Foreword

Introduction Data Logging

This manual provides information needed to operate This vehicle is equipped with a control module that
and understand the chassis and its components. performs data logging capabilities.
More detailed information is contained in the Owner’s
This vehicle is equipped with one or more devices
Warranty Information for North America booklet, and
in the vehicle’s workshop and maintenance manuals. that record specific vehicle data and may perform
some of the same functionality as a regulated Event
Custom-built Freightliner chassis are equipped with Data Recorder but the device(s) are not subject to,
various chassis and cab components; not all of the nor designed pursuant to, 49 C.F.R. Part 563.
information contained in this manual applies to every
vehicle. If parts on your chassis differ from those The type and amount of data recorded varies de-
pending on how the vehicle is equipped (such as the
shown, they may have been installed by the vehicle
final-stage manufacturer. brand of engine, if an air bag is installed, or if the
vehicle features a collision avoidance system, etc.).
The safety or performance of your vehicle could be GPS location data, fault codes, and other technical
adversely affected by the installation of nonstandard data may be recorded.
components. Note the limitations and specifications
This data may help provide a better understanding of
provided in the vehicle and chassis manuals, and
the circumstances of a crash.
consult your selling dealer before making any altera-
tions to the vehicle or chassis. Personal data such as name, gender, and age are
not recorded. However, other parties such as law
For your reference, keep this manual in the vehicle
enforcement, could combine the data logger’s con-
at all times.
tents with the type of personally identifying data rou-
IMPORTANT: Descriptions and specifications in tinely acquired during a crash investigation.
this manual were in effect at the time of printing.
For the most up-to-date information, visit Emissions and Fuel Efficiency
[Link] for the latest version of the
driver’s and maintenance manuals. Freightliner Compliance
Custom Chassis Corporation reserves the right This vehicle must be regularly inspected and main-
to discontinue models and to change specifica- tained as indicated in the S2 Chassis Maintenance
tions or design at any time without notice and Manual, and in the Pre- and Post-Trip Inspections
without incurring obligation. Descriptions and and Maintenance chapter in this manual, in order to
specifications contained in this publication pro- continue satisfactory performance and ensure cover-
vide no warranty, expressed or implied, and are age of the vehicle under the manufacturer’s warranty.
subject to revisions and editions without notice. Many maintenance procedures ensure that the ve-
hicle and engine continue to comply with applicable
Environmental Concerns and emissions standards. Maintenance procedures, using
components engineered to comply with greenhouse
Recommendations gas emissions and fuel efficiency regulations, may be
performed by an authorized Daimler Truck North
Whenever you see instructions in this manual to dis-
America dealer, an independent outlet, or the vehicle
card materials, you should first attempt to reclaim
owner or operator.
and recycle them. To preserve our environment, fol-
low appropriate environmental rules and regulations The vehicle owner is responsible for determining the
when disposing of materials. suitability of replacement components to maintain
compliance with federal and local jurisdictional regu-
IMPORTANT: Modifications to fuel systems, lations. Components including, but not limited to, low-
emission related components, or air conditioning rolling resistance tires are specifically designed and
systems may constitute a noncompliant EPA or manufactured to exacting standards for regulatory
CARB vehicle and such actions are prohibited.

STI-479-7 (06/22/2022)
A24-01453-000
Printed in U.S.A.
Foreword

fuel efficiency and greenhouse gas emissions compli- For more information about motor vehicle safety,
ance. It is important that these components are al- go to [Link].
ways replaced with components that meet or exceed
the performance of the originally installed compo- To contact Freightliner Custom Chassis Corpora-
nents. tion regarding a concern about a specific vehicle,
call the Customer Assistance Center at
1-800-385-4357 or 1-800-FTL-HELP.
Customer Assistance Center
Vehicles domiciled in Canada that are thought to
Having trouble finding service? Call the Customer
have a defect that could cause a crash, injury, or
Assistance Center at 1-800-385-4357 or
1-800-FTL-HELP. Call night or day, weekdays or death, should immediately be reported to Trans-
weekends, for dealer referral, vehicle information, port Canada and Freightliner Custom Chassis Cor-
breakdown coordination, or Fleetpack assistance. For poration.
specification requests and all other concerns and If Transport Canada receives similar complaints, it
inquiries, the Customer Assistance Center is avail- may open an investigation; if it finds that a safety
able 24 hours a day, seven days a week. Our people defect exists in a group of vehicles, it may order a
are knowledgeable, professional, and committed to
recall and remedy campaign. However, Transport
following through to help you keep your vehicle mov-
Canada cannot become involved in individual
ing.
problems between you, your dealer, or Freightliner
Custom Chassis Corporation.
Reporting Safety Defects
To contact Freightliner Custom Chassis Corpora-
Vehicles domiciled in the USA that are thought to tion regarding concerns about a specific vehicle,
have a defect which could cause a crash or could call the Customer Assistance Center at
cause injury or death, you should immediately in- 1-800-385-4357 or 1-800-FTL-HELP.
form the National Highway Traffic Safety Adminis-
tration (NHTSA) in addition to notifying Freightliner To contact Transport Canada, call the Defect In-
Custom Chassis Corporation. vestigations and Recalls Division toll-free in
Canada at 1-800-333-0510 or 1-819-994-3328 in
If the NHTSA receives similar complaints, it may the Gatinuau-Ottawa area or internationally.
open an investigation, and if it finds that a safety
defect exists in a group of vehicles, it may order a Contact Transport Canada by mail at: Transport
recall and remedy campaign. However, NHTSA Canada, 330 Sparks Street, Ottawa, Ontario, K1A
cannot become involved in individual problems 0N5 Canada.
between you, your dealer, or Freightliner Custom
The following websites contain more information
Chassis Corporation.
on Canadian recalls:
To contact NHTSA, call the Vehicle Safety Hotline
English: [Link]/recalls.
toll-free at 1-888-327-4236 (TTY: 1-800-424-9153).
French: [Link]/rappels.
To e-mail NHTSA, go to [Link].
For additional road safety information, visit the
Contact NHTSA by mail at: Administrator, NHTSA
Road Transportation website:
Headquarters, 1200 New Jersey Avenue SE, West
Building, Washington, DC 20590. English: [Link]/en/services/road
French: [Link]/fr/services/routier
© 2007–2022 Daimler Truck North America LLC. All rights reserved. Daimler Truck 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 Truck North America LLC. For additional information, please contact Daimler Truck North America

STI-479-7 (06/22/2022)
A24-01453-000
Printed in U.S.A.
 Foreword

LLC, Service Systems and Documentation, P.O. Box 3849, Portland OR 97208–3849 U.S.A. or refer to [Link]-
[Link] and [Link].

STI-479-7 (06/22/2022)
A24-01453-000
Printed in U.S.A.
 Contents
Chapter Page
Introduction, Environmental Concerns and Recommendations,
Data Logging, Emissions and Fuel Efficiency Compliance,
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 Electrical Systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.1
7 Heater, Ventilating, and Air Conditioner (HVAC) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.1
8 Engines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.1
9 Exhaust Aftertreatment Systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.1
10 Transmission . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.1
11 Drive Axles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11.1
12 Steering System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12.1
13 Hydraulic and Air Brake Systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13.1
14 Pre- and Post-Trip Checklists . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14.1
15 Pre- and Post-Trip Inspections and Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15.1
16 Cleaning and Care . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16.1
17 In an Emergency . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17.1
18 Headlight Aiming . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18.1
19 Propane Fuel System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19.1
20 Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20.1
Index . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I.1
 1
Vehicle Identification
Component Information Label . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.1
Vehicle Identification Number . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.1
Emissions Labels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.1
Vehicle Identification

Component Information Label Incomplete chassis intended for service in the U.S.
have an incomplete vehicle certification label at-
NOTE: Labels shown in this chapter are ex- tached by the final-stage manufacturer. This label will
amples only. Actual specifications may vary from be attached to the incomplete vehicle document in-
vehicle to vehicle. cluded with the vehicle, and certifies that the vehicle
conforms to all applicable FMVSS regulations in ef-
The component information label lists the manufac- fect on the date of completion.
turer, month and year of manufacture, vehicle identifi-
cation number (VIN), gross vehicle weight rating
(GVWR), front and rear gross axle weight ratings Vehicle Identification Number
(GAWR), and tire and wheel information. It also indi- The chassis vehicle identification number (VIN) is
cates if the vehicle has been certified as compliant stamped on a metal plate permanently attached to
with Federal Motor Vehicle Safety Standard the vehicle, and the last six digits (designating the
(FMVSS). See Fig. 1.1. chassis serial number) are stamped into the metal
frame. See Fig. 1.2. A VIN label is also mounted by
the body builder. Mounting locations vary, to include
the glove box. See Fig. 1.3.

4UZA4FVC0TC748531
GAFFNEY, SOUTH CAROLINA, USA

04/18/2005 f080061a

Fig. 1.2, Vehicle Identification Number, Typical

NOTE: Always include the chassis serial num-

ber (last six digits of the VIN) when communi-
cating to Daimler Trucks North America.

Emissions Labels
Aftertreatment System Indicators
Label
Model year 2007 and later diesel engines in vehicles
domiciled in the U.S. or Canada are required to meet
09/11/2002 f080123 all EPA exhaust gas emission regulations effective as
per the applicable emission model year, and are
Fig. 1.1, Component Information Label
equipped with an emission aftertreatment system
The tire and rim portion of the component information (ATS). Vehicles domiciled outside of the U.S. and
label certifies suitable tire and rim combinations that Canada may not have aftertreatment equipment, de-
can be installed on the vehicle for the given gross pending upon local statutory emissions guidelines.
axle weight rating. Tires and rims installed on the A reference label included with the driver’s documen-
vehicle at the time of manufacture may have a higher tation package contains important warning indicators
load capacity than that certified by the tire and rim in the instrument cluster that pertain to the ATS. See
label. If the tires and rims currently on the vehicle Fig. 1.4. See Table 1.1 and Table 1.2 for additional
have a lower load capacity than that shown on the EPA information.
tire and rim label, then the tires and rims determine
It is a violation of U.S. federal law to alter exhaust
the load limitations on each of the axles.
plumbing, ATS, or other components in any way that

1.1
 Vehicle Identification

would bring the engine/vehicle 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.

12/04/2001 f080122

Fig. 1.3, Vehicle Identification Number Label, Typical

Vehicle Emission Control Information

Label
Model year 2013 and later vehicles meet require-
ments as specified by GHG14, GHG17 and GHG21
regulations, respectively. These vehicles are
equipped with components that increase fuel effi-
ciency and reduce greenhouse gas (GHG) emis-
sions. Components may include, but are not limited
to, low-rolling resistance tires; aerodynamic devices
such as hood, vehicle speed limiters; and idle shut-
down timers.
A Vehicle Emission Control Information Label indi-
cates compliance with emission regulations. See
Fig. 1.5. Among other GHG relevant information the
label indicates the emission model year of the ve-
hicle. It is the owner’s responsibility to maintain the
vehicle so that it conforms to EPA and National High-
way Traffic Safety Administration (NHTSA)
regulations.

1.2
Vehicle Identification

10/23/2020 f080234

Fig. 1.4, ATS Indicators, EPA10 and Newer

EPA Regulations
Regulation Emissions Components
EPA07 (Reduction of nitrogen
oxides (NOx) emissions to 1.1 Aftertreatment device (ATD) containing a diesel particulate filter that traps soot and
g/bhp-hr, and particulate matter ash.*
emissions to 0.01 g/bhp-hr)
EPA10 (Reduction of NOx EPA07-type ATD, with additional selective catalyst reduction (SCR) technology that
emissions to 0.2 g/bhp-hr) utilizes diesel exhaust fluid (DEF) to convert NOx to nitrogen and water vapor.
Fuel efficiency components including, but not limited to, engines, tires, aerodynamic
GHG14 (Reduction of greenhouse
components, vehicle speed limiters, and idle reduction timers specifically designed to
gas emissions)
meet regulatory fuel efficiency and greenhouse gas emissions standards.
Fuel efficiency components including, but not limited to, engines, tires, aerodynamic
GHG17 components, vehicle speed limiters, and idle reduction timers specifically designed to
meet regulatory fuel efficiency and greenhouse gas emissions standards.
GHG14/17 components plus additional components including, but not limited to,
GHG21 transmissions, axles, predictive technologies, idle reduction technologies for
vocational vehicles, tire pressure monitoring systems.
* Cummins, Detroit, and Mercedes-Benz ATD’s are also equipped with a diesel oxidation catalyst to break down pollutants.

Table 1.1, EPA Regulations

1.3
 Vehicle Identification

Emission Regulations by Model Year

Model Year Engine Regulation Vehicle Regulation
2007–2009 EPA07 N/A
2010–2012 EPA10 N/A
2013–2015 EPA10, GHG14 GHG14
2016 EPA10, GHG17 GHG14
2017–2020 EPA10, GHG17 GHG17
2021–and later EPA10, GHG21 GHG21
Table 1.2, Emission Regulations by Model Year

03/02/2012 f080183

Fig. 1.5, Vehicle Emission Control Information Label

1.4
 2
Vehicle Access
Battery Access . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.1
Hood Opening and Closing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.1
Vehicle Access

Battery Access
Battery Compartment
The battery compartment is located behind the
driver’s area, attached to the frame rail. To open the
battery access door, insert and turn the key, then pull
the access door open. Pull the pull-pin spring latches
out to slide the battery tray forward. See Fig. 2.1.

01/18/95 f600150a

Fig. 2.2, Battery Disconnect Switch

Hood Opening and Closing

2 3 2 A torsion spring helps to raise and lower the hood.
Hood restraint cables prevent the hood from over-
travel. An optional hood damper limits the closing
1
speed. In the operating position, the hood is secured
to the half-fenders by a hold-down latch on each
side.
12/05/2003 f544365
1. Battery Access Door 3. Battery Tray Tilting the Hood
2. Pull-Pin Spring Latch 4. Battery
1. Apply the parking brakes.
Fig. 2.1, Battery Access
2. Release both hood hold-down latches by pulling
With the battery access door open, it is easy to get the ends outward. See Fig. 2.3.
access to the battery terminals for cleaning, charg-
ing, or emergency jump starting.
To return the battery to the compartment, slide the
3
battery tray in until the pin spring latch is in the
locked position. Lock the battery access door with 2
the key.

Battery Disconnect Switch, Optional

A battery disconnect switch, if so equipped, cuts off
all battery power to the vehicle. It is also used when- 4
ever the vehicle is placed out of service for extended
periods to prevent battery discharge. The battery dis-
connect switch is located on the side of the battery 1
box. See Fig. 2.2. 10/24/2001 f880555

1. Fender 3. Latch Handle

NOTICE 2. Latch Hook 4. Half-Fender
Fig. 2.3, Hood Hold-Down Latch
The batteries must be disconnected if the vehicle
is not in use for a period exceeding two weeks,
or the vehicle may not start, and permanent bat-
tery damage could occur.

2.1
 Vehicle Access

NOTICE
Do not let the hood free-fall to the fully open po-
sition. To do so could damage the hood or hood
straps.
3. Standing in front of the hood, tilt the rear of the
hood upward until it reaches the over-center po-
sition (45-degrees from vertical). Then slowly
bring it to a stop.

Closing the Hood

1. Push the hood over center.
2. As the hood goes over center, the damper (if
equipped)automatically slows its rate of descent.
If needed, you can also slow the rate of descent
with your hand.
3. Make sure the hood is flush with the cowl, then
secure the hood by engaging both hood hold-
down latches.
IMPORTANT: Make sure that both hold-down
latches are fully engaged before operating the
vehicle.

2.2
 3
Instruments
Instrumentation Control Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.1
Warning and Indicator Lamps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.3
Speedometer and Tachometer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.7
Standard Instruments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.7
Optional Instruments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.9
Instruments

Instrumentation Control Unit Dash Message Center

Figure 3.1 and Fig. 3.2 show a typical set of instru- The dash message center houses all of the standard
ments for vehicles equipped with the S2 Chassis and optional warning and indicator lamps. Warning
ICU3 instrument cluster. messages and diagnostic fault codes will appear in
the driver display screen.
NOTE: This instrument cluster is shown with the
U.S. speedometer, which shows miles per hour Ignition Sequence
(mph) more prominently than kilometers per
hour (km/h). When the ignition is turned on, all the electronic

1 2 3 4 5

13
9

07/08/2011 12 11 10 f611047
1. Engine Oil Pressure Gauge 6. Diesel Exhaust Fluid (DEF) Gauge 10. Speedometer
2. Dash Message Center 7. Primary Air Pressure Gauge 11. Tachometer
3. Headlight High-Beam Indicator 8. Mode/Reset Switch 12. Transmission Temperature Gauge
4. Dash Driver Display Screen 9. Secondary Air Pressure Gauge 13. Coolant Temperature Gauge
5. Fuel Level Gauge
Fig. 3.1, Gauge Layout (typical, U.S.), EPA10 and Newer Engines

The ICU3 instrument cluster receives information gauges complete a full sweep of their dials, the
from the datalink and sensors installed on the ve- warning and indicator lamps illuminate, and the
hicle, and sends that information to electronic buzzer sounds for 3 seconds.
gauges.
NOTE: The air gauges do not sweep.
There can be up to eight gauges on the driver’s in-
The following lamps illuminate during the ignition se-
strument panel (six electronic and two mechanical).
quence:
Only the air gauges operate mechanically.
• fasten seat belt warning
The S2 Chassis instrument clusters have the capabil-
ity to drive independent stand-alone gauges such as • low battery voltage warning
those installed on the auxiliary dash panel.

3.1
 Instruments

1 2 3 4 5

OPT OPT OPT OPT OPT OPT OPT OPT OPT

50 1/2
CHECK STOP ABS ABS

PSI
BRAKE
0 100 E F
OIL FUEL

150 200
20 25 45 50 100
6
F°
15 35 55 PSI
70
100 250
30 25 50
90
65 0 150
WATER
10 30
110 AIR
PUSH−
MODE
7
15 75 HOLD−
RESET

225 130
12 5 10 50 100
8
F° 5 85 PSI

0 RPM km/h
100 350
X100 MPH 0 150
TRANS AIR

10/26/2006 11 10 9 f610837b
1. Engine Oil Pressure Gauge 5. Fuel Level Gauge 9. Speedometer (U.S. version)
2. Dash Message Center 6. Primary Air Pressure Gauge 10. Tachometer (optional)
3. Headlight High-Beam Indicator 7. Mode/Reset Switch 11. Coolant Temperature Gauge
4. Dash Driver Display Screen 8. Secondary Air Pressure Gauge

Fig. 3.2, Gauge Layout (typical, U.S.), EPA07-Compliant

• high coolant temperature warning • Second line (units): TRIP MI KM HOURS

• low engine oil pressure warning • Third line (voltmeter): 38.8 VOLTS
• low air pressure warning • Fourth line: SERVICE ENGINE
• parking brake on indicator During the second half of the self-test, the software
revision level is displayed.
• all engine indicator/warning lights, including
check engine and stop engine If there are no active faults, the driver display screen
displays the odometer.
• all ABS indicator/warning lights, including
wheel spin, and tractor ABS (if installed) If however, the instrument cluster has received active
fault codes from other devices, it displays them one
NOTE: While the engine and ABS warning after the other until the parking brake is released, or
lamps illuminate during the ignition sequence, the ignition switch is turned off. Once the parking
they are not controlled by the instrument cluster brake is released, the dash message center displays
but by their own system electronic control unit the odometer again.
(ECU). NOTE: If active faults are present, take the ve-
When the ignition switch is turned on, the ICU per- hicle to an authorized Freightliner service facility
forms a self-test, looking for active faults. During the as soon as possible.
first half of the self-test, all segments of the display
If the fault requires immediate attention, the stop en-
illuminate as follows:
gine system will activate. In most cases, the check
• First line (odometer): 888888.8 engine lamp will also illuminate.

3.2
Instruments

Some examples include:

• high coolant temperature
PUSH−
• low air pressure
MODE
• low coolant level
• low engine oil pressure HOLD−
NOTE: The check engine lamp does not illumi- RESET
nate for a low air pressure fault.
09/25/99 f610340
The legend SERVICE ENGINE can appear on the
driver display screen as an active fault code. If this Fig. 3.3, Mode/Reset Switch
legend appears, it means the trip miles (or hours)
have gone beyond the next required service interval, • Press the mode/reset switch a third time and
as set by the vehicle operator. the SELECT screen and the current units, MI
or KM, will display.
IMPORTANT: If the legend SERVICE ENGINE
• Press the mode/reset switch a fourth time to
does appear on the driver display screen while
return to the odometer reading.
operating the vehicle, bring the vehicle to an
authorized Freightliner service facility when To reset trip miles and/or trip hours to zero, press the
convenient. mode/reset switch for 1 second or longer. To toggle
between MI (miles) or KM (kilometers), press the
Odometer mode/reset switch while in the SELECT screen.

The odometer is a seven-digit display with a decimal Warning and Indicator Lamps
point, until the vehicle has traveled 999,999.9 miles
or kilometers (km). At one million miles (km), the There can be up to 27 warning and indicator lamps
odometer resets itself to 1,000,000, without the deci- (telltales) installed in the dash message center. See
mal point, and can continue up to 9,999,999. The Fig. 3.4 and Fig. 3.5.
odometer only displays significant figures (no leading
The instrument cluster has an emergency buzzer that
zeros).
sounds when serious conditions that require immedi-
The odometer is set to display in either miles or kilo- ate attention occur.
meters, depending on the primary scale of the
speedometer. The legend, either MI or KM, illumi- A description of the standard warning and indicator
nates between the odometer and the volts display lamps are listed below.
when the engine is running or the headlights are
turned on. Check Engine Warning
The check engine warning indicator illuminates when
Mode/Reset Switch certain faults are detected. If a critical engine condi-
The mode/reset switch, shown in Fig. 3.3, is located tion exists (for example, low oil pressure or high
on the right side of the instrument cluster. The mode/ coolant temperature), the check engine indicator will
reset switch is used to scroll through the displays on illuminate to alert the driver to correct the condition
the message display screen, and to reset the trip dis- as soon as possible. If the condition gets worse, the
tance and trip hours values to zero. stop engine indicator will illuminate.
When the odometer reading is displayed and the NOTE: If the check engine indicator illuminates
parking brake is applied: during vehicle operation, take the vehicle di-
rectly to an authorized Freightliner service facil-
• Press the mode/reset switch once and the trip
ity.
distance will display.
• Press the mode/reset switch a second time Stop Engine Warning
and the trip hours (engine hours) will display.
The stop engine warning indicator illuminates when
the protection system available for the engine has

3.3
 Instruments

1 2 3 4 5 6 7 1 2 3 4 5 6 7

OPT OPT OPT OPT OPT OPT OPT OPT OPT OPT OPT OPT OPT OPT OPT OPT OPT OPT

CHECK STOP ABS ABS CHECK STOP ABS ABS

BRAKE

8 9 10 11 12 13 8 9 10 11 12 13
14 15 16 17 18 19 20 21 14 15 16 17 18 19
07/08/2011 f611066 09/28/2006 f610838
1. Optional Indicator 1. Optional Indicator
2. Check Engine Warning 2. Check Engine Warning
3. Stop Engine Warning 3. Stop Engine Warning
4. Malfunction Indicator Lamp (MIL) 4. Malfunction Indicator Lamp
5. ABS Warning 5. ABS Warning
6. Transmission Overheat Warning 6. Transmission Overheat Warning
7. Trailer ABS Indicator (not used) 7. Trailer ABS Indicator (not used)
8. Low Oil Pressure Warning 8. Low Oil Pressure Warning
9. High Coolant Temperature Warning 9. High Coolant Temperature Warning
10. Fasten Seat Belt Warning 10. Fasten Seat Belt Warning
11. Parking Brake On Warning 11. Parking Brake On Warning
12. Diesel Particulate Filter (DPF) Lamp 12. Diesel Particulate Filter (DPF) Lamp
13. High Exhaust System Temperature (HEST) Lamp 13. High Exhaust System Temperature (HEST) Lamp
14. Left-Turn Indicator 14. Left-Turn Indicator
15. Low Battery Voltage Warning 15. Low Battery Voltage Warning
16. Water In Fuel Indicator 16. Dash Driver Display Screen
17. Dash Driver Display Screen 17. Headlight High-Beam Indicator
18. Headlight High-Beam Indicator 18. Low Air Pressure Warning
19. Cruise Control Indicator 19. Right-Turn Indicator
20. Low Air Pressure Warning
21. Right-Turn Indicator Fig. 3.5, Warning and Indicator Lights, EPA07-
Compliant
Fig. 3.4, ICU3 Warning and Indicator Lights, EPA10 and
Newer Engines IMPORTANT: Do not attempt to restart the en-
gine while the vehicle is moving. Bring the ve-
been activated. On some engines, the engine elec- hicle to a safe stop and restart the engine with
tronic control unit (ECU) will derate the engine, allow-
the vehicle stopped.
ing it to run, but at lower rpm and slower vehicle
speed. The vehicle may be driven to a safe location.
Malfunction Indicator Lamp (MIL)
The engine ECU will derate the engine. The driver
must safely bring the vehicle to a stop on the side of The malfunction indicator lamp (MIL) indicates an
the road. engine emissions-related fault. See the engine op-
eration manual for details.
NOTICE ABS Warning
Because operating the engine when the stop en- The ABS indicator illuminates when there is a mal-
gine indicator is illuminated can lead to severe function in the vehicle antilock brake system (ABS).
engine damage, the driver must move the vehicle
to a safe location as quickly as possible. NOTE: For more information about this indicator
and the ABS system, see Chapter 13.
To restart the engine turn the ignition switch to OFF,
leave it there a few seconds, and turn the switch to
START.

3.4
Instruments

Transmission Overheat Warning chime activates. The warning chime will remain ac-
tive for 10 seconds. The warning indicator remains
The transmission overheat indicator illuminates when illuminated until the driver’s seat belt is fastened.
the temperature of the transmission fluid goes above
the preset level set by the transmission manufac- Parking Brake On Warning
turer.
The parking brake on indicator activates when the
For more information, see the transmission manufac- parking brake is engaged.
turer’s manual provided with the vehicle.
If the vehicle is moving at a speed of 2 mph (3 km/h)
Low Oil Pressure Warning or more, the emergency buzzer will sound until the
parking brake is released.
The low oil pressure warning indicator and emer-
gency buzzer activate whenever the engine oil pres- Diesel Particulate Filter (DPF) Lamp
sure goes below the preset minimum specified by the
engine manufacturer. See Table 3.1. A solid illumination indicates a regeneration is re-
quired. Change to a more challenging duty cycle,
Oil Pressure Specifications* such as highway driving, to raise exhaust tempera-
Pressure at Pressure at tures for at least 20 minutes, or perform a stationary
Engine Model regeneration. See the engine operator’s manual for
Idle RPM Rated RPM
details.
Mercedes-Benz 50 psi (345
50 psi (345 kPa)
MBE900† kPa) A blinking lamp indicates that a stationary regenera-
Cummins ISB 10 psi (69 kPa) 30 psi (207 kPa) tion is required immediately. An engine derate and
* Oil pressures are given with the engine at operating temperature. With shutdown will occur. See the instructions in the en-
the engine cold, oil pressure may be higher. Individual engines may vary gine operator’s manual to perform a stationary regen-
from the listed pressures; observe and record pressures when the engine
is new to create a guide for checking engine condition.
eration.
† EPA07 MBE900 engines are equipped with an oil pressure switch.
When above minimum pressure, the dash gauge will display the values High Exhaust System Temperature
listed in this table. If below minimum oil pressure, the dash gauge will
read 0 psi. (HEST) Lamp
Table 3.1, Oil Pressure Specifications
The high exhaust system temperature (HEST) lamp
alerts the operator of high exhaust temperature dur-
High Coolant Temperature Warning ing the regen process when the speed is below 5
mph (8 km/h), or during a manual regen. The HEST
The high coolant temperature indicator and emer- lamp does not signify the need for any kind of ve-
gency buzzer activate whenever the coolant tem- hicle or engine service; it only alerts the vehicle op-
perature goes above a preset maximum specified by erator to high exhaust temperatures.
the engine manufacturer. See Table 3.2.
IMPORTANT: Make sure the engine exhaust
Maximum Coolant Temperature pipe outlet is not directed at any person, or at
Engine Model °F (°C)
any surface or material that will melt, burn, or
Mercedes-Benz MBE900 221 (105)
explode.
Cummins ISB 220 (104)
Left-Turn Indicator
Table 3.2, Maximum Coolant Temperature
The left-turn indicator flashes on and off when the
left-turn signal lights are flashing.
Fasten Seat Belt Warning Both turn signal indicators flash when the hazard
The fasten seat belt warning indicator (seat belt icon) warning flasher is turned on.
illuminates for 3 seconds after the ignition switch is
turned on. Low Battery Voltage Warning
When the engine is operating, if the driver’s seat belt The low battery voltage warning indicator (battery
is unfastened and the park brake is not set, the seat icon) illuminates when the battery voltage drops
belt warning indicator illuminates and a warning below 12 volts.

3.5
 Instruments

Water In Fuel Indicator • The parking brake is set with the vehicle mov-
ing at a speed greater than 2 mph (3 km/h).
The water in fuel indicator notifies the driver the fuel
may contain water. Drain any water collected in the Optional Warning and Indicator
fuel/water separator.
Lamps
NOTICE A description of some commonly used optional warn-
ing and indicator lamps are listed below.
Water in the fuel/water separator will appear as
beads. With the engine off, drain the separator Air Filter Warning
only enough to remove the water; about two tea- The air filter warning indicator (AIR FILTER legend)
spoons at a time. Do not drain the separator illuminates when the air cleaner filter element is
completely or it will be necessary to prime the clogged, restricting the intake air flow. See Table 3.3.
fuel system before the vehicle can be started
again. If the air filter indicator light is steadily illuminated for
any period of time, check the air intake restriction
Headlight High-Beam Indicator gauge. If needed, replace the air filter, and reset the
air intake restriction gauge.
The high-beam indicator (sideways beam icon) illumi-
nates when the headlight high beams are on. Air Intake Maximum Restriction Values (inH2O)
Pre-EPA07 EPA07 and
Cruise Control Indicator Engine
Engines Newer Engines
The cruise control indicator illuminates when the Cummins 25 25
cruise control is activated. Mercedes-Benz 22 22
Table 3.3, Air Intake Maximum Restriction Values
Low Air Pressure Warning (inH2O)
The low air pressure warning indicator (BRAKE icon)
and emergency buzzer activate when the engine is IMPORTANT: Never attempt to clean the air fil-
turned on if air pressure in the primary or secondary ter.
air reservoir is below 65 to 75 psi (448 to 517 kPa),
and remain on until air pressure rises above that Alternator No Charge Indicator
level in both reservoirs. The alternator no charge indicator lamp (NO
CHARGE legend) illuminates when the alternator is
Right-Turn Indicator not charging properly.
The right-turn indicator flashes on and off when the
right-turn signal lights are flashing. Check Transmission Warning (diesel
engine only)
Both turn signal indicators flash when the hazard
warning flasher is turned on. NOTE: Although it appears in the row of op-
tional indicators, the check transmission indica-
Emergency Buzzer tor is a standard indicator.
The emergency buzzer sounds during the ignition The check transmission indicator, shown in Fig. 3.6,
sequence and whenever one of the following condi- notifies the driver of three things. Any of the following
tions exists: items could be the cause for activating the indicator:
• The engine oil pressure falls below the preset • the oil needs to be changed
level shown in Table 3.1.
• the filter(s) need to be changed
• The coolant temperature rises above the pre-
• clutch maintenance is required
set level shown in Table 3.2.
• The air pressure falls below the preset level,
which is 65 psi (448 kPa).

3.6
Instruments

Standard Instruments
Engine Oil Pressure Gauge
NOTICE
A sudden decrease or absence of engine oil
pressure may indicate mechanical failure. Bring
the vehicle to a safe stop and investigate the
cause to prevent further damage. Do not operate
02/28/2011 f611115
the engine until the cause has been determined
Fig. 3.6, Check Transmission Indicator and corrected.
See Fig. 3.8 for an example of the engine oil pres-
When the check transmission indicator illuminates, sure gauge. If the engine oil pressure falls below the
refer to the Allison Operator’s Manual or contact cus- preset levels shown in Table 3.1, first the check en-
tomer support at Allison Transmission to determine gine lamp will illuminate, and, if the condition does
the specific cause activating the indicator. not improve, the stop engine lamp will also illuminate
and the buzzer will sound. At this point, the engine
Speedometer and Tachometer will derate or shut down, depending on the type of
engine protection system installed.
Speedometer
Three kinds of speedometer faces are available. The
U.S. version of the speedometer registers speed in
both miles per hour (mph) and kilometers per hour 50
(km/h), with mph in larger numbers. See Fig. 3.7.

PSI

20 25 45
35 55
15
30 25
70
90 0 100
50
65
10 30
110
OIL
15 75
130
5 10
5 85 10/09/2001 f610528
0 RPM km/h
X100 MPH
Fig. 3.8, Engine Oil Pressure Gauge

1 2
Coolant Temperature Gauge
10/09/2001 f610527
1. Tachometer 2. Speedometer NOTICE
Fig. 3.7, Speedometer and Tachometer A sudden increase in coolant temperature may
indicate engine or cooling system failure. Bring
The NAFTA version (not shown) of the speedometer the vehicle to a safe stop and investigate the
face reverses this arrangement, with km/h in larger cause to prevent further damage. Do not operate
numbers. The metric only version (not shown) shows the engine until the cause has been determined
km/h exclusively. and corrected.

Tachometer During normal engine operation, the coolant tem-

perature gauge should read 175 to 195°F (79 to
The tachometer indicates engine speed in revolutions 91°C). See Fig. 3.9. If the temperature remains
per minute (rpm) and serves as a guide for shifting
the transmission and keeping the engine in the ap-
propriate rpm range. See Fig. 3.7.

3.7
 Instruments

below 160°F (71°C), or exceeds the maximum tem-

perature shown in Table 3.2, inspect the cooling sys-
1
tem to determine the cause. See Group 20 of the S2
Chassis Workshop Manual. 1/2
ULTRA LOW SULFUR
DIESEL FUEL ONLY

4 E F
150 200
DEF
F°
E F
100 250 3

WATER 2
08/21/2009 f611045

10/09/2001 f610565
1. Diesel Fuel Level Indicator
2. DEF Level Indicator
Fig. 3.9, Coolant Temperature Gauge 3. Low DEF Warning Lamp (amber below 10% DEF)
4. Low Fuel Warning Lamp (amber at 1/8 tank of fuel)
If the coolant temperature rises above the preset lev- Fig. 3.10, Fuel/DEF Gauge, EPA10
els shown in Table 3.2, first the check engine warn-
ing indicator will illuminate, and, if the condition does
not improve, the stop engine warning indicator will
also illuminate and the buzzer will sound. At this
point, the engine will derate or shut down, depending 1/2
on the type of engine protection system installed.

Fuel/Diesel Exhaust Fluid (DEF)

Gauge
E F
For engines that are EPA10-compliant or newer, the
fuel and DEF levels are measured in a dual purpose FUEL
fuel/DEF gauge. See Fig. 3.10.
10/09/2001 f610566
The diesel fuel level is indicated at the top of the
gauge, with a low-level warning lamp that illuminates Fig. 3.11, Fuel Level Gauge, EPA07 Vehicles
when the diesel fuel level registers 1/8th of capacity.
One fuel gauge is standard. If equipped with a sec- Primary and Secondary Air Pressure
ond (optional) fuel gauge, each fuel tank level is indi-
cated on a separate gauge.
Gauges
The DEF level is indicated in the lower portion of the
gauge. There is a low DEF level warning lamp that WARNING
illuminates when the DEF level reaches 10% of ca-
If air pressure falls below minimum pressure, the
pacity. See Chapter 9 for details of the DEF gauge
braking ability of the vehicle will be limited. Slow
functions.
the vehicle down and bring it to a gradual stop.
Figure 3.11 shows a fuel gauge installed on EPA07 Do not attempt to move the vehicle until air pres-
vehicles. sure has risen above the minimum level. Moving
a vehicle without adequate braking power could
cause an accident resulting in property damage,
personal injury, or death.
Air pressure gauges register the pressure in the pri-
mary and secondary air systems. Normal pressure

3.8
Instruments

with the engine running is 100 to 120 psi (690 to 827 of a fully charged battery is 12.7 to 12.8 volts when
kPa) in both systems. See Fig. 3.12. the engine is stopped. Battery voltage under 12.0
volts is considered a low battery, and a completely
discharged battery will produce only about 11.0 volts.
The voltmeter will indicate lower voltage as the ve-
hicle is being started or when electrical devices in
the vehicle are being used.
If the voltmeter shows an undercharged or over-
charged condition for an extended period, have the
charging system and batteries checked at a repair
facility.
1
Optional Instruments
Optional instruments are not found on every vehicle.
They are stand-alones, not driven by the instrument
cluster, and are usually located on the auxiliary dash
panel. They are listed here in alphabetical order, to
make the information easier to find.

Air Intake Restriction Gauge

2 The air intake restriction gauge indicates the vacuum
on the engine side of the air cleaner. On standard
installations, it is mounted on the air intake duct in
10/22/2009 f610567 the engine compartment. See Fig. 3.13. As an option
1. Primary Air Pressure Gauge for easier viewing, the intake-air restriction indicator
2. Secondary Air Pressure Gauge can be mounted on the dash, usually on the right-
hand control panel.
Fig. 3.12, Air Pressure Gauges

Air pressure gauges are required on all vehicles with

air brakes. A low-air-pressure warning lamp and
buzzer, connected to both the primary and secondary
systems, activate when air pressure in either system
drops below a minimum pressure of 65 to 75 psi
(448 to 517 kPa).
When the engine is started, the warning lamp and
buzzer remain on until air pressure in both systems
exceeds minimum pressure.

Voltmeter
The voltmeter is a digital readout located on the bot-
tom line of the driver display screen whenever the
ignition switch is turned on.
It indicates the vehicle charging system voltage when
the engine is running and the battery voltage when
the engine is stopped. By monitoring the voltmeter, 10/10/2001 f610568
the driver can be aware of potential charging system
problems and have them fixed before the batteries Fig. 3.13, Air Intake Restriction Indicator
discharge enough to create starting difficulties.
Air intake restriction vacuum is measured in inches
The voltmeter will normally show approximately 13.7 of water (inH2O). For vehicles equipped with a gradu-
to 14.1 volts when the engine is running. The voltage ated indicator or a restriction gauge on the dash,

3.9
 Instruments

check the gauge with the engine off. If the yellow

signal stays locked in the red zone once the engine
is shut down, or is at or above 25 inH2O, the air
cleaner element needs to be replaced.
NOTE: Rain or snow can wet the filter and
cause a temporarily higher than normal reading.

Ammeter
An optional ammeter measures current flowing to
and from the battery. See Fig. 3.14. When the batter-
ies 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 10/10/2001 f610571
side. A consistent negative reading when the engine
is running indicates a possible problem with the Fig. 3.15, Axle Oil Temperature Gauge
charging system.
Digital Clock
The optional digital clock has black characters on a
constantly backlighted green display, with a bright-
ness that automatically adjusts for day or night. The
clock has a 24-hour alarm, with a three-minute
snooze feature. See Fig. 3.16.

10/10/2001 f610573

Fig. 3.14, Ammeter

Axle Oil Temperature Gauge, Rear

NOTICE 10/11/2001 f610576

A sudden increase in oil temperature that is not Fig. 3.16, Digital Clock
caused by a load increase may indicate mechani-
cal failure. Bring the vehicle to a safe stop and 1. To set the time of day:
investigate the cause to prevent further damage.
Do not operate the vehicle until the cause has 1.1 Push the Run/Set (lower) switch to the
been determined and corrected. right (TIME-SET position).
During normal operation, the optional rear axle oil NOTE: When the hour setting is for a time
temperature gauge should read between 160 and between noon and midnight, the small letters
220°F (71 and 104°C) for Detroit™ and Meritor™ drive PM will appear in the lower left corner of the
axles. See Fig. 3.15. display; no PM display indicates an AM set-
Under heavy loads, such as when climbing steep ting.
grades, temperatures up to a maximum of 250°F
(121°C) are not unusual.

3.10
Instruments

1.2 Advance the hour setting to the correct Engine Oil Temperature Gauge
number by pushing and releasing the hour
button as many times as needed. Or if the
button is pressed and held in for longer NOTICE
than 2 seconds, the numbers will continue
to advance until the button is released. A sudden increase in oil temperature that is not
caused by a load increase may indicate mechani-
1.3 Advance the minute setting by repeatedly cal failure. Bring the vehicle to a safe stop and
pushing, or pushing and holding the min- investigate the cause to prevent further damage.
ute button as needed. Do not operate the engine until the cause has
1.4 Push the Run/Set switch to the middle been determined and corrected.
(RUN) position. During normal operation, the optional engine oil tem-
perature gauge should read in the following tempera-
2. To set the alarm time:
ture range:
2.1 Push the Run/Set switch to the left • 180 to 225°F (82 to 107°C) for Cummins ISB
(ALARM-SET position).
engines
2.2 Set the alarm time by using the same pro- • 177 to 203°F (81 to 95°C) for Mercedes-Benz
cedure used to set the time of day; re-
MBE900 engines
member to set the hour for AM (no letters
in the corner of the display), or PM as de- NOTE: Under heavy loads, such as when climb-
sired. ing steep grades, temperatures that exceed the
2.3 Return the Run/Set switch to the middle normal oil temperature range for a short period
(RUN) position; the readout will return to are not unusual. If the temperature returns to
the time-of-day setting. normal when the load decreases, there is no
problem. See Fig. 3.17.
3. To operate the alarm:
3.1 With the alarm time set, push the alarm
(upper) switch to the left. An alarm "wave"
symbol and the letters AL will appear in
the upper left corner of the display when
the alarm is on.
3.2 When the displayed time of day coincides
with the alarm time, the alarm will sound.
If the SNOOZ button is not pushed or the
alarm switch is not moved, the alarm will
automatically stop sounding after 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 10/10/2001 f610569
for 3 minutes. The alarm symbol will flash
in the display when the button is pushed Fig. 3.17, Engine Oil Temperature Gauge
and will continue to flash until the alarm
switch is moved or the alarm has sounded Transmission Fluid Temperature
for one minute. The snooze procedure can
be done as many times as desired.
Gauge
3.4 Move the alarm switch to the right when During normal operation, the transmission fluid tem-
you wish to shut off or cancel the alarm; perature gauge reading should not exceed 250°F
the alarm symbol will disappear. (121°C) at the sump. See Fig. 3.18.

3.11
 Instruments

200 275
F

125 350
TRANS

10/30/2001 f610600

Fig. 3.18, Transmission Fluid Temperature Gauge

NOTICE
A sudden increase in transmission fluid tempera-
ture that is not caused by a load increase may
indicate mechanical failure. Bring the vehicle to a
safe stop and investigate the cause to prevent
further damage. Do not operate the vehicle until
the cause has been determined and corrected.
NOTE: Under heavy loads, such as when climb-
ing steep grades, temperatures may climb
above those given here for limited periods.

Turbocharger Boost Pressure Gauge

A turbocharger boost pressure gauge measures the
pressure in the intake manifold, in excess of atmos-
pheric pressure, being created by the turbocharger.
See Fig. 3.19.

10/10/2001 f610574

Fig. 3.19, Turbo Boost Pressure Gauge

3.12
 4
Controls
Ignition Switch and Key . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.1
Lighting Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.1
Multifunction Turn Signal Lever . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.2
Aftertreatment System (ATS) Regen Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.4
Horn Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.4
Cruise Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.4
Powertrain Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.6
Braking Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.8
Controls

Ignition Switch and Key Headlight/Parking Light Switch

The ignition switch can be turned to four positions: The headlights and parking lights are operated with a
ACCESSORY, OFF, ON, and START. See Fig. 4.1. paddle switch, shown in Fig. 4.2. When the paddle is
lowered, the parking lights (front turn signals, marker
and identification lights, and the taillights) illuminate.
When the paddle is raised, the low-beam headlights
illuminate, along with all of the parking lights. To turn
off all lights, return the paddle to the center position.

09/12/2001 f610509

Fig. 4.1, Ignition Switch Positions

The key can be inserted and removed only in the 10/15/2001 f610580
OFF position. The headlights (low beams), taillights, Raise the paddle to illuminate the low-beam headlights.
brake lights, road lights, clearance lights, turn sig-
nals, hazard warning lights, horn, CB radio, clock, Lower the paddle to illuminate the parking lights.
and electric oil pan heater operate with the ignition Fig. 4.2, Headlight/Parking Light Switch
switch in the OFF position, regardless of whether the
key is inserted. NOTE: The front turn signal is the amber lens in
All of the components that are operable in the OFF each headlight unit. The low-beam headlight is
position are operable in the ACCESSORY position, the top clear lens in each headlight unit.
as well as the radio (if so equipped), mirror heat, air When the headlights or parking lights are on, the
dryer, and backup lights. panel lights also illuminate. A light in the switch back-
Turn the key fully clockwise to the START position to lights either the top icon (for headlights and parking
start the engine. When the engine starts, release the lights) or the bottom icon (for parking lights only).
key.
Daytime Running Lights
All electrical systems are operable in the ON posi-
tion. The warning lights and the buzzer for low air Turning on the ignition and releasing the parking
pressure and low oil pressure operate until minimum brakes automatically activates the daytime running
pressures are built up. lights, if so equipped. The daytime running lights will
operate until the parking brakes are applied or the
headlights are turned on.
Lighting Controls
The daytime running lights illuminate at about two-
The lighting controls are operated with two types of thirds of normal power.
switches located on the dash:
• Paddle switches—a single paddle located in Panel Light Increase/Decrease Switch
the center of the switch that can be raised or When the panel lights are on, they can be brightened
lowered to perform a function. or dimmed by using the INCR/DECR switch, just
• Rocker switches—can be pressed up or down below the headlight switch. When the panel lights are
to perform a function. Certain rocker switches on, both legends of the switch are backlit. See
are guarded to prevent them from being Fig. 4.3. Push the top of the switch to increase the
switched on or off accidentally. panel brightness. Push the bottom of the switch to
dim.

4.1
 Controls

• high-beam headlights
• hazard warning lights
See Fig. 4.5 for the multifunction switch and its com-
ponent parts.

10/29/2001 f610598
1
Fig. 4.3, Panel Light Increase/Decrease Switch 2

Marker Lamp Interrupt Switch 3

The optional marker lamp interrupt (MRKR INT)
paddle switch temporarily deactivates the marker 11/16/2001 f820386
lamps and taillights. See Fig. 4.4.
Press down on the upper part of the rocker switch to
activate the hazard warning lights.
1. Washer Button
2. Wiper Control Dial
3. Turn Signal Lever
4. Hazard Warning Light Rocker Switch (red)
5. Multifunction Switch Module
Fig. 4.5, Multifunction Turn Signal Lever

Turn Signal Lever

Moving the multifunction turn signal lever down acti-
vates the left turn signal lights; moving it up activates
05/09/2002 f610581 the right turn signal lights. See Fig. 4.6 for an ex-
Raise the paddle to flash the marker lights. ample of the multifunction turn signal lever.
Fig. 4.4, Marker Light Interrupt Switch

With the vehicle lights on, raise and hold the paddle
switch to briefly turn off the marker lamps and tail-
lights. When the paddle switch is released the
marker lamps and taillights return to normal opera-
tion. With the vehicle lights off, raise the paddle
switch to momentarily turn the marker lamps and tail-
lights on.

Multifunction Turn Signal

Lever
The multifunction turn signal lever has the following 10/17/2001 f820384
functions: Move the lever down to activate the left turn signals.
• turn signals Move the lever up to activate the right turn signals.
• windshield wipers and washers Fig. 4.6, Turn Signal Controls

4.2
Controls

When a turn signal is activated, a green indicator

arrow flashes at the far left or far right of the instru-
ment panel. 2
The lever automatically returns to the neutral position
(self-cancels the switch) when the steering wheel
returns to the straight ahead position after a turn. To 3
cancel the signal manually, move the lever to the 1
neutral position.
4
Windshield Wiper/Washer Controls 5

NOTICE 10/29/2001 f820383

Rotate the control dial forward to turn the wipers on, or
Do not move the wiper arms manually. Wiper increase their speed.
motor damage will occur if the arms are moved.
Rotate the control dial backward to decrease the wipers
The wipers are operated by a rotary switch in the speed, or turn them off.
wiper control dial, located on the end of the turn sig- 1. Washer Button
nal lever. See Fig. 4.7. There are five delay settings, 2. OFF Position
marked on the dial by lines of increasing length, and 3. Delay Positions
two steady speed settings, LO and HI. 4. Wipers On, Low Speed
5. Wipers On, High Speed
Rotating the control dial forward (in a counterclock-
wise direction) turns the wipers on. If they are al- Fig. 4.7, Wiper/Washer Controls
ready on, rotating the handle further forward in-
creases the speed of the wipers through the various
delay settings, and to the LO and HI settings.
1
Rotating the control dial in the opposite direction
(clockwise) reduces the speed of the wipers. Rotat-
ing the control dial clockwise as far as it will go (to
the OFF setting) turns the wipers off. 2
The washers are operated by a button at the very
end of the turn signal lever. To operate the washers,
press the button in and hold it.

High-Beam Headlights
NOTE: The ignition switch must be on for the
high beams to work. 10/17/2001 f820385
To activate the high-beam headlights, push the turn Move the lever forward to activate the high-beam
signal lever forward, towards the windshield. Pull the headlights. Move the lever back to its original position to
lever back to its original position to turn the high- turn the high-beam headlights off.
beam headlights off. See Fig. 4.8. The low beams Move the lever back toward the steering wheel to flash
remain on during high beam operation. the high beams momentarily.
When the high-beam headlights are on, a blue light 1. Turn Signal Lever 2. Boot
illuminates on the instrument panel. For vehicles built
for domicile in the United States, the road lights turn Fig. 4.8, Headlight High Beams
off when the high beams are activated.
Hazard Warning Lights
To flash the high beams momentarily, pull the lever
backward, towards the steering wheel. To activate the hazard warning lights, press down on
the upper part of the rocker switch located on the top
of the multifunction switch module (towards the

4.3
 Controls

dash). See Fig. 4.5. When the rocker switch is

pushed down, all of the turn control lights will flash.
To cancel the hazard warning lights, press down on
the lower part of the rocker switch (towards the
steering wheel). 1

Aftertreatment System (ATS)

Regen Switch
NOTE: Alternative fueled vehicles are not
equipped with a regeneration (regen) switch.
10/17/2001 f461918
A regen switch, located on the dash, allows the
driver to control three states. See Fig. 4.9. These 1. Horn Button
include:
Fig. 4.10, Electric Horn Control
• request regeneration
The air horn is controlled by a wire lanyard hanging
• default (automatic regeneration) down just inboard on the driver’s door. See Fig. 4.11.
• inhibit regeneration Pull downward on the lanyard to sound the air horn.

06/19/2012 f611199
10/17/2001 f610592
Fig. 4.9, Regen Switch To sound the air horn, pull down on the lanyard (arrow).
See the engine operation manual for details on op- Fig. 4.11, Air Horn Control
eration of the regen switch.
Cruise Control
Horn Controls Cruise Control Switch
NOTE: It is possible to have both the electric
and the air horn installed on one vehicle. WARNING
A single electric horn is standard. Dual electric horns
are available as an option. Do not use the cruise control system when driv-
ing conditions do not permit maintaining a con-
Electric Horn stant speed, such as heavy traffic or on roads
that are winding, icy, snow covered, slippery, or
The button for the horn is located in the center of the roads with a loose driving surface. Failure to fol-
steering wheel. To sound the horn, press the center low this precaution could cause a collision or
of the steering wheel pad. See Fig. 4.10. loss of vehicle control, possibly resulting in per-
sonal injury or property damage.
Air Horn
Single and dual air horns are available as options.

4.4
Controls

above the paddle and SET/CST below the

NOTICE paddle.
If equipped with a manual transmission, do not 1. To cruise at a particular speed:
attempt to shift gears without using the clutch 1.1 Press the upper half of the On/Off rocker
pedal when the cruise control is engaged. Failure switch.
to follow this precaution will result in a temporar-
ily uncontrolled increase in engine speed; trans- 1.2 Hold the accelerator pedal down until the
mission damage and gear stripping could result. speedometer reaches the desired speed.
NOTE: Maximum cruise control speed varies 1.3 Momentarily lower the Set/Resume switch
according to vehicle specifications, but cannot paddle.
be higher than 75 mph (121 km/h). 2. To disengage the cruise control:
2.1 Depress the brake pedal (on automatic or
manual transmission) or
Depress the clutch pedal (on manual
transmission only)
1 2.2 Press the lower half of the On/Off rocker
switch.
3. To resume a preselected cruise speed:
3.1 If the On/Off rocker switch is off, turn it on.
3.2 Momentarily raise the paddle of the Set/
Resume switch to RES/ACC. Cruise will
return to the last speed selected.
NOTE: If the ignition is shut off, the speed
2 memory will be lost.
4. To adjust cruise speed up, raise and hold the
paddle of the Set/Resume switch to RES/ACC
09/13/2001 f610510 until the vehicle accelerates to the desired
speed.
To turn the cruise control on, press the upper half of the
On/Off (rocker) switch. To turn cruise control off, press 5. To adjust the cruise speed down, lower and hold
the lower half of the On/Off (rocker) switch. the paddle of the Set/Resume switch to SET/
1. Cruise Control On/Off (rocker) Switch CST until the vehicle decelerates to the desired
2. Cruise Control Set/Resume (paddle) Switch speed.
Fig. 4.12, Cruise Control Switches, Dash-Mounted NOTE: For more information about cruise con-
trol operation, see the engine manufacturer’s
On standard models, cruise control is activated by
two dash switches. See Fig. 4.12. On some models,
service manual.
the cruise control can be activated by a button on the
transmission shift knob. Fast Idle System
• The On/Off Switch—this two-position rocker If the vehicle is equipped with this option, it is avail-
switch bears the legend SPD CNTL on the able for use only with cruise control. There are three
lower half of the switch. When the cruise con- preset speeds available: 800, 900, or 1000 rpm.
trol is on, an amber light illuminates in the top The fast idle system can be used to increase engine
part of the switch. idle speed whenever the following conditions are
• The Set/Resume Switch—this three-position met.
paddle switch bears the legend RES/ACC • The brake pedal is not pressed.

4.5
 Controls

• The vehicle must not be moving and the

throttle must not be pressed.

Fast Idle Operation

1. To enable the fast idle system, press and release
the cruise control On/Off rocker switch.
2. For the preset fast idle, press and release the
cruise control set switch. This will set the preset
fast idle speed.
IMPORTANT: The fast idle system does not
have any type of light activation in the instru-
ment panel. The only light that will be illumi-
nated is the cruise indicator.
Any of the following actions will turn off the fast idle
system:
• Applying the brake.
• Moving the transmission shifter out of Park (P)
or Neutral (N); this will engage the transmis-
sion.
• Pressing and releasing the cruise control On/
Off rocker switch when it is on.

Powertrain Controls
For complete transmission operating instructions see
Chapter 10.

Automatic Transmissions
Vehicles equipped with a standard Allison On-
Highway series automatic transmission, have a
T-handle shift selector. See Fig. 4.13.
When the transmission is in D (drive), the vehicle will 09/21/2012 f270165

operate in 4th and 5th gear as needed. To shift down

Fig. 4.13, T-Handle Shift Selector
into a lower gear, pull the lower half of the T-handle
selector up. Select the gear needed and release the shifting. When the switch is in the on position (the
lower half of the T-handle selector. top of the rocker switch is pushed down), the trans-
On vehicles with an Allison MD Series automatic mission shift pattern changes from primary (perfor-
transmission or an Eaton Autoshift automated trans- mance) shift mode to secondary (economy) shift
mission, a push-button shift selector, shown in mode. When the transmission mode switch is in the
Fig. 4.14, provides four, five, or six forward ranges off position (the bottom of the rocker switch is
and one reverse range. See Chapter 10 for more pushed down), the transmission reverts back to the
information about the push-button shift selector. primary shift mode.
NOTE: Primary and secondary shift mode cali-
Transmission Mode Switch
bration varies by vehicle.
Some vehicles are equipped with a transmission
mode switch, shown in Fig. 4.15. The transmission
mode switch is a fuel conservation option that allows
the driver to choose either performance or economy

4.6
Controls

Differential Lock Switch

1
NOTICE
2 Differential lock should only be engaged when
3 the vehicle is stopped or moving slowly at low
throttle. This will prevent internal axle damage.
4
The optional differential lock switch is a two-position
guarded rocker switch. It causes the wheels on each
axle governed by the switch to rotate together. It is
also known as side-to-side wheel lock. See
Fig. 4.16.

07/27/2006 f610804
1. Digital Display
2. Mode Identification Label
3. Mode Indicator LED
4. Mode Button
Fig. 4.14, Push-Button Shift Selector

10/26/2001 f610596

Fig. 4.16, Differential Lock Switch

To lock the wheels together, press the upper half of

the rocker switch momentarily. To turn off differential
lock, press the upper half of the rocker switch again.
When the panel lights are on, the double-axle icon is
backlit in green.
IMPORTANT: The differential lock switch is
guarded to prevent unintentional switch activa-
01/21/2016 f611330
tion. If the LED in the switch begins to blink dur-
ing normal operation, when the switch has not
Fig. 4.15, Transmission Mode Switch been activated, this indicates an error condition.
Take the vehicle to an authorized Freightliner
Axle Switches dealer as soon as possible.
All axle switches contain a red LED that illuminates
the switch when it is turned on (the upper part of the Rear Suspension Dump Switch
rocker is pressed). The legend under the LED, if any,
is not visible until the switch is turned on. For more NOTICE
information on axle switch function, see Chapter 11.
Do not operate the vehicle over uneven ground
IMPORTANT: A guard is positioned around all such as ramps, speed bumps, curbs, etc., with
axle switches to prevent unintentional activation. the air springs deflated. Doing this may lead to
air bag separation from the piston, preventing the
suspension air springs from reinflating.

4.7
 Controls

NOTE: The vehicle must be moving less than 5 See Chapter 13 for further information about the
mph (8 km/h) before the rear suspension will brake system.
deflate.
Meritor™ WABCO® Antilock Braking
The rear suspension dump switch is a two-position
guarded rocker switch. See Fig. 4.17. It allows the System (ABS)
air in the vehicle rear air suspension to be quickly The Meritor WABCO ABS has an indicator lamp
exhausted, lowering the rear of the vehicle. (ABS legend) and, if equipped with automatic traction
To lower the rear of the vehicle quickly, press the control (ATC), a wheel spin indicator lamp (WHEEL
upper half of the rocker switch momentarily; the light- SPIN legend). See Fig. 4.19.
emitting diode (LED) indicator at the top of the dump See the brake system operating instructions in Chap-
switch blinks. When conditions are met for the sus- ter 13 for more information about ABS.
pension to be dumped—the vehicle is moving at a
speed less than 5 mph (8 km/h)—the LED indicator
illuminates steady. To raise the suspension to its nor- OPT 1
LOW
WATER
WAIT TO
START
DEF
QUALITY
WHEEL
SPIN
RANGE
INHIBIT
CHECK
TRANS OPT 8 OPT 9

mal height, press the upper half of the rocker switch CHECK STOP ABS ABS
again or drive the vehicle at a speed greater than 5
mph (8 km/h). BRAKE

BRAKE
AIR

1 2
06/19/2012 f611198
1. Wheel Spin Indicator 2. Tractor ABS Indicator
Fig. 4.19, ABS Indicator Lights

Exhaust Brake Switch

An exhaust brake is an optional auxiliary braking sys-
tem that assists, but does not replace the service
10/15/2018 f611541 brake system. The exhaust brake is controlled by a
dash-mounted rocker switch to help slow the vehicle
Fig. 4.17, Rear Suspension Dump Switch when the accelerator is released.
Braking Controls To enable the exhaust brake, press the upper part of
the rocker switch. The engine determines when the
Parking Brake Control Knob exhaust brake is needed (going down a hill for ex-
ample) and activates the exhaust brake. See
All pneumatic-braked vehicles are equipped with a Fig. 4.20.
diamond-shaped parking brake control knob. See
Fig. 4.18. Pull the knob to apply the parking brake.
In air brake systems, before the parking brake can
be released, the air pressure in either brake system
must be at least 65 psi (448 kPa).

10/15/2018 f611540
03/30/2010 f421624
Fig. 4.20, Exhaust Brake Switch
Fig. 4.18, Parking Brake Control Knob

4.8
 5
Cab Features
Windows . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.1
Mirrors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.1
Seats . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.2
Seat Belts and Tether Belts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.6
Cab Amenities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.9
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
driver’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
the area adjacent to the right side of the cab. See
Fig. 5.5.

5.1
 Cab Features

will come into contact with the rear wall of the cab. It
2 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
1 available on one or more seats. Not all seats have all
of the adjustments listed below.
1. Seat Slide (fore-and-aft): When this adjustment is
made, the entire seat moves forward or back-
ward on its track. See Fig. 5.6.

10/05/2001 f610523
To adjust the mirror position, press the keypad on the
door in the direction you want the mirror to move. B

1. Mirror Select Switch 2. Keypad

Fig. 5.4, Power Mirror Switch Pad A

10/05/2001 f910482
A. Seat Slide (fore-and-aft) Adjustment
B. Isolator Feature
1
Fig. 5.6, Seat Slide Adjustment and Isolator Feature
10/05/2001 f720396
2. Isolator: This feature (also referred to as back-
1. Mirror
slap isolator or Chugger-Snubber®) reduces the
Fig. 5.5, Down View Mirror (optional) amount of road shock by isolating the occupant
from the motion of the vehicle, and allowing the
Seats upper seat to move in a simple pendulum mo-
tion. Whenever the isolator is not desired, it can
General Information be locked out. See Fig. 5.6.
3. Lumbar Support: Lumbar support changes the
WARNING shape of the seat back to give more or less sup-
port to the occupant’s lumbar (lower back) area.
Keep hands, tools, and other objects away from This adjustment is either mechanical or air con-
the scissor points under the seats. Failure to do trolled, depending on the make and model of the
so could cause personal injury. seat. See Fig. 5.7.
Unless otherwise noted, all seat adjustments should 4. Headrest: When this adjustment is made, the
be made while seated and before the engine is upper part of the backrest (back cushion)
started. changes angle to provide head and upper back
Due to the high degree of adjustability found in high- support as shown in Fig. 5.7.
back air suspension seats, it is possible to set the 5. Backrest Tilt: This adjustment pivots the backrest
seat back recline adjustment and the seat slide ad- forward or backward as shown in Fig. 5.8.
justment in such a combination that the seat back

5.2
Cab Features

8. Ride Height Adjustment: The entire seat moves

B
up or down when adjusting the ride height. The
adjustment is either manual or air controlled, de-
pending on the make and model of the seat. See
Fig. 5.9.

10/05/2001 f910483
A. Lumbar Support B. Headrest Adjustment
Fig. 5.7, Lumbar Support and Headrest Adjustment

10/05/2001 f910485
A. Ride Height
Fig. 5.9, Ride Height Adjustment

A 9. Damper: When you sit on the seat, a leveling

valve places you in the center of the ride zone.
B When the damper is adjusted properly under nor-
mal driving conditions, the seat should not top or
bottom against the limits of the vertical travel.
10. Ride Firmness: A firmer ride gives a better feel
for the road but less protection against uneven-
ness in the road surface. A softer ride smooths
out the bumps.

Bostrom Seat
10/05/2001 f910484 Seat Slide Adjustment
A. Backrest Tilt B. Seat Cushion Tilt
Move the seat slide and isolator lever, shown in
Fig. 5.8, Cushion Tilt Adjustments Fig. 5.10, to the left and hold it there to slide the
seat forward or backward to the desired position.
6. Seat Cushion Tilt: This adjustment raises or low-
ers the front and/or back of the seat (bottom) Isolator
cushion. This adjustment is easier to perform
when all weight is removed from the seat. See To engage the isolator, put the seat slide and isolator
Fig. 5.8. lever in the center position. Lock out the isolator by
moving the lever to the right.
7. Seat Tilt: When this adjustment is made, the seat
assembly, both backrest and seat cushion, tilts
forward or backward as shown in Fig. 5.8.

5.3
 Cab Features

Ride Height and Damper Adjustment

To raise the seat, press the upper portion of the
height adjustment switch. To lower the seat, press
the lower portion of the switch.
Press the damper adjustment switch to adjust the
damper.

1
National 2000 Series Seat
7
Seat Slide Adjustment
Move the seat slide lever, shown in Fig. 5.11, to the
left and hold it there to slide the seat forward or
backward to the desired position. Move the lever
back to its original position to lock the seat in place.
6 2
3
4
5
10/10/96 f910131
1. Backrest Tilt Lever
2. Air Lumbar Support Control Valve (optional)
3. Damper Adjustment Switch
4. Height Adjustment Switch 7
5. Seat Cushion Tilt Knob
6. Seat Slide and Isolator Lever
7. Lumbar Support Knob (standard)
6
Fig. 5.10, Bostrom Seat

Lumbar Support 1
5
To increase lumbar support, rotate the lumbar sup-
port knob forward. To decrease lumbar support, ro-
tate the knob rearward. 2
4 3
On seats equipped with air lumbar support, press the
control valve upward to increase lumbar support.
Press the control valve downward to decrease lum- 11/14/2000 f910445
bar support. 1. Backrest Tilt Knob
2. Lumbar Support Switch
Seat Cushion Tilt 3. Height Adjustment Switch
4. Seat Slide Lever
Rotate the seat cushion tilt knob to increase or de- 5. Front Cushion Height Adjustment Handle
crease seat cushion tilt. 6. Isolator Handle
7. Rear Cushion Adjustment Knob
Backrest Tilt
Fig. 5.11, National 2000 Series Seat
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
position and release the lever to lock the backrest in To use the isolator feature, turn the isolator handle to
place. the horizontal position. Turn the isolator handle down
to lock out the isolator.

5.4
Cab Features

Lumbar Support Isolator

To adjust the lumbar support, use the lumbar support To engage the isolator (if installed), move the seat
switch on the side of the seat to give more or less slide and isolator lever shown in Fig. 5.13 all the way
support to your lower back. to the right. To lock out the isolator, move the isolator
lever to the center position.
Backrest Tilt
To tilt the backrest, turn the backrest tilt knob until
the desired position is reached.

Seat Cushion Adjustment

1
To adjust the height of the front of the seat cushion,
lift the front cushion height adjustment handle, and
pull forward or push back to the desired setting.
To adjust the height of the rear of the seat cushion,
remove your weight from the seat and turn the rear
cushion adjustment knob to one of three positions. 2
4
Ride Height Adjustment
To raise or lower the height of the seat, use the 5
height adjustment switch on the side of the seat. 6
3
8
Sears Seat
Seat Slide Adjustment
7
Push the seat slide (fore-and-aft adjustment) lever, 10/09/2001 f910486
shown in Fig. 5.12, all the way to the left and slide NOTE: Armrests are optional.
the seat forward or backward, as desired. Release 1. Lumbar Support Lever
the lever to lock the seat in the desired position. 2. Backrest Lever
3. Ride Height Knob
4 4. Shock Absorber Bracket (ride firmness)
3 5. Pin (ride firmness)
6. Snap Ring (ride firmness)
7. Seat Slide and Isolator Lever
8. Seat Cushion Adjustment
5
Fig. 5.13, Sears Fleetmaster Seat (with isolator)
2
Lumbar Support
1 Move the three-position lumbar support lever upward
to increase lumbar support (firmer). Move the lever
downward to decrease lumbar support (less firm).
NOTE: This three-position lever (see inset) does
10/08/2001 f910487
not rotate a full 360 degrees.
1. Seat Slide Lever
2. Seat Cushion Tilt Adjustment For seats with air support, use the aft rocker switch
3. Ride Height Knob on the control panel on the left-hand side of the seat.
4. Lumbar Support Lever See Fig. 5.14. Press up to make the seat firmer;
5. Backrest Lever press down to make the seat less firm.
Fig. 5.12, Sears Low Profile Seat

5.5
 Cab Features

Seat Belts and Tether Belts

General Information
Seat belt assemblies are designed to secure persons
in the vehicle to help reduce the chance of injury or
the amount of injury resulting from accidents or sud-
den stops. For this reason, Freightliner Custom
Chassis Corporation (FCCC) urges that the driver
and all passengers, regardless of age or physical
condition, use seat belts when riding in the vehicle.

WARNING
10/08/2001 1 2 f910488

1. Ride Height Switch Always use the vehicle’s seat belt system when
2. Air Lumbar Support Switch operating the vehicle. Failure to do so can result
in severe personal injury or death.
Fig. 5.14, Air Controls, Sears Seat
Seat belt assemblies in FCCC vehicles meet Federal
Seat Cushion Tilt Motor Vehicle Safety Standard 209, "Type 1" and
"Type 2" requirements.
To raise the seat cushion, lift upward on the front of
When transporting a child, always use a child re-
the seat cushion, and then push it rearwards. To
straint system or the vehicle seat belts as appropri-
lower the seat cushion, pull forward on the front of
ate. To determine whether a child restraint system is
the seat cushion, and then push downwards.
required, review and comply with applicable state
Backrest Adjustment and local laws. Any child restraint used must comply
with Federal Motor Vehicle Safety Standard 213,
To adjust the backrest, push downwards on the back- "Child Restraint Systems." When providing a child
rest lever just below the bottom of the backrest cush- restraint system, always carefully read and follow all
ion. With the lever down, lean forward or backward instructions pertaining to installation and usage for
to the desired position. Release the lever to lock the the child. Make certain the child remains in the re-
backrest in place. straint system at all times when the vehicle is in mo-
tion.
Ride Height Adjustment In addition to seat belt assemblies, tether belts are
Push the ride height knob inwards to inflate the air installed on suspension-type seats. Tether belts help
cylinder, raising the height of the seat. Pull the ride secure the seat to the floor and are intended to re-
height knob outwards to deflate the air cylinder, low- strain the seat and seat belt in case of an accident or
ering the height of the seat. sudden stop.
For seats with air support, use the forward rocker IMPORTANT: Seat belts have a finite life which
switch on the control panel on the left-hand side of may be much shorter than the life of the vehicle.
the seat. See Fig. 5.14. Press up to raise the seat; Regular inspections and replacement as needed
press down to lower the seat. are the only assurance of adequate seat belt
security over the life of the vehicle.
Ride Firmness Adjustment
For a softer ride, remove the snap ring and pin from Seat Belt Inspection
the shock absorber bracket (see inset). Relocate the
pin in the other set of holes in the bracket and se- WARNING
cure it with the snap ring.
Inspect and maintain seat belts and tethers as
instructed below. Seat belts and tethers that were
damaged or stressed in an accident must be re-
placed, and their anchoring points must be

5.6
Cab Features

checked. When any part of a seat belt system

needs replacement, the entire seat belt must be
replaced, both the retractor and the buckle side.
Do not attempt to modify the seat belt system;
doing so could change the effectiveness of the
system. Failure to replace damaged or stressed
seat belts or any modifications to the system A B
may result in personal injury or death.
Inspect the seat belts and tether belts (if so
equipped).
1. Check the web for fraying, cuts, or extreme wear,
especially near the buckle latch plate and in the
D-loop guide area.
2. Check the web for extreme dirt or dust, and for
severe fading from exposure to sunlight.
3. Check the buckle and latch for operation and for
wear or damage.
4. Check the Komfort Latch or the Sliding Komfort
Latch (if equipped) for function and cracks or 03/11/2010 f910620
other damage. A. Disengaged B. Engaged
5. Check web retractor for function and damage. Fig. 5.15, Komfort Latch
6. Check the mounting bolts for tightness and
tighten any that are loose.

Seat Belt Operation

Three-Point Seat Belt With Komfort Latch
or Sliding Komfort Latch

WARNING
Wear three-point seat belts only as described
below. Three-point seat belts are designed to be
worn by one person at a time. In case of an acci-
dent or sudden stop, personal injury or death
could result from misuse.
Fasten the seat belts before driving. Fastening a
three-point seat belt while driving creates a haz-
ard.
11/18/2010 f910621a
When engaged and used properly, the Komfort Latch
and the Sliding Komfort Latch, shown in Fig. 5.15 Fig. 5.16, Sliding Komfort Latch
and Fig. 5.16 respectively, introduce a small amount
of slack into the seat belt, resulting in a more com- allow the belt to retract slightly, then slowly pull it
fortable ride. out again.
1. Slowly pull the latch end of the three-point seat 2. Fasten the three-point seat belt by pushing the
belt out of the retractor and pull it across your latch into the buckle. Listen for an audible click.
lap (from outboard to inboard) far enough to en- See Fig. 5.17.
gage the buckle. If the retractor locks too soon,

5.7
 Cab Features

02/03/2017 f910048a
01/18/95 f910004a
A. 1 Inch (2.5 cm) Maximum
Fig. 5.17, Fastening the Three-Point Belt Fig. 5.18, Adjusting Shoulder Harness Clearance,
Komfort Latch
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
so 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. 5.16. To activate the latch,
lean forward until you hear a click. This will allow 02/03/2017 f910144
for approximately 1 inch (2.5 cm) of slack be-
tween your chest and the shoulder harness. Fig. 5.19, Locking the Komfort Latch
Once engaged, the latch will allow you to lean 6. Unbuckle the three-point seat belt and release
forward about 5 inches (13 cm) without having to the Komfort Latch or the Sliding Komfort Latch
reset the latch. Leaning forward more than 5 as follows.
inches (13 cm) will disengage the Sliding Kom-
fort Latch, requiring it to be reset. If equipped with a Sliding Komfort Latch, un-
buckle the seat belt, then tug on the shoulder
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 posi-
on your shoulder and chest. Allow no more than tion, then unbuckle the seat belt.
1 inch (2.5 cm) of slack between your chest and
the shoulder harness. More slack can signifi- If equipped with a Komfort Latch, unbuckle the
cantly reduce the seat belt effectiveness in an seat belt, then release the Komfort Latch by giv-
accident or a sudden stop. While holding the belt ing the shoulder belt a quick tug. If you lean for-
slack, press the Komfort Latch lever up, clamp- ward against the shoulder belt, the Komfort Latch
ing the seat belt webbing. See Fig. 5.18 and will automatically release, and will need to be
Fig. 5.19. reset.

5.8
Cab Features

NOTE: Neither the Komfort Latch nor the Sliding

Komfort Latch need to be manually released in
an emergency situation. Each will release by
itself under rough road or other abnormal condi-
tions. Make sure the three-point seat belt is
completely retracted when it is not in use.

Cab Amenities
Cup Holders
There are two cup holders molded into the lower part
of the auxiliary dash panel, one on either side of the
HVAC control head.

Cab Storage
There is a dash storage bin located under the cup
holders on the center panel. The bin has a hinged
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. 5.20. The overhead storage
bin is often removed and replaced with a CB radio.

1 2

10/08/2001 f680027
1. Overhead Storage Bin 2. Overhead Console 3. Map Holder Netting
Fig. 5.20, Overhead Storage

Two map holders with netted openings are located

overhead, one on either side of the overhead con-
sole.

5.9
 6
Electrical Systems
Electrical System General Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.1
Power Distribution Modules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.1
Electrical Systems

Electrical System General

Information
The S2 Chassis uses an electrical system where
multiple electrical signals are carried along a simpli-
fied set of wires, reducing the size of wiring bundles.
There are significantly fewer wires overall, meaning
less chance of damage, shorts, and other problems.
The information in this chapter is to help familiarize
1
the driver with the basic electrical system. Servicing
the electrical system requires special skills and
equipment and should be performed only by a quali-
fied technician. Take the vehicle to an authorized
Freightliner service facility for repairs.

WARNING
2
Do not attempt to modify, add, splice, or remove
electrical wiring on this vehicle. Doing so could 09/25/2001 f543935
damage the electrical system and result in a fire 1. Bulkhead Module 2. Main PDM
that could cause serious personal injury or prop-
erty damage. Fig. 6.1, Location of the Main PDM (under driver side
hood, above fender)
Power Distribution Modules Main PDM Fuse Identification
There are three electrical modules, a main power CAV Description Fuse
distribution module (PDM) located under the hood on F1 Engine VCU (spare) 10A
the driver’s side above the fender, a chassis module F2 Blower Motor 30A
located between the frame rails, and a cab module F3 Engine ECU 20A
located to the left of the driver under the switch F4 Spare 30A
panel.
F5 Ignition Switch 5A
The main PDM distributes battery power to the vehi- F6 HydroMax RLY (if equipped with 30A
cle’s control modules and contains the fuses required hydraulic brakes)
to protect the power feed circuits to the control mod- F7 Bulkhead Module 30A
ules. See Fig. 6.1. While the main PDM provides F8 ICU3 10A
power to the modules, the modules themselves con- F9 Transmission ECU 10A
trol power flow and circuit protection to the various F10 Spare —
components of the vehicle electrical systems. Be- F11 Spare —
cause of this, traditional PDM devices such as relays
F12 Radio/Diagnostic 20A
and circuit breakers are no longer necessary on the
main PDM. F13 Chassis Module 30A
F14 Spare —
Inside the lid of the fuse box there is a sticker that F15 Bulkhead Module 30A
shows the locations of the fuses and describes the F16 ABS ECU 25A
circuit(s) that each fuse protects. Fuse configuration F17 Chassis Module 30A
will vary depending on the PDM assembly installed.
F18 Bulkhead Module 30A
See Fig. 6.2. See Table 6.1 for descriptions of a
typical set of fuses. F19 Chassis Module 30A
F20 Bulkhead Module 30A
Because the electrical system is multiplexed, no re- F21 Spare —
lays are needed. The multiplexing module performs F22 Bulkhead Module 30A
the functions normally provided by relays. F23 Spare —

6.1
 Electrical Systems

Main PDM Fuse Identification

CAV Description Fuse
F24 Hydraulic Pump and RLY (if equipped 25A
with hydraulic brakes)
F25 Spare —
F26 Spare —
Table 6.1, Main PDM Fuse Identification

3 4

12/19/2003 f544381
1. Battery Power Mega Fuse 1 3. Engine Harness (green) 5. Forward Chassis Harness (gray)
2. Battery Power Mega Fuse 2 4. Forward Chassis Harness (blue) 6. Frontwall Harness (black)

Fig. 6.2, Main PDM (top view)

6.2
 7
Heater, Ventilating, and Air
Conditioner (HVAC)
Climate Control Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.1
Heater, Ventilating, and Air Conditioner (HVAC)

Climate Control Panel able on a system without air conditioning. See

Fig. 7.3. A system with air conditioning has 11 air
The climate control panel controls the HVAC for the selection modes, four of which are air conditioning
driver. The climate control panel without air condition- modes. See Fig. 7.4.
ing is shown in Fig. 7.1. The climate control panel
with air conditioning is shown in Fig. 7.2. Air Selection Switch Without Air
Standard controls consist of an eight-speed fan
Conditioning
switch, an air selection switch, and a temperature 1. Face Mode: Directs all airflow through the face
control switch. See Fig. 7.1. On vehicles with air or instrument panel outlets.
conditioning, the panel also contains a telltale light
emitting diode (LED) and an air recirculation button. 2. Selection between Face Mode and Bi-Level
Mode: Directs 75 percent of the airflow through
NOTE: The vehicle may be equipped with a We- the face outlets and 25 percent through the floor
basto heating system. The Webasto heating outlets.
system warms the engine prior to starting the 3. Bi-Level Mode: Directs the airflow equally to the
vehicle, and also assists in generating additional face outlets and the floor outlets.
heat for the passengers during operation. For
operating instructions see the Webasto Opera- 4. Selection between Bi-Level Mode and Floor
tor’s Manual. Mode: Directs 25 percent of the airflow through

1 2 3

2
1 3

0 4

06/17/2003 f831452a
1. Fan Switch 2. Air Selection Switch 3. Temperature Control Switch
Fig. 7.1, Climate Control Panel Without Air Conditioning

Fan Switch the face outlets and 75 percent through the floor
outlets.
The fan switch controls the fan speed and forces
fresh or recirculated air through the air outlets. The 5. Floor Mode: Directs all airflow through the floor
fan switch has eight fan speeds and an off position. outlets.

To increase airflow, turn the fan switch clockwise to a 6. Selection between Floor Mode and Floor/
higher number. To decrease the airflow, turn the Defrost Mode: Directs 75 percent of the airflow
switch counterclockwise to a lower number. through the floor outlets and 25 percent through
the defrost outlets.
Air Selection Switch 7. Floor/Defrost Mode: Directs the airflow equally
The air selection switch allows the driver to control to the floor outlets and the defrost outlets.
the flow of air through the face outlets, the floor out- 8. Selection between Floor/Defrost Mode and
lets, the defrost (windshield) outlets, or a combination Defrost Mode: Directs 75 percent of the airflow
of these outlets. Nine air selection modes are avail-

7.1
 Heater, Ventilating, and Air Conditioner (HVAC)

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. 7.2, Climate Control Panel With Air Conditioning

4 6
3 5 5 7
2 6 4 8

1 7 3 9
A
8 2 10

9 1 11
06/18/2003 f831462
06/17/2003 f831455
A. Air Conditioning Modes
1. Face Mode
2. Selection Between Face Mode and Bi-Level Mode 1. Air Conditioning Face Mode
3. Bi-Level Mode 2. Selection Between Air Conditioning Face Mode and
4. Selection Between Bi-Level Mode and Floor Mode Air Conditioning Bi-Level Mode
5. Floor Mode 3. Air Conditioning Bi-Level Mode
6. Selection Between Floor Mode and Floor/Defrost 4. Selection Between Air Conditioning Bi-Level Mode
Mode and Face Mode
7. Floor/Defrost Mode 5. Face Mode
8. Selection Between Floor/Defrost Mode and Defrost 6. Selection Between Face Mode and Floor Mode
Mode 7. Floor Mode
9. Defrost Mode 8. Selection between Floor Mode and Floor/Defrost
Mode
Fig. 7.3, Air Selection Switch Without Air Conditioning 9. Floor/Defrost Mode
10. Selection between Floor/Defrost Mode and Defrost
through the defrost outlets and 25 percent Mode
through the floor outlets. 11. Defrost Mode

9. Defrost Mode: Directs all airflow through the Fig. 7.4, Air Selection Switch With Air Conditioning
defrost outlets.

7.2
Heater, Ventilating, and Air Conditioner (HVAC)

Air Selection Switch With Air Fresh Air Mode

Conditioning
Fresh air, or outside air, is circulated through the
1. Air Conditioning Face Mode: Directs all airflow heating and air conditioning system unless the recir-
through the face or instrument panel outlets. culation mode, if equipped, is turned on.
2. Selection between the Air Conditioning Face
Mode and the Air Conditioning Bi-Level
Recirculation Mode
Mode: Directs 75 percent of the airflow to the The recirculation mode is only available on vehicles
face outlets and 25 percent to the floor outlets. with air conditioning.
3. Air Conditioning Bi-Level Mode: Directs the The recirculation mode limits the amount of outside
airflow equally to the face outlets and the floor air entering the cab. Press the recirculation button to
outlets. prevent dusty or smoky air from entering the cab.
4. Selection between the Air Conditioning Bi- The recirculation mode can also be used to decrease
Level Mode and the Face Mode: Directs 25 the time required to cool or heat the cab interior dur-
percent of the airflow to the face outlets and 75 ing extreme outside temperature conditions. When
percent to the floor outlets. the recirculation mode is on, the recirculation indica-
tor will illuminate. See Fig. 7.2.
5. Face Mode: Directs all airflow through the face The recirculation mode is not available when the air
outlets. selection switch is in one of the following modes:
6. Selection between Face Mode and Floor • floor/defrost mode
Mode: Directs the airflow equally through the
face outlets and the floor outlets. • selection between floor/defrost mode and de-
frost mode
7. Floor Mode: Directs all airflow through the floor
outlets. • defrost mode
8. Selection between Floor Mode and Floor/ When the recirculation mode is turned on, it will stay
Defrost Mode: Directs 75 percent of the airflow on for 20 minutes, or until the recirculation button is
through the floor outlets and 25 percent through pressed again, or the air selection switch is turned to
the defrost outlets. a defrost mode.
9. Floor/Defrost Mode: Directs the airflow equally IMPORTANT: The HVAC system enters a partial
to the floor outlets and the defrost outlets. The recirculation mode for five minutes after being in
recirculation button will not work in this mode. full recirculation mode for 20 minutes. This cycle
10. Selection between Floor/Defrost Mode and repeats every 20 minutes.
Defrost Mode: Directs 75 percent of the airflow
through the defrost outlets and 25 percent Defrosting
through the floor outlets. The recirculation button Before using any of the defrost modes, clear the
will not work in this mode. screen at the base of the windshield if snow or ice is
11. Defrost Mode: Directs all airflow through the present.
defrost outlets. The recirculation button will not
work in this mode. Air Conditioning
Temperature Control Switch There are four air conditioning modes on the air se-
lection switch. The air conditioning settings on the air
The temperature control switch is used to select the selection switch are blue, in addition to the selection
desired temperature. Turn the switch to the left between the air conditioning bi-level mode and the
(counterclockwise) for cool air, or to the right (clock- face mode.
wise) for hot air. There are 21 positions on the tem-
IMPORTANT: Operate the air conditioner at
perature control switch ranging from full cool air to
full hot air. least five minutes each month, even during cool
weather. This helps prevent drying and cracking

7.3
 Heater, Ventilating, and Air Conditioner (HVAC)

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 authorized Freightliner dealer
for repairs.

7.4
 8
Engines
Engine Starting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.1
Engine Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.2
Engine Shutdown . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.4
Engines

Engine Starting IMPORTANT: On vehicles equipped with an in-

take air preheater, the INTAKE HEATER indica-
For cold-weather starting, refer to the Cummins or tor stays on for a minimum of two seconds, re-
Mercedes-Benz engine manufacturer’s operator’s gardless of coolant temperature. Wait until the
manual, as applicable, for detailed instructions. INTAKE HEATER indicator goes out before at-
tempting to start the engine.
General Information
NOTE: On vehicles equipped with a neutral start
NOTE: Before starting the engine, read Chap- switch, the transmission must be in neutral be-
ter 3 and Chapter 4 in this manual for detailed fore the engine can be started.
information on how to read the instruments and
operate the controls. 3. For manual transmissions, place the transmis-
sion in neutral and depress the clutch pedal.
Before operating the vehicle, perform the engine pre-
trip inspection and daily maintenance checks in For automatic transmissions, make sure that the
Chapter 14 and Chapter 15 of this manual. transmission shift control is in Neutral (N), or if
so equipped, the Park (P) or Park Brake (PB)
position.
NOTICE
IMPORTANT: Do not depress the throttle pedal
When starting a vehicle equipped with a manual while starting the engine.
transmission and clutch lockout switch, the
clutch pedal must be fully depressed during the 4. Turn the ignition switch to the START position.
entire start sequence. Failure to do so can cause After the engine starts, release the key.
the pinion to release and re-engage, which could
cause ring gear and starter pinion damage. NOTICE
If a vehicle does not start on the first attempt, Do not crank the engine for more than 30 sec-
make sure that the engine has completely onds at a time. Wait two minutes after each try to
stopped rotating before reapplying the starter allow the starter to cool. Failure to do so could
switch. Failure to do so can cause the pinion to cause starter damage.
release and re-engage, which could cause ring
gear and starter pinion damage. NOTE: Some starters are equipped with op-
Moving a vehicle with the starter and/or using the tional overcrank protection. If overcranking oc-
starter to bump the engine for maintenance pro- curs, a thermostat breaks the electrical circuit to
cedures is strictly prohibited. Use of these meth- the starter motor until the motor has cooled.
ods to bump the engine over or move the vehicle 5. Bring the engine up to operating speed gradually
can cause the pinion to release and re-engage, as it warms up and develops stable oil pressure.
which could cause ring gear and starter pinion
damage. IMPORTANT: When the engine is started, it
takes a short time to build up a lubricating oil
NOTICE film between the shafts and bearings, and be-
tween the pistons and cylinder walls. The oil
Never attempt to start any Cummins or pressure gauge indicates any drop in lubricating
Mercedes-Benz engine using ether or any other oil pressure within 15 seconds of engine startup.
starting fluid. Serious engine damage could re- See the applicable engine manufacturer’s op-
sult. erator’s manual for minimum idle oil pressure
1. Set the parking brake. specifications.
2. Turn the ignition switch to the ON/RUN position.
The low air pressure and low oil pressure warn-
Starting After Extended Shutdown or
ing lights (or messages) and buzzer operate until Oil Change
the engine is started and pressure is built up.
NOTE: An engine in storage for an extended
period of time (over winter, for example) may

8.1
 Engines

accumulate water in the oil pan. Oil diluted by

water cannot provide adequate bearing protec- DANGER
tion at start-up. For this reason, change the en-
Do not operate the engine in an area where flam-
gine oil and filters after extended storage. mable vapors such as gasoline or diesel fumes
Do the following steps after an oil change or are present. Shut down the engine when in an
after the engine has been shut down for more area where flammable liquids or gases are being
than three days: handled. Failure to observe these precautions
could result in serious injury or death.
1. Make sure the transmission is filled with the cor-
rect type of fluid, as recommended by the trans- All diesel engines have been built to comply with the
mission manufacturer. requirements of the Federal (U.S.) Clean Air Act.
Once an engine is placed in service, the responsibil-
2. Make sure the fuel tank is full. If air has entered ity for meeting both state and local regulations is with
the fuel system, prime the fuel system, using the the owner/operator. Good operating practices, regular
engine manufacturer’s instructions. maintenance, and correct adjustments are factors
that will help to stay within the regulations.
3. If the engine is equipped with a fuel/water sepa-
rator, drain off any accumulated water. Adequate maintenance of the engine, which is the
responsibility of the owner/operator, is essential to
4. Check the drive belts to make sure they are in
keep the emission levels low.
good condition and properly adjusted. Replace
any drive belts that are cracked, worn, or glazed. The driver should be familiar with the vehicle warning
system in order to bring the vehicle to a safe stop if
5. Check the turbocharger for signs of oil or ex-
the engine malfunctions. If the driver doesn’t under-
haust leaks. Correct any problems before starting
stand how the warning system works, an engine
the engine.
shutdown could occur, causing a safety hazard. See
6. Check the engine mounting bolts for tightness. Chapter 3 for information on the control panel for
Retighten them if necessary. these engines.
7. Make sure the battery cable connections are Follow the directions in the Cummins or Mercedes-
clean and tight. Check that the batteries are Benz engine manufacturer’s operator’s manual and
charged. in this manual for trouble-free, economical vehicle
engine operation.
8. Start the engine. See the "Engine Starting" head-
ing in this chapter.
NOTICE
Engine Operation Stop the engine at the first sign of malfunction.
IMPORTANT: For cold-weather starting, engine Almost all malfunctions give some warning to the
break-in, and cold-weather operation, refer to operator before significant damage occurs. Many
the Cummins or Mercedes-Benz engine manu- engines are saved because alert operators heed
the warning signs (sudden drop in oil pressure,
facturer’s operator’s manual, as applicable, for unusual noises, etc.) and immediately shut down
detailed instructions. the engine.
Operating vehicles in areas where there are concen- 1. Cummins and Mercedes-Benz diesel engines are
trated flammable vapors (such as diesel, gasoline, or designed to operate successfully at full throttle
propane fumes) can create a hazardous situation. under transient conditions down to rated rpm.
These vapors can be drawn into the engine through This is consistent with recommended operating
the air intake, and cause engine overspeed. Be es- practices.
pecially cautious of low-lying or closed-in areas, and
always check for signs that flammable vapors may 2. Depending on the vehicle gearing, the posted
be present. speed limit can sometimes allow operation in ei-
ther of the top two gears; however, for improved
operating efficiency (fuel economy and engine
life), operate in the top gear at reduced rpm

8.2
Engines

rather than in the next lower gear at the maxi- temperatures drop so low that the fuel may not
mum rpm. burn completely. This will cause carbon to clog
3. Cruise at partial throttle whenever road condi- the injector spray holes and piston rings, and
tions and speed requirements permit. This driv- can result in stuck valves.
ing technique permits operating within the most 11. If the engine starts to overheat, reduce the
economical power range of the engine. power output of the engine. Do one, or both, of
4. When approaching a hill, open the throttle the following: (1) Release pressure on the accel-
smoothly to start the upgrade at full power, then erator pedal; (2) Shift to a lower gear. If the tem-
shift down as desired to maintain the optimum perature does not return to normal, shut down
vehicle speed. The high torque of the engine the engine.
may permit topping some grades without shifting.
5.
High Idle Options
Engines are designed to operate over a wide
speed range. More frequent shifting than neces- NOTE: To operate the high idle options listed
sary does not allow proper utilization of this flex- below, the vehicle must be stopped, the trans-
ibility. The driver who stays in top gear and uses mission shift lever placed in the Neutral (N) or
the wider speed range will achieve the best fuel Park (P) position, and the parking brake set.
economy.
IMPORTANT: Do not idle the engine for exces-
6. The Cummins and Mercedes-Benz engines are
sively long periods. The extreme heat can cause
effective as a brake on downhill grades, but take
care not to overspeed the engine going downhill. the bearings to seize or the oil seals to leak.
The governor has no control over engine speed
when the engine is being pushed by the loaded High Idle with Cruise Control
vehicle. 1. Place the shift lever in Neutral (N) or Park (P)
and set the parking brake.
NOTICE 2. Press the cruise switch located on the dash to
the ON position. Press the RESUME switch to
Do not allow the engine to exceed its governed accelerate the engine revolutions per minute
speed, or serious engine damage could result. (rpm) to the minimum set speed. To increase the
7. Never turn the ignition switch to the OFF position engine rpm, press and hold the RESUME switch.
while going downhill. With the engine still in gear, To decrease the engine rpm, press and hold the
fuel pressure will build up against the shutdown SET switch.
valve and can prevent it from opening when the
NOTE: The rpm can also be increased by de-
ignition switch is turned to the ON/RUN position.
pressing the throttle pedal until the desired rpm
8. Use a combination of brakes and gears to keep is met, and then pressing the SET switch.
the vehicle under control at all times, and to
keep the engine speed below the rated governed 3. Disengage the cruise control by depressing the
rpm. service brake pedal, or by moving the ON/OFF
switch to the OFF position.
9. Check the coolant temperature and oil pressure
gauges frequently. Voltage-Based Auto High Idle
1. Place the shift lever in Neutral (N) or Park (P)
NOTICE and set the parking brake.
Continuous operation below 140°F (60°C), above 2. The idle rpm will automatically increase when the
212°F (100°C), or with the oil pressure below 10 voltage drops below 12.2 volts. The rpm will in-
psi (69 kPa), can damage the engine. crementally increase every five seconds until
13.4 volts is achieved and maintained.
10. Do not idle the engine for more than 10 minutes.
Long periods at low idle can damage the engine. 3. The Voltage-Based Auto High Idle system is dis-
engaged by depressing the service brake pedal.
NOTE: Long periods of idling are not good for
an engine because the combustion chamber

8.3
 Engines

IMPORTANT: The Voltage-Based Auto High Idle

system will not return to normal operation until NOTICE
one of the following occurs: The parking brake
Do not rev the engine before shutting it down.
is depressed and released, the key switch is Revving the engine before shutdown will damage
turned to the OFF position, or the transmission the turbocharger.
gears are changed.
4. Shut down the engine by turning the ignition
switch to the OFF position.
Engine Shutdown
Shut down the engine immediately if:
• the oil pressure gauge needle swings back and
forth or falls sharply;
• engine power and rpm fall, even though the
accelerator pedal remains steady;
• the exhaust pipe gives off heavy smoke;
• the coolant and/or oil temperature climb abnor-
mally;
• abnormal sounds suddenly occur in the engine
or turbocharger.
IMPORTANT: Bearings and seals in the turbo-
charger are subjected to the high heat of com-
bustion exhaust gases. While the engine is run-
ning, this heat is carried away by oil circulation,
but if the engine is stopped suddenly, the turbo-
charger temperature may rise as much as 115°F
(46°C).
1. With the vehicle stopped, place the transmission
in Neutral (N), or if so equipped, the Park (P) or
Park Brake (PB) position.
2. Set the parking brake.
3. Idle the engine for three to five minutes before
shutting it down. This allows the lubricating oil
and the coolant to carry heat away from the
combustion chambers, bearings, shafts, etc. This
is especially important with turbocharged en-
gines. The extreme heat can cause bearings to
seize or oil seals to leak.
NOTE: Long periods of idling are not good for
an engine because the combustion chamber
temperatures drop so low that the fuel may not
burn completely. This will cause carbon to clog
the injector spray holes and piston rings, and
can result in stuck valves.

8.4
 9
Exhaust Aftertreatment
Systems
Aftertreatment System, EPA10 and Newer Engines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.1
Diesel Exhaust Fluid and Tank, EPA10 and Newer Engines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.5
EPA07 Aftertreatment System (ATS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.7
Exhaust Aftertreatment Systems

Aftertreatment System, EPA10 do so could lead to engine damage and is not

warrantable.
and Newer Engines IMPORTANT: Using non-specification fuels or
Model year 2007 and later vehicles and/or engines oils can lead to shortened diesel particulate filter
domiciled in the U.S. or Canada are designed to (DPF) cleaning or replacement intervals. For
meet Emission and Fuel Efficiency Standards of the example, using CK-4+ oil with 1.3% sulfated ash
U.S. Federal Environmental Protection Agency (30% more ash content) may result in the need
(EPA), the National Highway Traffic Safety Adminis- for DPF cleaning or replacement 20 to 30%
tration (NHTSA), Emission Regulations under the
sooner than would normally be required.
Canada Motor Vehicle Safety Act in Canada, and the
California Air Resources Board (CARB) effective as IMPORTANT: See the engine manufacturer’s
per the applicable emission model year. To determine operation manual for complete details and op-
an engine’s or vehicle’s emission model year, refer to eration of the ATS.
the respective EPA/CARB certification label.
After exhaust gasses leave the engine, they flow into
IMPORTANT: Depending on local jurisdictional the ATS. First they flow into a two-part ATD, com-
guidelines, vehicles that are domiciled outside of prised of a diesel oxidation catalyst (DOC), and a
the U.S. and Canada may not have emissions diesel particulate filter (DPF). The DPF traps soot
aftertreatment systems (ATS) that are compliant particles, then exhaust heat converts the soot to ash
with EPA regulations. in the DPF, in a process called regeneration (regen).
The harder an engine works, the better it disposes of
Principles of Operation soot. When the engine is running under load and
regen occurs without input, it is called passive regen.
To meet EPA guidelines, engines that are compliant If the engine isn’t running hot enough, the electronic
with EPA10 and newer regulations use an aftertreat- controls may initiate an active regen, whereby extra
ment system (ATS) with an aftertreatment device fuel is injected into the exhaust stream before the
(ATD) and Selective Catalytic Reduction (SCR) tech- diesel particulate filter, to superheat the soot trapped
nology to reduce NOx downstream of the engine. in the filter and burn it to ash. Both types of regen
occur without driver input.
NOTICE
WARNING
Follow these guidelines for engines that comply
with EPA10 or newer regulations, or damage may Active regeneration can occur automatically any-
occur to the ATD and the warranty may be com- time the vehicle is moving. The exhaust gas tem-
promised. perature could reach 1500°F (816°C), which is hot
• Use ultralow-sulfur diesel with 15 ppm sul- enough to cause a fire, heat damage to objects
fur content or less. or materials, or personal injury to persons near
the exhaust outlet. See Regen-Inhibit Switch later
• Do not use fuel blended with used engine in this chapter for instructions on preventing au-
lube oil or kerosene. tomatic regen if necessary.
• Engine lube oil must have a sulfated ash The exhaust temperature can remain high even
level less than 1.0 wt %; currently referred after the vehicle has stopped. When stopping the
to as CK-4 oil. vehicle shortly after an automatic regen, ensure
the exhaust outlets are directed away from struc-
• Use only certified diesel exhaust fluid (DEF)
tures, vegetation, flammable materials, and any-
in the DEF tank.
thing else that may be harmed by exposure to
high heat.
NOTICE Operating at reduced engine load will allow soot to
FA-4 engine lube oil is available, but is not com- accumulate in the DPF. When this occurs, the DPF
patible with all engines. See the engine manufac- lamp illuminates, indicating that a regen must be per-
turer’s operation manual to determine if FA-4 oil formed, and the driver must either bring the vehicle
can be used in your vehicle’s engine. Failure to up to highway speed to increase the load, or park

9.1
 Exhaust Aftertreatment Systems

the vehicle and initiate a parked regen. See Parked

Regen, later in this chapter for instructions.
NOTE: Beginning September 2, 2014 some
chassis are equipped with an option that allows
a regen to occur at 0 or 1 mph (0 or 2 km/h),
instead of the standard 5 mph (8 km/h) thresh-
old. Based on the engine programming param-
eter, if a regen occurs and vehicle speed is re-
duced to either 0 or 1 mph (0 or 2 km/h), the
regen process will not be cancelled.
09/25/2006 f610815a
If the vehicle is programmed for the 0 mph (0
km/h) parameter, vehicle speed can be reduced Fig. 9.1, Diesel Particulate Filter (DPF) Status Lamp
to 0 mph (0 km/h) and the regen will continue.
Vehicles with this option are equipped with a
regen inhibit switch to cancel the regen if
needed.
If the vehicle is programmed for the 1 mph (2
km/h) parameter, vehicle speed can be reduced
to 1 mph (2 km/h) and the regen will continue. If
vehicle speed is less than 1 mph (2 km/h), the
regen will be cancelled.
After the exhaust stream passes through the ATD, it
flows through another canister housing the SCR de- 09/25/2006 f610816a
vice. A controlled quantity of DEF is injected into the
Fig. 9.2, High Exhaust System Temperature (HEST)
exhaust stream, where heat converts it to ammonia
Lamp
(NH3) gas. This mixture flows through the SCR de-
vice, where the ammonia gas reacts with the NOx in
the exhaust, to produce harmless nitrogen (N2) and
Parked Regen
water vapor (H2O), which then exits out of the tail-
pipe. DANGER
ATS Warning Lamps During parked regeneration, exhaust tempera-
tures are very high, and could cause a fire, heat
Warning lamps in the driver’s message center alert damage to objects or materials, or personal in-
the driver of situations with the ATS. jury to persons near the exhaust outlet.
• An illuminated DPF lamp indicates a regen is Before initiating a parked regeneration, make cer-
needed. See Fig. 9.1. tain the exhaust outlets are directed away from
• A slow, 10-second flashing of the HEST lamp structures, vegetation, flammable materials, and
alerts the driver that a parked regen is in prog- anything else that may be harmed by prolonged
ress, but the exhaust temperatures are still exposure to high heat.
relatively cool. See Fig. 9.2. It also indicates A reference label is included with the driver’s docu-
that the high-idle speed is being controlled by mentation package initially in the glove box, that ex-
the engine software, not the driver. plains the ATS warnings, and actions required to
• A steadily illuminated HEST lamp alerts the avoid further engine protection sequences. See
operator of high exhaust temperatures when Fig. 9.3.
vehicle speed is below 5 mph (8 km/h) while it The regen switch, located on the dash, is used to
is performing an automatic regen, and during a initiate a parked regen of the aftertreatment device.
parked regen. See Fig. 9.2. See Fig. 9.4.

9.2
Exhaust Aftertreatment Systems

10/23/2020 f080234

Fig. 9.3, Exhaust-Aftertreatment Warnings Reference Label

regeneration process. Depressing the regen-inhibit

switch will prevent a regen from occurring during a
drive cycle. After the vehicle has been shut down
and restarted, regens will occur normally unless the
inhibit switch is pressed again. See Fig. 9.5.

06/19/2012 f611199

Fig. 9.4, Regen Switch

NOTE: The regen switch can initiate a parked

regen only when the DPF lamp is illuminated
(because the engine software is signaling for a 07/30/2009 f610944
parked regen).
Fig. 9.5, Regen Inhibit Switch (optional when available)
The regen-inhibit switch (optional when available)
provides additional control over the aftertreatment

9.3
 Exhaust Aftertreatment Systems

To initiate a parked regeneration, perform the follow-

ing steps.
1. Park the vehicle away from all combustible and
flammable materials. Chock the tires. Start and
warm the engine until the coolant temperature is
at least 150°F (66°C).
2. Set the parking brake. If the parking brake was
already set, you must release it, then set it 1
again. 2
For manual transmissions, fully depress the 3
clutch pedal, put the transmission in neutral, then
release the pedal.
If the vehicle has a two-pedal automated trans-
mission, shift it into gear, then back to neutral.
IMPORTANT: The driver is responsible for 02/11/2009 f545207
ensuring, during the entire regen cycle, that 1. Primary Lock 3. Plug
anything that could be harmed by exposure to 2. Secondary "Red" Lock
high heat does not come in contact with the Fig. 9.6, Shorting Plug
exhaust gases flowing from the outlets.
2. Set the parking brake. If the parking brake was
3. Press and hold the regen switch for 4 seconds.
The engine will increase rpm and initiate the already set, it must be released, then set again.
regen process. For manual transmissions, fully depress the
clutch pedal, put the transmission in neutral, then
4. After the parked regen has run for 20 to 40 min-
release the pedal.
utes, the regen cycle is completed. The engine
idle speed will drop to normal, and the vehicle If the vehicle has a two-pedal automated trans-
may be driven normally. The HEST lamp may be mission, shift it into gear, then back to neutral.
illuminated, but will go out when the vehicle
IMPORTANT: The driver is responsible for
speed exceeds 5 mph (8 km/h), or the system
has cooled to normal operating temperature. ensuring, during the entire regen cycle, that
anything that could be harmed by exposure to
5. To stop a parked regen at any time during the high heat does not come in contact with the
process, engage the clutch, brake, or throttle exhaust gases flowing from the outlets.
pedal, or turn off the engine.
3. Disconnect the shorting plug, as follows.
Shorting Plug 3.1 Slide the secondary red lock away from
NOTE: The DPF lamp must be illuminated be- the white cover. See Fig. 9.6, Ref. 2.
fore the shorting plug will initiate a parked 3.2 Push the primary lock in. See Fig. 9.6,
regen. See Fig. 9.1. Ref. 1.
The shorting plug is used to initiate a parked regen 3.3 Pull the plug apart. See Fig. 9.6, Ref. 3.
of the ATD. The shorting plug is located under the
dash, next to the steering column. Mounting locations 4. Wait four seconds.
vary. See Fig. 9.6. 5. Connect the shorting plug.
To initiate a parked regeneration, perform the follow- 6. Engine rpm will rise, and initiate the regen pro-
ing steps. cess.
1. Park the vehicle away from all combustible and 7. The regen cycle will finish after 20 to 60 minutes,
flammable materials. Chock the tires. Start and at which time engine idle speed will drop to nor-
warm the engine until the coolant temperature is mal and the vehicle can be driven normally. The
at least 150°F (66°C). HEST lamp may be illuminated, but will go out

9.4
Exhaust Aftertreatment Systems

when the vehicle speed exceeds 5 mph (8 km/h), DEF supply lines with engine model year 2013 and
or the system has cooled to normal operating newer are designed to survive freezing conditions
temperature. See Fig. 9.2. The DPF lamp will while containing DEF, so purging is not required.
shut off.
8. To stop a parked regen at any time during the
DEF Tank
process, engage the clutch, service brake, or Engines that are compliant with EPA10 and newer
accelerator pedal, or turn off the engine. regulations are equipped with a DEF tank located
between the ATS and the fuel tank, or an optional
DPF Maintenance location forward of the fuel tank. The DEF tank has a
19 mm filler neck inlet that prevents the hose from a
Eventually ash will accumulate in the DPF and the
diesel outlet from being inserted, and has a blue cap
filter will require servicing. DPF servicing must be
for easy identification.
performed by an authorized technician, following the
engine manufacturer’s instructions. A record must be The DEF tank will require filling a minimum of ap-
maintained for warranty purposes, that includes: proximately every second diesel refuel depending on
the DEF tank capacity. The S2 Chassis has an 11.5-
• date of cleaning or replacement; gallon tank capacity. DEF consumption is approxi-
• vehicle mileage; mately 2% of fuel consumption, dependent on ve-
hicle operation. For every 50 gallons of diesel fuel
• particulate filter part number and serial number. consumed, approximately 1 gallon of DEF will be
consumed.
Diesel Exhaust Fluid and Tank,
EPA10 and Newer Engines Fuel/DEF Gauge
The fuel and DEF levels are measured in a dual pur-
Diesel Exhaust Fluid pose fuel/DEF gauge. See Fig. 9.7.
Diesel exhaust fluid (DEF) is used in the ATS to Fuel level is indicated at the top of the gauge. Below
lower NOx in the exhaust stream. DEF is colorless the fuel level, a low fuel warning lamp illuminates
and close to odorless (it may have a slightly pungent amber when the fuel level drops below 1/8th of the
odor similar to ammonia). It is nontoxic, nonflam- capacity.
mable, and biodegradable. It is mildly corrosive to
The lower portion of the gauge has a DEF warning
aluminum, but does not affect the strength or struc-
lamp that illuminates when the DEF tank is near
ture of the aluminum.
empty, and a DEF lightbar that indicates the level in
White crystals may be noticeable around compo- the DEF tank as follows.
nents that come into contact with DEF. The crystals
are easily removed with water. • Four bars illuminated green—Between 75%
and 100% full
DEF consumption varies depending on ambient con-
ditions and vehicle application. • Three bars illuminated green—Between 50%
and 75% full
Freezing Conditions • Two bars illuminated green—Between 25%
DEF freezes to slush at around 12°F (-11°C). It is not and 50% full
damaged or destroyed if frozen, and is fully usable • One bar illuminated green—Between approxi-
when thawed. The DEF in the tank is allowed to mately 10% and 25% full
freeze while a vehicle is non-operational. At start-up,
normal operation of the vehicle is not inhibited if the • One bar illuminated amber—DEF low, refill
DEF is frozen; an immersion heater with engine cool- DEF
ant flowing through it warms the DEF once the en- • One bar flashing red—DEF empty, refill DEF
gine is running, allowing the SCR system to operate.
Pre-2013 DEF supply lines are electrically-heated DEF Warnings and Engine Limits
and are purged when the engine is shut down; com- IMPORTANT: Ignoring the DEF warning lamps
plete purging of the DEF lines requires approximately
and not refilling the DEF will result in limited en-
five minutes after the engine is shut down.
gine power with a speed limit of 5 mph (8 km/h)

9.5
 Exhaust Aftertreatment Systems

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 low, refill DEF.
1. Low Fuel Warning Lamp (amber at 1/8 tank of fuel) 2. Low DEF Warning Lamp
Fig. 9.7, Fuel/DEF Gauge

eventually being applied. See the Cummins Op- DEF Level Low—Critical Warning
eration and Maintenance Manual for further in-
When the DEF level reads low, the following warn-
formation.
ings are activated. See Fig. 9.9.
DEF Level Low—Initial Warning • The CHECK engine lamp flashes for 30 sec-
onds when the vehicle is started.
When the DEF level reads low the following warnings
strongly encourage the driver to refill the DEF tank. • The DEF warning lamp illuminates.
See Fig. 9.8.
• One bar of the DEF-level lightbar flashes red.
• The CHECK engine lamp flashes for 30 sec-
onds when the vehicle is started. Engine performance is limited, with progressively
harsher engine power limits applied.
• The DEF warning lamp illuminates.
The DEF tank must be filled to cancel the warning
• One bar of the DEF-level lightbar illuminates sequence.
solid amber.
The DEF tank must be filled to cancel the warning
sequence. A

A
B

07/09/2009 f470537
B A. DEF Warning Lamp (illuminates constantly)
B. DEF-Level Lightbar (1 bar flashing red)
07/09/2009 f470537 Fig. 9.9, DEF Level Low—Critical Warning
A. DEF Warning Lamp (illuminates constantly)
B. DEF-Level Lightbar (1 bar solid amber)
Fig. 9.8, DEF Level Low—Initial Warning

9.6
Exhaust Aftertreatment Systems

DEF Empty
When the DEF level reads empty, the following warn- A
ings are activated. See Fig. 9.10.
• One bar of the DEF-level lightbar flashes red.
• The DEF warning lamp flashes.
• The CHECK engine lamp illuminates. B

Engine performance is limited, with progressively

11/18/2010 f470540b
harsher engine power limits applied.
NOTE: The STOP engine, CHECK engine, and DEF
The DEF tank must be filled to cancel the warning lamps illuminate, engine power is limited, speed limit of
sequence. 5 mph (8 km/h).
A. DEF Warning Lamp (flashing)
B. DEF-Level Lightbar (1 bar flashing red)
A Fig. 9.11, DEF Empty and Ignored Warning

fault is not corrected, the STOP engine lamp illumi-

nates and a 5 mph (8 km/h) speed limit is applied
after the next engine shutdown, or while parked and
B idling. See Fig. 9.11.

07/09/2009 f470538
EPA07 Aftertreatment System
NOTE: Engine performance is limited. (ATS)
A. DEF Warning Lamp (flashing)
B. DEF-Level Lightbar (1 bar flashing red) All on-road diesel engines built after December 31,
2006, (EPA07 engines) must meet strict new guide-
Fig. 9.10, DEF Empty Warning lines for reduced exhaust emissions of particulate
matter and nitrogen oxides (NOx). NOx is limited to
DEF Level Empty and Ignored just over 1 gram per brake horsepower hour (g/bhp-
If the empty warning is ignored and the DEF is not hr) and particulate matter cannot exceed 0.01 g/bhp-
refilled, the DEF warning lamp flashes, one bar of hr.
the DEF-level lightbar flashes red, and the red STOP EPA07-compliant engines require ultralow-sulfur die-
engine lamp illuminates in addition to the CHECK sel (ULSD) fuel, and they should never be run on
engine warning lamp. See Fig. 9.11. fuel with sulfur content higher than 15 ppm. In addi-
If the DEF tank is not refilled, a 5 mph (8 km/h) tion, they require low-ash engine oil. The following
speed limit will be applied after the next engine shut- guidelines must be followed or the warranty may be
down, or while parked and idling. compromised.
• Use ultralow-sulfur diesel (ULSD) fuel with 15
DEF Quality or SCR Tampering ppm sulfur content or less, based on ASTM
D2622 test procedure.
NOTICE • Do not use fuel blended with used engine lube
oil or kerosene.
Once contaminated DEF or tampering has been
detected in the SCR system, the vehicle must be • Engine lube oil must have a sulfated ash level
taken to an authorized service center to check less than 1.0 wt %; meeting the API CJ-4 index
the SCR system for damage, and to deactivate specifications.
the warning lamp and engine limits.
IMPORTANT: Using non-specification fuels or
If contaminated DEF or tampering is detected, the oils can lead to shortened Diesel Particulate Fil-
DEF warning lamp flashes, and engine power is lim- ter (DPF) cleaning or exchange intervals. For
ited with progressively harsher limits applied. If the example, using CI-4+ oil with 1.3% sulfated ash

9.7
 Exhaust Aftertreatment Systems

(30% more ash content) may result in the need anything else that may be harmed by prolonged
for DPF cleaning or exchange 20 to 30% sooner exposure to high heat.
than would normally be required. The warning lamps in the driver message center alert
The "exhaust system" in EPA07-compliant vehicles is the driver of a regen in progress, of high exhaust
called the aftertreatment system (ATS). The ATS var- temperatures, of the need to perform a parked regen
ies according to engine manufacturer and vehicle either soon or immediately, and of an engine fault
configuration, but instead of a muffler, an aftertreat- that affects the emissions.
ment system has a device that outwardly resembles A slow (10-second) flashing of the high exhaust sys-
a muffler, called the aftertreatment device (ATD). tem temperature (HEST) lamp indicates that a
IMPORTANT: See your engine operation manual parked regen is in progress, and the engine’s high
for complete details and operation of the after- idle speed is being controlled by the engine software,
not the driver.
treatment system.
A steadily illuminated HEST lamp alerts the operator
Inside the ATD, the exhaust first passes over the die- of high exhaust temperature during the regeneration
sel oxidation catalyst (DOC), then it passes through process, if vehicle speed is below 5 mph (8 km/h).
the DPF, which traps soot particles. If exhaust tem- See Fig. 9.2. The HEST lamp does not indicate the
perature is high enough, the trapped soot is reduced need for any kind of vehicle or engine service; it only
to ash in a process called passive regeneration alerts the vehicle operator of high exhaust tempera-
(regen). Passive regeneration occurs as the vehicle tures. Make sure the engine exhaust pipe outlet is
is driven normally under load; the driver is not even not directed at any person, or at any surface or ma-
aware that it is happening. The harder an EPA07 en- terial that will melt, burn, or combust.
gine works, the better it disposes of soot, as the ex-
haust heat alone is enough to burn the soot to ash.
Over the course of a workday, however, passive re- WARNING
generation cannot always keep the ATD filter clean,
so the filter must undergo active regeneration. In When the HEST lamp is on, be certain that the
active regeneration, extra fuel is injected into the ex- exhaust pipe outlet is not directed at combustible
haust stream to superheat the soot trapped in the material or toward anyone. To do so could cause
DPF and turn it to ash. Active regeneration happens damage to the vehicle and serious personal in-
only when the vehicle is moving above a certain jury to others.
speed, determined by the engine manufacturer. Con-
sult manufacturers’ documentation for details. WARNING
Both active and passive regeneration happen auto-
Active regeneration can occur automatically any-
matically, without driver input.
time the vehicle is moving. The exhaust gas tem-
Only when operating conditions do not allow for ATD perature could reach 1500°F (816°C), which is hot
filter cleaning by at-speed active or passive regen- enough to cause a fire, heat damage to objects
eration, the vehicle may require a driver-activated or materials, or personal injury to persons near
parked regeneration. The vehicle must be standing the exhaust outlet. See Regen-Inhibit Switch later
still, and the driver must initiate parked regen. Com- in this chapter for instructions on preventing au-
pleting a parked regen takes 20 minutes to an hour, tomatic regen if necessary.
depending on ambient conditions.
The exhaust temperature can remain high even
after the vehicle has stopped. When stopping the
DANGER vehicle shortly after an automatic regen, ensure
the exhaust outlets are directed away from struc-
During parked regeneration, exhaust tempera- tures, vegetation, flammable materials, and any-
tures are very high, and could cause a fire, heat thing else that may be harmed by exposure to
damage to objects or materials, or personal in- high heat.
jury to persons near the exhaust outlet.
IMPORTANT: Due to the high exhaust tempera-
Before initiating a parked regeneration, make cer- ture during the regen process, a diffuser is used
tain the exhaust outlets are directed away from to reduce the temperature at the exhaust pipe
structures, vegetation, flammable materials, and
outlet. See Fig. 9.12. If the diffuser is damaged,

9.8
Exhaust Aftertreatment Systems

it must be replaced to ensure proper operation The DPF regen switch, located on the dash, may
of the vehicle and to reduce the possibility of have three selectable positions:
damage or injury. • Request Regeneration
• Default (can include appropriate normal state
condition—either in an automatic regeneration
or inhibit state)
• Inhibit regeneration (optional when available)
NOTE: The regen switch can start a regen only
when at least one of two conditions exists: ei-
ther the DPF lamp is lit, or the engine software
calls for it. If neither of those conditions exist,
the regen switch cannot cause a regen to hap-
pen.
09/11/2007 f490294
The function of the switch will vary by the engine
Fig. 9.12, Exhaust Diffuser make and model in the vehicle. See the engine op-
eration manual for switch operation details.
A steadily illuminated yellow DPF lamp indicates a
regen is required soon. Bring the vehicle to highway When diesel particulate filter servicing is needed, it
speeds to allow for an active regen, or a parked must be performed by an authorized technician, and
regen should be scheduled for the earliest conve- a record must be maintained for warranty purposes.
nient time. See Fig. 9.1. The record must include:
IMPORTANT: Failure to regen could cause en- • date of cleaning or replacement
gine problems, including derate or loss of • vehicle mileage
power. As soon as allowed after the DPF lamp
illuminates, maintain highway speeds to allow • particulate filter part number and serial number
automatic regeneration, or park the vehicle in a A steadily illuminated Malfunction Indicator Lamp
safe location and perform a parked regen. (MIL) indicates an engine fault that affects the emis-
A DPF lamp blinking at the same time as a steadily sions. The MIL lamp applies to the Mercedes-Benz
illuminated yellow Check Engine lamp indicates that engine only. See Fig. 9.14.
a parked regen must be performed immediately, or
an engine derate will occur. If the red Stop Engine
lamp illuminates with the blinking DPF lamp and the
yellow Check Engine lamp, a parked regen must
occur or an engine shutdown will occur. Park the ve-
hicle and perform a parked regen. See Fig. 9.13 and
Fig. 9.4.

CHECK STOP
09/25/2006 f610814a

Fig. 9.14, Malfunction Indicator Lamp (MIL)

1 2 3
07/09/2009 f611036 High-Soot-Load Idle Shutdown
1. Malfunction Indicator Lamp (MIL)
2. Check-Engine Lamp Extended idle operation can cause soot to accumu-
3. Stop-Engine Lamp late in the DPF, which can eventually trigger an ECM
fault, cause the Stop Engine lamp to illuminate, and
Fig. 9.13, Engine Protection Lamps require replacement of the DPF. The High-Soot-Load

9.9
 Exhaust Aftertreatment Systems

Idle Shutdown feature (if equipped), determines if the

extended engine idling needs to be shut down before
there is a triggering of the stop engine warning.
The High-Soot-Load Idle Shutdown feature monitors
the soot load during the idle or high-idle operation. If
high-soot-load occurs, the DPF lamp will illuminate,
then the Check Engine lamp will flash for 30 sec-
onds, before the engine shuts down.

9.10
 10
Transmission
Driving Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.1
Allison On-Highway Transmissions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.1
Eaton® Fuller® Straight-Shift Transmissions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.6
Clutches . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.7
Transmission

Driving Precautions When driving on icy or graveled surfaces, reduce

speed. Avoid sharp turning maneuvers.
The vehicle operator should use care when acceler-
ating or downshifting on slippery road surfaces. Sud- Allison On-Highway
den acceleration or engine braking, caused by shift-
ing to a lower gear range, can result in a loss of Transmissions
vehicle control. This is very important on snow or ice
The Allison on-highway transmissions are fully auto-
covered roads. See Chapter 13 for information on
brake operation. matic and include the 2100 Series, B210 Series,
2200 Series, B220 Series, 2500 Series, 3000 Series,
If the vehicle is stuck in sand or mud, do not attempt and B300 Series. For Allison Transmission Operators
to pull the vehicle out under its own power. Request Manual and Warranty Information for on-highway ve-
professional towing assistance. hicle applications, visit
[Link]/my-allison/
NOTICE customer or scan the QR code for additional infor-
mation. See Fig.10.1.
Do not attempt to rock the vehicle. If rocking the
vehicle is necessary, even at low speeds, it may
cause engine overheating, axle damage, trans-
mission damage or failure, or tire damage.
Do not coast the vehicle in neutral. Severe trans-
mission damage may result and the vehicle will
not have the benefit of engine braking.

WARNING
To reduce the risk of personal injury, before 05/17/2022 f261566
going down a steep or long grade, reduce speed
and downshift the transmission. Do not hold the Fig. 10.1, Allison Transmission QR Code
brake pedal down too long or too often while
going down a steep or long grade. This could Safety Precautions
cause the brakes to overheat, reducing their ef- 2000 and B200 Series
fectiveness. As a result, the vehicle will not slow
down at the usual rate. Failure to take these
steps could result in loss of vehicle control. WARNING
To avoid skidding on slippery roads, do not downshift Do not leave the vehicle unattended with the en-
into L (low) at speeds above 20 mph (32 km/h). gine running. If you leave the vehicle and the en-
On slippery surfaces, avoid quick movements of the gine is running, the vehicle can move suddenly,
steering wheel. Decrease speed and allow for extra which could result in personal injury or property
stopping distance required by these conditions. For damage.
non-ABS brakes, apply the brakes by pumping the On vehicles with Allison 2000 or B200 series trans-
pedal steadily and evenly to avoid wheel lock-up and missions, do the following steps if you have to leave
loss of vehicle control. the vehicle with the engine running (for example,
Avoid driving through flooded areas unless you are when checking the transmission fluid).
sure the water is no higher than the bottom of the
wheel rims. Drive through slowly. Allow adequate
Without Auto-Apply Parking Brake
stopping distance since wet brakes do not grip well. 1. Bring the vehicle to a complete stop using the
After driving through water, gently apply the brakes service brake.
several times while the vehicle is moving slowly to
dry the brakes. 2. Ensure that the engine is at low idle rpm.
3. Put the transmission in neutral.

10.1
 Transmission

4. Apply the parking brake, and make sure it is Operating Instructions, 2000 and
properly engaged.
B200 Series Transmissions
5. Chock the rear tires and take any other steps
necessary to keep the vehicle from moving. 2000 and B200 series transmissions are electroni-
cally controlled. The shift selector provides four for-
With Auto-Apply Parking Brake ward ranges and one reverse range. A T-handle shift
control is used by the driver to select the ranges.
1. Bring the vehicle to a complete stop using the See Fig. 10.2.
service brake.
2. Ensure that the engine is at low idle rpm.
3. Put the transmission in PB (auto-apply parking
brake).
4. Apply the parking brake (if so equipped), and
make sure it is properly engaged.
5. Chock the rear tires and take any other steps
necessary to keep the vehicle from moving.

Range Inhibit Indicator, 2000 and

B200 Series
A RANGE INHIBIT indicator is a standard feature of
the 2000 and B200 series transmissions. The
RANGE INHIBIT indicator comes on to alert the
driver that transmission operation is being inhibited
and that the range shifts being requested by the
driver may not occur. When certain operating condi-
tions are detected by the transmission control mod-
ule (TCM), the controls will lock the transmission in
the current operating range.
Shift inhibits occur under the following conditions:
• Shifts from neutral to reverse or from neutral to
a forward range when the engine is above idle,
greater than 900 rpm.
• Forward/reverse directional shifts are typically
not permitted if appreciable output shaft speed
is detected.
• When some types of unusual transmission op-
erating conditions are detected by the TCM,
the TCM temporarily limits transmission opera-
tion until the vehicle can be driven to a service
location. When this type of situation is de-
tected, the TCM will lock the transmission in a 09/21/2012 f270165

safe gear range. Fig. 10.2, T-Handle Shifter (standard)

• The TCM will prevent shifts from park or neu-
tral to another range when auxiliary equipment P (Park)
is in operation. Use park, if so equipped, when turning the engine on
• If a shift from a higher to a lower gear causes or off, to check vehicle accessories, or to operate the
the engine to overspeed. engine in idle for longer than 5 minutes. This position

10.2
Transmission

places the transmission in neutral and engages the D (Drive)

park pawl of the transmission.
In the drive position, the transmission will initially go
NOTE: This does not apply the parking brake. into first range when drive is selected. As vehicle
speed increases, the transmission will upshift auto-
The park pawl is standard on the 2200 series matically through each available range up to fourth or
transmission. The park pawl effectively grounds fifth range. As the vehicle slows, the transmission will
the transmission output shaft, thereby prevent- downshift automatically.
ing rotation of the driveline. Provided the vehicle
is stationary, selecting P (park) on the shift se- When going downhill, downshift to a lower transmis-
lector, if so equipped, places the transmission in sion range to increase engine braking and to help
maintain control. The transmission has a feature to
neutral and engages the park pawl.
prevent automatic upshifting above the lower range
selected. However, during downhill operation, the
PB (Auto-Apply Parking Brake, optional transmission may upshift to the next higher range, if
on 2000 and B200 Series) the engine is exceeding its governed speed in the
The auto-apply parking brake places the transmis- lower range.
sion in neutral and applies the parking brake. NOTE: The shift into drive may not succeed if a
range inhibitor is active. Check for illumination
R (Reverse)
of the RANGE INHIBIT indicator.
Reverse is used to back the vehicle. When the selec-
tor is in reverse, the reverse warning signal will 3 and 2 (Third and Second Ranges)
sound. Always bring the vehicle to a complete stop
Use the third or second range for heavy city traffic
before shifting from a forward range to reverse, or
and for braking on steeper downgrades.
from reverse to a forward range.
Do not idle in reverse for more than 5 minutes. When L (Low Range)
time at idle exceeds 5 minutes, select N(neutral), or
Use low range when pulling through mud or deep
if so equipped, P (park) or PB (auto-apply parking
snow, when maneuvering in tight spaces, or when
brake).
driving up or down very steep grades. Low range
NOTE: The shift into reverse may not succeed if provides the vehicle with its maximum driving torque
a range inhibitor is active. Check for illumination and maximum engine braking effect.
of the RANGE INHIBIT indicator. NOTE: To have the transmission select these
ranges automatically, leave the selector lever in
N (Neutral)
D(drive).
The neutral position places the transmission in neu-
tral. When neutral is selected, the vehicle service Operating Instructions, 3000 and
brakes, parking brake, or emergency brake must be B300 Series
applied. Selecting neutral does not apply vehicle
brakes unless an auxiliary system to apply the park- The Allison 3000 and B300 series transmissions are
ing brake is installed. electronically controlled and have a push-button shift
control that provides five or six forward ranges and
This position is used when starting the engine and
one reverse range. The push-button shift selector
for stationary operation. It is also used to shut down
has R (reverse), N (neutral), and D (drive) ranges, up
the vehicle when P (park) or PB (auto-apply parking
and down arrows, a mode button, and a digital dis-
brake) are not available on the shifter. In this case,
play. See Fig. 10.3.
the parking brake must be applied.
Do not let the vehicle coast in neutral. If the vehicle R (Reverse)
is allowed to coast in neutral, the engine brake will
Press the R button to select reverse. The digital dis-
not work and the driver could lose control of the ve-
play will show R when reverse is selected. Always
hicle.
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.

10.3
 Transmission

When neutral is selected, the vehicle service brakes,

parking brake, or emergency brake must be applied.
Selecting neutral does not apply vehicle brakes un-
1 less an auxiliary system to apply the parking brake is
2 installed.

3
WARNING
4
Do not coast in neutral. Coasting in neutral can
cause an accident, possibly resulting in severe
personal injury or death.
Do not let the vehicle coast in neutral. If the vehicle
is allowed to coast in neutral, the engine brake will
not work and the driver could lose control of the ve-
hicle.
07/27/2006 f610804 Always select neutral before turning off the engine.
1. Digital Display 3. Mode Indicator LED
2. Mode Identification 4. Mode Button D (Drive)
Label
When the D button is pushed, the highest forward
Fig. 10.3, Push-Button Shift Selector range will appear in the display. The transmission will
normally go into first range when drive is selected
(except for those units programmed to start in sec-
NOTICE ond range). As vehicle speed increases, the trans-
Extended idling in reverse may cause transmis- mission will upshift automatically through each range.
sion overheating and damage. As the vehicle slows, the transmission will downshift
automatically.
Do not idle in reverse for more than 5 minutes. Se-
lect neutral when time at idle exceeds 5 minutes. NOTICE
NOTE: The shift into reverse may not succeed if
a range inhibitor is active. When reverse is se- Do not idle in drive for more than 5 minutes. Ex-
tended idling in drive may cause transmission
lected, always be sure that R is not flashing.
overheating and damage. Always select neutral if
N (Neutral) time at idle is longer than 5 minutes.
NOTE: The shift into drive may not succeed if a
WARNING range inhibitor is active. When drive is selected
always be sure that D is not flashing.
When starting the engine, make sure that the ser-
vice brakes are applied. Failure to apply the ser- 5, 4, 3, and 2 (Fifth, Fourth, Third, and
vice brakes may result in unexpected vehicle Second Ranges)
movement, which could cause severe personal
injury or death. Failure to apply the vehicle park- Occasionally, road conditions, load, or traffic condi-
ing brakes when the transmission is in neutral tions will make it desirable to restrict automatic shift-
may allow the vehicle to move unexpectedly, pos- ing to a lower range. Lower ranges provide greater
sibly causing property damage or personal injury. braking for going down grades. The lower the range,
the greater the braking effect.
Press the N button to select neutral. The digital dis-
play will show N when neutral is selected. It is not Push the up or down arrows on the push-button shift
necessary to press neutral before starting the ve- selector to select individual forward ranges. The digi-
hicle. The electronic control unit (ECU) or TCM auto- tal display will show the selected range. When a
matically places the transmission in neutral at start- lower range is selected, the transmission may not
up. downshift until the vehicle speed or engine RPM (en-
gine governed speed) is reduced.

10.4
Transmission

the ECU or TCM. Pressing the MODE button

WARNING changes transmission operation for a specific func-
tion.
When going downhill, use a combination of
downshifting, braking, and other retarding de- Mode Indicator LED
vices to control vehicle speed and the engine’s
rated governed speed. Failure to do so could re- When the MODE button is pressed, the mode indica-
duce vehicle braking, possibly causing loss of tor LED illuminates. A mode identification label, lo-
vehicle control and resulting in personal injury or cated above the MODE button, identifies the function
property damage. associated with a mode change.
When going downhill, downshift to a lower transmis- Digital Display
sion range to increase engine braking and to help
maintain control. The transmission has a feature to The dual digital display shows both the selected
prevent automatic upshifting above the lower range range (SELECT) and actual range attained (MONI-
selected. However, during downhill operation, if the TOR). The single digital display shows the selected
engine governed speed is exceeded in the lower range.
range, the transmission may upshift to the next
higher range. Oil Level Sensor
Allison 3000 and B300 Series transmissions have an
1 (First Range) electronic oil level sensor to read fluid level informa-
Use the first range when pulling through mud or tion. The fluid level diagnostic will display whether
deep snow, when maneuvering in tight spaces, or the oil level is OK, too low, or too high. It will also
when driving up or down steep grades. First range display a default code and indicate if the precondi-
provides the vehicle with its maximum driving torque tions (of receiving the fluid level information) are not
and maximum engine braking effect. Push the down met.
arrow until the first range appears on the display. IMPORTANT: Maintain the proper fluid level at
Up and Down Arrows all times. If the fluid level is too low, the con-
verter and clutch do not receive an adequate
When a lower range is desired, after D has been supply of fluid. If the level is too high, the trans-
pressed, press the down arrow until the desired mission may shift erratically or overheat.
range is shown on the display. Pressing the down
arrow continuously causes the range position to con- To access the oil level display mode, park the vehicle
tinue to go down until the button is released or the on a level surface, shift to N (neutral), apply the
lowest range is attained. parking brake, and idle the engine. Then simultane-
ously press both the up and down arrows once. The
When the transmission is in drive and the down oil level will display at the end of a two-minute count-
arrow has the transmission in a lower range position, down.
press the up arrow to shift to a higher selector posi-
tion. Continuously pressing the up arrow causes the Diagnostic Codes
range position to continue to rise until the button is
released or the highest available position is attained. Diagnostic codes are numerical indications relating to
a malfunction in transmission operation. These codes
Continuously pressing the up or down arrows does are logged in the TCM/ECU memory. The most se-
not override the transmission automatic shifting op- vere or most recent code is listed first. A maximum of
eration. If a higher or lower position is selected, the five codes (numbered d1-d5) may be listed in
transmission continues shifting through the ranges memory at one time. If the mode indicator LED is
according to the vehicle operating characteristics illuminated, the displayed code is active. If it is not
until the highest or lowest selection position is illuminated, the displayed code is not active.
reached.
NOTE: During normal operation, an illuminated
Mode Button mode indicator LED signifies the specialized
mode operation is in use.
The MODE button starts a specialized input or output
function that has been previously programmed into

10.5
 Transmission

To enter diagnostics mode, first park the vehicle and Operation, Straight-Shift
apply the parking brake. Then simultaneously press
both the up and down arrows twice. 1. Always use first gear when starting to move the
vehicle forward.
Eaton® Fuller® Straight-Shift
Transmissions NOTICE
Refer to the Eaton website for additional information, Do not rest your foot on the clutch pedal while
[Link]. driving. This causes partial clutch disengagement
which could cause premature clutch wear.
General Information, Straight-Shift 2. On synchronized models, press the clutch pedal
to the floor when shifting gears. Double-clutching
Eaton Fuller 5-speed FS models are fully synchro- is unnecessary.
nized. They have five forward speeds and one re-
verse. See Fig. 10.4 for the shift pattern. On unsynchronized models, press the clutch
pedal to the floor to contact the clutch brake only
when engaging the first or reverse gears.
NOTE: If the vehicle is moving when shifting,
R 2 4 depress the pedal just far enough to disengage
the clutch. Pressing it to the floor will engage
N the clutch brake, if so equipped, causing prema-
ture clutch brake wear.
1 3 5 3. To upshift, do the following steps:
3.1 Accelerate to engine governed speed.
05/21/2008 f261049
3.2 On synchronized models, depress the
Fig. 10.4, Shift Pattern, 5-Speed FS Models clutch pedal and move the shift lever to
second gear.
Eaton Fuller 6-speed FS and FSO models are fully
synchronized. They have six forward speeds and one On unsynchronized models, depress the
reverse. See Fig. 10.5 for the shift pattern. clutch pedal and move the shift lever to
neutral. Release the clutch pedal again.
With the shift lever in neutral, depress the
clutch pedal and move the shift lever to
second gear.
R 1 3 5
3.3 Release the clutch pedal and note the
drop in engine rpm before accelerating up
N to engine governed speed again.
3.4 Continue upshifting using the same se-
2 4 6 quence described in the previous step.
Follow the pattern on the shift lever.
05/21/2008 f261048
4. To downshift, do the following steps:
Fig. 10.5, Shift Pattern, 6-Speed FS and FSO Models 4.1 Wait until the engine speed drops to the
These transmissions are designed for use with on- rpm noted immediately after the upshift.
highway, fuel economy engines where a minimum of 4.2 On synchronized models, depress the
shifting is desired and less gear reduction is accept- clutch pedal and move the shift lever to
able. the next lower gear.
On unsynchronized models, depress the
clutch pedal and move the shift lever to
neutral. Release the clutch pedal again.

10.6
Transmission

With the shift lever in neutral, depress the also put a constant thrust load on the release bear-
clutch pedal and move the shift lever to ing, which can thin out the lubricant. Release bearing
the next lower gear. failures can be attributed to this type of misuse.
4.3 Release the clutch pedal smoothly. Holding the Vehicle on an Incline With a
4.4 Use the sequence described above to Slipping Clutch
shift progressively down through each
successive lower gear, as driving condi- A slipping clutch accumulates heat faster than it can
tions require. be dissipated, resulting in early clutch failures. Never
use the clutch to hold a vehicle on a hill.
Clutches Coasting With the Clutch Released
Clutch Operation (pedal down) and the Transmission in
Gear
Applying the Clutch Brake
The purpose of the clutch brake is to stop the trans- WARNING
mission gears from rotating in order to engage the
transmission gears quickly in making an initial start. Do not allow the vehicle to coast with the clutch
To apply the clutch brake, put the transmission in released (pedal down) and the transmission in
neutral and press the clutch pedal to the floor. gear. If the clutch facing is thrown off the disc,
flying debris could cause injury to persons in the
NOTICE vehicle.
If the transmission remains in a low gear and the ve-
Never apply the clutch brake while the vehicle is hicle gains speed, as may occur on a downgrade,
moving. The clutch pedal should never be the input shaft and clutch driven disc will turn at
pressed down fully before putting the transmis- speeds that are higher than normal. This occurs be-
sion in neutral. Considerable heat will be gener- cause the rear wheels and the driveline become the
ated, which will be detrimental to the friction input for the transmission, and a higher-than-normal
discs, release bearings, and transmission front speed for a given transmission gear translates to a
bearings. higher rpm value for the clutch driven disc.
Applying the clutch brake with the transmission still in Clutch driven discs are designed to allow for some
gear puts a reverse load on the gear. At the same amount of excess rotational speed, but the facing
time, it will have the effect of trying to stop or decel- has a limited burst strength. If the clutch driven disc
erate the vehicle with the clutch brake. Rapid wear of rpm increases too much, the clutch facing can be
friction discs will take place, necessitating frequent thrown off the disc(s).
replacement.
Engaging the Clutch While Coasting
Vehicle Overload, or Overloading the
Clutch Engaging the clutch while coasting can result in tre-
mendous shock loads and possible damage to the
clutch as well as to the entire drivetrain.
NOTICE
Report Erratic Clutch Operation Promptly
Overloading will not only result in damage to the
clutch, but also to the entire powertrain. Reporting erratic clutch operation as soon as pos-
sible will give maintenance personnel a chance to
Clutches are designed for specific vehicle applica- inspect the clutch components.
tions and loads. These limitations should not be ex-
ceeded.
CAUTION
Riding the Clutch Pedal
Operating the vehicle with incorrect clutch pedal
Riding the clutch pedal is destructive to the clutch. free-travel could result in clutch damage. See
Partial clutch engagement permits slippage, and gen- Group 25 of the S2 Chassis Workshop Manual for
erates excessive heat. Riding the clutch pedal will

10.7
 Transmission

free-pedal adjustment procedures and specifica- Clutch Lubrication

tions.
The release bearing should be lubricated at frequent
On mechanical clutch linkages, free-pedal travel intervals. See Group 25 of the S2 Chassis Mainte-
should be included and commented on daily in the nance Manual for intervals and procedures.
driver’s report, since clutch free-pedal travel is the
best guide to the condition of the clutch and the re-
lease mechanism. NOTICE
Clutch Wear Failure to lubricate the release bearing as recom-
mended could result in release bearing damage
The major reason clutches wear out too soon is ex- and damage to the clutch.
cessive heat. Clutches are designed to absorb and
dissipate more heat than encountered in typical op-
eration. The temperatures developed in typical op-
eration will not break down the clutch friction sur-
faces. However, if a clutch is slipped excessively or
required to do the job of a fluid coupling, high tem-
peratures develop quickly and destroy the clutch.
Temperatures generated between the flywheel,
driven discs, and pressure plates can be high
enough to cause the metal to flow and the friction
facing material to char and burn.

NOTICE
Do not allow sustained slippage of the clutch;
this could severely damage the clutch disc, pres-
sure plate, or flywheel. Damage caused by clutch
slippage due to improper break-in is not warrant-
able.
Slipping and excessive heat are practically nonexis-
tent when a clutch is fully engaged. But during the
moment of engagement, when the clutch is picking
up the load, it generates considerable heat. An incor-
rectly adjusted or slipping clutch will rapidly generate
sufficient heat to destroy itself.
The most important items that a driver should be
aware of to ensure long service life of the clutch in-
clude: starting in the right gear, recognizing clutch
malfunctions, and knowing when to adjust a clutch.

Clutch Adjustments
Some clutches have an internal adjustment. See the
applicable section in Group 25 of the S2 Chassis
Workshop Manual for clutch adjustment procedures
and specifications.

NOTICE
Operating the vehicle with the clutch incorrectly
adjusted could result in clutch or clutch brake
failure.

10.8
 11
Drive Axles
Drive Axles, Detroit™ and Meritor™ . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11.1
Drive Axles

Drive Axles, Detroit™ and IMPORTANT: The differential lock rocker switch
is guarded to prevent unintentional switch acti-
Meritor™ vation. If the light emitting diode (LED) in the
For additional information regarding Meritor axles, switch begins to blink during normal operation,
visit the Meritor website at [Link]. when the switch has not been activated, an
error condition exists. Bring the vehicle to an
Drive Axles With Differential Lock authorized Freightliner service facility as soon
as possible.
The optional driver-controlled differential lock should
only be used under adverse road conditions where When the differential lock switch is pressed, three
greater traction is needed. With the differential lock responses are possible: a normal response, a slow
on, the turning radius is increased and vehicle han- response, and an abnormal response.
dling is affected. The red differential lock indicator
Normal Response: The LED in the switch blinks until
light illuminates on the dash message center when the axle has responded to the request to lock the
the differential lock is engaged. wheels. At this point, the LED remains illuminated
A differential lock provides maximum traction under constantly. In normal operation, the wheels may lock
slippery conditions. When the differential lock is en- so quickly that the blinking of the switch is barely
gaged, the clutch collar completely locks the differen- noticeable.
tial case, gearing, and axle shafts together, maximiz-
If operation of the switch is not possible for any rea-
ing the traction of both wheels and protecting against
son (ignition is turned off, vehicle is moving faster
spinout. Do not exceed 25 mph (40 km/h) when the
than 25 mph, etc.), the LED will stop blinking and
differential lock is engaged.
turn off.
Under normal traction conditions, do not use the dif-
ferential lock feature. Slow Response: If operation of the switch is slowed
for any reason (vehicle moving too fast, low air pres-
Differential Lock Switch sure, etc.), the switch will continue to blink until the
wheels are able to lock. As in the normal response,
the LED remains illuminated when the differential
NOTICE lock is engaged.
The differential lock should only be engaged NOTE: If the vehicle is moving too fast, let up
when the vehicle is stopped or moving slowly at slightly on the accelerator. As the vehicle slows,
low throttle. This will prevent internal axle dam- the wheels will lock.
age.
Abnormal Response: If the LED blinks for more than
A two-position guarded rocker switch controls the 30 seconds, the lock mechanism may not be fully
differential lock. See Fig. 11.1. To lock the wheels engaged/disengaged. Bring the vehicle to an autho-
together, momentarily press the upper half of the rized Freightliner service facility for testing.
switch. To unlock the wheels, press the upper half of
the switch again. Differential Lock Operation

WARNING
Locking the wheels when the vehicle is traveling
down steep grades or when the wheels are slip-
ping could damage the differential and/or lead to
loss of vehicle control, causing personal injury
and property damage.

10/26/2001 f610596
NOTICE
The differential lock should be engaged when the
Fig. 11.1, Differential Lock Switch, Optional
vehicle is stopped or moving at a low, constant
speed and the wheels are not spinning, slipping,

11.1
 Drive Axles

or losing traction. Engagement at high speed or A

power can damage the axle(s).
Do not permit rear wheels to spin freely for more
than ten seconds when traction is lost. Shift into
lock to prevent damage to interaxle and main
differentials. B

Lock the wheels only when the vehicle is standing

still or moving at very low speed, less than 5 mph (8
km/h). Never lock the wheels when the vehicle is
traveling down steep grades or when the wheels are 02/03/2017 f350079a
slipping. A. Turning Radius When the Differential Lock is
NOTE: On some vehicles, the differential lock Engaged (understeer condition).
B. Turning Radius When the Differential Lock is
system is connected through the low speed Disengaged.
range of the transmission. If this system is used,
the transmission must be in the low speed Fig. 11.2, Turning Radii
range for the wheels to fully lock.

WARNING
A vehicle with locked wheels can still slip side-
ways, causing possible loss of vehicle control,
personal injury, and property damage.
Be especially careful when driving under slippery
conditions with the wheels locked. Though forward
traction is improved, the vehicle can still slip side-
ways.
If the vehicle is moving, maintain a constant vehicle
speed when the differential lock is turned on. Briefly
let up on the accelerator to relieve torque on the
gearing, allowing the wheels to lock completely.
When the wheels are fully locked, the turning radius
will increase because the vehicle understeers. See
Fig. 11.2. Drive cautiously and do not exceed 25
mph (40 km/h).
To disengage the differential lock after leaving poor
road conditions, press the upper half of the switch,
while maintaining vehicle speed. Let up momentarily
on the accelerator to allow the wheels to fully unlock,
then resume driving at normal speed.
NOTE: If the differential lock system is con-
nected with the transmission in its low speed
range, shifting out of the low speed range will
also disengage the differential lock function. The
switch will blink until the wheels unlock, and
then go out.

11.2
 12
Steering System
Steering Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12.1
Steering System

Steering Controls
1

WARNING
Make sure that the steering column is locked be-
fore driving the vehicle. Never tilt or telescope
the steering wheel while driving the vehicle.
Doing so could cause loss of vehicle control,
personal injury, and property damage.
When there is no load on the vehicle and the front
tires are pointed straight ahead, the steering wheel
spokes should be at the 9 o’clock and 3 o’clock posi-
2
tions, or within 10 degrees to either side as shown in
Fig. 12.1. See Group 46 of the S2 Chassis Work-
shop Manual for steering adjustment procedures.
3

11/14/2001 f461922
10° 10°
Push the foot pedal down to adjust the steering column.
1. Steering Wheel 3. Foot Pedal
1 2 2. Steering Column
Fig. 12.2, Adjustable Steering Column
10° 10°
NOTE: For safety, the steering column is locked
at all times unless the foot pedal is pressed
11/14/2001 f461923
down.
1. 9 o’Clock 2. 3 o’Clock
Fig. 12.1, Steering Wheel Centered

On some vehicles, the steering column may be tilted

forward or aft to provide the most comfortable angle
for steering the vehicle. The steering column can
also be telescoped (raised or lowered) to provide the
most comfortable height above the floor.
To tilt the steering column, press down on the foot
pedal located below the steering wheel to release the
steering column lock. Adjust the column to the de-
sired position. Release the foot pedal to lock the
steering column in place. See Fig. 12.2.
To telescope the steering column, press down on the
foot pedal to release the steering column lock. Pull
the steering wheel upwards or push the steering
wheel downwards until it is at the desired height. Re-
lease the foot pedal to lock the steering column in
place.

12.1
 13
Hydraulic and Air Brake
Systems
Dual Air Brake System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13.1
Air Brake Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13.1
Bosch Hydraulic Pin Slide Brakes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13.3
Meritor Cam-Master® Q Plus Brakes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13.3
Meritor WABCO Pneumatic Antilock Braking System (ABS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13.4
Exhaust Brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13.5
Engine Brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13.6
Brake Burnishing (new vehicle) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13.7
Hydraulic and Air Brake Systems

Dual Air Brake System Air Brake Operation

A dual air brake system consists of two independent
air brake systems that use a single set of brake con- WARNING
trols. Each system has its own reservoir, plumbing,
and brake chambers. The primary air system oper- Do not operate the vehicle with the front brakes
ates the service brakes on the rear axle; the second- backed off or disconnected. Backing off or dis-
ary air system operates the service brakes on the connecting the front brakes will not improve ve-
front axle. hicle handling and may lead to loss of vehicle
control, resulting in property damage or personal
Primary Air Brake System injury.

Loss of air pressure in the primary air system causes Before driving the vehicle, secure all loose items in
the rear service brakes to become inoperative. The the vehicle so that they will not fly forward during a
front brakes will continue to be operated by the sec- full brake application.
ondary air system.
Parking Brake Interlock, Optional
Secondary Air Brake System
Loss of air pressure in the secondary air system
NOTICE
causes the front axle brakes to become inoperative. Do not continually press down on the parking
The rear service brakes will continue to be operated brake control valve (yellow knob) without press-
by the primary air system. ing down on the service brake pedal. This will
damage the safety interlock.
Emergency Braking System
The service brakes and parking brakes have a safety
When air pressure is lost in one air system, the air interlock that prevents the unintentional release of
compressor will operate, but the air supply in the the parking brake. These instructions need to be fol-
leaking system will not be replenished. There will be lowed for the appropriately equipped vehicle to re-
enough air in the working system to stop the vehicle lease the parking brake interlock.
safely. The dual air brake system thus provides
emergency braking capability. When the low air pres- Parking Brake Interlock Release
sure warning light and emergency buzzer first come
1. Depress the brake pedal.
on, stop the vehicle immediately. Do not drive the
vehicle until the cause of the problem is corrected. 2. Push the parking brake control valve in.

Parking Brakes Parking Brake and Ignition Key Release

Pulling out the yellow diamond-shaped knob (parking 1. Turn the ignition key to the ON position.
brake control valve) on the auxiliary dash panel ap- 2. Depress the brake pedal.
plies the parking brakes (spring brakes). See
Fig. 13.1. 3. Push the parking brake control valve in.

Parking Brake, Ignition Key, Wheel Chair

Lift Interlock Release
1. Turn the ignition key to the ON position.
2. Check to see that the wheel chair lift is in the
stowed position.
3. Confirm that the wheel chair lift switch is in the
OFF position.
11/21/2006 f430360a 4. Depress the brake pedal.

Fig. 13.1, Parking Brake Control Valve 5. Push the parking brake control valve in.

13.1
 Hydraulic and Air Brake Systems

Transmission Shifter Interlock Release 5. When the forward speed of the vehicle has de-
creased almost to the idling speed of the engine,
1. If the vehicle is equipped with a wheel chair lift, press in the clutch pedal (on manual transmis-
make sure the lift is in the stowed position, and sions) and shift the transmission to neutral. Apply
that the wheel chair lift switch is in the OFF posi- the parking brakes, if the vehicle is to be parked.
tion.
2. Depress the service brake pedal to move the NOTICE
vehicle shifter out of the park position.
Do not use the spring parking brakes if the ser-
Operating the Brakes vice brakes are hot, such as after descending a
steep grade. Also, do not use the spring parking
To ensure safe operation and minimum brake wear, brakes during freezing temperatures if the ser-
follow the steps below when operating the brakes. vice brakes are wet. To do so could damage the
1. When the ignition switch is turned on, the low air brakes if hot, or cause them to freeze during cold
pressure warning light (pressure circle icon) illu- weather.
minates and the emergency buzzer sounds. If the brakes are wet, drive the vehicle in low
1.1 Monitor the air pressure system by ob- gear and lightly apply the brakes to heat and dry
serving the low air pressure warning light, them. Allow hot brakes to cool before using the
the emergency buzzer, and both the pri- spring parking brakes. Always chock the tires.
mary and secondary air pressure gauges.
Caging the Parking Brakes
1.2 The warning light and buzzer shut off
when air pressure in both systems
reaches 65 to 75 psi (448 to 517 kPa). WARNING
2. Before driving the vehicle, continue to monitor Do not drive the vehicle with the parking brakes
the air pressure system until the air compressor caged. If the vehicle is driven with the parking
has built up a minimum pressure of 95 psi (655 brakes caged, there would be no means of stop-
kPa) in both the primary and secondary air sys- ping the vehicle if a complete loss of air pressure
tems. occurred. This could result in serious personal
3. While driving, the low air pressure warning light injury or vehicle damage.
and buzzer come on if air pressure drops below To move a vehicle with insufficient system air pres-
65 to 75 psi (448 to 517 kPa) in either system. sure, it is necessary to release the parking brake
3.1
springs.
If this happens, check the air system pres-
sure gauges to determine which system There are two ways to do this:
has low air pressure. • Apply an external air source at the gladhands;
3.2 Although vehicle speed can be reduced • Cage (manually release) the parking brakes.
using the service brake, either the front or
rear service brakes will not be operating, IMPORTANT: Before caging the parking brakes,
causing a longer stopping distance. make the connection to a towing vehicle or
3.3 Bring the vehicle to a safe stop and have chock the tires.
the air system repaired before continuing. After correcting the brake system problem, uncage
4. During normal brake stops, depress the service the parking brakes before resuming normal vehicle
brake until braking action slows down the ve- operation.
hicle. Increase or decrease the pressure on the
pedal so that the vehicle comes to a smooth,
safe stop.
IMPORTANT: In the event of a total loss of ser-
vice brakes, use the parking brake control valve
to bring the vehicle to a complete stop in the
safest location possible.

13.2
Hydraulic and Air Brake Systems

Bosch Hydraulic Pin Slide stop. Apply the hand parking brake if the vehicle is to
be parked.
Brakes IMPORTANT: Make sure that the fluid level in
General Information the master cylinder reservoirs is at the bottom of
the fill-neck. See Fig. 13.2. Use only DOT 3
The Bosch hydraulic pin slide disc brake is a two-
brake fluid in the Bosch hydraulic pin slide
piston sliding caliper brake and is used at both the
front and rear wheel locations. Each pin slide caliper brake system.
disc brake wheel installation is made up of a caliper
assembly, anchor plate assembly, and disc brake B
pads.

Caliper Assembly
The caliper assembly has two hydraulic piston bores.
The piston bores contain pistons, piston seals, and
piston boots. The caliper assembly attaches and A
slides on sealed pins located in the anchor plate.
The caliper housing is the main component of the
caliper assembly. The material of the caliper housing
is ductile iron and has a protective coating to provide
additional environmental protection. The disc brake
caliper housing straddles the rotor, the inner pad,
and the outer pad.

Anchor Plate Assembly

The anchor plate assembly includes lubricated float-
ing guide pins sealed by rubber boots. The anchor
plate abutments are protected by stainless steel slip-
pers.

Disc Brake Pads 07/31/2015 f460513b

There are two pads per caliper assembly, and they A. Open caps and check fluid level.
are the inner and outer pads. The inner pad is lo- B. Fill to this level.
cated between the caliper piston and rotor. The outer
pad is located between the rotor and caliper housing Fig. 13.2, Master Cylinder Reservoir
legs. The pads are made of friction material and a
stamped steel backing plate. The pads are referred Meritor Cam-Master® Q Plus
to as the shoe and lining assembly. These brake
pads can be removed without removing the caliper.
Brakes
Cam-Master brakes are air-actuated, cam-operated,
Operation foundation brakes. The Q Plus increases service life
and mileage between relines by providing more lining
Before driving the vehicle, secure all loose items in thickness. A specially designed S-cam and heavy-
the vehicle so that they will not fly forward during a duty shoe return spring allow additional shoe travel
full brake application. Check that the brake system required to fully wear the thicker lining blocks. An
warning light is off after releasing the hand brake. If improved camshaft bushing contributes to longer ser-
the warning light does not go off, correct the problem vice life.
before continuing operation of the vehicle.
During normal braking stops, depress the foot brake Cam-Master Q Plus Operation
control pedal until braking action slows down the ve-
hicle. Increase or decrease the pressure on the When the brake pedal is depressed, compressed air
pedal so that the vehicle comes to a smooth, safe enters the brake chamber, causing the diaphragm to
move a pushrod assembly.

13.3
 Hydraulic and Air Brake Systems

The pushrod turns the slack adjuster and brake cam- cident if the driver is speeding or following too
shaft. As the camshaft turns, the S-type cam head closely on slippery road surfaces.
forces the brake shoes against the brake drum and Even if the ABS system is partially or completely in-
braking occurs. operative, normal braking ability is usually main-
When the brakes are released and air is exhausted tained.
from the brake chamber, the actuator return spring
(within the brake chamber) and the brake shoe return IMPORTANT: If a solenoid control valve (or
spring return the camshaft, brake shoes, slack ad- combination solenoid control valve) is damaged
juster, and pushrod to their released positions. and inoperative, normal braking may be im-
paired.
Meritor WABCO Pneumatic Automatic Traction Control
Antilock Braking System (ABS) Vehicles with electronic engines and ABS may have
Pneumatic ABS is an electronic wheel speed moni- Automatic Traction Control (ATC). On these vehicles,
toring and control system that works with the air the ATC system automatically limits wheel spin dur-
brake system. It passively monitors vehicle wheel ing reduced-traction situations. In normal braking ap-
speed at all times, but controls wheel speed during plications, the standard air brake system is in effect.
an emergency or reduced-traction stop. In normal During reduced-traction situations, the ATC solenoid
braking applications, the standard air brake system is valve controls air pressure to the modulator valves
in effect. and they in turn increase, hold, or reduce pressure to
the appropriate brake chambers to provide better
Pneumatic ABS Operation traction whenever wheel spin occurs.
The Meritor WABCO ABS is a four-sensor system. It When the ATC system is in the NORMAL mode, it
combines one front-axle control channel with one will apply gentle braking to the spinning wheel, to
rear-axle control channel to form one control circuit. feed power to the wheel(s) with better traction. If
Example: The sensor and solenoid control valve at both wheels are spinning, the system will signal the
the left front wheel form a control circuit with the sen- engine to reduce power.
sor and solenoid valve at the right rear axle. ATC may include a deep snow and mud option to
ABS includes signal-generating tone wheels and sen- increase available traction on extra soft surfaces like
sors located in the wheel hubs of each sensed axle. snow, mud, or gravel. If so equipped, a momentary
The sensors transmit vehicle wheel speed informa- contact rocker switch labeled ATC will be located on
tion to an electronic control unit. the dash. Pressing the switch will temporarily allow
more wheel spin. The activation of the deep snow
IMPORTANT: For proper ABS system operation, and mud option is indicated by a flashing WHEEL
do not change tire sizes. The sizes of the tires SPIN lamp. Pressing the switch again will cycle the
installed during production are programmed into system back to normal operation.
the electronic control unit. Installing different
sized tires could result in a reduced braking NOTICE
force, leading to longer stopping distances.
The deep snow and mud option is intended to be
During emergency or reduced traction stops, fully
used under specific slippery conditions that re-
depress the brake pedal until the vehicle comes to a
quire momentary increased wheel spin. Using
safe stop. Do not pump the brake pedal. With the
this option for an extended period of time may
brake pedal fully depressed, the ABS system will
damage the vehicle brake system.
control all wheels to provide steering control and a
reduced braking distance. After the ignition switch is turned on, the ABS indica-
tor light and the WHEEL SPIN indicator light illumi-
Although the ABS system improves vehicle control
nate for about three seconds. After three seconds,
during emergency braking situations, the driver still
the warning lights go out if all of the ABS compo-
has the responsibility to change driving styles de-
nents are working.
pending on the existing traffic and road conditions.
For example, the ABS system cannot prevent an ac- During vehicle operation, solid illumination of the
ABS light indicates a problem with the vehicle ABS.

13.4
Hydraulic and Air Brake Systems

Repair the ABS immediately to ensure full braking in combination with the accelerator and clutch pedal
capability. (if so equipped), to make maximum use of the ex-
haust brake in off-highway and mountain driving as
If equipped with ATC, an amber WHEEL SPIN indica-
well as in traffic or high-speed highway driving.
tor light illuminates if one of the drive wheels spins
during acceleration. When the light illuminates, par- The exhaust brake is controlled by a dash-mounted
tially release the throttle pedal to stop the spinning rocker switch, shown in Fig. 13.3, to help slow the
wheel. The light goes out when the wheel stops spin- vehicle when the accelerator is released.
ning. To turn the exhaust brake on, press on the upper
If slippery road conditions continue, turn on the differ- part of the rocker switch. When the exhaust brake
ential lock switch. See Chapter 11 for axle switch in- switch is on, an amber light emitting diode (LED) illu-
structions. minates inside the switch. When the panel lights are
on, the EXHST BRK legend is backlit in green.
NOTICE
Do not turn the differential lock switch on while
the WHEEL SPIN indicator light is on. To do so
could damage the rear axle.

Automatic Slack Adjusters

NOTICE
Manually adjusting an automatic slack adjuster to
bring the pushrod stroke within legal limits is
11/28/2001 f610589
likely masking a mechanical problem. Adjustment
is not repairing. In fact, continual adjustment of Fig. 13.3, Exhaust Brake Switch
automatic slack adjusters may result in prema-
ture wear of the adjuster itself. Further, the im- The exhaust brake is only active when engine speed
proper adjustment of some automatic slack ad- is between 1100 and 2700 rpm. Depressing the ac-
justers may cause internal damage to the celerator or clutch pedal deactivates the exhaust
adjuster, thereby preventing it from properly brake. The ABS system, when active, also deacti-
functioning. vates the exhaust brake.
Automatic slack adjusters should never be manually The exhaust brake is a butterfly valve mounted in the
adjusted except during routine maintenance of the exhaust pipe. When the driver’s foot is not on the
foundation brakes (e.g., replacing shoes), during accelerator pedal and the upper half of the exhaust
slack adjuster installation, or in an emergency situa- brake switch is pressed in, with the amber light on
tion. the switch illuminated, an air cylinder shuts the but-
When the brake pushrod stroke exceeds the legal terfly valve, which restricts the flow of exhaust gases
brake adjustment limit on a vehicle, there is likely a and retards the engine. This retarding action is car-
mechanical problem with the foundation brake com- ried through the engine and drivetrain, slowing the
ponents or the adjuster is improperly installed. vehicle and reducing the need for frequent service
brake applications.
Visit a repair facility as soon as possible when
brakes equipped with automatic slack adjusters are Exhaust brakes are not intended for use as the pri-
determined to be out of adjustment. mary braking system during vehicle operation.

Starting the Engine

Exhaust Brake
Before starting the engine, make sure that the lower
General Information half of the exhaust brake switch is pressed in and
An exhaust brake is an optional auxiliary braking sys- the amber light is not illuminated. Do not turn the ex-
tem that assists, but does not replace, the service haust brake on until the engine has reached normal
brake system. The driver can use the exhaust brake, operating temperatures.

13.5
 Hydraulic and Air Brake Systems

Operating Characteristics NOTICE

WARNING Do not allow the engine to exceed its governed
speed, or serious engine damage could result.
Do not use the exhaust brake when driving on
slippery or low-traction road surfaces. Failure to Apply the service brakes to reduce the engine rpm or
follow this precaution could result in a loss of make a slower descent by using a lower gear.
vehicle control and possible personal injury or
property damage. Shutting Down the Engine
When you remove your feet from both the accelera- Make sure the exhaust brake switch is turned off be-
tor and clutch pedal (if so equipped), and the upper fore shutting down the engine.
half of the exhaust brake switch is pressed in with
the amber LED illuminated, the exhaust brake is ap- Engine Brake
plied. The following conditions should exist if the
brake is operating properly: Engine Brake Switch
• A slight change in the sound of the engine may The engine brake switch controls the degree of en-
be noticed when the exhaust brake is applied. gine braking. Normally there are two paddle
• Exhaust smoke should appear as normal. switches, a two-position On/Off Switch to activate the
engine brake, and a two-position Hi-Lo Switch to
• Engine temperature should remain in the nor- control the amount of engine braking.
mal operating range.
To turn the two-position On/Off Switch on, raise the
• Road speed usually decreases when the ex- paddle. When the two-position switch is on, an
haust brake is applied during a descent. When amber light-emitting diode (LED) illuminates inside
the vehicle is carrying a heavy load or the the switch.
grade is extremely steep, the driver may need To turn the two-position Hi-Lo Switch on high, raise
to apply the service brakes occasionally. the paddle. To turn the two-position Hi-Lo Switch on
• Do not expect a retarding effect similar to sud- low, lower the paddle. See Fig. 13.4.
den hard application of the service brakes. The
exhaust brake retards the vehicle with a
smooth braking effect. 1 2
• During a descent, the tachometer usually
shows a drop in rpm depending on the grade
and the vehicle load.
• Depending on the grade and vehicle load, you
may or may not feel the retarding force acting
against your body when the brake is applied.
The retarding force of the brake may not al-
ways be noticed, but it is actually preventing
the vehicle from going much faster. 10/17/2001 f610588

1. On/Off Switch 2. Hi-Lo Switch

Driving Downhill
Fig. 13.4, Engine Brake Switches
While approaching a steep grade, make sure that the
upper half of the exhaust brake switch is pressed in, A three-position switch is used on MBE900 engines
with the amber LED illuminated. The exhaust brake equipped with both the regular engine brake and the
comes on as soon as you remove your foot from the constant-throttle (decompression) brake. It works the
accelerator pedal. While going down the grade, use same as the two-position Hi-Lo switch, except that
a low enough gear to safely descend with a minimum there is a third (off) position when the switch is left at
application of the service brakes. As a general guide- its normal position.
line, use the same gear as you would to ascend the
hill.

13.6
Hydraulic and Air Brake Systems

When the panel lights are on, the Hi-Lo icon is back- NOTE: After performing the burnishing proce-
lit in amber on the three-position switch. On both the dure, there should be no brake noise and the
three-position switch and the two-position switch, the brakes should have good stopping ability.
ENG BRK legend is backlit in green when the panel
lights are on. 5. If the brakes pull the vehicle to one side or grab
after the burnishing procedure, contact a Freight-
Constant-Throttle Valves liner dealer for assistance.

To increase braking performance, Mercedes-Benz

engines are equipped with optional constant-throttle
valves in each combustion chamber. Small valves
built into the cylinder head allow a small amount of
compressed air to escape through the exhaust port
during the combustion stroke. The constant-throttle
valves are open during the entire time that the en-
gine brake is activated. Although some braking ability
is lost because the valves are constantly open,
constant-throttle braking is quieter in operation than
other types of engine brakes.
When both the exhaust brake and the constant
throttles are installed, a three-position switch on the
dash controls the amount of engine braking deliv-
ered. Like the exhaust brake, the constant throttles
are deactivated when the accelerator or clutch pedal
is depressed. The ABS system, when active, also
deactivates constant-throttle braking.
The engine brake will deactivate if the engine speed
falls below a preset level. This level is program-
mable, but is set at the factory at 1100 rpm.

Brake Burnishing (new

vehicle)
IMPORTANT: Check the brake system and en-
sure that it is in proper operating condition be-
fore attempting the brake burnishing procedure.
1. In a safe area, make 10 sharp brake applications
or "snubs," slowing the vehicle from 40 to 20
mph (64 to 32 km/h) using light (approximately
10 to 20 psi [69 to 138 kPa]) brake pressure.
2. Make 10 stops from 20 mph (32 km/h) using
moderate (20 to 30 psi [138 to 207 kPa]) brake
pressure.
3. Make 2 stops from 20 mph (32 km/h) using hard
(full application of air pressure) brake applica-
tions.
NOTE: After the hard brake applications, it is
normal to notice a hot brake odor.
4. Drive the vehicle 5 to 7 miles (8 to 11 km) allow-
ing the brakes to cool, and then come to a stop.

13.7
 14
Pre- and Post-Trip
Checklists
Pretrip and Post-Trip General Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14.1
Daily Pretrip Inspection and Maintenance Checklist . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14.1
Weekly Post-Trip Inspection and Maintenance Checklist . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14.3
Monthly Post-Trip Inspection and Maintenance Checklist . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14.3
Pre- and Post-Trip Checklists

Pretrip and Post-Trip General For the daily pretrip inspection and maintenance
checklist see Table 14.1.
Information
Regulations in both Canada and the United States
clearly indicate that it is the driver’s responsibility to
perform an inspection and ensure the complete road-
worthiness of a vehicle before placing it into service
for the day. Commercial vehicles may be subject to
inspection by authorized inspectors, and an unsafe
vehicle can be put "out of service" until the driver or
owner repairs it.
IMPORTANT: The pre- and post-trip checklists,
and inspections and maintenance procedures
detailed in this chapter, are not all-inclusive.
Also refer to other component and body manu-
facturers’ instructions for specific inspection and
maintenance instructions.
Use the pretrip inspection checklist to ensure that
vehicle components are in good working condition
before each trip. Use the weekly and monthly post-
trip inspection checklists to note any items that re-
quire attention before the next trip. A driver that is
familiar with the vehicle, and drives it regularly, can
perform the daily inspections, then add the weekly
and monthly post-trip inspections as scheduled. If the
driver does not operate the vehicle on a consistent
basis, all three of the inspection procedures should
be performed before the trip.
Pre- and post-trip inspections cannot be done
quickly. However, careful inspections save time by
eliminating stops later to adjust items overlooked or
forgotten.
Numbers in parentheses within each of the checklists
reference the corresponding detailed instructions
found under "Daily (D), Weekly (W), or Monthly (M)
Procedures" in Chapter 15.
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 S2 Chassis Workshop
Manual for procedures and specifications, or take the
vehicle to an authorized Freightliner dealer.

Daily Pretrip Inspection and

Maintenance Checklist
IMPORTANT: Before performing any of these
checks, apply the parking brake and chock the
tires.

14.1
 Pre- and Post-Trip Checklists

Procedure Performed Procedure

Daily Pretrip Inspections/Checks
(check off) Reference
Drain manually drained air reservoirs (that are not equipped with automatic drain
_______ D1
valves)
Check _______ windshield washer reservoir fluid D2
Inspect _______ wheel seal and hub cap (for leakage) —
Check _______ surge tank coolant level 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, and connections D8
Check _______ fuel level D9
Check _______ fuel/water separator 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
Check _______ automatic transmission fluid level —
Inspect _______ air brake chambers and pushrods D22
Inspect _______ air brake lines D23
Inspect _______ slack adjusters D24
Check _______ air brake system operation D25
Check _______ Bendix® Hydro-Max Power Booster D26
Inspect _______ frame rails (missing bolts), 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)
_______ Remove chocks and test service brakes D27

Inspector___________________________________________________ Date ________________

Table 14.1, Daily Pretrip Inspection and Maintenance Checklist

14.2
Pre- and Post-Trip Checklists

Weekly Post-Trip Inspection For the weekly post-trip inspection and maintenance
checklist see Table 14.2.
and Maintenance Checklist
IMPORTANT: Before performing any of these
checks, apply the parking brake and chock the
tires.

Procedure Performed Procedure

Weekly Post-Trip Inspections/Checks
(check off) Reference
_______ 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 _______ drive belt tension W5
Inspect _______ seat belts and tether belts W6

Inspector___________________________________________________ Date ________________

Table 14.2, Weekly Post-Trip Inspection and Maintenance Checklist

Monthly Post-Trip Inspection For the monthly post-trip inspection and maintenance
checklist see Table 14.3.
and Maintenance Checklist
IMPORTANT: Before performing any of these
checks, apply the parking brake and chock the
tires.

Procedure Performed Procedure

Monthly Post-Trip Inspections/Checks
(check off) Reference
_______ 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)
fluid level in the hydraulic brake reservoir (if applicable, and if necessary, fill with
Check _______ M3
DOT 3 brake fluid)
Check _______ steering wheel play M4
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 M5
Inspect _______ driveshaft —

Inspector___________________________________________________ Date ________________

Table 14.3, Monthly Post-Trip Inspection and Maintenance Checklist

14.3
 15
Pre- and Post-Trip
Inspections and
Maintenance
Safety Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15.1
Daily Pretrip Inspection and Maintenance Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15.1
Weekly Post-Trip Inspection and Maintenance Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15.11
Monthly Post-Trip Inspection and Maintenance Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15.12
Pre- and Post-Trip Inspections and Maintenance

Safety Precautions dryer, it will not remove the water from the
air brake system, which could adversely
affect braking.
DANGER 2. Check the fluid level in the windshield washer
When working on the vehicle, shut down the en- reservoir.
gine, set the parking brake,and chock the tires. Add washer fluid as needed. Unscrew the cap to
before working under the vehicle, always place add fluid.
jack stands under the frame rails to ensure the
vehicle can not drop. Failure to follow these
steps could result in serious personal injury or
WARNING
death. Washer fluids may be flammable and poisonous.
Daily Pretrip Inspection and Do not expose washer fluid to an open flame or
any burning material, such as a cigarette. Always
Maintenance Procedures comply with the washer fluid manufacturer’s rec-
Whenever equipment requires adjustment, replace- ommended safety precautions.
ment, and/or repair, see the S2 Chassis Workshop 3. Check the coolant level in the surge tank.
Manual for procedures and specifications. Specific
references to the manual will be found where appro- See Fig. 15.1. If the coolant is low, add a 50/50
priate. mixture of water and antifreeze. Refer to the en-
gine manufacturer’s service literature for ap-
1. Drain the brake system air reservoirs (reservoirs proved coolants. Fill the surge tank with coolant
without automatic drain valves only). to the FULL line when the tank is cool. If the
Water and oil normally enter the air reservoir in surge tank was empty, start the engine after re-
the form of vapor because of the heat generated filling and check the level again when the engine
during compression. After the water and oil con- is at operating temperature.
dense, drain the resulting emulsion as follows:
1.1 Open the wet tank valve. The drain cock
or pull chain drain is located on the for-
ward end of the supply air reservoir, which
is connected directly to the air compres-
sor. Block the valve open.

WARNING
When draining the air reservoir, do not look into
the air jets or direct them toward anyone. Dirt or
sludge particles may be in the airstream and
could cause injury. 11/02/2001 f820382

Add coolant here (arrow).

1.2 Exhaust the remaining air and moisture
from the system by opening the drain Fig. 15.1, Coolant Level Checking
cocks on the bottoms of the remaining air
reservoirs. Block the valves open.
NOTICE
1.3 Water and oil emulsion often form pockets
that will not drain while compressed air is Coolant must be filled to the full line of the surge
in the reservoirs. Because of these pock- tank. Low coolant could result in engine over-
ets, leave the valves blocked open during heating, which could cause engine damage.
the first part of the pretrip inspection.
4. Inspect the radiator and charge air cooler.
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

15.1
 Pre- and Post-Trip Inspections and Maintenance

4.1 Inspect the radiator and charge air cooler

for clogged fins. Use compressed air or
water directed from the fan side of the
core to backflush any material restricting
airflow.
4.2 Inspect the radiator and charge air cooler
for damage and accumulated debris. 1
Straighten bent or damaged fins to permit
airflow across all areas of the cores.
NOTE: When traveling through areas of high 2
insect concentration, it may be necessary to
clean the exterior of the radiator or the
charge air cooler core as often as every 200
miles (320 km).
4.3 Also inspect and clean the condenser. If
clogged, the condenser can restrict airflow
through the radiator.
4.4 Check the radiator for leaks. If leaks are
found, have the radiator repaired or re-
09/12/2001 f090363
placed. See Group 20 of the S2 Chassis
Workshop Manual for instructions, or take 1. Primary Filter Element
the vehicle to an authorized Freightliner 2. Secondary or Safety Filter Element
dealer. Fig. 15.2, Air Cleaner Filter Elements
5. Inspect the engine and chassis wiring.
NOTE: After replacing the filter element,
Check for loose wiring, chafed insulation, and reset the restriction indicator by pressing the
damaged or loose hold-down clamps. Tighten rubber reset button.
loose wires or hold-down clamps; replace dam-
aged wiring or clamps. 6.3 Inspect the secondary or safety filter ele-
ment in the air cleaner when replacing the
6. Inspect the air intake system for leaks or dam-
primary element, and replace it when
age.
clogged or dirty. This element should be
replaced with every third primary element
NOTICE replacement.

Failure to maintain a sealed air intake system 6.4 Check the engine air intake piping from
could allow entry of dirt and contaminants into the air cleaner to the engine intake. In-
the engine. This could adversely affect engine spect the piping for loose connections,
performance and result in engine damage. cracks, torn or collapsed hoses, punc-
tures, and other damage. Tighten loose
6.1 Check the intake-air restriction indicator. connections, and have damaged compo-
6.2 Replace the primary filter element in the nents replaced. Make sure the piping sys-
air cleaner if the yellow signal stays tem is airtight so that all intake air passes
locked at 20 inH2O for Mercedes-Benz through the air cleaner.
engines and 25 inH2O for Cummins ISB
engines. See Group 09 of the S2 Chassis NOTICE
Workshop Manual for filter element re-
placement instructions, or take the vehicle Operating the engine with the oil level below the
to an authorized Freightliner dealer. See minimum fill (or "add") mark or above the maxi-
Fig. 15.2. mum fill (or "full") mark could result in engine
damage.

15.2
Pre- and Post-Trip Inspections and Maintenance

IMPORTANT: On engines that comply with

1 2
EPA07 or newer regulations, use CJ-4 engine
oil with less than 1% sulfated ash. Failure to
use CJ-4 oil may void the warranty on emission
aftertreatment components. 01/13/99 f011525
1. Maximum Fill Level 2. Minimum Fill Level
7. Check the engine oil level.
Fig. 15.4, Oil Dipstick (Mercedes-Benz engine)
NOTICE
Operating the engine with the oil level below the
minimum fill (or "add") mark or above the maxi-
mum fill (or "full") mark could result in engine
damage.
7.1 Park the vehicle on a level surface. Allow
several minutes for the oil to drain back 08/05/2010 f012186
into the oil pan to ensure an accurate Oil should be within the cross-hatched area of the
reading. dipstick.

NOTE: For diesel engines, follow the engine Fig. 15.5, Oil Dipstick (LPG engine)
manufacturer’s guidelines for engine shut-
down time requirements prior to checking NOTICE
the oil level.
Failure to use the recommended oil can result in
7.2 Pull out the dipstick and clean it with a engine or aftertreatment component damage and
paper towel or cloth, then push the dip- will void the warranty.
stick back in all the way. Remove it again,
keeping the tip down, and check the oil 8. Inspect the fuel tanks, fuel lines, and connections
level. for leaks.
7.3 If the oil is below the cross-hatched area, 8.1 Check that the fuel tanks are secured to
or the add mark, at the tip of the dipstick, their mounting brackets and that the
add at least one quart (liter) of the recom- mounting brackets are secured to the
mended oil. See Fig. 15.3 and Fig. 15.4 frame.
for diesel engines, and Fig. 15.5 for pro-
8.2 Replace leaking fuel tanks.
pane engines.
For diesel engines that comply with 8.3 If lines or connections are leaking, have
EPA07 or newer regulations, use CJ-4 them repaired or replaced.
engine oil with less than 1% sulfated ash. For repair and/or replacement procedures,
For liquid propane gas (LPG) engines, use see Group 47 of the S2 Chassis Work-
SAE 5W–30 oil that meets GM standard shop Manual, or take the vehicle to an
GM6094M and has the American Petro- authorized Freightliner dealer.
leum Institute (API) symbol. Do not use 8.4 If equipped with fuel tank shutoff valves,
SAE 10W–40 or 20W–50. be sure the valves are fully open.

WARNING
FULL ADD 2 QT
Never operate the engine with the fuel tank shut-
10/26/2012 f012203
off valves partly closed. This could damage the
fuel pump, causing sudden loss of engine power,
Fig. 15.3, Oil Dipstick (Cummins engine) possibly resulting in serious personal injury due
to reduced vehicle control.
9. Check the fuel level in the fuel tank(s).

15.3
 Pre- and Post-Trip Inspections and Maintenance

To keep condensation to a minimum, fuel tanks

should be filled at the end of each day. Federal
regulations prohibit filling a fuel tank to more
than 95 percent of its liquid capacity. Select the
proper grade of fuel as specified by the engine
manufacturer.

WARNING
Do not mix gasoline or alcohol with diesel fuel.
This mixture could cause an explosion, possibly
resulting in serious personal injury or death. Do
not fill the fuel tanks in the presence of sparks,
open flames, or intense heat. These could ignite
the fuel, possibly causing severe burns.
IMPORTANT: Use ultralow-sulfur diesel
(ULSD) fuel with 15 ppm sulfur content or 11/30/95 f470167
less, based on ASTM D2622 test procedure.
Failure to use ultralow-sulfur diesel fuels Fig. 15.6, Alliance Fuel/Water Separator
may void the warranty on emission compo-
nents. 11. Inspect the front and rear suspension compo-
nents, including springs, spring hangers, shocks,
9.1 Fuel should always be strained or filtered and suspension brackets.
before being put into the tanks. This will
11.1 Check for broken spring leaves, loose
lengthen the life of the engine fuel filter
and reduce the chances of dirt getting into U-bolts, cracks in the suspension
the engine. brackets, and loose fasteners in the spring
hangers and shackles.
9.2 Before installing the fuel cap, clean the
11.2 Inspect the shock absorbers for loose fas-
area with a rag, or if necessary, clean the
cap with solvent. teners and leaks.

9.3 If needed, prime the fuel system. For 11.3 Tighten all loose fasteners and have any
priming procedures, see the applicable components replaced that are worn,
engine manufacturer’s manual. cracked, or otherwise damaged.

10. If equipped with a fuel/water separator, check for 11.4 On vehicles with air suspensions, check
water. for leaks. Check air suspension compo-
nents for cuts and bulges.
Drain any water found. Check the fuel/water
separator for leaks and contaminants. 12. Clean the headlights, mirrors, windshield, side,
and rear windows with a long-handled or tele-
For an Alliance Model, see Fig. 15.6. Place a scoping window cleaning device and standard
suitable container under the fuel/water separator. cleaning solutions. Stand only on the ground, on
Check the water level in the sight bowl, if so a stepladder, or an elevated walkway. The ve-
equipped. To drain the water, loosen the valve at hicle entry/exit steps and handholds are not de-
the bottom and allow the water to run out. Close signed for this purpose. The tires, fenders, en-
and tighten the valve finger-tight. gine, and other under-hood components do not
IMPORTANT: When draining fluid from a fuel/ have adequate gripping surfaces and handholds.
water separator, drain the fluid into an appropri- Check the condition of the windshield wiper arms
ate container and dispose of it properly. Many and blades.
states now issue fines for draining fuel/water Be sure the windshield wiper blades are ten-
separators onto the ground. On all types of sioned against the windshield.
separators, stop draining fluid when you see
fuel come out of the separator drain valve.

15.4
Pre- and Post-Trip Inspections and Maintenance

Inspect the wiper blades for damage and deterio- the parking brake is released or the ignition
rated rubber. switch is turned off. See Chapter 3 for detailed
operating instructions for the ICU.
Replace the wiper arms if the wiper blades are
not tensioned against the windshield. 15. Make sure that the horn, windshield wipers, and
Replace damaged or deteriorated wiper blades. windshield washers are operating properly.
These devices must be in good working order for
safe vehicle operation.
WARNING
15.1 Make sure that the horn works. If a horn is
When cleaning windshields and windows, always not working, have it repaired before trip
stand on the ground or on a secure ladder or departure.
platform. Use a long-handled window cleaner. Do 15.2 Check the wiper and washer control on
not use the cab steps, tires, fenders, fuel tanks, the multifunction turn signal switch. If the
engine, or under-hood components to access the wipers and/or washers are not working,
windshield or windows. Doing so could cause a have them repaired before trip departure.
fall and result in an injury.
16. During cold weather, make sure the heater, de-
Replace wiper arms and blades when necessary froster, and optional mirror heat controls are op-
to maintain good visibility. Poor visibility could erating properly. If so equipped, turn on the mir-
interfere with the driver’s ability to control the ror heat switch and make sure the system is
vehicle, possibly resulting in serious personal working.
injury or death.
17. Check the operation of all the panel lights and
13. Check the oil- and air-pressure warning systems.
interior lights.
When the engine is started, oil- and air-pressure Turn on the headlights, dash lights, and four-way
warnings will come on until the oil and air pres- flashers and leave them on. If any of the gauge
sure rise above a preset minimum. After starting bulbs, the dome light bulbs, or the right- and left-
the engine, make sure the oil- and air-pressure turn indicator bulbs are not working, replace
warning systems are operating and that the them. See Chapter 19 of this manual for re-
buzzer stops sounding when the preset minimum placement bulb identification.
is reached.
18. Make sure all the exterior lights are working
13.1 If the warning systems do not come on properly.
when the ignition is turned on, have the
systems repaired. Check that all the lights and reflectors are clean.
See Fig. 15.7.
13.2 If the air pressure in both systems is
above the preset minimum when the en- 18.1 Check that the brake lights, taillights,
gine is started, test the low air pressure headlights, parking lights, turn signals,
warning system by lowering the pressure road lights (if so equipped), and front
to below this range, or until the warning clearance lights are working properly and
system comes on. are clean.
NOTE: The air pressure in both the primary 18.2 Test the high and low beams of the head-
and secondary air reservoir systems must lights.
be above 65 psi (448 kPa) on most vehicles. 18.3 Replace light bulbs or sealed beam units
For vehicles with an optional Bendix dryer that are not working.
reservoir module (DRM), the cut-out pres-
18.4 Be sure all reflectors and lenses are in
sure is 130 psi (896 kPa). good condition and are clean. Replace
14. Check the instrumentation control unit (ICU) for any broken reflectors or lenses.
fault codes. 19. Check tire inflation pressures using an accurate
During the ignition sequence, if an active fault is tire pressure gauge.
detected in any device that is connected to the
datalink, the message display screen will show
the active fault codes, one after the other, until

15.5
 Pre- and Post-Trip Inspections and Maintenance

IMPORTANT: The load and cold inflation pres-

4 sure must not exceed the wheel manufacturer’s
recommendations, even though the tire may be
approved for a higher load inflation. Some
wheels are stamped with a maximum load and
maximum cold inflation rating. If they are not
3 stamped, consult the wheel manufacturer for the
correct tire inflation pressure for the vehicle
load. If the load exceeds the maximum wheel
4
capacity, the load must be adjusted or reduced.
IMPORTANT: Low-rolling resistance (LRR) tires
minimize wasted energy as a tire rolls, thereby
decreasing rolling effort and improving fuel effi-
ciency. If tire replacement is necessary, replace-
ment tires must meet or exceed the rolling resis-
2 1 tance of the originally installed tires in order to
maintain compliance with greenhouse gas and
fuel efficiency regulations.
08/15/2006 f544882
1. Headlight High Beam 3. Side-View Mirror Contact your tire manufacturer/supplier to deter-
2. Headlight Low Beam 4. Marker Light mine the rolling resistance of the originally in-
stalled tires. Visit [Link]/smartway for
Fig. 15.7, Exterior Lights
additional information and resources.
Tires should be checked when cool. For inflation 20. Inspect each tire for wear, bulges, cracks, cuts,
pressures and maximum loads (per tire) see the penetrations, and oil contamination. A weekly
tire manufacturer’s guidelines. pressure loss of 4 psi (28 kPa) or more in a tire
19.1 Be sure valve stem caps are on every tire may indicate damage. The tire should be in-
and that they are screwed on finger-tight. spected and if necessary, repaired or replaced.
19.2 Inflate the tires to the applicable pressures 20.1 Check the tire tread depth. If tread is less
if needed. than 4/32 inch (3 mm) on any front tire, or
less than 2/32 inch (1.5 mm) on any rear
19.3 If a tire has been run flat or underinflated, tire, replace the tire.
check for possible wheel or tire damage
before adding air. 20.2 Inspect each tire for bulges, cracks, cuts,
and penetrations.
Moisture inside a tire can result in body
ply separation or a sidewall rupture. Dur- 20.3 Inspect each tire for oil contamination.
ing tire inflation, compressed air reservoirs Fuel oil, gasoline, and other petroleum
and lines must be kept dry. Use well- derivatives, if allowed to contact the tires,
maintained inline moisture traps and ser- will soften the rubber and destroy the tire.
vice them regularly. 21. Check the wheel nuts for indications of loose-
ness. Examine each wheel component.
WARNING 21.1 Remove all dirt and foreign material from
Do not operate the vehicle with underinflated or the assembly. Dirt or rust streaks from the
overinflated tires. Incorrect inflation can stress stud holes, metal buildup around stud
the tires and make the tires and wheels suscep- holes, or out-of-round or worn stud holes
tible to damage, possibly leading to wheel or tire may be caused by loose wheel nuts. See
failure and loss of vehicle control, resulting in Fig. 15.8 and Fig. 15.9.
serious personal injury or death. 21.2 Examine the wheel components (including
studs, and nuts) for cracks, or other dam-
age.

15.6
Pre- and Post-Trip Inspections and Maintenance

21.3 Make sure all wheel nuts are tightened

450 to 500 lbf·ft (610 to 678 N·m) for Ac-
curide wheels with unlubricated threads.
Use the tightening pattern in Fig. 15.10 for
10-hole wheels and the tightening pattern
in Fig. 15.11 for 8-hole wheels. See
Group 40 of the S2 Chassis 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
02/09/95 f400058 wheel nut torque can break studs, damage
threads, and crack discs in the stud hole area.
Fig. 15.8, Dirt and Rust Streaks from the Stud Holes

02/09/95 f400001

Fig. 15.9, Worn Stud Holes

See Group 33 or Group 35 of the S2

Chassis Workshop Manual for service pro- 1
cedures on the studs and hubs, and see 10 8
Group 40 in the same manual for wheel
and tire servicing, or take the vehicle to an
authorized Freightliner dealer. 3 6

WARNING
5 4
Have any worn or damaged wheel components
replaced by a qualified person using the wheel
manufacturer’s instructions and the wheel indus- 7 9
try’s standard safety precautions and equipment. 2
Otherwise a vehicle or workshop accident could 08/23/93 f400081a
occur, possibly resulting in serious personal in-
jury or death. Fig. 15.10, Tightening Pattern, 10-Hole Wheels

Use the recommended torque values and follow

the proper tightening sequence.

15.7
 Pre- and Post-Trip Inspections and Maintenance

death may result from sudden release of the

1 2 power spring.
Before doing any repairs or adjustments on a
service/parking brake chamber, read the appli-
7 4 cable warnings and instructions in Group 42 of
the S2 Chassis Workshop Manual.

WARNING
5 6 Do not operate the vehicle with the front brakes
backed off or disconnected. Backing off or dis-
connecting the front brakes will not improve ve-
hicle handling and may lead to loss of vehicle
3 8
03/08/2012 f400052a control resulting in property damage or personal
injury.
Fig. 15.11, Tightening Pattern, 8-Hole Wheels

NOTE: Vehicles operating under severe or ad-

NOTICE
verse conditions should be checked more fre- If the external breather tube or breather cap is
quently. missing or incorrectly installed, road dirt and de-
22. Inspect the air brake chamber and the air brake bris can adversely affect the operation of the
chamber pushrods. See Fig. 15.12. brake chamber. Once inside of the chamber, dirt
and debris can cause the internal parts of the
chamber to deteriorate faster.
1
22.1 Check that the air brake chamber is
mounted securely on its mounting bracket,
A and that there are no loose or missing
bolts.
22.2 Look for worn clevis pins on brake cham-
ber pushrods, and missing or damaged
cotter pins on brake chamber pushrod
clevis pins. Replace worn clevis pins and
install new cotter pins if necessary.
22.3 See if the chamber piston rod is in line
with the slack adjuster. Misalignment can
cause the piston rod to rub on the non-
pressure chamber and cause a dragging
brake. See Group 42 of the S2 Chassis
Workshop Manual.
02/22/2017 f421352
22.4 Inspect the exterior surfaces of the cham-
A. Do not remove this clamp ring. ber for damage. Make sure that breather
1. MGM TR–T (TR Series) Brake Chamber Shown holes in the non-pressure section(s) are
Fig. 15.12, Parking Brake Chamber Clamp open and free of debris. See Group 42 of
the S2 Chassis Workshop Manual to re-
place any damaged parts.
DANGER 22.5 On all parking brake installations, make
Do not loosen or remove the parking brake clamp sure the end cover cap or dust plug is se-
ring for any purpose. See Fig. 15.11. The parking/ curely snapped into place.
emergency brake section of the brake chamber is NOTE: On most MGM parking brake cham-
not intended to be serviced. Serious injury or bers equipped with an integral release bolt,

15.8
Pre- and Post-Trip Inspections and Maintenance

an end cover cap is installed over the re- Both wheel air lines must be inspected
lease bolt. with the emergency brake set, engine
idling, air pressure at 80 to 90 psi (550 to
22.6 Check for rusted connections, missing 620 kPa), and the brake pedal held down.
snap rings, and damaged camshaft
grease seals. Have damaged or missing 23.8 Turn the wheels to full lock in one direc-
parts repaired or replaced. tion and inspect both air lines where they
connect to the air chambers, then turn the
23. Inspect the air brake lines. wheels to full lock in the other direction
23.1 Check the clearance between the hoses and inspect both lines. If a hose is leak-
and the exhaust manifold or other hot ing, have it replaced.
spots. Excessive heat will cause material IMPORTANT: ABS-equipped vehicles operat-
in the hoses to deteriorate rapidly or be- ing in regions where especially corrosive ice
come brittle. Provide at least 6 inches
removal chemicals are used may experience
(150 mm) of clearance. More clearance is
recommended if the hose is located above higher than normal rotor corrosion. Tone
the heat source. rings should be routinely inspected for corro-
sion. Severe corrosion of the integral ABS
23.2 Check for kinks, dents, or swelling of the tone ring may cause the ABS warning lamp
hoses. If damaged, have the hose re- in the dash to illuminate due to false wheel
placed with the same size and type.
speed readings. If the ABS warning lamp
NOTE: Do not route the hose on top of any- illuminates at any time other than at vehicle
thing likely to be stepped on. start-up, have the problem repaired immedi-
23.3
ately.
Check for damage to hoses located near
moving parts, such as drivelines, kingpins, 24. Inspect the slack adjusters.
suspensions, and axles. If moving parts
are catching or pinching the lines, correct 24.1 Meritor Slack Adjusters: Check the boot
as needed. for cuts, tears, or other damage. Have it
replaced if necessary.
23.4 Check for hose damage caused by abra-
sion. If abraded, have the hose replaced. 24.2 Gunite Slack Adjusters: Inspect the slack
Check for the cause of abrasion, such as adjuster for any signs of damage. If dam-
loose or damaged hose clamps. Have the aged, have the slack adjuster replaced.
clamps repaired or replaced as needed. Inspect the slack adjuster boot for cuts or
23.5 Observe the hose cover condition, espe- tears. If the boot is damaged, have it re-
cially hoses exposed to water splash and placed. See Fig. 15.13.
ice. If dried out or ragged (the wire or liner 24.3 Haldex Slack Adjusters: Inspect each
is showing through the cover), have the slack adjuster and anchor strap for dam-
hose(s) replaced. age. Have any damaged components re-
23.6 Inspect the air tubing, especially tubing placed.
made of nylon. In cold weather, nylon tub- 25. Check the air brake system for proper operation.
ing is sensitive to damage, such as nicks
or cuts. Have nicked or cut tubing re- 25.1 Check the air governor cut-in and cut-out
placed, even if it is not leaking. pressures as follows:
Run the engine at fast idle. The air gover-
NOTE: The front brake lines flex continu-
nor should cut out the air compressor at
ously in vehicle operation, so they require approximately 120 psi (827 kPa). With the
special examination. Give particular attention engine idling, apply the brake pedal sev-
to the areas near where they connect to the eral times. The air governor should cut in
front air brake chambers. the air compressor at approximately 100
23.7 This inspection requires two people, one psi (689 kPa). If the air governor does not
in the driver seat, and another to inspect cut in and out as described above, it must
the brake line connections at the wheels. be adjusted to these specifications. If the

15.9
 Pre- and Post-Trip Inspections and Maintenance

drop. If it drops more than 25 psi (172

kPa), all areas of leakage must be elimi-
4 nated before operating the vehicle.
5
6 25.4 Check the air leakage in the system as
7
follows:
3 8 With the parking brake (spring brake) ap-
plied, the transmission out of gear, and
2
the tires chocked, charge the air system
9 until cut-out pressure of 120 psi (827 kPa)
is reached.
1
With the service brakes released, shut
10 down the engine, wait 1 minute and note
the air pressure gauge reading. Observe
the air pressure drop in psi (kPa) per min-
ute.
02/03/2017 f421398
Charge the air system until cut-out pres-
1. 7/16-inch Adjusting Nut
sure of 120 psi (827 kPa) is reached. With
2. Grease Fitting
3. Boot the parking brakes released and the ser-
4. Link vice brake applied, shut down the engine,
5. Brake Chamber Piston Rod wait 1 minute and note the air pressure
6. Clevis gauge reading. Observe the air pressure
7. ½-inch Clevis Pin drop in psi (kPa) per minute.
8. 1/4-inch Clevis Pin
9. Grease Relief Opening If leakage exceeds the limits shown in
10. Slack Adjuster Spline Table 15.1, repair all areas of leakage be-
fore driving the vehicle.
Fig. 15.13, Gunite Automatic Slack Adjuster
Maximum Allowable Service Brake Leakage
air governor cannot be adjusted or re-
Maximum Air Leakage Per Minute
paired, replace it before operating the ve-
hicle. Brakes Released Brakes Applied
2 psi (14 kPa) 3 psi (21 kPa)
25.2 Check the air pressure buildup time as
follows: Table 15.1, Maximum Allowable Service Brake
Leakage
With the air system fully charged to 120
psi (827 kPa), make one full brake appli- 26. Check the operation of the Bendix® Hydro-Max
cation and note the air pressure reading brake booster, as follows.
on the gauge. Continue to reduce the air
pressure by moderate brake applications 26.1 With the ignition off, depress the brake
to a maximum of 90 psi (620 kPa), then pedal and listen for the back-up motor to
run the engine at governed rpm. If the engage. The operator should also feel the
time required to raise the air pressure to pedal force relieve and the pedal should
120 psi (827 kPa) (from the pressure depress easily.
noted after one brake application) is more
26.2 With the engine running, and the parking
than 30 seconds, eliminate any leaks or
brake released, ensure that the BRAKE
replace the air compressor before operat-
warning indicator light is not on. This is a
ing the vehicle.
dual indicator, and indicates that the park-
25.3 Check the air pressure reserve as follows: ing brake is set, and warns if there is a
With the air system fully charged to 120 Hydro-Max failure condition other than
psi (827 kPa), stop the engine and note loss of back-up motor power.
the air pressure. Then make one full brake 27. Test the service brakes.
application and observe the pressure

15.10
Pre- and Post-Trip Inspections and Maintenance

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.
1
Weekly Post-Trip Inspection
and Maintenance Procedures 1
1. Inspect the batteries and battery cables.

WARNING 2 1

Battery posts, terminals, and related accessories 3

contain lead and lead compounds, chemicals 3
known to the State of California to cause cancer
and reproductive harm. To prevent possible per-
sonal injury, always wash your hands after han-
dling battery parts and related accessories. 05/16/2017 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. 15.14, Steering Gear Fasteners
1.2 If the battery is equipped with a built-in
hydrometer, examine the hydrometer. If a 3.3 Inspect the steering drive shaft and steer-
green dot shows in the sight glass, the ing linkage for excessive looseness, or
battery is sufficiently charged. other damage.
If the sight glass is dark, the charge is low 3.4 Tighten loose nuts and have damaged
and the battery must be recharged. parts replaced as needed.
If the sight glass is clear, the battery has a 4. Check the condition of the serpentine drive belt.
low level of electrolyte and must be re- Look for signs of glazing, wear (frayed edges),
placed. damage (breaks or cracks), or oil contamination.
2. Check the level of the wheel bearing lubricant in If a belt is glazed, worn, damaged, or oil soaked,
the hub cap at each end of the front axle. have the belt replaced, following the instructions
in Group 01 of the S2 Chassis Workshop
If needed, fill the hubs to the level indicated on Manual.
the hub cap. See Chapter 19, for recommended
lubricants.
IMPORTANT: Before removing the fill plug, al-
ways clean the hub cap and plug.
3. Examine the steering components.
A
See Fig. 15.14. If repairs are needed, see
Group 46 of the S2 Chassis Workshop Manual B
for instructions, or take the vehicle to an autho-
rized Freightliner dealer.
3.1 10/31/94 f200036a
Check the mounting bolts and pitman arm
nut, for tightness. A. Deflection B. Belt Free-Span
3.2 Check the drag link nuts for missing cotter Fig. 15.15, Checking Belt Tension
pins.

15.11
 Pre- and Post-Trip Inspections and Maintenance

5. Check the drive belt for proper tension. Monthly Post-Trip Inspection
Use your index finger to apply force at the center and Maintenance Procedures
of the belt free-span. See Fig. 15.15. There is no
adjustment for belt tension on engines with auto-
matic belt tensioners. If there is not proper ten- WARNING
sion, have the belt tensioner replaced. See
Group 01 of the S2 Chassis Workshop Manual Battery posts, terminals, and related accessories
for instructions, or take the vehicle to an autho- contain lead and lead compounds, chemicals
rized Freightliner dealer. known to the State of California to cause cancer
and reproductive harm. To prevent possible per-
6. Inspect the seat belts and tether belts. sonal injury, always wash your hands after han-
dling battery parts and related accessories.
WARNING 1. Clean the batteries.
Inspect and maintain seat belts as instructed 1.1 Remove any corrosion from the hold-down
below. Worn or damaged seat belts could fail and the top of the battery.
during a sudden stop or crash, possibly resulting
in serious injury or death.
NOTICE
IMPORTANT: Seat belts have a finite life
which may be much shorter than the life of Take care to keep the vent plugs tight so that the
the vehicle. Regular inspections and re- neutralizing solution does not enter any of the
placement as needed are the only assur- battery cells and damage the battery.
ance of adequate seat belt security over the 1.2 Use a soda solution to neutralize the acid
life of the vehicle. present, then rinse off the soda solution
with clean water.
NOTE: When any part of a seat belt needs
replacement, the entire seat belt must be 1.3 If the battery posts or cable terminals are
replaced, both retractor and buckle side. corroded, disconnect the terminals from
the posts. Clean them with a soda solution
6.1 Check the web for fraying, cuts, or ex- and a wire brush. After cleaning, connect
treme wear, especially near the buckle the terminals to the battery posts, then
latch plate and in the D-loop guide area. apply a thin coat of petroleum jelly to the
6.2 Check the web for extreme dirt or dust posts and terminals to help retard corro-
and for severe fading from exposure to sion.
sunlight. 2. Inspect the radiator and heater hoses, including
6.3 Check the buckle and latch for operation the clamps and support brackets.
and for wear or damage. 2.1 Make sure the radiator inlet and outlet
6.4 Check the Komfort Latch for function and hoses are pliable and are not cracking or
cracks or other damage. ballooning. Replace hoses that show signs
of cracking, weakening, or ballooning.
6.5 Check the web retractor for function and
2.2 Make sure the heater hoses are pliable
damage.
and are not cracking or ballooning. Re-
6.6 Check the mounting bolts for tightness place hoses that show signs of cracking,
and tighten any that are loose. weakening, or ballooning.
2.3 Tighten hose clamps as necessary, but do
not overtighten, as hose life can be ad-
versely affected.
2.4 Be sure the hose support brackets are
securely fastened. Make sure the hoses
are not located near sources of wear,
abrasion, or high heat.

15.12
Pre- and Post-Trip Inspections and Maintenance

IMPORTANT: Replace all hoses, including

heater hoses, at the same time. Service-type
knitted or braided yarn-reinforced neoprene
hose is acceptable. Silicone hoses having an
extended service life can be substituted for the
reinforced neoprene type. See the Freightliner
A
Service Parts Catalog or contact your Freight-
liner dealer.
3. Check the fluid level in the hydraulic brake fluid
reservoir, if so equipped.
If needed, fill the reservoir to the bottom of the
fill-neck with DOT 3 heavy-duty brake fluid. See
Fig. 15.16.

B 10/10/95 f461057

A. Lash Area
Fig. 15.17, Measuring Lash at the Steering Wheel

4.3 Measure the lash (free play) at the rim of

the steering wheel. Excessive lash exists
A if steering wheel movement exceeds 2-1/4
inches (57 mm) with an 18-inch (450-mm)
steering wheel.
See local/federal regulations for accept-
able ranges of lash.
5. 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.
5.1 Check that brake linings are free of oil and
grease.
5.2 Inspect the thickness of the brake linings.
If the axle assembly is equipped with a
07/31/2015 f460513b
dust shield or backing plate, remove the
inspection plugs. If any brake linings are
A. Open caps and check fluid level. worn to less than approximately 1/4 inch
B. Fill to this level.
(6.4 mm) at the thinnest point, have the
Fig. 15.16, Hydraulic Brake Reservoir linings replaced on all brake assemblies
on that axle. See Group 42 of the S2
4. Check the steering wheel for excessive play. See Chassis Workshop Manual for lining re-
Fig. 15.17. placement instructions and camshaft end-
play inspection.
4.1 With the front tires straight ahead, turn the
steering wheel until motion is observed at 5.3 Check the brake drums for wear and
the front wheels. cracks.
4.2 Align a reference mark on a ruler, then 5.4 Check that the inspection plugs in the dust
slowly turn the steering wheel in the oppo- shields or backing plates, if so equipped,
site direction until motion is again detected are installed.
at the wheels.

15.13
 16
Cleaning and Care
Washing and Polishing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16.1
Care of Fiberglass Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16.1
Care of Chrome Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16.1
Care of Exterior Lights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16.1
Dashboard and Instrument Panel Care . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16.1
Vinyl Upholstery Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16.2
Velour Upholstery Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16.3
Cleaning and Care

Washing and Polishing Care of Fiberglass Parts

Wash unpainted fiberglass air fairings and shields
NOTICE 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 new vehicle’s finish, 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 the 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 the 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 the other material. Do not use steel wool.
vehicle. To help protect the chrome after cleaning, apply a
To extend the life of the 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 the vehicle in the hot sun. Al-
ways use water. After the vehicle 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.
NOTICE
• 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 the use of a high quality lens.
brand of cleaner or cleaner-polish and polish-
ing wax. Dashboard and Instrument
• Do not let diesel fuel or antifreeze stand on a Panel Care
painted surface. If either should occur, rinse
the surface off with water.
• To prevent corrosion, have any nicks or other
NOTICE
damage on the finish touched up as soon as When cleaning the dashboard, instrument panel,
possible. or gauge lens covers, do not use Armor-All Pro-
• Park the vehicle in a sheltered area whenever tectant®, STP Son-of-a-Gun®, window cleaner, or
possible. other equivalent treatments. These cleaners con-
tain vinyl plasticizers which can cause stress
crazing in the interior plastic panels and can re-
sult in cracking of the panels. Some cleaners can

16.1
 Cleaning and Care

also have an adverse effect on the clear plastic Paint and Shoe Heel Marks
of instrument panels and gauge lens covers, re-
sulting in a foggy or cloudy appearance. This Paint should be removed immediately. Do not use
type of damage is not covered by vehicle war- paint remover or liquid-type brush cleaner on vinyl.
ranty. An unprinted cloth, dampened with naphtha or tur-
pentine may be used. Use care to prevent contact
To clean the dashboard, instrument panel, and gauge with parts of the upholstery that are not vinyl.
lens covers, use a cloth dampened with warm soapy
water. Make certain to wring the cloth out well before Sulfide Stains
cleaning, as excess water will damage the electrical
components. Sulfide compounds, such as those found in eggs and
some canned goods, can stain after prolonged con-
Vinyl Upholstery Cleaning tact with vinyl. These stains can be removed by plac-
ing a clean, unprinted piece of cloth over the spotted
To prevent soiling, frequent vacuuming or light brush- area and pouring a liberal amount of 6 percent hy-
ing to remove dust and dirt is recommended. Harsh drogen peroxide onto the cloth. Allow the saturated
cleaning agents can cause permanent damage to cloth to remain on the spot for 30 to 60 minutes. For
vinyl upholstery. To preserve the upholstery and pre- stubborn spots, allow the hydrogen-peroxide satu-
vent damage, carefully review the following sections rated cloth to remain on the area overnight. Use cau-
for recommended cleaning procedures. Waxing or tion to prevent the solution from seeping into the
refinishing improves soil resistance and cleanability seams or it will weaken the cotton thread.
for all vinyls. Any hard wax, such as that used on
automobiles, may be used. Nail Polish and Nail Polish Remover
Ordinary Dirt Prolonged contact with these substances causes per-
manent damage to vinyl. Careful blotting immediately
Wash the upholstery with warm water and mild soap, after contact minimizes damage. Do not spread the
such as saddle or oil soap. Apply soapy water to a liquid during removal.
large area and allow to soak for a few minutes, then
rub briskly with a cloth to remove the dirt. This can Shoe Polish
be repeated several times as necessary.
Most shoe polishes contain dyes which penetrate
If dirt is deeply imbedded, use a soft bristle brush vinyl and stain it permanently. Shoe polish should be
after applying the soap. wiped off as quickly as possible using naphtha or
If dirt is extremely difficult to remove, wall-washing lighter fluid. If staining occurs, try the procedure used
preparations normally found around the home can be for sulfide stains.
used. Powdered cleaners, such as those used for
sinks and tiles, are abrasive and must be used with Ball Point Ink
caution as they can scratch the vinyl or give it a per-
Ball point ink can sometimes be removed if rubbed
manent dull appearance.
immediately with a cloth damp with water or rubbing
alcohol. If this does not work, try the procedure used
Chewing Gum for sulfide stains.
Harden the gum with an ice cube wrapped in a plas-
tic bag, then scrape it off with a dull knife. Any re- Miscellaneous
maining traces of gum can be removed with an all-
If stains do not respond to any of the treatments de-
purpose light oil (peanut butter will also work) and
scribed above, it is sometimes helpful to expose the
wiped off.
vinyl to direct sunlight for up to 30 hours. Mustard,
ball point ink, certain shoe polishes, and dyes often
Tars, Asphalts, and Creosote bleach out in direct sunlight, leaving the vinyl undam-
Tars, asphalts, and creosote stain vinyl after pro- aged.
longed contact. They should be wiped off immedi-
ately and the area carefully cleaned, using a cloth
dampened with naphtha.

16.2
Cleaning and Care

Velour Upholstery Cleaning

To prevent soiling, frequent vacuuming or light brush-
ing to remove dust and dirt is recommended. Spot
clean with a mild solvent or an upholstery shampoo,
or the foam from a mild detergent. When using a sol-
vent or a dry-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.

16.3
 17
In an Emergency
Hazard Warning Lights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17.1
Emergency Starting With Jumper Cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17.1
Raising and Lowering a Vehicle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17.3
Towing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17.3
Running Out of Fuel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17.4
Changing a Flat Tire . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17.5
Fire Extinguisher . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17.6
First Aid Kit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17.6
Flare Kit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17.6
In an Emergency

Hazard Warning Lights NOTICE

The hazard warning light switch is part of the multi-
function turn signal switch. It is a red rocker switch Make sure that both starting systems are the
located on the top of the multifunction switch module. same voltage. Electronic devices on both ve-
See Fig. 17.1. hicles can be damaged when connected to a ve-
hicle with a different operating voltage.
1. Apply the parking brakes and turn off all lights
4 and other electrical devices.
IMPORTANT: Do not attempt to jump start a
5 damaged battery.
2. Open the battery door to access the batteries.
1 Pull both pull-pin spring latches and slide the
2 battery tray out. See Fig. 17.2.

3 4

11/16/2001 f820386
Press down on the upper part of the rocker to activate
the hazard warning lights.
1. Washer Button
2. Wiper Control Dial
3. Turn Signal Lever
4. Hazard Warning Light Switch (red) 2 3 2
5. Multifunction Switch Module

Fig. 17.1, Multifunction Turn Signal Switch

1
To activate the hazard warning lights, press down on
the upper part of the rocker switch (towards the 12/05/2003 f544365
dash). To cancel the hazard warning lights, press
1. Battery Access Door 3. Battery Tray
down on the lower part of the rocker switch (towards
2. Pull-Pin Spring Latch 4. Battery
the steering wheel).
Fig. 17.2, Battery Access
Emergency Starting With
Jumper Cables NOTICE
When using jumper cables, follow the instructions Always connect the batteries and jumper cables
below. correctly (positive-to-positive and negative-to-
negative). Connecting a charging device back-
WARNING wards (positive-to-negative) can severely damage
the vehicle electrical content and cause non-
Batteries release explosive gas. Do not smoke warrantable failures.
when working around batteries. Put out all flames 3. Connect the positive (+) jumper cable to the
and remove all sources of sparks or intense heat positive terminal on the discharged battery. See
in the vicinity of the battery. Do not allow the ve- Fig. 17.3.
hicles to touch each other. Do not lean over the
batteries when making connections, and keep all 4. Connect the other end of the positive jumper
other persons away from the batteries. Failure to cable to the positive terminal on the booster bat-
follow these precautions could lead to severe tery providing the charge.
personal injury as a result of an explosion or
acid burns.

17.1
 In an Emergency

4
D

B
3 E
2

+
+ − −

+ +
− −
C
+ −
+
1 −

01/07/2011 f545725
Disconnect jumper cables in the REVERSE order that they were connected.
A. Discharged Battery C. Positive Jumper Cable E. Booster Battery
B. Negative Ground Stud D. Negative Jumper Cable
1. 1st Connection: Positive Jumper Cable to Discharged Battery
2. 2nd Connection: Positive Jumper Cable to Booster Battery
3. 3rd Connection: Negative Jumper Cable to Booster Battery
4. 4th Connection: Negative Jumper Cable to Negative Ground Stud (discharged battery)
Fig. 17.3, Jumper Connections (three battery system shown for clarity)

6. Connect the other end of the negative jumper

WARNING cable to the negative ground stud on the vehicle
requiring the jump start.
Do the next step exactly as instructed and do not
allow the clamps of one cable to touch the 7. Start the engine of the vehicle providing the jump
clamps of the other cable. Otherwise, a spark start and let the engine run for a few minutes to
could occur near a battery, possibly resulting in charge the batteries of the other vehicle.
severe personal injury from explosion or acid
burns.
5. Connect the negative (-) jumper cable to the
negative terminal on the booster battery.

17.2
In an Emergency

IMPORTANT: Only lift unloaded vehicles and

NOTICE vehicles disconnected from trailers. Unload ve-
hicles with bodies (drilling rigs, mixers) as much
Do not crank the engine for more than 30 sec-
onds at a time during any of the following proce- as possible.
dures. Wait two minutes after each try to allow 2. Place a floor jack under the axle housing, the
the starter to cool. Failure to do so could cause clamp group, or the frame rail.
starter damage.
8. Attempt to start the engine of the vehicle with the NOTICE
batteries receiving the charge.
NOTICE: Do not place jack stands under any of
9. When the engine starts, let it idle for a few min- the suspension components; doing so could
utes. cause suspension component damage. Jack
stands can be placed at any point below the axle,
WARNING including the differential area.

Do the next step exactly as instructed and do not 3. Raise the vehicle. Add additional jack stands, as
allow the clamps of one cable to touch the needed, to support the vehicle.
clamps of the other cable. Otherwise, a spark
could occur near a battery, possibly resulting in Lowering a Vehicle without Air
severe personal injury from explosion or acid Suspension
burns.
10. Disconnect the negative jumper cable from the WARNING
negative cable stud on the jump started vehicle.
Do not use bottle jacks to raise the vehicle. Al-
11. Disconnect the negative jumper cable from the ways use floor jacks. Bottle jacks can slip, allow-
booster battery. ing the vehicle to fall, which could result in dam-
12. Disconnect the positive cable from the booster age to the vehicle, serious injury, or death.
battery.
13. Disconnect the other end of the positive jumper NOTICE
cable from the jump started vehicle.
NOTICE: Do not place jack stands under any of
14. Pull both pull-pin spring latches and slide the the suspension components; doing so could
battery tray back into position. Release the pull- cause suspension component damage. Jack
pin spring latches to lock the battery tray, then stands can be placed at any point below the axle,
close the battery door. including the differential area.
1. Using the floor jack, raise the vehicle to remove
Raising and Lowering a any jack stands used to support the vehicle.
Vehicle 2. Slowly lower the vehicle to the ground.
Raising a Vehicle without Air
Suspension Towing
1. Park the vehicle on a level surface, set the park- WARNING
ing brakes, and shut down the engine. Chock the
tires. Do not tow an unbraked vehicle if the combined
weight of both vehicles is more than the sum of
WARNING the gross axle weight ratings (GAWR) of the tow-
ing vehicle. Otherwise brake capacity will be in-
Do not use bottle jacks to raise the vehicle. Al- adequate, which could result in personal injury or
ways use floor jacks. Bottle jacks can slip, allow- death.
ing the vehicle to fall, which could result in dam-
age to the vehicle, serious injury, or death.

17.3
 In an Emergency

IMPORTANT: When it is necessary to tow the 6. Connect the clearance lights, taillights, and sig-
vehicle, make sure the instructions below are nal lights. Connect any special towing lights re-
closely followed to prevent damage to the ve- quired by local regulations.
hicle.
NOTE: Towing rules and regulations vary from
WARNING
federal, state, local, and transit authority. These Failure to chock the tires or connect the tow
laws must be followed when towing the vehicle. truck’s air brake system before releasing the
spring parking brakes could allow the disabled
Front Towing Hookup vehicle to suddenly roll. This could cause prop-
erty damage or personal injury.
NOTICE
NOTICE
The vehicle should never be towed from the rear.
The gross axle weight rating (GAWR) of the front Before attempting to tow a vehicle with an air
axle may not be sufficient to support the in- suspension (and during the towing operation),
creased load when towing from the rear. This ensure that the air suspension is properly
could damage the front axle. charged. Charge the suspension through the
Schrader valve on the air dryer. Attempting to
1. Disconnect the battery ground cables. tow a vehicle with an improperly charged air sus-
pension may result in damage to the chassis and
NOTICE body.

Failure to remove the axle shafts when towing 7. Chock the tires on the disabled vehicle and con-
the vehicle with the rear wheels on the ground nect the towing vehicle’s air brake system to the
could result in damage to the transmission and vehicle being towed. Then, release the spring
other parts. parking brake and remove the chocks.

2. Remove the drive axle shaft. 8. On vehicles equipped with hydraulic disc brakes
be sure the parking brake is released before
IMPORTANT: Cover the ends of the hubs with starting the towing process.
metal plates or plywood cut to fit the axle open-
ing, and drilled to fit the axle shaft studs. This Running Out of Fuel
prevents lubricant from leaking out and will keep
contaminants from getting into and damaging
the wheel bearings and axle lubricant.
WARNING
Do not mix gasoline or alcohol with diesel fuel.
NOTICE This mixture could cause an explosion. When fill-
ing fuel tanks, do not smoke or use an open
Failure to protect the frame rails from the chains flame near the fuel tanks. Combustion of diesel
could cause damage, leading to eventual frame fuel oil or fuel vapors could result, possibly caus-
failure. ing personal injury or property damage.
3. Remove the bumper. 1. If possible, stop the vehicle on a level surface,
4. Attach the towing device. Due to the many vari- away from traffic.
ables that exist in towing, positioning the lifting 2. Apply the parking brake.
and towing device is the sole responsibility of the
towing-vehicle operator. IMPORTANT: Any time the vehicle runs out of
fuel, the fuel system should be primed. This will
5. Lift the vehicle and secure the safety chains. If purge any trapped air in the system and allows
extra towing clearance is needed, remove the fuel to fill the fuel filter.
front wheels.
3. See the engine manufacturer’s manual for in-
structions to prime the fuel system.

17.4
In an Emergency

4. If further assistance is needed, call the Freight-

liner Customer Assistance Center at 1-800-385- WARNING
4357 or 1-800-FTL-HELP.
This vehicle is very heavy. Jacking this vehicle
should be done with extreme caution. The vehicle
NOTICE could slip, causing personal injury or death.
Do not crank the engine for more than 30 sec- IMPORTANT: The jacking point for the front
onds at a time during the following procedure. wheels is on the front axle beam and other loca-
Wait two minutes after each try to allow the tions shown in Fig. 17.4. The jacking point for
starter to cool. Failure to do so could cause rear wheels is on the rear axle and at the loca-
starter damage. tions on the rear suspension H-frame, shown in
5. Add fuel to the fuel tank. Fig. 17.4.
6. After adding fuel to the fuel tank, start the en- Only use the front bumper locations if the ve-
gine. Once the vehicle is running, let the engine hicle is equipped with a jackable bumper. When
idle until it operates smoothly before driving the jacking the front bumper, the jacking point(s)
vehicle. must be centered and within the bottom surface
of the bumper support as shown in Fig. 17.4.
Changing a Flat Tire Do not position the jack under the dropped
frame rails in the center section of the vehicle.
DANGER 6. Place the jack on a solid surface. Insert the jack
handle and pump the handle slightly. Do not
When working on the vehicle, shut down the en- raise the wheel off of the ground yet. Loosen the
gine, set the parking brake,and chock the tires. wheel lug nuts, but do not remove them.
before working under the vehicle, always place
jack stands under the frame rails to ensure the IMPORTANT: The dual rear wheels are attached
vehicle can not drop. Failure to follow these using two-element lug nuts. The larger nut re-
steps could result in serious personal injury or tains the outer dual. The inner square stud re-
death. tains the inner dual. Remove and install these
nuts separately. The rear dual outer lug nut
WARNING must be loosened to check and retighten the
inner nut.
Wheel lug nut torque is very high and the
wheel/tire assemblies are very heavy. Changing a 7. Raise the vehicle until the wheel is off of the
tire could result in back injury. If possible, call a ground. Remove the lug nuts and the wheel.
qualified service facility to change a flat tire. 8. Install the spare wheel and lug nuts. Make sure
IMPORTANT: If a flat tire occurs while driving, that the beveled sides of the nuts face inward,
gradually decrease vehicle speed. Holding the or, on hub-piloted wheels, make sure that the
steering wheel firmly, move to a safe place on hub-pilot pad is centered at the top.
the side of the road. IMPORTANT: When a tire is changed, the ve-
1. Stop the vehicle on a level surface, away from
hicle should be taken to a mechanic as soon as
traffic. possible, to have the lug nuts tightened properly
with an impact air gun.
2. Apply the parking brake, place the transmission
in neutral (N), and shut down the engine. 9. In a star pattern, tighten the nuts evenly until
snug. See Group 40 of the S2 Workshop
3. Turn on the hazard warning lights. Manual for wheel tightening patterns and torque
4. Block the wheel diagonally opposite the wheel specifications. Lower the vehicle until the wheel
being changed. touches the ground. Tighten the nuts.
5. Remove the spare wheel, jack, jack handle, and 10. Finish lowering the vehicle to the ground, then
lug wrench from storage. remove the jack.

17.5
 In an Emergency

1 2

12/13/2010 f311093
1. Jack Locations—Front Axle 2. Jack Locations—Rear Axle 3. Jack Locations—Front Bumper
Fig. 17.4, Jack Placement

11. Remove the block, then stow the jack, jack

handle, and lug wrench.
12. After operating the vehicle for 50 to 100 miles
(80 to 161 km), retighten the wheel nuts to the
specified torque values.

Fire Extinguisher
An optional fire extinguisher is located in the front of
the cab, between the driver and passenger seats.

First Aid Kit

An optional first aid kit is mounted to the back of the
cab, between the driver and passenger seats.

Flare Kit
An optional flare kit is located in the center of the
cab, between the driver and passenger seats.

17.6
 18
Headlight Aiming
Preliminary Checks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18.1
Checking Headlight Aim . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18.1
Adjusting Headlight Aim . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18.1
Headlight Aiming

Preliminary Checks 3. Mark the vertical distances found in step 2 on

the screen or wall, directly in front of the head-
Before checking or adjusting the headlight aim, do lights. These marks represent the desired loca-
the following: tions of each headlight bulb center in the follow-
ing steps. See Fig. 18.2, Items 2 and 3.
• Check that the hood is closed and latched.
4. Turn on the low-beam headlights.
• Check the suspension for proper functioning of
the leveling mechanism. On vehicles with air 5. Identify the center of each beam projection by
suspensions, make sure that the height is marking the area of brightest intensity on the
properly adjusted. wall. The area of brightest intensity should fall on
or very near the marks made during step 3. See
• Remove any large amounts of mud or ice from Fig. 18.3.
the underside of the fenders.
6. Use Table 18.1 to determine the maximum verti-
• Check the springs for sagging or broken cal distance allowable between the marks made
leaves. in step 3 and the marks made in step 5. If the
• Check for damage to the hood and hinge as- vertical distance between the marks made in
sembly. Repair as necessary. steps 3 and 5 is greater than the maximum dis-
tance given in Table 18.1, adjust the vertical po-
• Clean the headlight lenses. Use a soft cloth sitioning of that headlight.
with mild, non-caustic soap or detergent, and
water.
Adjusting Headlight Aim
• With the vehicle unloaded, check that the tires
are inflated to the recommended air pressure. NOTE: Because of the various headlight assem-
bly options offered, the location of adjustment
screws on the vehicle’s headlight assembly may
Checking Headlight Aim vary from what is shown here.
1. Park the vehicle on a level surface, 25 ft (7.6 m) 1. Lift the flap over the rear end of the headlight
away from, and perpendicular to, a vertical bucket to expose the two plastic adjusting knobs
screen or wall. Shut down the engine and set the on each headlight. See Fig. 18.4.
parking brake. Chock the tires.
2. If necessary, adjust the horizontal positioning of
2. Each headlight has a height adjusting dot. See the headlights so that each projection points di-
Fig. 18.1. Measure the distance from the ground
rectly forward.
to the height adjusting dot on each headlight.
Note those distances. See Fig. 18.2, Ref. A. 3. Turn the vertical adjustment knob to adjust the
headlight beam to meet the desired height. See
Table 18.1. Turn the knob clockwise to raise the
beam; turn the knob counterclockwise to lower it.
4. Adjust the other headlight.

11/06/2002 f544236

Measure beam height from the ground to the small dot

roughly in the center of the headlight lens.
Fig. 18.1, Headlight Beam Height Adjusting Dot

18.1
 Headlight Aiming

2
3

A
A
B
B

7.6 m)
25 ft (
1
10/15/2012 f545850g
A. Measure the distance from the ground to the center of each headlight bulb.
B. Mark where the center of each headlight projection should appear.
1. Screen or Wall 3. Center of Left-Hand Headlight Projection
2. Center of Right-Hand Headlight Projection
Fig. 18.2, Headlight Aiming Screen/Wall

1
2

10/15/2012 f545851g
1. Low-Beam Angle Upper Limit 3. Low-Beam Angle Lower Limit
2. Ideal Low-Beam Projection
Fig. 18.3, Vertical Low-Beam Headlight Variation Limits

18.2
Headlight Aiming

1
2

11/05/2002 f544235

NOTE: The right-hand side headlight bucket is shown.

The left-hand side is opposite.
1. Horizontal (inboard) Adjusting Knob
2. Vertical (outboard) Adjusting Knob
Fig. 18.4, Headlight Adjusting Knobs

Vertical Low-Beam Headlight Variation Limits

Distance Between Ground Desired Variation ( Fig. 18.3, Upper Limit ( Fig. 18.3, Item Lower Limit ( Fig. 18.3, Item
and Headlight: in (mm) Item 2): in (mm) 1): in (mm) up 3): in (mm) down
22–36 (560–900) 0 3.9 (100) 3.9 (100)
36–48 (900–1200) 2 (50) down 2 (50) 6 (150)
48–54 (1200–1400) 2.5 (64) down 1.6 (40) 6.5 (165)
Table 18.1, Vertical Low-Beam Headlight Variation Limits

18.3
 19
Propane Fuel System
General Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19.1
Ignition Switch and Key . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19.1
Engine Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19.2
Transmission . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19.3
Propane Refueling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19.4
Warning and Indicator Lamps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19.6
Speedometer and Tachometer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19.8
Standard Instruments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19.9
Grade Brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19.10
Ametek Instrument Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19.10
Propane Fuel System

General Information tane and provides proper performance and emissions

control, which the fuel system is designed to deliver.

CAUTION The engine is designed to operate properly on a

wide variety of liquid propane gas (LPG) blends
The propane fuel system requires special tools to which can fall in the category of HD5, and is not af-
make repairs. Service and repair of the propane fected by "heavy ends" or other waxy hydrocarbons
fuel system should only be performed by trained that have traditionally affected other systems.
propane service technicians. To prevent personal
injury or damage to the fuel system, do not at- NOTICE
tempt repairs yourself.
LPG should be free of contaminants including,
DANGER but not limited to, rust, dirt, sand, water, salt, and
brine. These contaminants can cause engine
Never cut or weld on the propane storage tank. damage that is not covered by the engine war-
Severe bodily injury or fire could result. ranty.

Propane is highly flammable. Keep sparks and

open flames away from propane. Do not smoke
WARNING
when refueling the vehicle. Failure to observe The propane fuel system operates at pressures
these safety precautions could cause serious up to 312 psi (2151 kPa). A sudden release of
bodily injury or death. propane can cause serious injuries if it contacts
The information provided in this chapter is specific to the skin or eyes. Always wear protective gloves
the propane engine, however, other chapters in this and eye protection when handling propane.
manual pertain to the propane operated vehicle. LPG has no color. A distinctive odorant, similar to
These include, but are not limited to, the controls and sulfur or rotten eggs, is added to LPG to alert any-
pretrip inspection and daily maintenance chapters. one nearby in the event of a leak.
IMPORTANT: For assistance with propane en-
gine related questions, contact Freightliner Cus- Ignition Switch and Key
tom Chassis Corporation at 1-800-385-4357,
option 1. The ignition switch can be turned to four positions:
ACCESSORY, OFF, RUN, and START. See
NOTE: Oil consumption is normal during opera- Fig. 19.1.
tion of the propane engine. The rate of con-
sumption is highly dependent on vehicle loading
and duty cycles. New engines may experience
higher oil consumption during the engine
break-in period. For further information, refer to
the engine manufacturer’s manual.

NOTICE
If the ignition switch is in the RUN position for
more than 15 seconds and the fuel tank is empty,
the fuel pump must be unplugged. Failure to fol-
low this procedure will result in damage to the
08/27/2013 f610509a
fuel pump. Refer to the propane engine manual
for instructions on how to unplug the fuel pump. Fig. 19.1, Ignition Switch Positions
HD5 grade propane is recommended for propane
engines. HD5 is a heavy duty engine grade propane The key can be inserted and removed only in the
with a minimum of 90% propane and a maximum of OFF position. The headlights (low beams), taillights,
5% propylene. This grade of propane is 100 plus oc- brake lights, road lights, clearance lights, turn sig-
nals, hazard warning lights, horn, CB radio, clock,

19.1
 Propane Fuel System

and electric oil pan heater operate with the ignition in which could cause ring gear and starter pinion
the OFF position, regardless of whether the key is damage.
inserted.
In the ACCESSORY position, the key is turned coun-
Engine Starting
terclockwise. All of the components that are operable 1. Set the parking brake.
in the OFF position are operable in the ACCESSORY
position, as well as the radio (if so equipped), mirror 2. Turn the ignition switch to the RUN position.
heat, air dryer, and backup lights. The amber wait to start indicator light illuminates
IMPORTANT: The propane engine is equipped when the ignition is in the RUN position prior to
engine start-up. Do not crank the engine until the
with an amber wait to start indicator. The indica-
wait to start indicator light goes out.
tor illuminates when the ignition is in the RUN
position prior to engine start-up. Do not crank 3. Make sure that the transmission shift control is in
the engine until the wait to start indicator goes Neutral (N), or if so equipped, the Park (P) posi-
out. See the "Ametek Panel" information in this tion.
chapter for the location of the wait to start indi-
cator. WARNING
Turn the key fully clockwise to the START position to Never start the engine unless the parking brake
start the engine. When the engine starts, release the is applied. Accidental movement of the vehicle
key. could result in property damage, personal injury,
All electrical systems are operable in the RUN posi- or death.
tion. The warning lights and the buzzer for low air IMPORTANT: Do not depress the throttle pedal
pressure and low oil pressure operate until minimum while starting the engine.
pressures are built up.
4. Turn the ignition switch to the START position.
Engine Operation After the engine starts, release the key.

General Information NOTICE

NOTE: Before starting the engine, read the
Do not crank the engine for more than 30 sec-
"Ametek Panel" information in this chapter and onds at a time. Wait two minutes after each try to
Chapter 4 for detailed information on how to allow the starter to cool. Failure to do so could
read the instruments and operate the controls. cause starter damage.
Before operating the vehicle, perform the pretrip in- 5. Bring the engine up to operating speed gradually
spection and daily maintenance checks in Chap- as it warms up and develops stable oil pressure.
ter 14 and Chapter 15 of this manual.
IMPORTANT: When the engine is started, it
NOTICE takes a short time to build up a lubricating oil
film between the shafts and bearings, and be-
If a vehicle does not start on the first attempt, tween the pistons and cylinder walls. The oil
make sure that the engine has completely pressure gauge indicates any drop in lubricating
stopped rotating before reapplying the starter oil pressure within 15 seconds of engine startup.
switch. Failure to do so can cause the pinion to
release and re-engage, which could cause ring Engine Shutdown
gear and starter pinion damage.
Shut down the engine immediately if:
Moving a vehicle with the starter and/or using the
starter to bump the engine for maintenance pro- • the oil pressure gauge needle swings back and
cedures is strictly prohibited. Use of these meth- forth or falls sharply;
ods to bump the engine over or move the vehicle • engine power and rpm fall, even though the
can cause the pinion to release and re-engage, accelerator pedal remains steady;

19.2
Propane Fuel System

• the exhaust pipe gives off heavy smoke; P (Park)

• the coolant and/or oil temperature climb abnor- Use park, if so equipped, when turning the engine on
mally; or off, to check vehicle accessories, or to operate the
• abnormal sounds suddenly occur in the engine. engine in idle for longer than 5 minutes. This position
places the transmission in neutral and engages the
1. With the vehicle stopped, place the transmission park pawl of the transmission.
in Neutral (N), or if so equipped, the Park (P)
position. NOTE: This does not apply the parking brake.
2. Set the parking brake. The park pawl is standard on the 2350 series
transmission. The park pawl effectively grounds
3. Idle the engine for two to three minutes before the transmission output shaft, thereby prevent-
shutting it down. This allows the lubricating oil
ing rotation of the driveline. Provided the vehicle
and the coolant to carry heat away from the
combustion chambers, bearings, shafts, etc. is stationary, selecting P (park) on the shift se-
lector, if so equipped, places the transmission in
NOTE: Long periods of idling are not needed or neutral and engages the park pawl.
recommended.
4. Shut down the engine by turning the ignition
PB (Auto-Apply Parking Brake, optional
switch to the OFF position. on 2300 Series)
The auto-apply parking brake places the transmis-
Transmission sion in neutral and applies the parking brake.

T-Handle Shift Selector R (Reverse)

The S2 propane chassis is equipped with an Allison Reverse is used to back the vehicle. When the selec-
2300 or 2350 Series transmission. A T-handle shift tor is in reverse, the reverse warning signal will
selector is used by the driver to select the transmis- sound. Always bring the vehicle to a complete stop
sion ranges. See Fig. 19.2. Refer to [Link]- before shifting from a forward range to reverse, or
[Link] for additional information. from reverse to a forward range.
Do not idle in reverse for more than 5 minutes. When
time at idle exceeds 5 minutes, select N (neutral), or
if so equipped, P (park) or PB (auto-apply parking
brake).
NOTE: The shift into reverse may not succeed if
a range inhibitor is active. Check the driver dis-
play screen in the instrument panel for a
RANGE INHIBIT message.
N (Neutral)
The neutral position places the transmission in neu-
tral. When neutral is selected, the vehicle service
brakes, parking brake, or emergency brake must be
applied. Selecting neutral does not apply vehicle
brakes unless an auxiliary system to apply the park-
ing brake is installed.
This position is used when starting the engine and
for stationary operation. It is also used to shut down
03/25/2014 f270166 the vehicle when P (park) or PB (auto-apply parking
brake) are not available on the shifter. In this case,
Fig. 19.2, T-Handle Shift Selector
the parking brake must be applied.

19.3
 Propane Fuel System

Do not let the vehicle coast in neutral. If the vehicle pushed down), the transmission reverts back to the
is allowed to coast in neutral, the engine brake will primary shift mode.
not work and the driver could lose control of the ve-
hicle. NOTE: Primary and secondary shift mode cali-
bration varies by vehicle.
D (Drive)
In the drive position, the transmission will initially go
into first range when drive is selected. As vehicle
speed increases, the transmission will upshift auto-
matically through each available range up to fifth or
sixth range. As the vehicle slows, the transmission
will downshift automatically.
When going downhill, downshift to a lower transmis-
sion range to increase engine braking and to help
maintain control. The transmission has a feature to
prevent automatic upshifting above the lower range
selected. However, during downhill operation, the
01/21/2016 f611330
transmission may upshift to the next higher range, if
the engine is exceeding its governed speed in the Fig. 19.3, Transmission Mode Switch
lower range.
NOTE: The shift into drive may not succeed if a Propane Refueling
range inhibitor is active. Check the driver dis-
Agility Fuel Systems recommends that the Liquid
play screen in the instrument panel for a
Propane Injection® (LPI) vehicle be refilled with fuel
RANGE INHIBIT message. at stations that are specifically designed for vehicle
refueling. For assistance locating LPG fuel stations,
4 and 3 (Fourth and Third Ranges) contact Agility Fuel Systems at [Link]-
Use the fourth or third range for heavy city traffic and [Link] or at 1-949-267-7745.
for braking on steep downgrades. The propane fuel system utilizes a closed system,
with fuel supply and return lines. This requires more
L (Low Range) advanced refueling equipment due to variances in
Use low range when pulling through mud or deep pressure. When refueling the vehicle at a station not
snow, when maneuvering in tight spaces, or when specifically designed for dispensing propane (also
driving up or down very steep grades. Low range referred to as autogas), the refueling process may be
provides the vehicle with its maximum driving torque very slow or the tank may not fill at all. The vehicle
and maximum engine braking effect. propane tank is subjected to heat from the pavement
and chassis components, which cause a normal in-
NOTE: To have the transmission select these crease in tank pressure. The station pump may not
ranges automatically, leave the selector lever in be able to produce pressure high enough to over-
D (drive). come that of the tank on the vehicle. It is recom-
mended that the filling dispenser have a minimum of
Transmission Mode Switch 90 psi (621 kPa) pump differential boost pressure
over the storage tank pressure; most modern sta-
Some vehicles are equipped with a transmission tions are designed to 130 psi (896 kPa) differential
mode switch, shown in Fig. 19.3. The transmission pressure. It is recommended to refuel the vehicle at
mode switch is a fuel conservation option that allows a modern station to prevent any customer inconve-
the driver to choose either performance or economy nience.
shifting. When the switch is in the on position (the
top of the rocker switch is pushed down), the trans- LPI fuel tanks are equipped with both an 80% fixed
mission shift pattern changes from primary (perfor- liquid level gauge, and an automatic overfill protec-
mance) shift mode to secondary (economy) shift tion device (OPD). The LPI system is designed to be
mode. When the transmission mode switch is in the
off position (the bottom of the rocker switch is

19.4
Propane Fuel System

filled reliably and safely using only the OPD. There- 4. Turn the fuel tank cap counterclockwise and re-
fore, it is not recommended to use the 80% fixed liq- move it.
uid level gauge unless required by the filling station
5. Inspect the fill valve O-ring, making certain the
attendant, or for annual OPD verification. For instruc-
O-ring is seated in the groove and is not dam-
tions on how to perform the annual OPD verification
aged or missing.
test, go to [Link].
Propane is a liquid under pressure and is stored in a CAUTION
pressure vessel unlike a gasoline or diesel tank. A
propane tank must never be filled to more than 80% Never connect the propane fill nozzle to the tank
of its actual capacity, to allow room for expansion. fill valve if the O-ring is damaged or missing, as
80% is considered "full" for all propane tanks. When this could result in serious injury. Replace the
the tank is filled to the correct 80% level, the fuel O-ring before connecting the propane fill nozzle.
gauge should read full.
6. Connect the propane fill nozzle to the tank fill
The following steps describe a typical refueling pro- valve.
cedure. See Fig. 19.4 for an example of the dual
propane tank system. 7. Rotate the propane fill valve nozzle clockwise

1 2
A
3

7 6
B

10/30/2013 f470606
A. Front Side B. Back Side
1. Bleeder Valve 4. Fill Valve 6. Pressure Relief Valve
2. Fuel Level Gauge 5. Service Valve 7. Access Cover and Collar
3. Return Valve

Fig. 19.4, Propane Tank System

1. Park the vehicle on level ground to ensure that until it is firmly attached to the tank fill valve.
the tank is properly filled.
8. Close the fill nozzle vent valve if so equipped.
2. Turn the vehicle ignition to OFF and set the park-
9. Open the 80% bleeder valve only if required.
ing brake. Chock the tires if required.
Agility Fuel Systems does not recommend using
3. Ensure that there are no open flames or ignition the bleeder valve. Use of the valve in a low
sources in the area. emission fuel station is prohibited.
10. Open the valve on the refueling nozzle.

19.5
 Propane Fuel System

11. Turn the propane dispenser on to begin refuel- • Oil Change Required—alerts the driver that the
ing. engine has reached the recommended oil
change interval.
12. When the OPD stops the flow of fuel into the
tank, close the filling valve. • Air Filter Reminder—the air filter requires
checking or replacement.
If use of the 80% bleeder valve is required, stop
filling when liquid from the bleeder appears in the • Transmission Prognostics Warning—if the
form of a white cloudy vapor. transmission has prognostics enabled.
13. Turn the propane dispenser off.
Left-Turn Indicator
CAUTION The left-turn indicator flashes on and off when the
left-turn signal lights are flashing.
Never overfill the propane fuel tank. Overfilling Both turn signal indicators flash when the hazard
the fuel tank can cause a dangerous condition, warning flasher is turned on.
resulting in serious injury and damage to the ve-
hicle.
Check Engine Warning
After refueling, if a strong smell of propane per-
sists or if a hissing sound is heard, notify the The check engine warning indicator illuminates when
fuel station operator. Do not start the vehicle. certain faults are detected. If a critical engine condi-
tion exists (for example, low oil pressure or high
14. Disconnect the filling nozzle from the tank fill coolant temperature), the check engine indicator will
valve. illuminate to alert the driver to correct the condition
14.1 as soon as possible. If the condition gets worse, the
If necessary, first open the vent valve on
stop engine indicator will illuminate.
the nozzle, if so equipped, and release the
pressure from the valve for safety. NOTE: If the check engine indicator illuminates
14.2 Rotate the filling nozzle connector coun- during vehicle operation, take the vehicle di-
terclockwise and remove it. Then return it rectly to an authorized Freightliner service facil-
to the dispenser. ity.
15. Install the fuel cap.
Stop Engine Warning
16. Check for leaks on the fill valve and connecting
piping, and around the 80% bleeder valve. WARNING
17. Ensure that all of the fuel tank valves are in the
fully-closed position. When the red STOP engine lamp illuminates, the
driver must immediately move the vehicle to a
safe location at the side of the road to prevent
Warning and Indicator Lamps causing a hazardous situation that could cause
There are 19 warning and indicator lamps (telltales) bodily injury, property damage, or severe damage
installed in the dash message center. See Fig. 19.5. to the engine.

The instrument cluster has an emergency buzzer that The stop engine warning indicator illuminates when
sounds when serious conditions that require immedi- the protection system available for the engine has
ate attention occur. been activated. The engine ECU will derate the en-
gine, allowing it to run, but at lower rpm and slower
A description of the standard warning and indicator vehicle speed. The vehicle may be driven to a safe
lamps are listed below. location.

Maintenance Warning Lamp NOTICE

When amber maintenance warning lamp illuminates,
the message display center alerts the driver as fol- Because operating the engine when the stop en-
lows: gine indicator is illuminated can lead to severe

19.6
Propane Fuel System

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17

18

10/30/2012 19 f611201
1. Maintenance Warning Lamp 8. Headlight High-Beam Indicator 14. Check Transmission Indicator
2. Left-Turn Indicator 9. Wait to Start Indicator 15. Stop Transmission Indicator
3. Check Engine Warning 10. Hydraulic Brake System Warning 16. Right-Turn Indicator
4. Stop Engine Warning 11. ABS Warning 17. Fasten Seat Belt Warning
5. Malfunction Indicator Lamp (MIL) 12. Traction Control Indicator 18. Parking Brake On Warning
6. Low Air Pressure Warning 13. Shift Inhibit Indicator 19. Cruise Control Indicator
7. Engine Brake Light (not used)
Fig. 19.5, LPG Engine Warning and Indicator Lamps

engine damage, the driver must move the vehicle Low Air Pressure Warning
to a safe location as quickly as possible.
The low air pressure warning indicator (BRAKE icon)
If the engine is shut down while the vehicle is in ser- and emergency buzzer activate when the engine is
vice, a single restart attempt may be performed. De- turned on if air pressure in the primary or secondary
pending on the nature of the fault condition, a cool-
air reservoir is below 65 to 75 psi (448 to 517 kPa),
down period may be required before restarting. If,
and remain on until air pressure rises above that
upon restarting, the fault condition still exists the indi-
level in both reservoirs.
cator will come on and the engine should be shut
down. At this point, the vehicle is unsafe to drive and
should be transported to an authorized Freightliner
Headlight High-Beam Indicator
service facility. The high-beam indicator (sideways beam icon) illumi-
IMPORTANT: Do not attempt to restart the en- nates when the headlight high beams are on.
gine while the vehicle is moving. Bring the ve-
hicle to a safe stop and restart the engine with
Wait to Start Indicator
the vehicle stopped. The wait-to-start indicator illuminates when the intake
heater is active. Wait until the indicator goes off to
Malfunction Indicator Lamp (MIL) start the engine.
The malfunction indicator lamp (MIL) indicates an Hydraulic Brake System Warning
engine emissions-related fault. See the engine op-
eration manual for details. The brake system warning lamp illuminates if there is
a hydraulic brake system failure, or if the vehicle is
powered and the engine is not running.

19.7
 Propane Fuel System

ABS Warning If the vehicle is moving at a speed of 2 mph (3 km/h)

or more, the emergency buzzer will sound until the
The ABS indicator illuminates when there is a mal- parking brake is released.
function in the vehicle antilock brake system (ABS).
NOTE: For more information about this indicator Cruise Control Indicator
and the ABS system, see Chapter 13. The cruise control indicator illuminates when the
cruise control is activated.
Traction Control Indicator
The traction control indicator illuminates when the
Emergency Buzzer
wheels lose traction. The emergency buzzer sounds during the ignition
sequence and whenever one of the following condi-
Shift Inhibit Indicator tions exists:
The shift inhibit indicator illuminates when the trans- • The engine oil pressure falls below the preset
mission ECU prohibits shifting. level which is 6 psi (41 kPa) at 700 rpm, or 18
psi (124 kPa) at 4400 rpm.
Check Transmission Indicator • The air pressure falls below the preset level,
The LPG check transmission indicator has a different which is 65 psi (448 kPa).
icon (exclamation point), and illuminates when the • The parking brake is set with the vehicle mov-
transmission fluid temperature goes above a preset ing at a speed greater than 2 mph (3 km/h).
level set by the transmission manufacturer.
• The coolant temperature rises above 253°F
For more information, see the transmission manufac- (123°C) and the check engine and stop engine
turer’s manual provided with the vehicle. lamps illuminate. When the coolant tempera-
ture falls below 244° (118°C) the emergency
Stop Transmission Indicator buzzer and stop engine lamp turn off.
The stop transmission indicator illuminates when the NOTE: The check engine lamp will remain on
transmission control unit senses a malfunction. until the vehicle is inspected at an authorized
Freightliner service facility.
Right-Turn Indicator
The right-turn indicator flashes on and off when the Speedometer and Tachometer
right-turn signal lights are flashing.
Both turn signal indicators flash when the hazard
Speedometer
warning flasher is turned on. Three kinds of speedometer faces are available. The
U.S. version of the speedometer registers speed in
Fasten Seat Belt Warning both miles per hour (mph) and kilometers per hour
(km/h), with mph in larger numbers. See Fig. 19.6.
The fasten seat belt warning indicator (seat belt icon)
illuminates for 3 seconds after the ignition switch is The NAFTA version (not shown) of the speedometer
turned on. face reverses this arrangement, with km/h in larger
numbers. The metric-only version (not shown) shows
When the engine is operating, if the driver’s seat belt km/h exclusively.
is unfastened and the park brake is not set, the seat
belt warning indicator illuminates and a warning Tachometer
chime activates. The warning chime will remain ac-
tive for 15 seconds. The warning indicator remains The tachometer indicates engine speed in revolutions
illuminated until the driver’s seat belt is fastened. per minute (rpm) and serves as a guide for shifting
the transmission and keeping the engine in the ap-
Parking Brake On Warning propriate rpm range. See Fig. 19.6.
The parking brake on indicator activates when the
parking brake is engaged.

19.8
Propane Fuel System

1 2
30 30
40 50
60
20 40 MPH
RPM 20 70
10 X 100
50 40
60 80
100
10 120
80
20
0 60 0 0
140 90
09/18/2013 f611217
1. Tachometer 2. Speedometer
Fig. 19.6, Speedometer and Tachometer (U.S. version)

Standard Instruments cause an accident resulting in property damage,

personal injury, or death.
Fuel Level Gauge Air pressure gauges register the pressure in the pri-
The fuel level gauge indicates the level of fuel in the mary and secondary air systems. Normal pressure
fuel tank. See Fig. 19.7. A low-level warning lamp with the engine running is 100 to 120 psi (690 to 827
illuminates when the diesel fuel level registers 1/8th kPa) in both systems. See Fig. 19.8.
of capacity. Air pressure gauges are required on all vehicles with
air brakes. A low-air-pressure warning lamp and
buzzer, connected to both the primary and secondary
systems, activate when air pressure in either system
drops below a minimum pressure of 65 to 75 psi
(448 to 517 kPa).
1
When the engine is started, the warning lamp and
buzzer remain on until air pressure in both systems
F 1/2 exceeds minimum pressure.

Coolant Temperature Gauge

E NOTICE
10/01/2013 f611219
1. Low-Level Warning Lamp A sudden increase in coolant temperature may
indicate engine or cooling system failure. Bring
Fig. 19.7, Fuel Level Gauge the vehicle to a safe stop and investigate the
cause to prevent further damage. Do not operate
Primary and Secondary Air Pressure the engine until the cause has been determined
Gauges and corrected.
During normal engine operation, the coolant tem-
WARNING perature gauge should read 200 to 205°F (93 to
96°C). See Fig. 19.9. If the temperature remains
If air pressure falls below minimum pressure, the below 160°F (71°C) or exceeds 235°F (113°C), in-
braking ability of the vehicle will be limited. Slow spect the cooling system to determine the cause.
the vehicle down and bring it to a gradual stop. See the vehicle workshop manual for troubleshooting
Do not attempt to move the vehicle until air pres- and repair procedures.
sure has risen above the minimum level. Moving If the coolant temperature rises above 253°F
a vehicle without adequate braking power could (123°C), the check engine and stop engine warning
indicators will illuminate, and the buzzer will sound.

19.9
 Propane Fuel System

1 PSI P S PSI 4

75 150 150 75
2 3
0 0
09/18/2013 f611218
1. Primary Air Pressure Gauge 3. Low Secondary Air Pressure Warning Lamp
2. Low Primary Air Pressure Warning Lamp 4. Secondary Air Pressure Gauge
Fig. 19.8, Air Pressure Gauges

signed to downshift the transmission—when going

downhill for example—without overspeeding the en-
gine. Refer to the Allison Operator’s Manual for
proper operation of the grade brake. See Fig. 19.10
for an example of the grade brake switch. An amber
light activates at the top of the switch when the
grade brake is activated.
1

09/18/2013 f611220

1. High Coolant Temperature Warning Light

Fig. 19.9, Coolant Temperature Gauge

09/20/2013 f261458
At this point, the engine will derate and idle speed
will increase, to speed up the cooling fan and water Fig. 19.10, Grade Brake Switch
pump to cool the engine.
Ametek Instrument Panel
Grade Brake The following information describes the Ametek in-
IMPORTANT: The grade brake is an optional strument panel, used with liquid propane gas (LPG)
auxiliary brake system that works through the engines. The instrument panel is shown in
transmission. It should not be confused with ex- Fig. 19.11.
haust brake or engine brake. Furthermore, the NOTE: The instrument panel is shown with a
grade brake should not be used in place of the standard U.S. speedometer, which shows miles
service brakes to stop the vehicle. per hour (mph) more prominently than kilome-
Chassis equipped with a propane engine may have ters per hour (km/h).
an optional grade brake. The grade brake is de-

19.10
Propane Fuel System

Message Display Center Menu System

The message display is a graphical, backlit, liquid The menu system is shown on the driver display
crystal display (LCD) that relays information to the screen once the self-test is finished. The menu sys-
vehicle operator. The messages displayed include: tem responds to input from the driver and remains
active as long as the ignition is on. In order for the
• Odometer
driver to operate the menu system, the ignition must
• Trip Odometer 1/Trip Odometer 2 be ON, and the park brake must be set (ON). The
main features of the menu system are described
• Chassis Battery Voltage below.
• Instantaneous Fuel Rate • Setup—this is used to set various parameters,
• Average Fuel Rate which are saved when the ignition is turned off.
Setup has select display units, startup screen,
• Gear Attained Status LCD contrast, and reset parameters.
• Transmission Temperature • Maintenance—shows various maintenance in-
• Hour Meter tervals such as engine oil, air filter, etc.
• Boost Pressure • Diagnostics—this is used for setting and read-
ing inputs and outputs and checking the
• Engine Oil Pressure gauges. It also shows the hardware and soft-
• Coolant Temperature ware version of the instrument panel, and has
menus to retrieve active error codes from the
• Fuel Level engine, transmission, and ABS controllers.
• Percent Engine Load NOTE: No lines can be highlighted in the menu
• Engine RPM system screen. To get to the sections that can
be highlighted, press the right arrow toggle but-
During normal operation, the LCD displays the odom- ton and hold it for two seconds. The display
eter value and chassis battery voltage on the top
screen will change and the options shown can
line, and driver selected parameters, such as the trip
odometer and fuel rate, on the second and third then be highlighted. Once a selection has been
lines. chosen and changes are made, press the right
arrow toggle button to go back to the main mes-
Priority Messages sage display screen.
Priority messages (including warning messages) are Setup Menu
displayed in the LCD due to various inputs or data
messages. Unless noted otherwise, the priority mes- Select Display Units
sage will take over the whole screen, allowing mul- The set units screen allows the driver to choose be-
tiple messages to be displayed in five second inter- tween English or metric units of measurement for the
vals. displayed values. To navigate to the set units screen,
see Fig. 19.12, screens H, I, and J.
Self-Test
Startup Screen
When the ignition is turned on, a required self-test
automatically begins. Gauge needles will reset to The startup screen selection allows the driver to turn
zero during the self-test, and then immediately move the startup screen on or off.
to the position dictated by the data received. During
this time, the warning lights, alarm (buzzer), and LCD Contrast
driver display screen will also perform a self-test. Select contrast from the menu to set the LCD con-
trast. Use the down toggle button to set the contrast
NOTE: The driver can activate or deactivate the to the desired level. To navigate to the contrast
start-up self-test by accessing the setup menu. screen, see Fig. 19.12, screen M.

19.11
 Propane Fuel System

Reset Parameters All of the items in the diagnostic menu can be ac-
cessed by using the toggle buttons and selecting the
The reset parameters screen is included with ve- auxiliary screens. Then navigate to the diagnostic
hicles that have the Allison transmission prognostics sub-menu. Some of the more frequently used diag-
feature. nostic menus are described further below.
Maintenance Menu Engine Faults
The maintenance menu has the following three sub This screen displays engine fault codes that are re-
menus: ceived from the engine electronic control unit (ECU).
• maintenance intervals To navigate to the engine fault screen, see
Fig. 19.13, screen AA.
• transmission oil life remaining
• transmission oil filter life monitor Transmission Faults
This screen displays transmission fault codes that
Maintenance Intervals are received from the transmission ECU. To navigate
The maintenance intervals menu allows the driver to to the transmission fault screen, see Fig. 19.13,
set the change intervals for engine oil and engine air screen AB.
filter. If the intervals are set to zero, the maintenance
warnings must be disabled. ABS Diagnostics
This screen displays Antilock Brake System (ABS)
Transmission Oil Life Remaining fault codes that are received from the ABS ECU. To
If transmission prognostics are enabled, this menu navigate to the ABS diagnostic screen, see
indicates how much useful oil life remains. Fig. 19.13, screen AC.

Transmission Oil Filter Life Monitor Check Gauges

If transmission prognostics are enabled, the trans- The check gauges screen allows the driver to set
mission oil filter life monitor tells the driver if the each gauge as a percentage of scale (either 0, 50, or
transmission oil filter is clogged and in need of repair. 100%), as shown in the LCD. To navigate to the
A message will appear on the display screen as check gauges screen, see Fig. 19.14, AG screens.
TRANS OIL FILTER FUNCTIONAL or TRANS OIL
FILTER CLOGGED. Warning Lamp
The warning lamp screen allows the driver to test
Diagnostic Menu each warning lamp (not the vehicle load) on and then
off, displaying the lamp name and status in the LCD.
The diagnostic menu contains the following items:
To navigate to the warning lamp screen, see
• engine faults Fig. 19.14, screen AH.
• transmission faults Check LCD
• ABS faults Selecting the check LCD screen displays the Freight-
• check outputs liner Custom Chassis Corporation (FCCC) logo in
normal and reverse video three times and then re-
• odometer diagnostics turns to the menu. To navigate to the check LCD
• check gauges screen, see Fig. 19.14, screen AI.

• check indicators (warning lamps) Check Binary Inputs

• check LCD The check binary inputs screen displays the pin num-
ber and status of each binary input. The toggle but-
• check binary inputs tons allow the driver to select each binary input. This
• check analog inputs information is continuously updated to assist in
troubleshooting. To navigate to the check binary in-
• check datalink puts screen, see Fig. 19.14, screen AJ.
• hardware/software version

19.12
Propane Fuel System

in the message display center.

Check Analog Inputs
The check analog inputs screen displays the pin
number and actual value of each analog input de-
fined in the system. The toggle buttons allow the
driver to select each analog input. This information is
continuously updated to assist in troubleshooting. To
navigate to the check analog input screen, see
Fig. 19.15, screen AK.

Check Datalink
The check datalink screen allows the driver to view
all devices that communicate on the J1939, J1587,
and GMLAN datalinks. To navigate to the check da-
talink screen, see Fig. 19.15, screen AL.

Menu Navigation
The menu navigation screens are provided to illus-
trate the menu system. The paths to specific screens
are shown, along with instructions for using the
toggle buttons to move from one screen to another.
See Fig. 19.12, Fig. 19.13, Fig. 19.14, Fig. 19.15,
Fig. 19.16, Fig. 19.17, Fig. 19.18, Fig. 19.19,
Fig. 19.20, Fig. 19.21, Fig. 19.22, Fig. 19.23, and
Fig. 19.24.
IMPORTANT: Follow the steps below to change
the three items (also known as favorites) shown
in the message display center. The message
display center is referred to as screen C in
Fig. 19.18.
NOTE: The driver can check the pressure of the
propane in the fuel rail (pressure of the fuel in
both the tank and pump booster), and make this
one of the three items shown in the message
display center. Select the item with the fuel
pump and psi reading, then follow the directions
below to make it one of the favorites.
1. With the vehicle in park, turn the ignition to RUN,
and allow the self test to complete.
2. Press the down toggle button to select an item to
change. The selected item will now be high-
lighted.
3. Press the right toggle button once to enter the
favorites display menu, shown in Fig. 19.18, as
screen D.
4. Use the down toggle button to scroll through the
available items.
5. Highlight the new item, then press the right
toggle button. The selected item will now appear

19.13
 Propane Fuel System

1 2 3

6 7
4 5

8
10

12/05/2012 f611202
1. Tachometer 5. Primary Air Pressure Gauge 8. Dash Driver Display Screen
2. Dash Message Center 6. Secondary Air Pressure Gauge 9. Toggle Button, Down
3. Speedometer 7. Coolant Temperature Gauge 10. Toggle Button, Right
4. Fuel Level Gauge
Fig. 19.11, Gauge Layout (typical, U.S.), LPG Engines

19.14
Propane Fuel System

SETUP

Right Press
Or
Down Hold
Current Units =
English
Down Press Down Press
Current Units = Current Units =
English Metric

Current Units =
Right Press Metric
Select Display Right Press
Units highlighted Or
Down Hold

Right Press
Or
Startup Screen = Down Hold
Enabled
Right Press Down Press Down Press
Startup Screen
Startup Screen = Startup Screen =
highlighted
Enabled Disabled
Startup Screen =
Disabled
Right Press
Down Hold Or
Or (Right & Exit Down Hold
highlighted)
Down Press
Highlight next
line of list. Down Press
At middle, At Min Contrast /
wrap to top Set Contrast to Max

Right Press Right Press

Display Contrast Or
highlighted Down Hold

Down Press
Not At Min Contrast /
Decrease Contrast

Right Press Right Press

Reset Parameters Or
highlighted Down Hold

Right Hold
Reset Parameters

Right Press
Or
Down Hold

AUXILIARY
SCREENS

09/23/2009 f040792

Fig. 19.12, Setup Menu Screens

19.15
 Propane Fuel System

Diagnostics

Screens AA,AB,AC Format For J1587

Down Press
Note 5:
Display Next Fault
Screen Z scrolls to display the
following items:
ENGINE FAULTS
TRANSMISSION FAULTS Right Press Right Press
ABS FAULTS Engine Faults Or Menu
CHECK OUTPUTS Highlighted Down Hold
CHECK DATA INPUTS
ODOMETER DIAGNOSTICS
CHECK GAUGES
CHECK WARNING LAMPS
CHECK LCD Down Press
CHECK BINARY INPUTS Display Next Fault
CHECK ANALOG INPUTS
CHECK DATA LINK
VERSION INFORMATION
Right Press Right Press
EXIT
Trans Faults Or Menu
The text DIAGNOSTIC MENU
Highlighted Down Hold
remains fixed on the first line.

Menu
Down Press
Display Next Fault

Right Press Right Press

ABS Faults Or Menu
Highlighted Down Hold

Down Press
(Right & Exit Change to
highlighted) Next Output
Down Press
Highlight next Right Press Right Press
line of list. Check Outputs Or Menu
At bottom, Highlighted Down Hold
wrap to top
Right Hold
Toggle Output
State Between
Off and On

Screen AE For J1587

Right Press
Odometer Diag Right || Hold Down Menu
Highlighted

09/23/2009 f040795

Fig. 19.13, Diagnostic Menu Screens, Screen 1

19.16
Propane Fuel System

Other Text for Screen AG

Down Press
Change to
Next Gauge

Right Press
Check Gauges Right || Hold Down Menu
Highlighted

Right Hold
Step Gauge to
Next Position

Down Press
Change to
Next Telltale

Right Press
Warning Lamps Right || Hold Down Menu
Highlighted

Right Hold
Toggle State
Between
Off and On

Right Press Right ||

Check LCD 9 Seconds Elapsed Menu
Highlighted || Hold Down

Every 1.5 Seconds /

Invert Video of
Displayed Image

Down Press
Change to
Next Input

Right Press
Check Binary Inputs Right || Hold Down Menu
Highlighted

09/23/2009 f040796

Fig. 19.14, Diagnostic Menu Screens, Screen 2

19.17
 Propane Fuel System

Down Press
Change to
Next Input

Right Press Screen AK

Check Analog Inputs Input Name Right || Hold Down Menu
Highlighted Pin pp of 26
xx.x Units

Down Press
Scroll Screen
Down 1 Line

Screen AL
Right Press ECUs on Data Bus
Check Data Link J1939 SA xx Right || Hold Down Menu
Highlighted
J1939 SA yy

Right Press Screen AM

Version Information SOFTWARE VER: [Link] Right || Hold Down Menu
CONFIG: ccccccc
Highlighted HARDWARE VER: z

AUXILIARY
SCREENS

02/06/2012 f040797

Fig. 19.15, Diagnostic Menu Screens, Screen 3

19.18
Propane Fuel System

Ignition On or
Headlamps On or
Marker Lamps On or
Park Brake Off

ACTIVE

Ignition Off &

( Headlamps On or IGNITION
Marker Lamps On or OFF
Park Brake Off )

Ignition On
Ignition Ignition
On Off
IGNITION ON

NORMAL MODE

SELF TEST
H*
Self Test
Enabled

DISPLAY AUXILIARY DOWNLOAD

MESSAGES SCREENS MODE
Right Hold
H* Park Brake On

No Warnings Active or Active Warning

All Warnings Messages USB Drive Present &
Acknowledged Park Brake On &
Vehicle Speed = 0 &
Not in Self Test

WARNING
MESSAGES

Ignition Off &

Headlamps Off &
Marker Lamps Off &
Park Brake On
09/23/2009 f040788

Fig. 19.16, Ignition On, Normal Mode

19.19
 Propane Fuel System

SELF TEST

The Self Test screens display the FCCC

logo in normal video (Screen A) and in
reverse video (Screen B)

Startup Screen Enabled

Screen A
XXXXXXXXXXXXXXXXXXXXXX
XXXXXXXXXXXXXXXXXXXXXX
XXXXXXXXXXXXXXXXXXXXXX

Screen Displayed
for 1.5 Seconds

Startup Screen Disabled

Screen B
XXXXXXXXXXXXXXXXXXXXXX
XXXXXXXXXXXXXXXXXXXXXX
XXXXXXXXXXXXXXXXXXXXXX

Screen Displayed
for 1.5 Seconds

DISPLAY
MESSAGES

02/06/2012 f040789

Fig. 19.17, Self Test

19.20
Propane Fuel System

DISPLAY MESSAGES

Right Hold
Reset Highlighted Item Down Hold
(if resettable) Make No Changes

Screen C Screen D
Selected Line 1 Data Right Press Favorites Display Menu
Selected Line 2 Data Highlight First Item in List Average Fuel Economy
Selected Line 3 Data Gear Attained Status

Right Press Down Press

Down Press Put Data For Highlighted Item Move to, and Highlight,
Highlight CurrentLine In Display Line CurrentLine Next Item in List
HighlightTimer = 5 sec.

New Warning
Right Hold
Park Brake On
Message Active
HighlightTimer = 0

WARNING AUXILIARY
MESSAGES SCREENS

11/23/2011 f040790

Fig. 19.18, Display Messages

19.21
 Propane Fuel System

AUXILIARY SCREENS

Right Press
Setup SETUP
highlighted

SETUP.
Right Press
Maintenance MAINTENANCE
highlighted

Screen G
SETUP
MAINTENANCE
DIAGNOSTICS

Down Press Right Press

Highlight next Diagnostics DIAGNOSTICS
line of list. highlighted
At middle,
wrap to top
Down Hold

Right Press
Trip Data TRIP DATA
highlighted

DISPLAY
MESSAGES

02/06/2012 f040791

Fig. 19.19, Auxiliary Screens

19.22
Propane Fuel System

MAINTENANCE

Maint
Menu

Right Press
Or
Down Hold
(Right & Exit
Down Press
Highlight next
highlighted)
line of list.
At middle, Oil Change Baseline + Right Hold
wrap to top Oil Change
Oil Change Distance >=
Odometer Baseline =
Odometer

Right Press Right Press Right Press

Oil Change Distance = Or
Engine Oil else
Current Displayed Down Hold
Highlighted
Value

Down Press Right Hold

Display Next Oil Change Oil Change
Value of Oil Distance = 0 Baseline =
Change Distance Odometer

Right Press
Or
Down Hold

Air Change Baseline + Right Hold

Air Change Distance >= Air Change
Baseline =
Odometer
Odometer

Right Press Right Press

Air Change Distance =
Right Press
Engine Air Filter else Or
Current Displayed
Highlighted Down Hold
Value

Down Press Right Hold

Display Next Air Change Air Change
Value of Air Distance = 0 Baseline =
Change Distance Odometer

09/23/2009 f040793

Fig. 19.20, Maintenance Menu Screens, Screen 1

19.23
 Propane Fuel System

Right Press Right Press

Transmission Or
Oil Life Down Hold
Highlighted

Right Hold
Send SPN 1584 = 37

Right Press
Or
Down Hold

Right Press Right Press

Transmission
Or
Maint
Oil Filter
Down Hold Menu
Highlighted

Right Hold
Send SPN 1584 = 39

Right Press
Or
Down Hold

AUXILIARY
SCREENS

02/06/2012 f040794

Fig. 19.21, Maintenance Menu Screens, Screen 2

19.24
Propane Fuel System

Trip Data

Down Press
Highlight next
line of list.
At bottom,
wrap to top Right Press

Right Press Correct Passcode /

Reset All
Reset Trip
Highlighted
Data

(Right & Exit

highlighted)
Wrong Passcode /
Down Press
Note 6:
Screen AO scrolls to display
the following items:

Trip Time
Right Press Idle Time
Max RPM
Avg RPM
Max Speed
Avg Speed
Avg Fuel Economy
Reset All
Exit

AUXILIARY
SCREENS

09/23/2009 f040798

Fig. 19.22, Trip Data

19.25
 Propane Fuel System

WARNING MESSAGES

Msg Displayed for 5 Sec. /

/ Display Next Entry in
st
Display 1 Message Warning Message List
in Warning
Message List
Screen AN
WARNING Any Button Press
Warning Message

No Warning
Messages in List /

H*
DISPLAY
MESSAGES

02/06/2012 f040799

Fig. 19.23, Warning Messages

19.26
Propane Fuel System

IGNITION OFF

Park Brake Off

Park Brake On

Park Brake On

Ignition On Headlamps Off &

Marker Lamps Off &
Park Brake On

IGNITION
ON

02/06/2012 f040800

Fig. 19.24, Ignition Off (shown when ignition is keyed OFF)

19.27
 20
Specifications
Torque Charts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20.1
Conversion Charts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20.4
Fluids and Lubricants . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20.5
Fuse Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20.5
Bulb Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20.5
Specifications

Torque Charts
Torque Values for U.S. Customary Thread Fasteners With Lubricated* or Plated Threads†
Regular Hex Flanged
Thread
Grade 5 Grade 5 or Grade 8 or Grade 8 or Grade 5 Grade B Grade 8 or Grade G
Diameter—
Bolt B Nut 8.2 Bolt C Nut Bolt Nut 8.2 Bolt Nut
Pitch
Torque: lbf·ft (N·m) Torque: lbf·ft (N·m) Torque: lbf·ft (N·m) Torque: lbf·ft (N·m)

f230002 f230003 f230004 f230005 f230006 f230007 f230008 f230009

1/4–20 7 (9) 8 (11) 6 (8) 10 (14)

1/4–28 8 (11) 9 (12) 7 (9) 12 (16)
5/16–18 15 (20) 16 (22) 13 (18) 21 (28)
5/16–24 16 (22) 17 (23) 14 (19) 23 (31)
3/8–16 26 (35) 28 (38) 23 (31) 37 (50)
3/8–24 30 (41) 32 (43) 25 (34) 42 (57)
7/16–14 42 (57) 45 (61) 35 (47) 60 (81)
7/16–20 47 (64) 50 (68) 40 (54) 66 (89)
1/2–13 64 (87) 68 (92) 55 (75) 91 (123)
1/2–20 72 (98) 77 (104) 65 (88) 102 (138)
9/16–12 92 (125) 98 (133) 80 (108) 130 (176)
9/16–18 103 (140) 110 (149) 90 (122) 146 (198)
5/8–11 128 (173) 136 (184) 110 (149) 180 (244)
5/8–18 145 (197) 154 (209) 130 (176) 204 (277)
3/4–10 226 (306) 241 (327) 200 (271) 320 (434)
3/4–16 253 (343) 269 (365) 220 (298) 357 (484)
7/8–9 365 (495) 388 (526) 320 (434) 515 (698)
7/8–14 402 (545) 427 (579) 350 (475) 568 (770)
1–8 — 582 (789) — —
1–12 — 637 (863) — —
1–14 — 652 (884) — —
* Freightliner recommends that all plated and unplated fasteners be coated with oil before installation.
† Use these torque values if either the bolt or nut is lubricated or plated (zinc-phosphate conversion-coated, cadmium-plated, or waxed, Geomet 321XL
coated, or waxed).
Table 20.1, Torque Values for U.S. Customary Thread Fasteners With Lubricated or Plated Threads

20.1
 Specifications

Torque Values for U.S. Customary Thread Fasteners With Dry (Unlubricated)* Plain (Unplated) Threads†
Regular Hex Flanged
Thread
Grade 5 or B Grade 8 or 8.2 Grade 8 or C Grade 8 or 8.2
Diameter— Grade 5 Bolt Grade G Nut
Nut Bolt Nut Bolt
Pitch
Torque: lbf·ft (N·m) Torque: lbf·ft (N·m) Torque: lbf·ft (N·m)

f230002 f230003 f230004 f230005 f230008 f230009

1/4–20 8 (11) 10 (14) —

1/4–28 9 (12) 12 (16) —
5/16–18 15 (20) 22 (30) 22 (30)
5/16–24 17 (23) 25 (34) —
3/8–16 28 (38) 40 (54) 40 (54)
3/8–24 31 (42) 45 (61) —
7/16–14 45 (61) 65 (88) 65 (88)
7/16–20 50 (68) 70 (95) —
1/2–13 70 (95) 95 (129) 95 (129)
1/2–20 75 (102) 110 (149) —
9/16–12 100 (136) 140 (190) 140 (190)
9/16–18 110 (149) 155 (210) —
5/8–11 135 (183) 190 (258) 190 (258)
5/8–18 155 (210) 215 (292) —
3/4–10 240 (325) 340 (461) 340 (461)
3/4–16 270 (366) 380 (515) —
7/8–9 385 (522) 540 (732) —
7/8–14 425 (576) 600 (813) —
1–8 580 (786) 820 (1112) —
1–12 635 (861) 900 (1220) —
1–14 650 (881) 915 (1241) —
* Threads may have residual oil, but will be dry to the touch.
† Male and female threads (bolt and nut) must both be unlubricated and unplated. If either is plated or lubricated, use Table 20.3. Freightliner recommends
that all plated and unplated fasteners be coated with oil before installation.
Table 20.2, Torque Values for U.S. Customary Thread Fasteners With Dry (Unlubricated) Plain (Unplated) Threads

20.2
Specifications

Torque Values for Metric Thread Fasteners With Lubricated* or Plated Threads†
Thread Class 8.8 Bolt Class 8 Nut Class 10.9 Bolt Class 10 Nut
Diameter—
Pitch Torque: lbf·ft (N·m) Torque: lbf·ft (N·m)

8.8 8 10.9 10
f230010 f230011 f230012 f230013

M6 5 (7) 7 (9)
M8 12 (16) 17 (23)
M8 x 1 13 (18) 18 (24)
M10 24 (33) 34 (46)
M10 x 1.25 27 (37) 38 (52)
M12 42 (57) 60 (81)
M12 x 1.5 43 (58) 62 (84)
M14 66 (89) 95 (129)
M14 x 1.5 72 (98) 103 (140)
M16 103 (140) 148 (201)
M16 x 1.5 110 (149) 157 (213)
M18 147 (199) 203 (275)
M18 x 1.5 165 (224) 229 (310)
M20 208 (282) 288 (390)
M20 x 1.5 213 (313) 320 (434)
M22 283 (384) 392 (531)
M22 x 1.5 315 (427) 431 (584)
M24 360 (488) 498 (675)
M24 x 2 392 (531) 542 (735)
M27 527 (715) 729 (988)
M27 x 2 569 (771) 788 (1068)
M30 715 (969) 990 (1342)
M30 x 2 792 (1074) 1096 (1486)
* Freightliner recommends that all plated and unplated fasteners be coated with oil before installation.
† Use these torque values if either the bolt or nut is lubricated or plated (zinc-phosphate conversion-coated,
cadmium-plated, or waxed, Geomet 321XL coated, or waxed).
Table 20.3, Torque Values for Metric Thread Fasteners With Lubricated or Plated
Threads

20.3
 Specifications

Conversion Charts
When You Know U.S. Multiply When You Multiply
To Get Metric To Get U.S. Customary
Customary By Know Metric By
Length
inches (in) 25.4 millimeters (mm) 0.03937 inches (in)
inches (in) 2.54 centimeters (cm) 0.3937 inches (in)
feet (ft) 0.3048 meters (m) 3.281 feet (ft)
yards (yd) 0.9144 meters (m) 1.094 yards (yd)
miles (mi) 1.609 kilometers (km) 0.6215 miles (mi)
Area
square inches (in2) 645.16 square millimeters (mm2) 0.00155 square inches (in2)
square inches (in2) 6.452 square centimeters (cm2) 0.155 square inches (in2)
square feet (ft2) 0.0929 square meters (m2) 10.764 square feet (ft2)
Volume
cubic inches (in3) 16387.0 cubic millimeter (mm3) 0.000061 cubic inches (in3)
cubic inches (in3) 16.387 cubic centimeters (cm3) 0.06102 cubic inches (in3)
cubic inches (in3) 0.01639 liters (L) 61.024 cubic inches (in3)
fluid ounces (fl oz) 29.54 milliliters (mL) 0.03381 fluid ounces (fl oz)
pints (pt) 0.47318 liters (L) 2.1134 pints (pt)
quarts (qt) 0.94635 liters (L) 1.0567 quarts (qt)
gallons (gal) 3.7854 liters (L) 0.2642 gallons (gal)
cubic feet (ft3) 28.317 liters (L) 0.03531 cubic feet (ft3)
cubic feet (ft3) 0.02832 cubic meters (m3) 35.315 cubic feet (ft3)
Weight/Force
ounces (av) (oz) 28.35 grams (g) 0.03527 ounces (av) (oz)
pounds (av) (lb) 0.454 kilograms (kg) 2.205 pounds (av) (lb)
U.S. tons (t) 907.18 kilograms (kg) 0.001102 U.S. tons (t)
U.S. tons (t) 0.90718 metric tons (t) 1.1023 U.S. tons (t)
Torque/Work Force
inch–pounds (lbf·in) 11.298 Newton–centimeters (N·cm) 0.08851 inch–pounds (lbf·in)
foot–pounds (lbf·ft) 1.3558 Newton–meters (N·m) 0.7376 foot–pounds (lbf·ft)
Pressure/Vacuum
inches of mercury (inHg) 3.37685 kilo Pascals (kPa) 0.29613 inches of mercury (inHg)
pounds per square inch (psi) 6.895 kilo Pascals (kPa) 0.14503 pounds per square inch (psi)
Table 20.4, Metric/U.S. Customary Conversion

Then When You Multiply Then

When You Know Subtract To Get To Get
Divide By Know By Add
degrees Fahrenheit (°F) 32 1.8 degrees Celsius (°C) 1.8 32 degrees Fahrenheit (°F)
Table 20.5, Temperature Conversion

20.4
Specifications

Fluids and Lubricants

See Table 20.6 for fluid and lubricant specifications.

Fluid and Lubricant Specifications

Component Recommended Fluid or Lubricant
Front Axle Spindle Pins, Tie Rods, Drag Link, Multipurpose Grease Lithium 12- Hydroxy Stearate NLGI No. 2; for
Intermediate Steering Shaft, Front Brake and temperatures below 0°F (–18°C), use MIL-G-10924B
Pedal Shafts, Slip Spline and Universal Joints
Hydraulic Brake Master Cylinder Heavy-Duty DOT 3 Brake Fluid
Brake and Pedal Pivots Starplex 2 (lithium soap-based grease)
Engine See Manufacturer’s Recommendations
Transmission Mobil Delvac Synthetic ATF
Fuel Ultralow-Sulfur Diesel Fuel
HD5 Grade Propane
Disc Brake Caliper Rails FCCC No. 4JD623 Brake Caliper Slide Grease
Rear Axle Differential See Manufacturer’s Recommendations
Hydraulic System Reservoir ATF must meet Dexron® III or TES-389 specifications
Engine Coolant Refer to the engine manufacturer’s service literature for approved
coolant.
Table 20.6, Fluid and Lubricant Specifications

Fuse Information Main PDM Fuse Identification

CAV Description Fuse
See Table 20.7 for descriptions of a typical set of
F20 Bulkhead Module 30A
fuses. Fuse identification varies with options.
F21 Spare —
Main PDM Fuse Identification F22 Bulkhead Module 30A
F23 Spare —
CAV Description Fuse
Hydraulic Pump and RLY (if equipped
F1 Engine VCU (spare) 10A F24 25A
with hydraulic brakes)
F2 Blower Motor 30A
F25 Spare —
F3 Engine ECU 20A
F26 Spare —
F4 Spare —
F5 Ignition Switch 5A Table 20.7, Main PDM Fuse Identification
Hydro-Max RLY (if equipped with
F6 30A
hydraulic brakes)
F7 Bulkhead Module 30A Bulb Replacement
F8 ICU3 10A
See Table 20.8 for bulb replacement information.
F9 Transmission ECU 10A
F10 Spare — Replacement Bulb Part Numbers
F11 Spare — Description Part Number
F12 Radio/Diagnostic 20A Headlight, Low Beam WEE 9006
F13 Chassis Module 30A Headlight, High Beam WEE 9005
F14 Spare — Front Turn Signal Light WEE 3157
F15 Bulkhead Module 30A Front Fender Marker Light WEE 194
F16 ABS ECU 25A
F17 Chassis Module 30A Table 20.8, Replacement Bulb Part Numbers
F18 Bulkhead Module 30A
F19 Chassis Module 30A

20.5
Index

Subject Page Subject Page

A C
Adjusting Headlight Aim . . . . . . . . . . . . . . . . . . . 18.1 Cab Amenities . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.9
Aftertreatment System (ATS) Cab Storage . . . . . . . . . . . . . . . . . . . . . . . . . . 5.9
Regen Switch . . . . . . . . . . . . . . . . . . . . . . . . . . 4.4 Cup Holders . . . . . . . . . . . . . . . . . . . . . . . . . . 5.9
Aftertreatment System, EPA10 Care of Chrome Parts . . . . . . . . . . . . . . . . . . . . . 16.1
and Newer Engines . . . . . . . . . . . . . . . . . . . . . . 9.1 Care of Exterior Lights . . . . . . . . . . . . . . . . . . . . 16.1
ATS Warning Lamps . . . . . . . . . . . . . . . . . . . . 9.2 Care of Fiberglass Parts . . . . . . . . . . . . . . . . . . . 16.1
DPF Maintenance . . . . . . . . . . . . . . . . . . . . . . 9.5 Changing a Flat Tire . . . . . . . . . . . . . . . . . . . . . . 17.5
Parked Regen . . . . . . . . . . . . . . . . . . . . . . . . . 9.2 Checking Headlight Aim . . . . . . . . . . . . . . . . . . . 18.1
Principles of Operation . . . . . . . . . . . . . . . . . . . 9.1 Climate Control Panel . . . . . . . . . . . . . . . . . . . . . . 7.1
Shorting Plug . . . . . . . . . . . . . . . . . . . . . . . . . 9.4 Air Conditioning . . . . . . . . . . . . . . . . . . . . . . . . 7.3
Air Brake Operation . . . . . . . . . . . . . . . . . . . . . . 13.1 Air Selection Switch . . . . . . . . . . . . . . . . . . . . . 7.1
Caging the Parking Brakes . . . . . . . . . . . . . . . 13.2 Defrosting . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.3
Operating the Brakes . . . . . . . . . . . . . . . . . . . 13.2 Fan Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.1
Parking Brake Interlock, Fresh Air Mode . . . . . . . . . . . . . . . . . . . . . . . . 7.3
Optional . . . . . . . . . . . . . . . . . . . . . . . . . . . 13.1
Recirculation Mode . . . . . . . . . . . . . . . . . . . . . 7.3
Allison On-Highway
Transmissions . . . . . . . . . . . . . . . . . . . . . . . . . 10.1 Temperature Control Switch . . . . . . . . . . . . . . . . 7.3
Operating Instructions, 2000 Clutches . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.7
and B200 Series Clutch Adjustments . . . . . . . . . . . . . . . . . . . . . 10.8
Transmissions . . . . . . . . . . . . . . . . . . . . . . . 10.2 Clutch Lubrication . . . . . . . . . . . . . . . . . . . . . 10.8
Operating Instructions, 3000 Clutch Operation . . . . . . . . . . . . . . . . . . . . . . 10.7
and B300 Series . . . . . . . . . . . . . . . . . . . . . 10.3 Clutch Wear . . . . . . . . . . . . . . . . . . . . . . . . . 10.8
Range Inhibit Indicator, 2000 Component Information Label . . . . . . . . . . . . . . . . 1.1
and B200 Series . . . . . . . . . . . . . . . . . . . . . 10.2 Conversion Charts . . . . . . . . . . . . . . . . . . . . . . . 20.4
Safety Precautions . . . . . . . . . . . . . . . . . . . . . 10.1 Cruise Control . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.4
Ametek Instrument Panel . . . . . . . . . . . . . . . . . . 19.10 Cruise Control Switch . . . . . . . . . . . . . . . . . . . . 4.4
Menu Navigation . . . . . . . . . . . . . . . . . . . . . 19.13 Fast Idle System . . . . . . . . . . . . . . . . . . . . . . . 4.5
Menu System . . . . . . . . . . . . . . . . . . . . . . . . 19.11
Message Display Center . . . . . . . . . . . . . . . . 19.11
Priority Messages . . . . . . . . . . . . . . . . . . . . . 19.11 D
Self-Test . . . . . . . . . . . . . . . . . . . . . . . . . . . 19.11 Daily Pretrip Inspection and
Maintenance Checklist . . . . . . . . . . . . . . . . . . . 14.1
B Daily Pretrip Inspection and
Maintenance Procedures . . . . . . . . . . . . . . . . . . 15.1
Battery Access . . . . . . . . . . . . . . . . . . . . . . . . . . 2.1 Dashboard and Instrument
Battery Compartment . . . . . . . . . . . . . . . . . . . . 2.1 Panel Care . . . . . . . . . . . . . . . . . . . . . . . . . . . 16.1
Battery Disconnect Switch, Diesel Exhaust Fluid and Tank,
Optional . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.1 EPA10 and Newer Engines . . . . . . . . . . . . . . . . . 9.5
Bosch Hydraulic Pin Slide DEF Tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.5
Brakes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13.3 DEF Warnings and Engine
General Information . . . . . . . . . . . . . . . . . . . . 13.3 Limits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.5
Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . 13.3 Diesel Exhaust Fluid . . . . . . . . . . . . . . . . . . . . 9.5
Brake Burnishing (new vehicle) . . . . . . . . . . . . . . . 13.7 Fuel/DEF Gauge . . . . . . . . . . . . . . . . . . . . . . . 9.5
Braking Controls . . . . . . . . . . . . . . . . . . . . . . . . . 4.8 Drive Axles, Detroit™ and
Exhaust Brake Switch . . . . . . . . . . . . . . . . . . . . 4.8 Meritor™ . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11.1
Meritor™ WABCO® Antilock Drive Axles With Differential
Braking System (ABS) . . . . . . . . . . . . . . . . . . 4.8 Lock . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11.1
Parking Brake Control Knob . . . . . . . . . . . . . . . 4.8 Driving Precautions . . . . . . . . . . . . . . . . . . . . . . 10.1
Bulb Replacement . . . . . . . . . . . . . . . . . . . . . . . 20.5 Dual Air Brake System . . . . . . . . . . . . . . . . . . . . 13.1
Emergency Braking System . . . . . . . . . . . . . . . 13.1
Parking Brakes . . . . . . . . . . . . . . . . . . . . . . . 13.1
Primary Air Brake System . . . . . . . . . . . . . . . . 13.1

I-1
 Index

Subject Page Subject Page

Secondary Air Brake System . . . . . . . . . . . . . . 13.1 Grade Brake . . . . . . . . . . . . . . . . . . . . . . . . . . 19.10

E H
Eaton® Fuller® Straight-Shift Hazard Warning Lights . . . . . . . . . . . . . . . . . . . . 17.1
Transmissions . . . . . . . . . . . . . . . . . . . . . . . . . 10.6 Hood Opening and Closing . . . . . . . . . . . . . . . . . . 2.1
General Information, Closing the Hood . . . . . . . . . . . . . . . . . . . . . . . 2.2
Straight-Shift . . . . . . . . . . . . . . . . . . . . . . . . 10.6 Tilting the Hood . . . . . . . . . . . . . . . . . . . . . . . . 2.1
Operation, Straight-Shift . . . . . . . . . . . . . . . . . 10.6 Horn Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.4
Electrical System General Air Horn . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.4
Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.1
Electric Horn . . . . . . . . . . . . . . . . . . . . . . . . . . 4.4
Emergency Starting With
Jumper Cables . . . . . . . . . . . . . . . . . . . . . . . . 17.1
Emissions Labels . . . . . . . . . . . . . . . . . . . . . . . . . 1.1 I
Aftertreatment System
Indicators Label . . . . . . . . . . . . . . . . . . . . . . 1.1 Ignition Switch and Key . . . . . . . . . . . . . . . . . . . . 4.1
Vehicle Emission Control Instrumentation Control Unit . . . . . . . . . . . . . . . . . . 3.1
Information Label . . . . . . . . . . . . . . . . . . . . . 1.2 Dash Message Center . . . . . . . . . . . . . . . . . . . 3.1
Engine Brake . . . . . . . . . . . . . . . . . . . . . . . . . . 13.6 Ignition Sequence . . . . . . . . . . . . . . . . . . . . . . 3.1
Constant-Throttle Valves . . . . . . . . . . . . . . . . . 13.7 Mode/Reset Switch . . . . . . . . . . . . . . . . . . . . . 3.3
Engine Brake Switch . . . . . . . . . . . . . . . . . . . 13.6 Odometer . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.3
Engine Operation . . . . . . . . . . . . . . . . . . . . . . . . 19.2
Engine Shutdown . . . . . . . . . . . . . . . . . . . . . . 19.2 L
Engine Starting . . . . . . . . . . . . . . . . . . . . . . . 19.2
General Information . . . . . . . . . . . . . . . . . . . . 19.2 Lighting Controls . . . . . . . . . . . . . . . . . . . . . . . . . 4.1
High Idle Options . . . . . . . . . . . . . . . . . . . . . . . 8.3 Headlight/Parking Light
Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.1
Engine Shutdown . . . . . . . . . . . . . . . . . . . . . . . . 8.4
Marker Lamp Interrupt
Engine Starting . . . . . . . . . . . . . . . . . . . . . . . . . . 8.1 Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.2
General Information . . . . . . . . . . . . . . . . . . . . . 8.1 Panel Light Increase/
Starting After Extended Decrease Switch . . . . . . . . . . . . . . . . . . . . . . 4.1
Shutdown or Oil Change . . . . . . . . . . . . . . . . . 8.1
EPA07 Aftertreatment System
(ATS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.7 M
High-Soot-Load Idle Meritor Cam-Master® Q Plus
Shutdown . . . . . . . . . . . . . . . . . . . . . . . . . . 9.9 Brakes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13.3
Exhaust Brake . . . . . . . . . . . . . . . . . . . . . . . . . . 13.5 Cam-Master Q Plus
Driving Downhill . . . . . . . . . . . . . . . . . . . . . . . 13.6 Operation . . . . . . . . . . . . . . . . . . . . . . . . . . 13.3
General Information . . . . . . . . . . . . . . . . . . . . 13.5 Meritor WABCO Pneumatic
Operating Characteristics . . . . . . . . . . . . . . . . 13.6 Antilock Braking System
Shutting Down the Engine . . . . . . . . . . . . . . . . 13.6 (ABS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13.4
Starting the Engine . . . . . . . . . . . . . . . . . . . . . 13.5 Automatic Slack Adjusters . . . . . . . . . . . . . . . . 13.5
Automatic Traction Control . . . . . . . . . . . . . . . . 13.4
Pneumatic ABS Operation . . . . . . . . . . . . . . . . 13.4
F Mirrors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.1
Fire Extinguisher . . . . . . . . . . . . . . . . . . . . . . . . 17.6 Down View Mirror, Optional . . . . . . . . . . . . . . . . 5.1
First Aid Kit . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17.6 Mirror Heat Switch, Optional . . . . . . . . . . . . . . . 5.1
Flare Kit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17.6 Power Mirrors, Optional . . . . . . . . . . . . . . . . . . 5.1
Fluids and Lubricants . . . . . . . . . . . . . . . . . . . . . 20.5 Monthly Post-Trip Inspection
Fuse Information . . . . . . . . . . . . . . . . . . . . . . . . 20.5 and Maintenance Checklist . . . . . . . . . . . . . . . . 14.3
Monthly Post-Trip Inspection
and Maintenance Procedures . . . . . . . . . . . . . . 15.12
G Multifunction Turn Signal Lever . . . . . . . . . . . . . . . 4.2
General Information . . . . . . . . . . . . . . . . . . . . . . 19.1 Hazard Warning Lights . . . . . . . . . . . . . . . . . . . 4.3

I-2
Index

Subject Page Subject Page

High-Beam Headlights . . . . . . . . . . . . . . . . . . . 4.3 Sears Seat . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.5
Turn Signal Lever . . . . . . . . . . . . . . . . . . . . . . 4.2 Speedometer and Tachometer . . . . . . . . . . . . . . . . 3.7
Windshield Wiper/Washer Speedometer . . . . . . . . . . . . . . . . . . . . . . . . . 3.7
Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.3 Tachometer . . . . . . . . . . . . . . . . . . . . . . . . . . 3.7
Standard Instruments . . . . . . . . . . . . . . . . . . . . . . 3.7
O Coolant Temperature Gauge . . . . . . . . . . . . . . . 3.7
Engine Oil Pressure Gauge . . . . . . . . . . . . . . . . 3.7
Optional Instruments . . . . . . . . . . . . . . . . . . . . . . 3.9 Fuel Level Gauge . . . . . . . . . . . . . . . . . . . . . 19.9
Air Intake Restriction Gauge . . . . . . . . . . . . . . . 3.9 Fuel/Diesel Exhaust Fluid
Ammeter . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.10 (DEF) Gauge . . . . . . . . . . . . . . . . . . . . . . . . 3.8
Axle Oil Temperature Gauge, Primary and Secondary Air
Rear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.10 Pressure Gauges . . . . . . . . . . . . . . . . . . . . . 3.8
Digital Clock . . . . . . . . . . . . . . . . . . . . . . . . . 3.10 Voltmeter . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.9
Engine Oil Temperature Steering Controls . . . . . . . . . . . . . . . . . . . . . . . . 12.1
Gauge . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.11
Transmission Fluid
Temperature Gauge . . . . . . . . . . . . . . . . . . . 3.11 T
Turbocharger Boost Torque Charts . . . . . . . . . . . . . . . . . . . . . . . . . . 20.1
Pressure Gauge . . . . . . . . . . . . . . . . . . . . . 3.12
Towing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17.3
Front Towing Hookup . . . . . . . . . . . . . . . . . . . 17.4
P Transmission . . . . . . . . . . . . . . . . . . . . . . . . . . . 19.3
Power Distribution Modules . . . . . . . . . . . . . . . . . . 6.1 T-Handle Shift Selector . . . . . . . . . . . . . . . . . . 19.3
Powertrain Controls . . . . . . . . . . . . . . . . . . . . . . . 4.6 Transmission Mode Switch . . . . . . . . . . . . . . . 19.4
Automatic Transmissions . . . . . . . . . . . . . . . . . . 4.6
Axle Switches . . . . . . . . . . . . . . . . . . . . . . . . . 4.7 V
Rear Suspension Dump
Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.7 Vehicle Identification Number . . . . . . . . . . . . . . . . . 1.1
Preliminary Checks . . . . . . . . . . . . . . . . . . . . . . . 18.1 Velour Upholstery Cleaning . . . . . . . . . . . . . . . . . 16.3
Pretrip and Post-Trip General Chewing Gum or Wax . . . . . . . . . . . . . . . . . . . 16.3
Information . . . . . . . . . . . . . . . . . . . . . . . . . . . 14.1 Grease and Oil-Based Stains . . . . . . . . . . . . . . 16.3
Propane Refueling . . . . . . . . . . . . . . . . . . . . . . . 19.4 Mildew . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16.3
Sugar and Water-Based
Stains . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16.3
R Vinyl Upholstery Cleaning . . . . . . . . . . . . . . . . . . 16.2
Raising and Lowering a Vehicle . . . . . . . . . . . . . . 17.3 Ball Point Ink . . . . . . . . . . . . . . . . . . . . . . . . . 16.2
Lowering a Vehicle without Chewing Gum . . . . . . . . . . . . . . . . . . . . . . . . 16.2
Air Suspension . . . . . . . . . . . . . . . . . . . . . . 17.3 Miscellaneous . . . . . . . . . . . . . . . . . . . . . . . . 16.2
Raising a Vehicle without Air Nail Polish and Nail Polish
Suspension . . . . . . . . . . . . . . . . . . . . . . . . 17.3 Remover . . . . . . . . . . . . . . . . . . . . . . . . . . 16.2
Running Out of Fuel . . . . . . . . . . . . . . . . . . . . . . 17.4 Ordinary Dirt . . . . . . . . . . . . . . . . . . . . . . . . . 16.2
Paint and Shoe Heel Marks . . . . . . . . . . . . . . . 16.2
S Shoe Polish . . . . . . . . . . . . . . . . . . . . . . . . . 16.2
Sulfide Stains . . . . . . . . . . . . . . . . . . . . . . . . 16.2
Safety Precautions . . . . . . . . . . . . . . . . . . . . . . . 15.1 Tars, Asphalts, and Creosote . . . . . . . . . . . . . . 16.2
Seat Belts and Tether Belts . . . . . . . . . . . . . . . . . . 5.6
General Information . . . . . . . . . . . . . . . . . . . . . 5.6
Seat Belt Inspection . . . . . . . . . . . . . . . . . . . . . 5.6 W
Seat Belt Operation . . . . . . . . . . . . . . . . . . . . . 5.7 Warning and Indicator Lamps . . . . . . . . . . . . . . . . . 3.3
Seats . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.2 ABS Warning . . . . . . . . . . . . . . . . . . . . . . . . . 3.4
Bostrom Seat . . . . . . . . . . . . . . . . . . . . . . . . . 5.3 Check Engine Warning . . . . . . . . . . . . . . . . . . . 3.3
General Information . . . . . . . . . . . . . . . . . . . . . 5.2 Check Transmission
National 2000 Series Seat . . . . . . . . . . . . . . . . . 5.4 Indicator . . . . . . . . . . . . . . . . . . . . . . . . . . . 19.8

I-3
 Index

Subject Page
Cruise Control Indicator . . . . . . . . . . . . . . . . . . 3.6
Diesel Particulate Filter
(DPF) Lamp . . . . . . . . . . . . . . . . . . . . . . . . . 3.5
Emergency Buzzer . . . . . . . . . . . . . . . . . . . . . . 3.6
Fasten Seat Belt Warning . . . . . . . . . . . . . . . . . 3.5
Headlight High-Beam
Indicator . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.6
High Coolant Temperature
Warning . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.5
High Exhaust System
Temperature (HEST) Lamp . . . . . . . . . . . . . . . 3.5
Hydraulic Brake System
Warning . . . . . . . . . . . . . . . . . . . . . . . . . . . 19.7
Left-Turn Indicator . . . . . . . . . . . . . . . . . . . . . . 3.5
Low Air Pressure Warning . . . . . . . . . . . . . . . . . 3.6
Low Battery Voltage Warning . . . . . . . . . . . . . . . 3.5
Low Oil Pressure Warning . . . . . . . . . . . . . . . . . 3.5
Maintenance Warning Lamp . . . . . . . . . . . . . . . 19.6
Malfunction Indicator Lamp
(MIL) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.4
Optional Warning and
Indicator Lamps . . . . . . . . . . . . . . . . . . . . . . 3.6
Parking Brake On Warning . . . . . . . . . . . . . . . . 3.5
Right-Turn Indicator . . . . . . . . . . . . . . . . . . . . . 3.6
Shift Inhibit Indicator . . . . . . . . . . . . . . . . . . . . 19.8
Stop Engine Warning . . . . . . . . . . . . . . . . . . . . 3.3
Stop Transmission Indicator . . . . . . . . . . . . . . . 19.8
Traction Control Indicator . . . . . . . . . . . . . . . . . 19.8
Transmission Overheat
Warning . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.5
Wait to Start Indicator . . . . . . . . . . . . . . . . . . . 19.7
Water In Fuel Indicator . . . . . . . . . . . . . . . . . . . 3.6
Washing and Polishing . . . . . . . . . . . . . . . . . . . . 16.1
Weekly Post-Trip Inspection
and Maintenance Checklist . . . . . . . . . . . . . . . . 14.3
Weekly Post-Trip Inspection
and Maintenance Procedures . . . . . . . . . . . . . . 15.11
Windows . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.1

I-4