (on vehicles with a Davco fuel/water separator) a 8. Install the filter collar over the filter cover. Tighten
spin-on fuel filter element.
the filter collar finger-tight.
If there is an emergency while driving, cautiously pull
9. Start the engine and run it at increased rpm for
off the road. Turn on the hazard warning lights. Place
one minute to purge air from the fuel lines.
the flares and reflector along the side of the road to
alert other drivers that an emergency situation exists.
13.1
In an Emergency
6
10
11/14/2001 f470416
1. Filter Vent 5. Filter Cover Seal 8. Threaded Stud
2. Filter Vent Seal 6. Spring 9. Fuel Port
3. Filter Collar 7. Filter Element 10. Drain
4. Filter Cover
Fig. 13.2, Davco Model 232 and 233 Fuel/Water Separator
Emergency Starting With in the vicinity of the battery. Do not allow the ve-
hicles to touch each other. Do not lean over the
Jumper Cables batteries when making connections, and keep all
other persons away from the batteries. Failure to
When using jumper cables, follow the instructions follow these precautions could lead to severe
below. personal injury as a result of an explosion or
acid burns.
WARNING
Batteries release explosive gas. Do not smoke
when working around batteries. Put out all flames
and remove all sources of sparks or intense heat
13.2
In an Emergency
3
8
9
6
10
11
11/14/2001 f470417
1. Filter Collar 5. Filter Cover Seal 9. Fuel Port
2. Filter Vent 6. Spring 10. Drain
3. Filter Vent Seal 7. Filter Element 11. Bottom Plate Collar
4. Filter Cover 8. Threaded Stud
Fig. 13.3, Davco Model 382 Fuel/Water Separator
1. Apply the parking brakes and turn off the lights

CAUTION and all other electrical devices.
Make sure both starting systems have the same 2. To gain access to the batteries, open the battery
voltage outputs, and avoid making sparks. Other- compartment. See Fig. 13.4. For detailed instruc-
wise the vehicle charging systems could be se- tions, see Chapter 2.
verely damaged. Also, do not attempt to charge
isolated, deep-cycle batteries with jumper cables. CAUTION
Follow the battery manufacturer’s instructions
when charging deep-cycle batteries. Always connect the battery, jumper cables, and
charger correctly (positive-to-positive and
NOTE: On vehicles equipped with an optional negative-to-negative). Connecting a charging de-
jump-start post, attach the positive cable clamp vice backwards (positive-to-negative) will blow
to that post instead of to the battery. fuses that power the bulkhead module (BHM) and
13.3
In an Emergency
chassis module (CHM), and the devices they con-

trol will not work. WARNING
3. Connect an end of one jumper cable to the posi- Do the next step exactly as instructed and do not
tive terminal of the booster battery (or jump-start allow the clamps of one cable to touch the
post if equipped), and connect the other end of clamps of the other cable. Otherwise, a spark
the cable to the positive terminal of the dis- could occur near a battery, possibly resulting in
charged battery (or jump-start post if equipped). severe personal injury from explosion and acid
See Fig. 13.5. burns.
4. Connect one end of the second jumper cable to
3
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
2 frame is usually a good ground. Do not connect
the cable to or near the discharged batteries.
WARNING
On vehicles with Mercedes-Benz AGS transmis-
sions, make sure the current gear indicator dis-
4 plays "N" before starting the vehicle. If the trans-
1 mision starts in gear, it could cause an accident
10/24/2001 f543933 resulting in death, serious personal injury, or
1. Top Step 3. Cab property damage.
2. Battery 4. Battery Access Door 5. Start the engine of the vehicle with the booster
Fig. 13.4, Battery Compartment, Open batteries, and let the engine run a few minutes to
charge the batteries of the other vehicle.
C 6. Attempt to start the engine of the vehicle with the
A batteries receiving the charge. Do not operate
B D the starter longer than 30 seconds, and wait at
least two minutes between starting attempts to
+ − + allow the starter to cool.
− E
E G 7. When the engine starts, let it idle a few minutes.
+ − +
− F WARNING
A
1 2
10/18/94 f540303a
Do the next step exactly as instructed and do not
allow the clamps of one cable to touch the
A. To Ground E. To Starter clamps of the other cable. Otherwise, a spark
B. 3rd F. 2nd
could occur near a battery, possibly resulting in
C. To Frame (ground) G. 1st
D. 4th severe personal injury from explosion and acid
burns.
1. Booster Battery
2. Discharged Battery 8. Disconnect the grounded cable from the frame or
other non-battery location, then disconnect the
Fig. 13.5, Jumper Connections
other end of the cable.
9. Disconnect the remaining cable from the newly
charged battery (or jump-start post if equipped)
first, then disconnect the other end.
13.4
In an Emergency
10. Close the battery compartment. For detailed in- to the vehicle frame. Use protection to keep the
structions, see Chapter 2. chains from damaging the frame.
5. Remove the bumper end caps and chrome
Towing bumper (if equipped).
When it is necessary to tow the vehicle, make sure
the instructions below are closely followed to prevent CAUTION
damage to the vehicle.
Do not pass a sling (for example, a rope or chain)
from one tow hook to another to fasten for tow-
WARNING ing (see Fig. 13.6). Known as reeving, this prac-
tice is not permissible in most industrial applica-
Do not tow an unbraked vehicle if the combined tions of towing and hoisting. Reeving can
weight of both vehicles is more than the sum of overload the hooks and result in damage to the
the gross axle weight ratings (GAWR) of the tow- vehicle.
ing vehicle. Otherwise brake capacity will be in-
adequate, which could result in personal injury or 6. Attach the towing device. Due to the many vari-
death. ables that exist in towing, positioning the lifting
and towing device is the sole responsibility of the
Front Towing Hookup towing-vehicle operator.
1. Disconnect the battery ground cables. 7. Lift the vehicle and secure the safety chains. If
extra towing clearance is needed, remove the
front wheels.
CAUTION
8. Connect the clearance lights, taillights, and sig-
Failure to remove the axle shafts when towing nal lights. Connect any special towing lights re-
the vehicle with the rear wheels on the ground quired by local regulations.
could result in damage to the transmission and
other parts. WARNING
2. Remove both drive axle shafts. On dual drive
axles, if the vehicle is to be lifted and towed, re- Failure to chock the tires or connect the tow
move only the rearmost drive axle shafts. truck’s air brake system before releasing the
spring parking brakes could allow the disabled
On vehicles equipped with an air fairing, remove vehicle to suddenly roll. This could cause prop-
both the forward and rearmost drive axle shafts if erty damage or personal injury.
there is insufficient towing clearance.
9. Chock the tires on the disabled vehicle and con-
3. Cover the ends of the hubs with metal plates or nect the towing vehicle’s air brake system to the
plywood cut to fit the axle opening, and drilled to vehicle being towed. Then, release the spring
fit the axle shaft studs. This prevents lubricant parking brakes and remove the chocks.
from leaking out and will keep contaminants from
getting into and damaging the wheel bearings Rear Towing Hookup
and axle lubricant.
CAUTION CAUTION
Using a rear towing hookup on a vehicle
Failure to protect the frame rails from the chains
could cause damage, leading to eventual frame equipped with a roof fairing could cause damage
failure. to the cab structure.
1. Place the front tires straight forward and secure
4. On dual drive axles, if the vehicle is to be lifted
and towed, chain the forward rear-axle assembly the steering wheel in this position.
2. Disconnect the battery ground cables.
13.5
In an Emergency
OK
2 1
1
OK
01/11/2006 f880694
IMPORTANT: Do not reeve when towing.

1. Tow Hook 2. Chain
Fig. 13.6, Reeving
Safety Administration. Federal Motor Vehicle Safety

CAUTION Standard #302 limits the flammability of specified
materials used inside the cab, but despite this, most
Failure to protect the frame rails from the chains materials will burn. The cab of this vehicle contains
could cause damage, leading to eventual frame urethane foam, which is of concern in this respect.
failure.
3. On dual drive axles, using protection to keep the WARNING
chains from damaging the vehicle frame, chain
the forward-rear drive axle to the frame. Urethane foam is flammable! Do not allow any
flames, sparks, or other heat sources such as
4. Attach the towing device. Due to the many vari- cigarettes or light bulbs to contact urethane
ables that exist in towing, positioning the lifting foam. Urethane foam in contact with such heat
and towing device is the sole responsibility of the sources could cause a serious, rapid fire, which
towing-vehicle operator. could result in death, severe burns, or gas poi-
5. Lift the vehicle and secure the safety chains. If soning, as well as damage to the vehicle.
extra clearance is needed, remove the bumper
extension if equipped. In Case of a Cab Fire
6. Connect the clearance lights, taillights, and sig- As quickly as possible, bring the vehicle to a safe
nal lights. Also connect any special towing lights stop, apply the parking brake, turn off the ignition,
required by local regulations. and get out of the vehicle.
Fire in the Cab

The incidence of fire in medium-duty trucks is rare,
according to data from the National Highway Traffic
13.6
14
Headlight Aiming
Preliminary Checks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14.1
Checking Headlight Aim . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14.1
Adjusting Headlight Aim . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14.2
Headlight Aiming
Preliminary Checks CAUTION

Before checking or adjusting the headlight aim, do
the following: Do not use a power buffer, paper towels, chemi-
cal solvents, or abrasive cleaners on the head-
• Remove large amounts of mud or ice from the light lens, all of which can remove the UV coating
underside of the fenders. from the surface, and result in yellowing of the
• Check the springs for sagging or broken lens.
leaves.
• Check the suspension for proper functioning of
Checking Headlight Aim
the leveling mechanism. On cabs with air sus- 1. Park the vehicle on a level surface 25 ft (7.6 m)
pensions, make sure that the height is properly from a screen or wall that can be used for aiming
adjusted. the headlights. Shut down the engine, apply the
• Check for damage to the hood and hinge as- parking brake, and chock the front tires. See
sembly. Repair as necessary. Fig. 14.1.
• With the vehicle unloaded, check that the tires NOTE: The low-beam headlight is the top bulb
are inflated to the recommended air pressure. in the dual-beam assembly.
• Clean the headlight lenses. Clean by hand 2. On each headlight, find the bulb center. See
only, using a flannel cloth with mild, non- Fig. 14.2.
caustic soap or detergent, and water. 3. Measure the distance from the ground to the
center of each low-beam bulb. Note those dis-
tances.
1 2
6 ft (1.8 m)
3
6
m)
t (7.6
5 25 f
01/20/2003 f544233
1. Vertical Centerline of Right Headlight 4. Projected Vehicle Centerline
2. Distance Between Headlights 5. Screen or Wall
3. Vertical Centerline of Left Headlight 6. Height of Lamp Centers
Fig. 14.1, Headlight Aiming Screen or Wall
14.1
Headlight Aiming
• If either or both headlights do not aim into

the inner edges of the centerline, follow the
adjusting procedure below.
• If both headlights come close to the inside
of each headlight centerline (as shown), no
further work is needed. Turn off the head-
lights and remove the chocks from the
front tires.
Adjusting Headlight Aim

11/06/2002 f544236 1. Lift the flap over the rear end of the headlight
Measure beam height from the ground to the small dot bucket to expose the two plastic adjusting knobs
roughly in the center of the headlight lens. on each headlight. See Fig. 14.4.
Fig. 14.2, Headlight Beam Height Adjusting Dot 1
4. On the screen or wall 25 ft (7.6 m) away, make 2
the appropriate markings directly across from
each headlight and at the same height as mea-
sured for the headlight.
5. Turn on the headlights to the low-beam setting.
See Fig. 14.3 for the ideal and acceptable pat-
terns for both headlights.
A
8"
B 11/05/2002 f544235
NOTE: The right-hand side headlight bucket is shown.

The left-hand side is opposite.
1. Inboard Adjusting Knob
8" 1 2. Outboard Adjusting Knob
Fig. 14.4, Headlight Adjusting Knobs

A
8" NOTE: Horizontal aim should not be adjusted in
the field.
B
2. With the vehicle parked 25 ft (7.6 m) from the
screen or wall, put the headlights on low beams,
and turn both adjusting knobs the same amount,
8" 1 as needed to adjust the lights until the beam pat-
01/11/2011 f544153 tern meets the acceptable standard. Turn the
NOTE: The top view shows the ideal beam pattern; the knobs clockwise to raise the beam and counter-
bottom view shows an acceptable standard. clockwise to lower it.
A. Vertical Centerline B. Horizontal Centerline NOTE: Blocking off each light is not necessary,
1. Bright Area but it can help to present a clearer beam pat-
Fig. 14.3, Headlight Beam Pattern tern.
3. Remove the chocks from the front tires.
14.2
15
Hybrid Electric Vehicle
Hybrid Electric Vehicle (HEV) Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15.1
Safety Precautions (HEV) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15.2
Starting, and Engine Shutdown (HEV) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15.2
Hybrid System Fault Lamps (HEV) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15.2
Emergencies (HEV) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15.3
Jumpstarting (HEV) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15.3
Towing (HEV) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15.3
Hybrid Electric Vehicle (HEV) High-Voltage Safety Features

Overview The HEV has high-voltage cables and a service
switch on the PEC.
A hybrid electric vehicle (HEV) has both a diesel en-
gine and an electric motor. Engine torque is aug- High-voltage cables are covered in orange insulation
mented with electrical torque. The electric motor is and conduit. Each high-voltage component is tagged
powered by batteries, which are charged by regen- with a warning or danger label.
erative braking and, on vehicles equipped with the IMPORTANT: The service switch on the PEC
ePTO option, the diesel engine. should only be used for an emergency shut-
The batteries cannot move the vehicle for long dis- down, or when the service manual or trouble-
tances at highway speeds. In the event of a diesel shooting guide calls for work on the high-voltage
engine failure, drive the vehicle to a safe location as system. The service manual and troubleshooting
quickly as possible. guide for the hybrid electric system are available
Eaton Corporation developed and supplies the hybrid from www.roadranger.com.
electric system for Freightliner Trucks. The primary The red service switch is located next to the high-
system components are the hybrid drive unit (or voltage cable connections at one end of the PEC.
"HDU", which includes the electric generator/motor Pushing in the red service switch will shut down the
and automated transmission), power electronics car- engine. The hybrid system will be disabled, and the
rier (PEC), and the motor inverter/controller. Electric high-voltage batteries in the PEC, though still live,
power take-off (ePTO) and auxiliary power generator are isolated in the PEC.
(APG) components are optional on the HEV system.
NOTE: The PEC may be mounted in an area
Freightliner Trucks designed the stand-alone liquid with limited access.
cooling system required to support the operation of
Eaton’s HEV system. Its primary system components For information on emergency shutdowns, see
are the electric water pump, reservoir/expansion "Emergencies" in this chapter.
tank, radiator, electric radiator fan, and coolant
plumbing. Cooling System
Body builders will develop the components for the The HEV requires a liquid cooling system for the
PTO, the PTO plumbing, and a safety switch to pre- HDU, inverter, DC/DC Converter (if ePTO equipped),
vent the diesel engine from starting when the hood is and APG (if equipped). The HEV’s cooling system is
open. separate from the engine cooling system.
For coolant, use a mixture of 50 percent ethylene
Regenerative Braking glycol and 50 percent water.
Regenerative braking reduces vehicle speed by con-
verting some of the vehicle’s kinetic energy into elec- Electric Power Take-Off (ePTO)
tric energy to charge the hybrid system’s batteries.
The Electric Power Take-Off (ePTO) option provides
When the accelerator pedal is at idle while coasting,
standard hydraulic functions without continuous die-
or the service brake is depressed to slow the vehicle,
sel engine operation. The PTO drive power is pro-
the hybrid system charges the batteries.
vided by the hybrid motor and hybrid batteries. When
The regeneration will feel as if the brake is being the hybrid batteries deplete, the diesel engine auto-
lightly applied when you remove your foot from the matically starts to recharge them and provide PTO
accelerator pedal. The full power of the service brake drive power. Once the batteries are fully charged, the
is always available to the driver, and regenerative engine shuts down automatically. Vehicles with the
braking is automatically shut off during an ABS (an- ePTO option are designed with a safety switch to
tilock brake) event. ensure the diesel engine does not start when the
The Eaton Hybrid Control Unit will automatically shut hood is open.
off regenerative braking when the batteries are fully A DC/DC converter is required for ePTO applications
charged. to convert high-voltage DC to 12-volt DC.
15.1
NOTE: To maintain a power supply from the ve- to return to the ON position. The engine will con-
hicle’s low-voltage batteries, the alternator tinue to run with the key in the ON position.
charges them when the vehicle is being driven. 5. Apply the service brake, then release the parking
brake.
Safety Precautions (HEV) 6. With the service brake applied, press the desired
The HEV has high-voltage components, including mode on the shift control to put the vehicle into
340-volt DC batteries and a 500-volt AC motor. gear.
Never cut high-voltage cables or connectors. Do not 7. Slowly release the service brake.
paint high-voltage cables.
NOTE: The vehicle may be powered by the
Avoid direct pressure wash on high-voltage connec- electric motor or the diesel engine, depending
tions (PEC, DC/DC Converter) and the air intake and
exhaust on the PEC.
on battery charge and the demand for driveline
torque. If the electric motor alone is powering
the driveline, the diesel engine will stay at idle.
Starting, and Engine Shutdown
(HEV) Engine Shutdown
The Cranking System 1. Place the transmission in neutral by selecting N
on the shift control.
The primary engine starter is the electric motor in the
HDU, which cranks the engine very quickly. The IMPORTANT: The transmission must be in neu-
back-up cranking system is the standard 12-volt tral for proper shutdown.
starter on the engine. If the hybrid system is offline 2. Set the parking brake.
or the hybrid batteries are insufficiently charged, the
vehicle will automatically use the 12-volt cranking 3. Turn the key counterclockwise to the OFF posi-
system to start the engine. tion.
NOTE: Intermittent noises such as clicking and
Starting transmission shifting may be audible from the
1. Set the parking brake. transmission while it completes a self-test and
2. Place the key in the ignition, and turn it clock-
shutdown.
wise to the ON position to initiate power to the
hybrid system. Hybrid System Fault Lamps
Wait for the gauges on the instrument panel to (HEV)
complete two sweeps (one from left to right, and
one from right to left) and return to their normal There are two lamps on the dashboard that indicate
ranges. a hybrid system fault is active — the red STOP HY-
BRID lamp and the amber CHECK HYBRID lamp.
3. Ensure the transmission is in neutral. The gear See Fig. 15.1. When the red STOP HYBRID lamp is
display should display a solid "N". illuminated, do not drive the vehicle; have it towed to
a Freightliner dealer or an authorized service center
WARNING for repairs. When the amber CHECK HYBRID lamp
is illuminated, the vehicle can still be driven, though it
Never start the engine unless the transmission is may operate without the assistance of the hybrid
in neutral and the brake is applied. Accidental electrical system.
movement of the vehicle could result in property
damage, personal injury, or death.
4. Turn the key clockwise to the START position.
The engine will crank after a brief delay. As soon
as the engine starts, release the key, allowing it
15.2
• Do not cut into or open the DC/DC converter.

• Do not cut into or open the inverter.
CHECK If it is necessary to remove occupants using cutting
HYBRID equipment, avoid high-voltage cables and the PEC.
Jumpstarting (HEV)
STOP
HYBRID Jumpstarting vehicles equipped with the Eaton® Hy-
brid System is identical to Non-Hybrid vehicles,
which use the vehicle 12-volt battery system.
07/09/2008 f611013
Towing (HEV)
Fig. 15.1, Hybrid System Fault Lamps
When towing the vehicle, the output shaft of the
Emergencies (HEV) transmission must not be allowed to spin or turn. If
the vehicle is towed with the drive wheels still in con-
Emergency Shutdown tact with the road surface, the vehicle axle shafts or
driveline must be removed or disconnected. See
WARNING "Towing" in Chapter 13.
After disabling the vehicle, power is maintained

in the high-voltage electrical system for up to five
minutes. Unprotected contact with any "live" high
voltage components can cause serious injury or
even death.
There are two options for performing an emergency
shutdown. The preferred method is to turn off the
ignition key. The other option is to disconnect the
low-voltage (12-volt) vehicle batteries. In either case,
the engine will shut down, dash lights will shut down,
the hybrid electrical system will shut down, and the
high-voltage batteries in the Power Electronics Car-
rier (PEC) will remain "live" but isolated in the PEC.
NOTE: If the service switch on the PEC is ac-
cessible, it may be pushed in to shut down the
hybrid electrical system and isolate the "live"
HEV batteries in the PEC.
In Case of an Accident or Fire

If the HEV becomes involved in an accident or fire,
be aware of the following:
• Use CO2 or dry chemical extinguishers. The
batteries in the PEC are lithium ion.
• Do not cut into high-voltage cables. The high-
voltage wiring is covered in orange insulation
or convoluted tubing.
• Do not cut into or open the PEC.
15.3
16
Natural Gas Vehicle
General Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16.1
Safety Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16.1
Fuel Tank Filling Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16.2
Gas Detection System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16.5
Engine Starting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16.9
Major Repair and Replacement of Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16.10
Natural Gas Vehicle
General Information Safety Precautions

The Business Class® M2 can be equipped with a
compressed natural gas (CNG) fuel system, or a liq- DANGER
uefied natural gas (LNG) fuel system. CNG is made
by compressing natural gas to less than 1% of its Natural gas is highly flammable. Failure to ob-
volume at standard atmospheric pressure. LNG is serve the following safety precautions could lead
created by condensing natural gas into a liquid by to the ignition of the natural gas, which could
cooling it to approximately -259°F (-162°C). cause serious bodily injury or death.
When vaporized at ambient temperatures, natural Follow these safety precautions when operating or
gas is less dense than air, and it rises and disperses. repairing a natural gas vehicle.
However, LNG is intially heavier than air due to its • Do not start the engine if a natural gas leak is
cryogenic temperature. When released in large detected.
amounts, it may drop or pool on the ground before
it’s temperature rises and the LNG vaporizes. Cold • Do not transfer CNG from one vehicle to an-
atmospheric conditions may prevent natural gas from other, as a buildup of static electricity could
dispersing quickly when released in large amounts. cause a spark and ignite the fuel.
Natural gas is nontoxic, but it can cause asphyxiation • Avoid open flames or sparks near a natural
if present in very large concentrations. gas vehicle.
CNG often contains an odor-producing chemical, • Cover eyes and exposed skin when working on
while LNG does not have any odor. Users of natural- a natural gas fuel system or fueling a natural
gas-fueled vehicles should never expect to detect gas vehicle.
natural gas leaks by scent. • Permit no smoking or other ignition sources
For natural gas to burn, it must first vaporize, then within thirty feet of a natural gas vehicle.
mix with air in the proper proportions (flammable • Have CO2 fire extinguishers (ABC minimum)
range is 5 to 15% by volume in air), and then be ig- located in a highly visible and easily accessible
nited. location.
A typical natural gas fuel system consists of: • Always purge the fuel lines before performing
• Fuel supply cylinders that store compressed maintenance or repairs on a natural gas fuel
gas at high pressure (CNG), or a tank that system. To purge the lines, close the manual
stores liquefied gas at an extremely low tem- fuel shutoff valve, and start the engine. Let the
perature (LNG). vehicle idle until the fuel lines are empty and
the engine stops.
• A vaporizor or heat exchanging device that
changes LNG to gaseous form (LNG fuel sys- • Always use a natural gas detector to test the
tems only). system for leaks, whether an odor is present or
not. Routinely inspect the fuel filtering and
• Pressure relief and manual fuel shutoff valves. regulating mechanisms, and the fuel lines. A
• A filling connection with a check valve that pre- bubble solution can be used to pinpoint the
vents the gas from flowing back out of the fuel exact location of leaks.
filling line. • Always tighten fasteners and fuel connections
• High-pressure and low-pressure fuel filters. to the required torque specification. Overtight-
ening or undertightening could cause leaks.
• A pressure control regulator that reduces the
high fuel tank or cylinder pressure to the lower • Close the fuel shutoff valve(s) before perform-
pressure needed for the engine. ing maintenance and repairs.
• A fuel contents gauge that indicates the fuel • Do not store a natural gas vehicle indoors for
supply in the tank or cylinders. any extended period of time. Do not bring a
natural gas vehicle inside indoors unless the
16.1
Natural Gas Vehicle
workshop is equipped with a methane detec- IMPORTANT: Close all windows and doors dur-
tion and ventilation system. ing the fueling process. Keeping windows and
doors closed allows for easier leak detection
Fuel Tank Filling Procedures inside the cab after fueling.
CNG Vehicle Fueling WARNING
CNG is moved from the fuel station storage tanks to
the vehicle cylinders through a metered dispenser. Natural gas fuel tanks, lines, and valves are al-
During fueling, as pressure inside of the vehicle cyl- ways pressurized. Always observe safety precau-
inders increases, so does the temperature. The dis- tions. Failure to do so could lead to loss of con-
penser shuts off when it determines the CNG cylin- trol over a filling hose or to ignition of the natural
ders are full. gas, which could cause serious bodily injury,
death, or severe property damage.
CNG fuel cylinders cannot be filled to their full capac-
ity of 3600 psi (24 800 kPa) in cooler weather. Since 2. Ensure all fuel cylinder shutoff valves are open.
temperature change causes gas to expand and con- See Fig. 16.1.
tract, less pressure in the cylinders on a cold day is
equal to the same amount of gas at a higher pres-
sure on a warm day. The fuel station dispenser has a 1 2
temperature-pressure compensating device, which
accounts for ambient temperature during fueling. See
Table 16.1 for approximate full cylinder pressures at
various temperatures.
CNG Temperature/Pressure Compensation Values

3 4
Fill Station Pressure Set Point
Temperature:
3000 psi (20 684 3600 psi (24 821
°F (°C)
kPa) Set Point kPa) Set Point
100 (37.8) 3415 (23 546) 4086 (28 172)
90 (32.2) 3276 (22 587) 3909 (26 952)
80 (26.7) 3138 (21 636) 3754 (25 883)
70 (21.1) 3000 (20 684) 3600 (24 821) 8 7 6 5
60 (15.6) 2861 (19 726) 3445 (23 752)
50 (10) 2723 (18 774) 3288 (22 670)
40 (4.4) 2584 (17 816) 3131 (21 587)
30 (-1.1) 2446 (16 865) 2973 (20 498)
20 (-6.7) 2307 (15 906) 2814 (19 402)
10 (-12.2) 2169 (14 955) 2655 (18 306)
0 (-17.8) 2031 (14 003) 2495 (17 202)
-10 (-23.3) 1893 (13 052) 2336 (16 106)
-20 (-28.9) 1755 (12 100) 2180 (15 031) 04/22/2010 f470554
-30 (34.4) 1616 (11 142) 2024 (13 955) 1. Fuel Cylinder Storage 5. Fuel Fill Port
-40 (-40) 1477 (10 184) 1868 (12 879) Box 6. Dust Cap
2. Fuel Cylinder Shutoff 7. Manual Shutoff Valve
Table 16.1, CNG Temperature/Pressure Compensation Valves (qty 5) 8. Fuel Panel Access
Values 3. High-Pressure Gauge Door
4. Low-Pressure Gauge
Use the following steps to fuel a CNG vehicle.
Fig. 16.1, CNG Fuel Cylinder Storage Box (5-cylinder
1. Shut down the engine and apply the parking system shown)
brake.
16.2
Natural Gas Vehicle
3. Ensure the vehicle fuel system main shutoff LNG Vehicle Fueling
valve is open.
The LNG fuel tank is designed to be filled from any
4. Open the CNG fuel panel access door and re- LNG fuel source that has a 100 micron or finer fuel
move the dust cap from the vehicle fuel fill port. filter and a fuel delivery pressure between 120 and
5. Ensure the O-ring is present inside the fuel fill 225 psi (827 and 1551 kPa).
port. If the O-ring has been dislodged or is miss- The LNG fuel tank is designed to be top-filled
ing, the station dispensing nozzle will not con- through a single hose with no vent return. As cold
nect securely to the fill port. LNG is sprayed into the vapor space of the tank, the
6. Turn the selector knob on the service pump to cold liquid condenses the vapor and creates space
the VENT position, if equipped. for itself inside the tank, eliminating any need to vent
during the filling process.
7. Connect the quick coupling on the dispensing
nozzle securely to the vehicle fuel fill port. The LNG tank is equipped with a small internal ul-
lage tank for vapor space, which allows for fuel ex-
8. Turn the selector knob on the service pump to pansion and increases vehicle standby time. When
the FILL position, if equipped. an LNG tank is full, fuel can continue to flow into the
ullage tank. However, if the ullage tank is completely
IMPORTANT: If at any time the service pump or
filled during fueling, standby time will be reduced to
vehicle begins to vent CNG uncontrollably, notify zero and the primary relief valve will open almost
a station attendant or activate the service sta- immediately after fueling, allowing excess LNG vapor
tion emergency shut-off switch to cease the flow to escape. If fueling is stopped when the ullage tank
of CNG. is empty (i.e., the fuel tank has sufficient vapor space
9. Switch on the service pump. A slight hissing to accommodate fuel expansion due to temperature
noise may be heard as the fuel cylinders fill. increase), the vehicle will have approximately one
week of standby time before venting will occur.
10. Watch the pressure gauge on the service pump.
Use the following steps to fuel an LNG vehicle.
When the gauge reads approximately 3600 psi
(24 800 kPa), or when the fill pressure stops 1. Shut down the engine and apply the parking
climbing, the CNG cylinders are full. The service brake.
pump will shut itself down automatically. See
Table 16.1 for pressure compensation values IMPORTANT: Close all windows and doors dur-
based on ambient temperatures. ing the fueling process. Keeping windows and
doors closed allows for easier leak detection
11. Move the selector knob on the service pump to inside the cab after fueling.
the VENT position, if equipped. A short hiss will
be heard as a small amount of natural gas is
vented into the hose. WARNING
Liquefied natural gas is a cryogenic liquid stored
WARNING at approximately -259°F (-162°C). Cryogenic
burns can be caused by coming into contact with
Do not attempt to remove the fill station nozzle the pressurized liquid stream, or by coming into
from the tank fill fitting until venting of pressure contact with fuel system components that have
is noted. If no venting occurs, ask for assistance been cooled to cryogenic temperatures. Always
from the station attendant. Removing an un- wear gloves and a face shield, and cover ex-
vented coupling could result in an uncontrolled posed skin when fueling.
hose, which could lead to property damage or
personal injury. 2. Remove the fuel fill fitting dust cap. See
Fig. 16.2.
12. Remove the station dispensing nozzle from the
vehicle fill port.
13. Install the dust cap on the vehicle fuel fill port
and close the fuel panel access door.
16.3
Natural Gas Vehicle
2 3
causing tank pressure to spike above 250 psi
(1724 kPa) and automatically shutting down the
station fuel pump. To prevent the pump from
4 shutting down, connect a vent line to the fill vent
fitting on the LNG tank to capture escaping
vapor, then open the shroud cover and open the
vapor shutoff valve (Fig. 16.3, Item 2).
6
6. Open the station’s fill valve, if equipped, and
start fueling. Monitor the flow or line pressure as
filling progresses. When filling begins, line pres-
sure will spike quickly until the vehicle tank cools
down. The flow and pressure will then remain
stable during the remainder of the filling
procedure.
5
1
8 9
7
05/29/2009
6 f470534
6 10
1. Fuel Fill Fitting 4. Fill Vent Fitting 5
2. Fuel Outlet Line 5. Shroud Cover 11
3. Primary Relief Vent 6. Shroud Cover Latches
Line
12
Fig. 16.2, LNG Fuel Tank
3. Using compressed air, remove any dirt, debris, or

water that may have collected in the fuel fill fit- 4
ting and the station dispensing nozzle. Contami-
nants in the fuel system can cause drivability 3
problems.
2
WARNING
1
Natural gas fuel tanks, lines, and valves are al-
ways pressurized. Always observe safety precau- 05/05/2010 f470533
tions. Failure to do so could lead to loss of con- 1. Pressure Control 7. Primary Relief Valve
trol over a filling hose or to ignition of the natural Regulator 8. Tank Pressure Gauge
gas, which could cause serious bodily injury, 2. Vapor Shutoff Valve 9. Fill Vent Fitting
death, or severe property damage. 3. Fuel Fill Hose 10. Excess Flow Valve
4. Secondary Relief 11. Fuel Shutoff Valve
4. Connect the station fueling nozzle to the tank Valve (red cap) (liquid)
fuel fill fitting. 5. Fuel Fill Fitting 12. Fill Check Valve
6. Fuel Level Sender
5. Connect an electrical ground clamp and cable to Box
the fuel tank.
Fig. 16.3, LNG Fuel Tank Plumbing Components
IMPORTANT: An LNG tank which is first in-
stalled, or is on a vehicle that has not been op- IMPORTANT: When fueling a hot tank, initially
erated in approximately ten days, is considered put 5 to 10 gallons (19 to 37 liters) of LNG in
to be a hot tank. When fueling a hot tank, LNG the tank and manually stop the fueling process.
entering the tank will immediately vaporize, Drive the vehicle for 15 to 20 minutes to cool
16.4
Natural Gas Vehicle
the tank and reduce tank pressure, then con- sor detects gas fumes in concentrations above 50%
tinue fueling the tank to full. LFL, and should allow ample time to utilize safety
procedures. However, individuals with special needs
7. When the tank is full, the line pressure will rap- should review the system with a professional safety
idly spike and the flow rate will fall. When a pres- engineer.
sure rise or flow rate drop is observed, close the
station’s fill valve, if equipped. Alarm Procedure
NOTE: Do not over-fill an LNG tank. If the ul- Before operating the vehicle, the driver must be fa-
lage tank is completely filled during fueling, tank miliar with the procedures as shown on the interior
standby time will be reduced to zero and the sticker on the overhead panel (Fig. 16.4) and the
primary relief valve will open almost immediately exterior sticker on the door (Fig. 16.5).
after fueling.
8. Disconnect the station hose from the tank fuel fill
fitting.
9. Disconnect the electrical ground clamp and cable
from the fuel tank.
10. Install the dust cap on the tank fuel fill fitting.
Gas Detection System

A gas detection system is used in all Daimler Trucks
natural-gas-fueled vehicles. This system has a sen-
sor in the engine compartment and one in the cab,
both situated in high areas to detect natural gas
buildup as a result of leaks.
The AMGaDS III Plus is a natural gas detection sys-
tem. This device is meant to serve as a supplemen- 04/28/2009 f080157
tal warning only. It is not intended to replace stan-
dard safety practices that should be conducted Fig. 16.4, Interior Warning Sticker
around flammable gases.
IMPORTANT: If an audible alarm activates, do
IMPORTANT: To function properly, the gas de- not operate any electrical switch, including
tection system must be powered at all times. lights. Avoid causing sparks and stay away from
The gas detection system is directly powered by arcing switches and equipment. Do not use a
the batteries, and can only be powered off by telephone, including cellular phones or any
disconnecting the batteries.When servicing a types of portable communication or electronic
natural-gas-fueled vehicle, disconnect the bat- devices that have a battery.
teries only when necessary, and do not leave
the batteries disconnected for extended periods If the vehicle is in motion when the audible alarm
activates, bring it to a safe stop, shut down the en-
of time. gine, and exit the vehicle. Do not open the hood.
The lower flammability limit (LFL) is the smallest If outside the vehicle when the audible alarm acti-
amount of the gas that supports a flame when mixed vates, do not open the cab door or hood.
with oxygen and ignited. Zero percent (0%) LFL indi-
cates a gas-free atmosphere. One hundred percent In the event of an audible alarm, immediately follow
(100%) LFL indicates that gas concentration has these procedures, as allowed by conditions:
reached its lower flammability limit (5% gas in air by 1. Immediately shut off all engines. Extinguish any
volume). The red warning light and audible alarm cigarettes, pilot lights, flames, or other sources of
located in the overhead console activate when a sen- ignition in the area and adjacent areas.
16.5
Natural Gas Vehicle
frontwall. The sensors are located in high areas,

where rising gas vapors will pass by or accumulate.
If the system detects that one of the sensors has
been disconnected or has malfunctioned, the sensor
fault light for that zone will illuminate. A failed sensor
may trigger and lock on an alarm. If a fault condition
or locked alarm continues after the sensor’s connec-
tion and wiring integrity has been verified, replace
the sensor.
The sensors are sensitive to all hydrocarbon vapors.
An alarm may be triggered by the use of chemicals
such as cleaners, paint, polish, lacquer, gasoline,
silicone, silicone spray, or other harsh chemicals.
The sensors will also detect hydrogen fumes from an
overcharged battery. If a sensor sends an alarm, but
no gas fumes are present, check for recent use of
chemicals or a battery charger.
NOTICE
Silicone-based chemicals and cleaners will per-
manently disable the sensors. When cleaning the
vehicle, cover the sensors with a plastic cover-
04/28/2009 f080158 ing. Keep the sensors covered until the area has
been cleared of any cleaning fumes.
Fig. 16.5, Exterior Warning Sticker
Harsh chemicals and extremely high tempera-
2. Manually close all fuel shutoff valves, including tures may damage the sensor.
those on the LNG tank or CNG cylinders. Puncture of or damage to the seal located inside
3. If the vehicle is indoors (as in a service shop), the sensor housing will significantly shorten the
immediately open windows and doors to provide sensor life.
extra ventilation to the area. Do not start the en- Frequent exposure to high concentrations of gas
gine or any other type of equipment until the gas will accelerate sensor deterioration.
leak is corrected and the area cleared of natural
gas. Overhead Console
4. Evacuate the area.
The overhead console consists of an alarm panel on
5. Check the fuel lines, LNG tank/CNG cylinders, the right side and the control module on the left side.
and fittings to locate the leak. After the area is
The alarm panel has a green light, a red light, a
cleared of natural gas and the alarm is no longer
buzzer, and a sensor. See Fig. 16.6. It is located
active, have the vehicle inspected by a qualified
within view from outside of the vehicle. The large
technician.
green light is continuously illuminated during normal
IMPORTANT: Do not consider the area clear operating conditions.
until all alarm indicators are off, and the alarm Before entering the vehicle, always verify that the
panel light returns to green. green light is illuminated. If the green light is not illu-
minated, do not enter the vehicle. Complete the
Sensors alarm procedure previously outlined.
Gas detection sensors are located on the cab over- The alarm panel meets the California Highway Patrol
head console and in the engine compartment on the Title 13-2008 and NFPA 52 2010 requirements. All
16.6
Natural Gas Vehicle
5 6
7
4
AMGaDS III Plus Gas Detection System
Power Push Silence

Gas Concentration: To Engaged
Silence
SIGNIFICANT 10 11
3 Trace
12 13
Zo
Zo
Shutdown Relay
ne
ne
Reset Engaged
1
Sensor Fault
Push To Test
2 1 9
04/28/2009 f611034
1. Test Button 6. Silence Button 10. Buzzer Alarm
2. Sensor Fault Indicator Lights 7. Silenced Engaged Light 11 Red Light
3. Zone 1 Leak Indicator Lights 8. Relay Engaged Light 12. Green Light
4. Power Indicator Light 9. Shutdown Reset Button 13. Sensor
5. Zone 2 Leak Indicator Lights
Fig. 16.6, AMGaDS III Plus Overhead Console
drivers and technicians using it should be trained re- • Significant Level: If either sensor detects gas
garding the red and green lights, and the audible fumes at a concentration greater than 50% to
warning. 60% LFL (2.5% gas in air by volume), the
small red light next to the SIGNIFICANT indi-
The control module, located on the left side of the
cator for that zone will flash. After approxi-
overhead console, contains the status lights and con-
mately 15 seconds, the large green light on the
trol buttons for the system. The areas that the sen-
alarm panel will switch off, the red light will illu-
sors monitor are defined as Zone 1 (cab) and Zone 2
minate, and the buzzer will sound. All alarm
(engine compartment). The control module has lights
indicators will remain on as long as fumes are
assigned to each zone that will illuminate if a sensor
detected.
detects a trace level leak (between 20% and 30%
LFL), a significant level leak (above 50% LFL), or if a • Sensor Fault: If the system detects that either
sensor is disconnected or malfunctioning. of the sensors has been disconnected or has
• Trace Level: If either sensor detects gas fumes malfunctioned, an amber light next to the Sen-
at a concentration greater than 20% to 30% sor Fault indicator for that zone will illuminate.
LFL (1% gas in air by volume), the amber light The control module also has buttons used to test or
next to the Trace indicator for that zone will reset the the control module after an alarm. Red
flash. There is no buzzer alarm for a trace lights next to each button indicate when they are en-
level detection, and the large green light on the gaged.
alarm panel will remain illuminated.
16.7
Natural Gas Vehicle
• Shutdown Reset: If an alarm has been acti- three times per calendar year at equal intervals. The
vated and the Relay Engaged light is illumi- testing procedure should simulate the same operat-
nated, the Shutdown Reset button will reset ing environment in which the vehicle is used, with the
the internal relay. Press the Shutdown Reset same gaseous fuel.
button only after the gas has cleared, the Test results validating the performance of the gas
buzzer has turned off, and the alarm panel detection system within the parameters established
light has returned to green. by the component manufacturer and NFPA 52 2010
• Push To Silence: If an alarm has been acti- should be maintained as a permanent part of the ve-
vated, the Push To Silence button will silence hicle service records. Use of alcohol, propane, and
the buzzer. other harsh liquids or gases are not acceptable
methods for testing.
See Table 16.2 for the functions of all lights and but-
tons on the overhead console. Always test the system and sensors after any com-
ponent has been replaced, or if the vehicle has been
Testing involved in an accident or fire. Ensure that the gas
detection system is wired directly to the battery.
Daimler Trucks North America strongly recommends
that all operators follow California Code of Regula- It is recommended that the highest level of safety
tions (CCR) inspection requirements, regardless of validation be utilized if there are multiple validation
where the vehicle is operated. Per Title 13 CCR § requirements in the state or locality where the vehicle
935 (2), gas detection systems should be tested is operated or domiciled.
Control Module Functions

Item Display Function Action Required
Illuminated System is on. None required.
Ensure the batteries are
Green Power Light connected and replace any blown
Detection system is not
Unlit fuses. If the gas detection system
functioning.
is still not functioning, replace the
system immediately.
Suspend vehicle operation
SIGNIFICANT Gas Dangerous gas concentration
Red (illuminated) immediately and follow alarm
Concentration Lights detected.
procedures.
Trace Gas Concentration Use caution and monitor the
Amber (flashing) Minor gas concentration detected.
Lights system.
Off Sensor is functioning properly. None required.
Sensor Fault Lights
On Sensor has malfunctioned. Replace the sensor immediately.
Press to reset the system only
after the gas has cleared, the
Resets the system after an alarm
Shutdown Reset Button — buzzer has turned off, and the
activation.
alarm panel light has returned to
green.
Relay is engaged and test or
On Press the Shutdown Reset button.
Relay Engaged Light alarm is being cleared.
Off Normal condition. None required.
Press and hold for one minute to
Tests the overhead console
Test Button — to activate a test of all overhead
operation and circuitry.
console components.
Silence Button — Silences the alarm buzzer. Press to silence the alarm buzzer.
16.8
Natural Gas Vehicle
Control Module Functions

Item Display Function Action Required
Suspend vehicle operation
Indicates the buzzer is active but
On immediately and follow alarm
Silence Engaged Light silenced.
procedures.
Off Normal condition. None required.
Table 16.2, Control Module Functions
Overhead Console Test 4. Ensure that the transmission shift control is in

Neutral (N), Park (P), or the Park Brake (PB) po-
Press and hold the Push To Test button for one sition.
minute. The system will proceed with a self-
diagnostic test that will include illumination of the 5. Without starting the engine, turn the ignition
Trace and SIGNIFICANT gas concentration lights, switch to the ON position (Fig. 16.7). The elec-
and the sensor fault lights. Verify the large red light tronic gauges on the instrumentation control unit
and buzzer activate, and that all lights illuminate or (ICU) will complete a full sweep of their dials, the
flash to ensure that all bulbs are operational. warning and indicator lights will illuminate, and
the buzzer will sound for three seconds.
Sensor Test
The gas detection system sensors must be tested
using certified test gas, which can be purchased as
part of a test kit. Testing with alcohol or heavy gases
such as butane or propane does not satisfy CCR §
935 (2) or NFPA 52 regulations.
Expose each sensor to certified test gas for at least
thirty seconds. The system will proceed through the
alarm procedure consistent with a significant leak
and the buzzer will sound after approximately fifteen
seconds. If a sensor fails to respond after exposure
to the test gas, replace the sensor.
09/12/2001 f610509
Engine Starting Fig. 16.7, Ignition Switch Positions
NOTE: Before starting the engine, read Chap-
ter 3 for detailed information on how to read the 6. Turn the ignition switch to the START position.
instruments and Chapter 4 for detailed informa- Press down on the clutch pedal, if equipped, but
tion on how to operate the controls. Read the do not press down on the accelerator pedal.
operating instructions in the engine manufactur- Release the key the moment the engine starts.
er’s operation manual before starting the en-
gine. 7. Bring the engine up to operating speed gradually
as it warms up and develops stable oil pressure.
1. Before engine start-up, complete the engine pre- If the vehicle has not been operated previously in
trip and post-trip inspections and maintenance a 24-hour period, allow the vehicle to idle for five
procedures in Chapter 11. minutes.
2. Ensure the fuel shutoff valve is open.
3. Set the parking brake.
NOTICE
Do not rev the engine if the oil pressure gauge
indicates no oil pressure. Shut down the engine
16.9
Natural Gas Vehicle
within approximately ten seconds to avoid engine

damage.
8. Check the oil pressure gauge for any drop in lu-
bricating oil pressure or mechanical malfunction
in the lubricating oil system.
Major Repair and Replacement

of Parts
If a natural-gas-fueled vehicle is involved in an acci-
dent, remove the fuel tank or cylinders from service
and have them inspected by a qualified technician.
Replace any leaking or damaged fuel tanks/cylinders
and fuel lines; repair or replace leaking or damaged
fittings. Install parts and components in accordance
with the manufacturer’s instructions.
16.10
Index
Subject Page Subject Page

A C
Adjustable Steering Column . . . . . . . . . . . . . . . . . 4.14 Cab Amenities . . . . . . . . . . . . . . . . . . . . . . . . . . 5.10
Adjusting Headlight Aim . . . . . . . . . . . . . . . . . . . 14.2 Cab Storage . . . . . . . . . . . . . . . . . . . . . . . . . 5.10
Aftertreatment System (ATS) . . . . . . . . . . . . . . . . . 7.1 Cup Holders . . . . . . . . . . . . . . . . . . . . . . . . . 5.10
EPA07 Aftertreatment Cab Door Locks and Handles . . . . . . . . . . . . . . . . 2.1
System (ATS) . . . . . . . . . . . . . . . . . . . . . . . . 7.1 Cab Entry and Exit, Vehicles
EPA10 Aftertreatment With One Step . . . . . . . . . . . . . . . . . . . . . . . . . 2.4
System (ATS) . . . . . . . . . . . . . . . . . . . . . . . . 7.3 Entering from the Driver’s
Air Bag, Optional . . . . . . . . . . . . . . . . . . . . . . . . . 5.9 Side . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.4
Air Bag Safety Guidelines . . . . . . . . . . . . . . . . 5.10 Entering from the
Air Brake System . . . . . . . . . . . . . . . . . . . . . . . . . 9.1 Passenger’s Side . . . . . . . . . . . . . . . . . . . . . 2.5
Air Brake Operation . . . . . . . . . . . . . . . . . . . . . 9.3 Exiting from the Driver’s Side . . . . . . . . . . . . . . . 2.4
Automatic Slack Adjusters . . . . . . . . . . . . . . . . . 9.3 Exiting from the Passenger’s
Emergency Braking System . . . . . . . . . . . . . . . . 9.2 Side . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.5
Meritor™ WABCO® Antilock Cab Entry and Exit, Vehicles
With Two Steps . . . . . . . . . . . . . . . . . . . . . . . . . 2.2
Braking System (ABS) for
Air Brakes . . . . . . . . . . . . . . . . . . . . . . . . . . 9.4 Entering from the Driver’s
Side . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.2
Parking Brakes, Tractor and
Trailer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.2 Entering from the
Passenger’s Side . . . . . . . . . . . . . . . . . . . . . 2.3
Primary Air Brake System . . . . . . . . . . . . . . . . . 9.1
Exiting from the Driver’s Side . . . . . . . . . . . . . . . 2.3
Secondary Air Brake System . . . . . . . . . . . . . . . 9.1
Exiting from the Passenger’s
Allison MD Series . . . . . . . . . . . . . . . . . . . . . . . . 8.5 Side . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.3
Operating Instructions, MD Cab Washing and Polishing . . . . . . . . . . . . . . . . . 12.1
Series . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.5
Canadian Motor Vehicle Safety
Safety Precautions . . . . . . . . . . . . . . . . . . . . . . 8.5 Standard (CMVSS) Labels . . . . . . . . . . . . . . . . . 1.2
Allison On-Highway Care of Chrome Parts . . . . . . . . . . . . . . . . . . . . . 12.1
Transmissions . . . . . . . . . . . . . . . . . . . . . . . . . . 8.3
Care of Exterior Lights . . . . . . . . . . . . . . . . . . . . 12.1
Operating Instructions, On-
Highway Transmissions . . . . . . . . . . . . . . . . . 8.4 Care of Fiberglass Parts . . . . . . . . . . . . . . . . . . . 12.1
Range Inhibit Indicator, 2000 Checking Headlight Aim . . . . . . . . . . . . . . . . . . . 14.1
and 2400 Series . . . . . . . . . . . . . . . . . . . . . . 8.3 Climate Control Panel . . . . . . . . . . . . . . . . . . . . . . 6.1
Safety Precautions . . . . . . . . . . . . . . . . . . . . . . 8.3 Air Conditioning, Optional . . . . . . . . . . . . . . . . . 6.4
All-Wheel-Drive Controls, Air Selection Switch . . . . . . . . . . . . . . . . . . . . . 6.1
Optional . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.12 Defrosting . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.3
AWD Operation Switch . . . . . . . . . . . . . . . . . . 4.12 Fan Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.1
AWD Range Switch . . . . . . . . . . . . . . . . . . . . 4.12 Fresh Air Mode . . . . . . . . . . . . . . . . . . . . . . . . 6.3
Recirculation Mode . . . . . . . . . . . . . . . . . . . . . 6.3
B Temperature Control Switch . . . . . . . . . . . . . . . . 6.3
Clutches . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.1
Back-of-Cab Access . . . . . . . . . . . . . . . . . . . . . . . 2.5 Clutch Adjustments . . . . . . . . . . . . . . . . . . . . . 8.2
Climbing Down from Back- Clutch Lubrication . . . . . . . . . . . . . . . . . . . . . . 8.2
of-Cab . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.6
Clutch Operation . . . . . . . . . . . . . . . . . . . . . . . 8.1
Entering Back-of-Cab . . . . . . . . . . . . . . . . . . . . 2.6
Clutch Wear . . . . . . . . . . . . . . . . . . . . . . . . . . 8.2
Battery Access . . . . . . . . . . . . . . . . . . . . . . . . . . 2.6
Sachs Hydraulic Clutch . . . . . . . . . . . . . . . . . . . 8.2
Battery Compartment . . . . . . . . . . . . . . . . . . . . 2.6
Cold-Weather Operation . . . . . . . . . . . . . . . . . . . 7.13
Cab (Battery) Isolation
Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.7 Cold-Weather Starting . . . . . . . . . . . . . . . . . . . . . 7.10
Braking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.13 Collision Warning System,
Eaton VORAD EVT–300 . . . . . . . . . . . . . . . . . . 3.17
Meritor™ WABCO® Antilock
Braking System (ABS) . . . . . . . . . . . . . . . . . 4.13 Driver Display Unit (DDU) . . . . . . . . . . . . . . . . 3.18
Parking Brake Control Valve . . . . . . . . . . . . . . . 4.13 In Case of Accident . . . . . . . . . . . . . . . . . . . . 3.21
Trailer Air Supply Valve . . . . . . . . . . . . . . . . . . 4.13 Maintenance and
Diagnostics . . . . . . . . . . . . . . . . . . . . . . . . . 3.21
Trailer Brake Lever . . . . . . . . . . . . . . . . . . . . . 4.13
I-1
Index

Side Sensor Display . . . . . . . . . . . . . . . . . . . . 3.20 Starting Precautions, All
Special Road Situations . . . . . . . . . . . . . . . . . 3.20 Engines . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.10
Cruise Control . . . . . . . . . . . . . . . . . . . . . . . . . . 7.11 EPA Emission Control . . . . . . . . . . . . . . . . . . . . . . 1.2
Dash-Mounted Switches . . . . . . . . . . . . . . . . . 7.11 EPA07 and EPA10 Emission
Shift Knob Controls, Optional . . . . . . . . . . . . . . 7.12 Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.2
Vehicle Noise Emission
Control Label . . . . . . . . . . . . . . . . . . . . . . . . 1.2
D Exhaust Braking Systems . . . . . . . . . . . . . . . . . . 7.15
Dashboard Care . . . . . . . . . . . . . . . . . . . . . . . . 12.1 Exhaust Brake Switch . . . . . . . . . . . . . . . . . . . 7.15
Mercedes-Benz Exhaust
Brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.16
E Pacbrake® Exhaust Brake . . . . . . . . . . . . . . . . 7.17
Eaton Fuller AutoShift™ . . . . . . . . . . . . . . . . . . . . 8.12
Automatic Mode . . . . . . . . . . . . . . . . . . . . . . . 8.13 F
Manual Mode . . . . . . . . . . . . . . . . . . . . . . . . 8.13
Federal Motor Vehicle Safety
Push-Button Shift Selector . . . . . . . . . . . . . . . . 8.12 Standard (FMVSS) Labels . . . . . . . . . . . . . . . . . 1.1
Selecting Gears . . . . . . . . . . . . . . . . . . . . . . . 8.14 Fifth Wheel Coupling . . . . . . . . . . . . . . . . . . . . . 10.1
Eaton Fuller Range-Shift Fontaine and Holland Fifth
Transmissions . . . . . . . . . . . . . . . . . . . . . . . . . . 8.9 Wheels Coupling . . . . . . . . . . . . . . . . . . . . . 10.1
General Information, Range- Jost Fifth Wheel Coupling . . . . . . . . . . . . . . . . 10.3
Shift . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.9
Fifth Wheel Slide . . . . . . . . . . . . . . . . . . . . . . . . 10.7
Operation, Deep-Reduction
Models . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.11 Air Slide Operation . . . . . . . . . . . . . . . . . . . . . 10.9
Operation, Range-Shift . . . . . . . . . . . . . . . . . . 8.10 Manual Slide Operation . . . . . . . . . . . . . . . . . . 10.7
Eaton Fuller UltraShift . . . . . . . . . . . . . . . . . . . . . 8.15 Fifth Wheel Uncoupling . . . . . . . . . . . . . . . . . . . . 10.4
General Information, Air-Actuated Uncoupling . . . . . . . . . . . . . . . . . 10.5
UltraShift ASW . . . . . . . . . . . . . . . . . . . . . . 8.15 Manual Uncoupling . . . . . . . . . . . . . . . . . . . . . 10.4
General Information, Fifth Wheels, General
UltraShift DM . . . . . . . . . . . . . . . . . . . . . . . 8.15 Information . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.1
Operation, UltraShift . . . . . . . . . . . . . . . . . . . . 8.16 Air-Suspension Dump Valve . . . . . . . . . . . . . . . 10.1
UltraShift Diagnostics . . . . . . . . . . . . . . . . . . . 8.20 Fifth Wheel Lubrication . . . . . . . . . . . . . . . . . . 10.1
Eaton® Fuller® Straight-Shift Fire Extinguisher . . . . . . . . . . . . . . . . . . . . . . . . 13.1
Transmissions . . . . . . . . . . . . . . . . . . . . . . . . . . 8.8 Fire in the Cab . . . . . . . . . . . . . . . . . . . . . . . . . 13.6
General Information, In Case of a Cab Fire . . . . . . . . . . . . . . . . . . . 13.6
Straight-Shift . . . . . . . . . . . . . . . . . . . . . . . . 8.8 Freightliner SmartShift Shift
Operation, Straight-Shift . . . . . . . . . . . . . . . . . . 8.8 Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.15
Electrical System . . . . . . . . . . . . . . . . . . . . . . . . . 4.1 General Information,
Emergencies (HEV) . . . . . . . . . . . . . . . . . . . . . . 15.3 SmartShift . . . . . . . . . . . . . . . . . . . . . . . . . 8.15
Emergency Shutdown . . . . . . . . . . . . . . . . . . . 15.3 Fuel Tank Filling Procedures . . . . . . . . . . . . . . . . 16.2
In Case of an Accident or CNG Vehicle Fueling . . . . . . . . . . . . . . . . . . . 16.2
Fire . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15.3 LNG Vehicle Fueling . . . . . . . . . . . . . . . . . . . . 16.3
Emergency Filter Replacement, Fuse Identification . . . . . . . . . . . . . . . . . . . . . . . . 2.8
Davco . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13.1 Main Fuse Box/PDM . . . . . . . . . . . . . . . . . . . . 2.8
Emergency Kit, Optional . . . . . . . . . . . . . . . . . . . 13.1 Trailer and Taillight Fuse
Emergency Starting With Boxes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.8
Jumper Cables . . . . . . . . . . . . . . . . . . . . . . . . 13.2
Engine Braking . . . . . . . . . . . . . . . . . . . . . . . . . 7.14
Engine Break-In . . . . . . . . . . . . . . . . . . . . . . . . . 7.10
G
Engine Operation . . . . . . . . . . . . . . . . . . . . . . . . 7.10 Gas Detection System . . . . . . . . . . . . . . . . . . . . 16.5
Engine Shutdown . . . . . . . . . . . . . . . . . . . . . . . . 7.14 Alarm Procedure . . . . . . . . . . . . . . . . . . . . . . 16.5
Engine Starting . . . . . . . . . . . . . . . . . . . . . . . . . 16.9 Overhead Console . . . . . . . . . . . . . . . . . . . . . 16.6
Pre-Start . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.9 Sensors . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16.6
Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16.8
I-2
Index

General Information . . . . . . . . . . . . . . . . . . . . . . 16.1
Grab Handles and Access
M
Steps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.1 Major Repair and Replacement
of Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16.10
H Mercedes-Benz Automated
Transmissions . . . . . . . . . . . . . . . . . . . . . . . . . 8.22
Hazard Warning Lights . . . . . . . . . . . . . . . . . . . . 13.1 AGS Diagnostics . . . . . . . . . . . . . . . . . . . . . . 8.26
Heater/Air Conditioner Control General Information, AGS . . . . . . . . . . . . . . . . 8.22
Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.15 Operation, AGS . . . . . . . . . . . . . . . . . . . . . . . 8.23
High-Altitude Operation . . . . . . . . . . . . . . . . . . . . 7.13 Mercedes-Benz Manual
Hood Opening and Closing . . . . . . . . . . . . . . . . . . 2.7 Transmissions . . . . . . . . . . . . . . . . . . . . . . . . . 8.22
To Close the Hood . . . . . . . . . . . . . . . . . . . . . . 2.7 Meritor™ Drive Axles . . . . . . . . . . . . . . . . . . . . . . 8.26
To Open the Hood . . . . . . . . . . . . . . . . . . . . . . 2.7 Axle Shift . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.29
Horn Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.7 Drive Axles With Differential
Air Horn, Optional . . . . . . . . . . . . . . . . . . . . . . 4.7 Lock . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.27
Electric Horn . . . . . . . . . . . . . . . . . . . . . . . . . . 4.7 Tandem Drive Axles With
Interaxle Lock . . . . . . . . . . . . . . . . . . . . . . . 8.28
Hybrid Electric Vehicle (HEV)
Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15.1 Mirrors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.1
Cooling System . . . . . . . . . . . . . . . . . . . . . . . 15.1 Down View Mirror, Optional . . . . . . . . . . . . . . . . 5.1
Electric Power Take-Off Mirror Heat Switch, Optional . . . . . . . . . . . . . . . 5.1
(ePTO) . . . . . . . . . . . . . . . . . . . . . . . . . . . 15.1 Power Mirrors, Optional . . . . . . . . . . . . . . . . . . 5.1
High-Voltage Safety Multifunction Turn Signal Switch . . . . . . . . . . . . . . . 4.5
Features . . . . . . . . . . . . . . . . . . . . . . . . . . 15.1 Hazard Warning Flasher . . . . . . . . . . . . . . . . . . 4.7
Regenerative Braking . . . . . . . . . . . . . . . . . . . 15.1 Headlight High Beams . . . . . . . . . . . . . . . . . . . 4.6
Hybrid System Fault Lamps Turn-Signal Controls . . . . . . . . . . . . . . . . . . . . . 4.5
(HEV) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15.2 Windshield Wiper/Washer
Hydraulic Brake System . . . . . . . . . . . . . . . . . . . . 9.6 Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.6
General Information . . . . . . . . . . . . . . . . . . . . . 9.6
Meritor™ WABCO® Antilock
Braking System (ABS) for
O
Hydraulic Brakes . . . . . . . . . . . . . . . . . . . . . . 9.7 Optional Instruments . . . . . . . . . . . . . . . . . . . . . . 3.14
Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.7 Ammeter . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.14
Axle Oil Temperature
I Gauges, Forward and Rear . . . . . . . . . . . . . .
Digital Clock . . . . . . . . . . . . . . . . . . . . . . . . .
3.14
3.14
Ignition Switch and Key . . . . . . . . . . . . . . . . . . . . 4.1 Engine Oil Temperature
Instrumentation Control Unit . . . . . . . . . . . . . . . . . . 3.1 Gauge . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.15
Dash Message Center . . . . . . . . . . . . . . . . . . . 3.1 Intake-Air Restriction
Ignition Sequence . . . . . . . . . . . . . . . . . . . . . . 3.2 Indicator . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.16
Mode/Reset Switch . . . . . . . . . . . . . . . . . . . . . 3.5 Pyrometer . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.16
Odometer . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.5 Turbocharger Boost
Pressure Gauge . . . . . . . . . . . . . . . . . . . . . 3.17
Other Dash-Mounted Controls . . . . . . . . . . . . . . . 4.14
J CB Radio Connections . . . . . . . . . . . . . . . . . . 4.14
Jumpstarting (HEV) . . . . . . . . . . . . . . . . . . . . . . 15.3 Cigarette Lighter . . . . . . . . . . . . . . . . . . . . . . 4.14
Suspension Autofill Override
Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.15
L Suspension Dump Switch . . . . . . . . . . . . . . . . 4.15
Lighting Controls . . . . . . . . . . . . . . . . . . . . . . . . . 4.1 Windshield-Fan Switches,
Control Panels . . . . . . . . . . . . . . . . . . . . . . . . 4.1 Optional . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.14
Exterior Light Controls . . . . . . . . . . . . . . . . . . . 4.2 Overhead Instrument Panel,
Optional . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.10
Interior Lights and Light
Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.4
I-3
Index

P Fuel/Diesel Exhaust Fluid
(DEF) Gauge, EPA10 . . . . . . . . . . . . . . . . . . 3.12
Power Takeoff (PTO) Governor . . . . . . . . . . . . . . . 7.13 Primary and Secondary Air
Powertrain Controls . . . . . . . . . . . . . . . . . . . . . . . 4.8 Pressure Gauges . . . . . . . . . . . . . . . . . . . . . 3.13
After-Treatment System Transmission Fluid
(ATS) Request/Inhibit Temperature Gauge . . . . . . . . . . . . . . . . . . . 3.12
Regen Switch . . . . . . . . . . . . . . . . . . . . . . . . 4.8 Voltmeter . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.13
Axle Switches . . . . . . . . . . . . . . . . . . . . . . . . 4.10 Starting After Extended
Cruise Control Switches . . . . . . . . . . . . . . . . . . 4.8 Shutdown or Oil Change . . . . . . . . . . . . . . . . . . 7.10
Engine Brake Switch, Starting, and Engine Shutdown
Optional . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.8 (HEV) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15.2
Engine Fan Switch, Optional . . . . . . . . . . . . . . . 4.9 Engine Shutdown . . . . . . . . . . . . . . . . . . . . . . 15.2
Exhaust Brake Switch, Starting . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15.2
Optional . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.9 The Cranking System . . . . . . . . . . . . . . . . . . . 15.2
Transmission Controls . . . . . . . . . . . . . . . . . . . 4.10 Steering System . . . . . . . . . . . . . . . . . . . . . . . . . 9.1
Preliminary Checks . . . . . . . . . . . . . . . . . . . . . . . 14.1 Power Steering System . . . . . . . . . . . . . . . . . . 9.1
Pretrip and Post-Trip Inspection Steering Wheel Adjustment . . . . . . . . . . . . . . . . 9.1
Checklists . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11.1
Pretrip and Post-Trip
Maintenance Procedures . . . . . . . . . . . . . . . . . . 11.3 T
Daily Pretrip Inspection and Tire and Rim Labels . . . . . . . . . . . . . . . . . . . . . . . 1.2
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . 11.3
Towing (HEV) . . . . . . . . . . . . . . . . . . . . . . . . . . 15.3
Monthly Post-Trip Inspection
and Maintenance . . . . . . . . . . . . . . . . . . . . 11.17 Towing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13.5
Weekly Post-Trip Inspection Front Towing Hookup . . . . . . . . . . . . . . . . . . . 13.5
and Maintenance . . . . . . . . . . . . . . . . . . . . 11.16 Rear Towing Hookup . . . . . . . . . . . . . . . . . . . 13.5
S V
Safety Precautions (HEV) . . . . . . . . . . . . . . . . . . 15.2 Vehicle Specification Decal . . . . . . . . . . . . . . . . . . 1.1
Safety Precautions . . . . . . . . . . . . . . . . . . . . . . . 16.1 Velour Upholstery Cleaning . . . . . . . . . . . . . . . . . 12.2
Seat Belts and Tether Belts . . . . . . . . . . . . . . . . . . 5.7 Chewing Gum or Wax . . . . . . . . . . . . . . . . . . . 12.3
General Information . . . . . . . . . . . . . . . . . . . . . 5.7 Grease and Oil-Based Stains . . . . . . . . . . . . . . 12.3
Seat Belt Inspection . . . . . . . . . . . . . . . . . . . . . 5.7 Mildew . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12.3
Seat Belt Operation . . . . . . . . . . . . . . . . . . . . . 5.7 Sugar and Water-Based
Seat Controls . . . . . . . . . . . . . . . . . . . . . . . . . . 4.16 Stains . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12.3
Bench Seat Adjustment Vinyl Upholstery Cleaning . . . . . . . . . . . . . . . . . . 12.2
Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.16 Ball Point Ink . . . . . . . . . . . . . . . . . . . . . . . . . 12.2
Suspension Seat Adjustment Chewing Gum . . . . . . . . . . . . . . . . . . . . . . . . 12.2
Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.16 Miscellaneous . . . . . . . . . . . . . . . . . . . . . . . . 12.2
Seats . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.2 Nail Polish and Nail Polish
Bench Seats . . . . . . . . . . . . . . . . . . . . . . . . . . 5.4 Remover . . . . . . . . . . . . . . . . . . . . . . . . . . 12.2
Bostrom Seat . . . . . . . . . . . . . . . . . . . . . . . . . 5.4 Ordinary Dirt . . . . . . . . . . . . . . . . . . . . . . . . . 12.2
General Information . . . . . . . . . . . . . . . . . . . . . 5.2 Paint, Shoe Heel Marks . . . . . . . . . . . . . . . . . 12.2
National 2000 Series Seat . . . . . . . . . . . . . . . . . 5.5 Shoe Polish . . . . . . . . . . . . . . . . . . . . . . . . . 12.2
Sears Seat . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.5 Sulfide Stains . . . . . . . . . . . . . . . . . . . . . . . . 12.2
Speedometer and Tachometer . . . . . . . . . . . . . . . 3.10 Tars, Asphalts, and Creosote . . . . . . . . . . . . . . 12.2
Speedometer . . . . . . . . . . . . . . . . . . . . . . . . 3.10
Tachometer, Optional . . . . . . . . . . . . . . . . . . . 3.11 W
Standard Instruments . . . . . . . . . . . . . . . . . . . . . 3.11
Coolant Temperature Gauge . . . . . . . . . . . . . . . 3.11 Warning and Indicator Lights . . . . . . . . . . . . . . . . . 3.6
Engine Oil Pressure Gauge . . . . . . . . . . . . . . . 3.11 Check Engine Indicator . . . . . . . . . . . . . . . . . . . 3.6
Fuel Level Gauge, Pre- Emergency Buzzer . . . . . . . . . . . . . . . . . . . . . . 3.8
EPA10 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.12 Engine Protection Warning . . . . . . . . . . . . . . . . 3.6
I-4
Index
Subject Page
Windows . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.1
Windshield Washer Reservoir . . . . . . . . . . . . . . . . 5.11
I-5

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Foreword

Introduction dealer referral, vehicle information, breakdown coor-

Customer Assistance Center

Vehicle Specification Decal 1 3

MANUFACTURED BY USE VEHICLE ID NO. Fig. 1.2, Certification Statement, U.S.

Fig. 1.1, Vehicle Specification Decal, U.S.-Built Vehicle

NOTE: Labels shown in this chapter are ex-

Federal Motor Vehicle Safety

1. Tire and Rim Information

VEHICLE NOISE EMISSION CONTROL INFORMATION

IMPORTANT: Certain Freightliner incomplete

It is a violation of US federal law to alter exhaust

Cab Door Locks and Handles 1 2

IMPORTANT: Each key is numbered. Record

To lock a door from outside the cab, do either one of

Use the cab access system (grab handles, access

Entering from the Driver’s Side

NOTE: The A-pillar grab handle is not installed

NOTE: You can also use the inner door grab

would going down a flight of stairs. It is easier to 1. Bottom Step

2. Grasp the steering wheel with both hands. Place

7. 2. Grasp the A-pillar cover grab handle with both

2. Place one foot on the bottom step and pull your-

Climbing Down from Back-of-Cab

Cab (Battery) Isolation Switch CAUTION

Fuse Identification, Main Fuse Box

These fuse boxes contain mini blade-type fuses, 12-

Fig. 3.1, Gauge Layout, Typical, U.S. (EPA10 shown)

Fig. 3.2, Gauge Layout, Basic (EPA10 shown)

Ignition Sequence NOTE: The air gauges do not sweep.

IF NO FAULTS IF FAULT DETECTED

• Third line (voltmeter): "88.8 % VOLTS SER-

If the fault is a serious problem that requires immedi-

WHEEL WASH INTAKE WATER WHEEL LOW CHECK ENG LOW

OPT OPT OPT OPT OPT OPT OPT OPT OPT

AIR WASH *WAIT* WHEEL LOW CHECK **IDLE**

CHECK STOP ABS ABS

Warning and Indicator Lights

Warning and Indicator Lights

Flashes on and off whenever the outside turn signal lights

Flashes on and off whenever the outside turn signal lights

High-Beam Indicator (blue) Indicates the headlights are on high beam.

For EPA07, activates with a buzzer when air pressure in the

Activates with a buzzer when engine oil pressure goes below

Indicates the parking brake is engaged, or hydraulic brake

Cruise Control Activated (green) Indicates the cruise control is active.

Illuminates for 15 seconds when the ignition key is turned to

Warning and Indicator Lights

Check Transmission Temperature Indicates high transmission temperature.

Check Transmission Indicates a transmission issue.

Overhead Instrument Panel, Speedometer and Tachometer

If coolant temperature rises above the preset levels

F° Fig. 3.15, Transmission Fluid Temperature Gauge

Under heavy loads, such as when climbing steep

10/09/2001 f610565 Fuel Level Gauge, Pre-EPA10

Transmission Fluid Temperature

NOTICE Fuel/Diesel Exhaust Fluid (DEF)

Fig. 3.20, Axle Oil Temperature Gauge

Under heavy loads, such as when climbing steep

AIR WASH WAIT WHEEL LOW CHECK IDLE