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Introduction

This manual provides information needed to operateand understand the vehicle and its components.More detailed information is contained in the Owner’sWarranty Information for North America booklet, andin the vehicle’s workshop and maintenance manuals.

Custom-built Freightliner vehicles are equipped withvarious chassis and cab components. Not all of theinformation contained in this manual applies to everyvehicle. For details about components in your ve-hicle, refer to the chassis specification pages in-cluded in all new vehicles and to the vehicle specifi-cation decal, located inside the vehicle.

For your reference, keep this manual in the vehicleat all times.

IMPORTANT: Descriptions and specifications inthis manual were in effect at the time of printing.Freightliner Trucks reserves the right to discon-tinue models and to change specifications ordesign at any time without notice and withoutincurring obligation. Descriptions and specifica-tions contained in this publication provide nowarranty, expressed or implied, and are subjectto revisions and editions without notice.

Environmental Concerns andRecommendations

Whenever you see instructions in this manual to dis-card materials, you should first attempt to reclaimand recycle them. To preserve our environment, fol-low appropriate environmental rules and regulationswhen disposing of materials.

Event Data Recorder

This vehicle is equipped with one or more devicesthat record specific vehicle data. The type andamount of data recorded varies depending on howthe vehicle is equipped (such as the brand of engine,if an air bag is installed, or if the vehicle features acollision avoidance system, etc.).

Customer Assistance Center

Having trouble finding service? Call the CustomerAssistance Center at 1-800-385-4357 or 1-800-FTL-HELP. Call night or day, weekdays or weekends, for

dealer referral, vehicle information, breakdown coor-dination, or Fleetpack assistance. Our people areknowledgeable, professional, and committed to fol-lowing through to help you keep your truck moving.

Reporting Safety DefectsIf you believe that your vehicle has a defect whichcould cause a crash or could cause injury ordeath, you should immediately inform the NationalHighway Traffic Safety Administration (NHTSA) inaddition to notifying Daimler Trucks North AmericaLLC.

If the NHTSA receives similar complaints, it mayopen an investigation, and if it finds that a safetydefect exists in a group of vehicles, it may order arecall and remedy campaign. However, NHTSAcannot become involved in individual problemsbetween you, your dealer, or Daimler Trucks NorthAmerica LLC.

To contact NHTSA, you may call the VehicleSafety Hotline toll-free at 1-888-327-4236 (TTY:1-800-424-9153); go to www.safercar.gov; orwrite to: Administrator, NHTSA, 1200 New JerseyAvenue, SE, Washington, DC 20590. You can alsoobtain other information about motor vehicle safetyfrom www.safercar.gov.

Canadian customers who wish to report a safety-related defect to Transport Canada, Defect Investi-gations and Recalls, may telephone the toll-freehotline 1-800-333-0510, or contact TransportCanada by mail at: Transport Canada, ASFAD,Place de Ville Tower C, 330 Sparks Street, Ot-tawa, Ontario, Canada K1A 0N5.

For additional road safety information, please visitthe Road Safety website at: www.tc.gc.ca/roadsafety.

Foreword

STI-455-4 (1/12)A24-01238-000

Printed in U.S.A.

© 2001–2012 Daimler Trucks North America LLC. All rights reserved. Daimler Trucks North America LLC is a Daimlercompany.

No part of this publication, in whole or part, may be translated, reproduced, stored in a retrieval system, or transmittedin any form by any means, electronic, mechanical, photocopying, recording, or otherwise, without the prior written per-mission of Daimler Trucks North America LLC. For additional information, please contact Daimler Trucks NorthAmerica LLC, Service Systems and Documentation, P.O. Box 3849, Portland OR 97208–3849 U.S.A. or refer towww.Daimler-TrucksNorthAmerica.comand www.FreightlinerTrucks.com.

Foreword

ContentsChapter Page

Introduction, Environmental Concerns and Recommendations,Event Data Recorder, Customer Assistance Center, ReportingSafety Defects . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Foreword

1 Vehicle Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.1

2 Vehicle Access . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.1

3 Instruments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.1

4 Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.1

5 Cab Features . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.1

6 Heater, Ventilator and Air Conditioner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.1

7 Engines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.1

8 Drivetrain . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.1

9 Steering and Brake Systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.1

10 Fifth Wheels and Trailer Couplings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.1

11 Pretrip and Post-Trip Inspections and Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11.1

12 Cab Appearance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12.1

13 In an Emergency . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13.1

14 Headlight Aiming . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14.1

15 Hybrid Electric Vehicle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15.1

16 Natural Gas Vehicle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16.1

Index . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I.1

1

Vehicle IdentificationVehicle Specification Decal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.1

Federal Motor Vehicle Safety Standard (FMVSS) Labels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.1

Canadian Motor Vehicle Safety Standard (CMVSS) Labels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.2

Tire and Rim Labels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.2

EPA Emission Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.2

Vehicle Specification Decal

The vehicle specification decal lists the vehiclemodel, identification number, and major componentmodels. It also recaps the major assemblies and in-stallations shown on the chassis specification sheet.One copy of the specification decal is attached to thedriver’s side sunvisor; another copy is inside the rearcover of the Owner’s Warranty Information for NorthAmerica booklet. An illustration of the decal is shownin Fig. 1.1.

NOTE: Labels shown in this chapter are ex-amples only. Actual specifications may vary fromvehicle to vehicle.

Federal Motor Vehicle SafetyStandard (FMVSS) LabelsNOTE: Due to the variety of FMVSS certificationrequirements, not all of the labels shown willapply to your vehicle.

Tractors with or without fifth wheels purchased in theU.S. are certified by means of a certification state-ment (Fig. 1.2) and the tire and rim information, com-bined into one label. This label is attached to the leftrear door post, as shown in Fig. 1.3.

If purchased for service in the U.S., trucks built with-out a cargo body have an incomplete certificationlabel (Fig. 1.4) attached to the left rear door post. Inaddition, after completion of the vehicle, a certifica-tion label similar to that shown in Fig. 1.2 must beattached by the final-stage manufacturer. This labelwill be located on the left rear door post and certifies

f08002111/21/96

USE VEHICLE ID NO.

WHEN ORDERING PARTS

WHEELBASE

ENGINE NO.

TRANS NO.

FRT AXLE NO.

REAR AXLE NO.

REAR AXLE NO.

RATIO

FOR COMPLETE PAINT INFORMATION

SEE VEHICLE SPECIFICATION SHEET

MANUFACTURED BY

MODEL

VEHICLE ID NO.

DATE OF MFR

ENGINE MODEL

TRANS MODEL MAIN

FRONT AXLE MODEL

REAR AXLE MODEL

PAINT MFR

PAINT NO.

PART NO. 24−00273−010

COMPONENT INFORMATION

IMRON PAINT−CAB

CAB COLOR A: WHITE (4775)

CAB COLOR B: BROWN (3295)

CAB COLOR C: BROWN (29607)

CAB COLOR D: DARK BROWN (7444)

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

11/14/2001 f080118

1

2

3

1. Date of Manufacture: by month and year2. Gross Vehicle Weight Rating: developed by taking

the sum of all the vehicle’s gross axle ratings3. Gross Axle Weight Ratings: developed by

considering each component in an axle system–including suspension, axle, wheels, and tires–andusing the lowest component capacity as the valuefor the system

Fig. 1.2, Certification Statement, U.S.

1

2

f08011711/13/2001

1. Tire and Rim Information2. Certification Statement

Fig. 1.3, Label Location

11/14/2001 f080120

Fig. 1.4, Incomplete Vehicle Certification Label, U.S.

Vehicle Identification

1.1

that the vehicle conforms to all applicable FMVSSregulations in effect on the date of completion.

Canadian Motor Vehicle SafetyStandard (CMVSS) Labels

In Canada, tractors with fifth wheels are certified bymeans of a "Statement of Compliance" label and theCanadian National Safety Mark (Fig. 1.5), which areattached to the left rear door post. In addition, tireand rim information (Fig. 1.6) is also included in thelabel attached to the left rear door post.

If purchased for service in Canada, trucks built with-out a cargo body and tractors built without a fifthwheel are certified by a "Statement of Compliance"label, similar to Fig. 1.2. This label must be attachedby the final-stage manufacturer after completion ofthe vehicle. The label is located on the left rear doorpost, and certifies that the vehicle conforms to allapplicable CMVSS regulations in effect on the dateof completion.

Tire and Rim Labels

Tire and rim labels certify suitable tire and rim combi-nations that can be installed on the vehicle, for the

given gross axle weight rating. Tires and rims in-stalled on the vehicle at the time of manufacture mayhave a higher load capacity than that certified by thetire and rim label. If the tires and rims currently onthe vehicle have a lower load capacity than thatshown on the tire and rim label, then the tires andrims determine the load limitations on each of theaxles.

See Fig. 1.6 for U.S. and Canadian tire and rim la-bels.

EPA Emission Control

Vehicle Noise Emission Control Label

A vehicle noise emission control label (Fig. 1.7) isattached either to the left side of the dashboard or tothe top-right surface of the frontwall between thedash and the windshield.

IMPORTANT: Certain Freightliner incompletevehicles may be produced with incomplete noisecontrol hardware. Such vehicles will not have avehicle noise emission control information label.For such vehicles, it is the final-stage manufac-turer’s responsibility to complete the vehicle inconformity to U.S. EPA regulations (40 CFR Part205) and label it for compliance.

EPA07 and EPA10 Emission Control

To meet EPA07 and EPA10 emissions regulations forvehicles domiciled in the USA or Canada, enginesmanufactured after December 31, 2006 (EPA07) orDecember 31, 2009 (EPA10) are equipped with anemission aftertreatment system. Vehicles domiciledoutside of the USA and Canada may not have after-treatment equipment, depending upon local statutoryemissions guidelines. There is a warning label(placement will vary), for important new warning indi-cators in the driver’s message display, that pertain tothe aftertreatment system.

f08002410/10/2006

Fig. 1.5, Canadian National Safety Mark

11/14/2001 f080119

1 2

1. Gross Weight Rating By Component in Axle System2. Gross Vehicle Weight Rating By Component in

Vehicle As a Whole

Fig. 1.6, Tire and Rim Information

10/06/98 f080026

24−00273−020

VEHICLE NOISE EMISSION CONTROL INFORMATION

FREIGHTLINER CORPORATIONTHIS VEHICLE CONFORMS TO U.S. EPA REGULATIONS FOR NOISE EMISSIONAPPLICABLE TO MEDIUM AND HEAVY TRUCKS.THE FOLLOWING ACTS OR THE CAUSING THEREOF BY ANY PERSON ARE PROHIBITED BYTHE NOISE CONTROL ACT OF 1972:A. THE REMOVAL OR RENDERING INOPERATIVE, OTHER THAN FOR PURPOSES OF MAINTENANCE, REPAIR, OR REPLACEMENT, OF ANY NOISE CONTROL DEVICE OR ELEMENT OF DESIGN (LISTED IN THE OWNER’S MANUAL) INCORPORATED INTO THIS VEHICLE IN COMPLIANCE WITH THE NOISE CONTROL ACT.B. THE USE THIS VEHICLE AFTER SUCH DEVICE OR ELEMENT OF DESIGN HAS BEEN REMOVED OR RENDERED INOPERATIVE.

DATE OF MANUFACTURE 01/96

Fig. 1.7, Vehicle Noise Emission Control Label


1.2

It is a violation of US federal law to alter exhaustplumbing or aftertreatment in any way that wouldbring the engine out of compliance with certificationrequirements. (Ref: 42 U.S.C. S7522(a) (3).) It is theowner’s responsibility to maintain the vehicle so thatit conforms to EPA regulations.


1.3

2

Vehicle AccessCab Door Locks and Handles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.1

Grab Handles and Access Steps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.1

Cab Entry and Exit, Vehicles With Two Steps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.2

Cab Entry and Exit, Vehicles With One Step . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.4

Back-of-Cab Access . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.5

Battery Access . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.6

Hood Opening and Closing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.7

Fuse Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.8

Cab Door Locks and Handles

One key operates the ignition switch and all of thedoor locks.

IMPORTANT: Each key is numbered. Recordthe number so a duplicate key can be made, ifneeded.

To unlock the driver’s door from outside the cab, in-sert the key in the lockset and turn it one-quarter turnclockwise (Fig. 2.1). To remove the key, turn it coun-terclockwise to its original position. Pull out on thedoor pull handle to open the door.

To unlock the passenger’s door from outside the cab,insert the key in the lockset and turn it one-quarterturn counterclockwise. Turn the key clockwise to theoriginal position to remove it.

NOTE: The cab door locks can be operatedwhen the doors are open.

To lock a door from outside the cab, do either one ofthe following:

• Insert the key in the lockset and turn it in thedirection opposite to the unlocking direction(counterclockwise for the driver’s door, clock-wise for the passenger’s door). Close the doorif it is open.

• Push down the inside lock button (Fig. 2.2).Close the door.

To open the door from the inside, lift up on the doorlever. This will unlatch the door whether or not it islocked. If it is open, close the door by pulling theinner door grab handle.

To lock either door from inside the cab, slide the lockbutton downwards (Fig. 2.3). To unlock the doorwithout unlatching it, push the lock button upwards. Ared dot will show below the lock button when it isunlocked.

Grab Handles and AccessSteps

For ease of entry and exit, there are three grabhandles, one on the A-pillar, one on the inner B-pillar,and an optional one on the inside of the door. In ad-dition, the steering wheel may be used to providesecure handholds. There are one or two accesssteps to provide secure footholds.

10/22/2001 f720397

1

2

3

1. Key2. Lock

3. Door Pull Handle

Fig. 2.1, Exterior Door Handle

10/25/2001 f720398

12

3 4

5

To open the door from the inside, lift up on the door lever(arrow).

1. Lock Button2. Armrest/Handle3. Door Lever4. Window Crank5. Inner Door Grab Handle (optional)

Fig. 2.2, Door Interior

Vehicle Access

2.1

NOTE: The A-pillar grab handle is not installedon the driver’s side.

The grab handles, access steps, and steering wheelare all part of the cab access system. Use these"helping hands" when getting into, or out of, the cab.They will increase your security and comfort.

Cab Entry and Exit, VehiclesWith Two Steps

WARNING

Wet or dirty shoe soles greatly increase thechance of slipping or falling. If your soles are wetor dirty, be especially careful when climbingonto, or down from, the back-of-cab area.

Always maintain three-point contact with theback-of-cab access supports while entering andexiting the back-of-cab area. Three-point contactmeans both feet and one hand, or both handsand one foot, on the grab handles, steps, anddeck plates. Other areas are not meant to sup-port back-of-cab access, and grabbing or step-ping in the wrong place could lead to a fall, andpersonal injury.

Be careful not to get hands or feet tangled inhoses or other back-of-cab equipment. Careless-ness could cause a person to trip and fall, withpossible injury.

Use the cab access system (grab handles, accesssteps, and steering wheel) to enter or exit the cab.

Entering from the Driver’s Side

To enter the cab from the driver’s side, do the follow-ing steps (Fig. 2.4):

1. Use the door pull handle to open the driver’sdoor, and place anything that you are carrying inthe cab.

2. Grasp the B-pillar grab handle with both hands.Reach up as far as is comfortable.

3. Place your right foot on the bottom step, and pullyourself up.

4. Place your left foot on the top step.

5. Grasp the steering wheel with your left hand, andstep up.

6. Step into the cab with your right foot first, andgrasp the steering wheel with your right hand.

10/24/2001 f720401

1

2

3

Move the button down to lock, and up to unlock (arrows).The door is unlocked when the red dot shows.

1. Door2. Lock Button

3. Red Dot

Fig. 2.3, Door Lock Button

11/02/2001 f720399

1

5

4

3

2

1. Steering Wheel2. B-Pillar Grab Handle3. Bottom Step4. Top Step5. Inner Door Grab Handle (optional)

Fig. 2.4, Cab Access System, Driver’s Side

Vehicle Access

2.2

NOTE: You can also use the inner door grabhandle, if available, as a support when gettingup or down from the bottom step.

Exiting from the Driver’s Side

To exit the cab from the driver’s side, do the follow-ing steps (Fig. 2.4):

IMPORTANT: Do not attempt to exit the cabwhile carrying any items in your hands.

1. If you wish to take any items with you, after youexit the cab, place them in an accessible locationon the seat or cab floor. Make sure they will notget in your way as you exit.

WARNING

Always face in when exiting the cab. Do not at-tempt to exit with your back to the cab, as youwould going down a flight of stairs. It is easier toslip or lose your balance. If you slip when exitingin this way, there is a greater likelihood of per-sonal injury.

2. Grasp the steering wheel with both hands. Placeyour left foot on the top step, and stand on thethreshold, facing into the cab.

3. Move your right hand to the B-pillar grab handle.

4. Move your right foot to the bottom step.

5. Move your left hand to the B-pillar grab handle.

6. Step to the ground with your left foot first.

7. Retrieve from the cab any items that you wish totake with you.


Entering from the Passenger’s Side

To enter the cab from the passenger’s side, do thefollowing steps (Fig. 2.5):

1. Open the passenger’s door, and place anythingthat you are carrying in the cab.

2. Grasp the B-pillar grab handle on the door withboth hands.

3. Place your left foot on the bottom step and stepup to the upper step with your right foot.

4. Move your right hand to the A-pillar cover grabhandle.

5. Place your left foot on the top step and step up.

6. Move your left hand to the A-pillar cover grabhandle.

7. Step into the cab with your left foot first.


Exiting from the Passenger’s Side

To exit the cab from the passenger’s side, do the fol-lowing steps (Fig. 2.5):


1. If you wish to take any items with you, after youexit the cab, place them in an accessible location

3

5

10/23/2001 f720400

1

2

4

1. Bottom Step2. Top Step3. B-Pillar Grab Handle4. Sidewall Grab Handle (optional)5. A-Pillar Cover Grab Handle

Fig. 2.5, Cab Access System, Passenger’s Side andBack of Cab

Vehicle Access

2.3

on the seat or cab floor. Make sure they will notget in your way as you exit.

WARNING


2. Grasp the A-pillar cover grab handle with bothhands, then place your right foot on the top stepwhile standing up from the seat facing inward.

3. Place your left foot on the top step.


5. Move your left foot to the bottom step.


7. Step to the ground with your right foot first.



Cab Entry and Exit, VehiclesWith One Step

WARNING

Wet or dirty shoe soles greatly increase thechance of slipping or falling. If your soles are wetor dirty, be especially careful when climbingonto, or down from, the back-of-cab area.

Always maintain three-point contact with theback-of-cab access supports while entering andexiting the back-of-cab area. Three-point contactmeans both feet and one hand, or both handsand one foot, on the grab handles, steps, anddeck plates. Other areas are not meant to sup-port back-of-cab access, and grabbing or step-ping in the wrong place could lead to a fall, andpersonal injury.

Be careful not to get hands or feet tangled inhoses or other back-of-cab equipment. Careless-

ness could cause a person to trip and fall, withpossible injury.

Use the cab access system (grab handles, accesssteps, and steering wheel) to enter or exit the cab.

Entering from the Driver’s Side

To enter the cab from the driver’s side, do the follow-ing steps (Fig. 2.4):

1. Use the door pull handle to open the driver’sdoor, and place anything that you are carrying inthe cab. Use the door armrest/handle and, ifavailable, the inner door grab handle, as a sup-port if needed.

2. Grasp the B-pillar grab handle with both hands.Reach up as far as is comfortable.

3. Place your right foot on the step, and pull your-self up.

4. Step into the cab with your left foot.

5. Grasp the steering wheel with your left hand.

6. Step into the cab with your right foot, and graspthe steering wheel with your right hand.


Exiting from the Driver’s Side

To exit the cab from the driver’s side, do the follow-ing steps (Fig. 2.4):



WARNING


Vehicle Access

2.4

2. Grasp the steering wheel with both hands. Placeyour left foot on the step, and stand on thethreshold, facing into the cab.



5. Move your right foot onto the step.

6. Step to the ground with your left foot first.



Entering from the Passenger’s Side

To enter the cab from the passenger’s side, do thefollowing steps (Fig. 2.5):

1. Open the passenger’s door, and place anythingthat you are carrying in the cab.

2. Grasp the B-pillar grab handle with both hands.

3. Place your left foot on the step and step up tothe cab with your right foot.

4. Move your right hand to the A-pillar cover grabhandle.

5. Move your left hand to the A-pillar cover grabhandle.

6. Step into the cab with your left foot.


Exiting from the Passenger’s Side

To exit the cab from the passenger’s side, do the fol-lowing steps (Fig. 2.5):



WARNING


2. Grasp the A-pillar cover grab handle with bothhands, then place your right foot on the stepwhile standing up from the seat facing inward.

3. Place your left foot on the step.



6. Step to the ground with your right foot first.



Back-of-Cab Access

When trailer air and electrical connections cannot bereached conveniently from the ground, Federal MotorCarrier Safety Regulations require commercial carri-ers to provide back-of-cab access.

Optional grab handles are mounted on each cabsidewall, or on the left sidewall only. See Fig. 2.6.Steps are mounted either on the fuel tank(s) or onmetal brackets. When a deck plate is necessary, it ismounted across the top of the frame rails.

IMPORTANT: Climb onto, and down from, back-of-cab access facing in toward the vehicle, asyou would on a ladder. Do not climb up or downfacing out away from the vehicle.

WARNING

Wet or dirty shoe soles greatly increase thechance of slipping or falling. If your soles are wetor dirty, be especially careful when climbingonto, or leaving, the back-of-cab area.

Always maintain three-point contact with theback-of-cab access supports while entering and

Vehicle Access

2.5

exiting the back-of-cab area. Three-point contactmeans both feet and one hand, or both handsand one foot, on the grab handles, steps, anddeck plates. Other areas are not meant to sup-port back-of-cab access, and grabbing or step-ping in the wrong place could lead to a fall, andpersonal injury.

Be careful not to get hands or feet tangled inhoses or other back-of-cab equipment. Careless-ness could cause a person to trip and fall, withpossible injury.

Entering Back-of-Cab

When climbing onto the deck plate, do the following:

1. Grasp the sidewall grab handle with both hands.Reach up as far as is comfortable.

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

3. Place your other foot on the top step.

4. Move your lower hand to a higher position on thegrab handle.

5. Step onto the deck plate.

Climbing Down from Back-of-Cab

To climb down from the back-of-cab area:

1. Grasp the sidewall grab handle with both hands.

2. Step one foot at a time onto the top step.

3. Move your upper hand to a lower position on thegrab handle.

4. Move one foot to the bottom step.

5. Move your upper hand to a lower position on thegrab handle.

6. Step to the ground with your upper foot first.

Battery Access

Battery Compartment

The battery compartment is located in the lower partof the cab beneath and to the rear of the driver’sdoor. It is fastened by a quarter-turn fastener. Toopen the battery access door, turn the quarter-turnfastener with a small screwdriver. See Fig. 2.7.

09/28/2007 f6023361

1

2

3

1. Steps2. Grab Handle

3. Deck Plate

Fig. 2.6, Back-of-Cab Access Supports (typical)

10/25/2001 f543934

Open the battery access door by turning the quarter-turnfastener (arrow) with a small screwdriver.

Fig. 2.7, Battery Compartment, Closed

Vehicle Access

2.6

With the battery access door open (Fig. 2.8), it iseasy to get access to the battery terminals for clean-ing, charging, or emergency jump starting.

To close the battery access door, do the followingsteps:

1. Swing the battery access door to line up thequarter-turn fastener with the hole in the cabdoor frame.

2. Close the battery access door and check to besure the quarter-turn fastener is engaged withthe hole.

3. Turn the fastener one-quarter turn.

Cab (Battery) Isolation Switch

The cab isolation switch (see Fig. 2.9) is located onthe cab floor at the left of the driver’s seat, or insidethe battery box. The battery isolation switch reducesthe power to the cab and engine power wiring. Use itwhenever the vehicle is to be put out of service forextended periods.

IMPORTANT: The battery disconnect switchdoes not completely isolate the batteries fromthe electrical system. For service operations thatrequire that the batteries be disconnected, al-ways shut down the engine and remove thenegative battery cables.

NOTE: Whenever battery power is discon-nected, clocks and electronically tuned radiosmust be reset.

Hood Opening and Closing

The hood can be raised to a full-open position. A tor-sion bar helps you to raise the hood, and to lower itto the operating position. Hood restraint cables pre-vent the hood from overtravel. A hood damper limitsthe closing speed. In the operating position, the hoodis secured to the cab-mounted half-fenders by ahold-down latch on each side of the hood.

To Open the Hood

1. Apply the parking brakes.

2. Release both hood hold-down latches by pullingthe ends outward. See Fig. 2.10.

CAUTION

Do not let the hood free-fall to the full-open posi-tion. To do so could cause damage to the hoodor hood straps.

3. Standing in front of the hood, raise the rear ofthe hood upward until it reaches the over-centerposition (45 degrees from vertical). Then slowlybring it to a stop.

To Close the Hood

1. Push the hood over center.

10/24/2001 f543933

1

2

3

4

1. Top Step2. Battery3. Cab4. Battery Access Door

Fig. 2.8, Battery Compartment, Open

01/18/95 f600150a

Fig. 2.9, Cab (Battery) Isolation Switch

Vehicle Access

2.7

2. As the hood goes over center, the damper auto-matically slows its rate of descent. If needed, youcan also slow its rate of descent with your hand.

3. Make sure the hood is flush with the cowl, thensecure the hood by engaging both hood hold-down latches.

IMPORTANT: Make sure that both hold-downlatches are fully engaged before operating thevehicle.

Fuse Identification

Main Fuse Box/PDM

The main fuse box, also known as the power distri-bution module, or PDM, is located under the hood onthe left front fender just forward of the bulkhead mod-ule. See Fig. 2.11. To open the fuse box, pull downon the wire clips holding the lid on the fuse box.

A sticker inside the lid of the fuse box shows the lo-cations of the fuses and describes the circuit(s) thateach fuse protects (see Fig. 2.12). See Table 2.1 fordescriptions of a typical set of fuses. The fuses in themain fuse box are mini blade-type fuses. Batterypower fuses, located near the batteries, are bolt-inmegafuses.

Because the electrical system is multiplexed, no re-lays are needed. The multiplexing module performsthe functions normally provided by relays.

Fuse Identification, Main Fuse Box

Pos.

No.Description Fuse Color Rating

F1 VCU (MBE900 only) Red 10 Amp

F2 Blower Motor Green 30 Amp

F3 Engine ECU Yellow 20 Amp

F4Transmission ControlUnit

Green 30 Amp

F5 Ignition Switch Tan 5 Amp

F6 Spare — —

F7 Bulkhead Module Green 30 Amp

F8 ICU Red 10 Amp

F9Transmission ControlUnit

Yellow 20 Amp

F10 Door Locks (optional) Red 10 Amp

F11 Mirrors (optional) Blue 15 Amp

F12 Radio/Diagnostics Yellow 20 Amp

F13 Chassis Module Green 30 Amp

F14L/H Power Windows(optional)

Blue 15 Amp


F16 ABS ECU Blue 15 Amp





F21R/H Power Windows(optional)

Blue 15 Amp


F23 Spare — —

F24 Spare — —

F25 Spare — —

F26 Spare — —

M1 Battery Power — 125 Amp



Table 2.1, Fuse Identification, Main Fuse Box

Trailer and Taillight Fuse Boxes

The trailer fuse box and the taillight fuse box, on ve-hicles so equipped, are mounted on a bracket withthe chassis module on the left-hand frame rail aft ofthe cab, or on a crossmember at the end of theframe rail. These may be referred to as the chassisfuse box or chassis PDM. See Fig. 2.13 for trailerfuse and relay information, and Fig. 2.14 for taillightfuse and relay information.

10/24/2001 f880555

1

2

3

4

1. Fender2. Latch Hook

3. Latch Handle4. Half-Fender

Fig. 2.10, Hood Hold-Down Latch

Vehicle Access

2.8

These fuse boxes contain mini blade-type fuses, 12-volt mini relays, and 12-volt micro relays.

09/25/2001 f543935

1

2

1. Bulkhead Module 2. Main Fuse Box

Fig. 2.11, Location of the Main Fuse Box

10/25/2001 f543936

Fig. 2.12, Main Fuse Box Diagram

09/28/2004 f544528

Fig. 2.13, Trailer Fuse Box Diagram

10/07/2004 f544541

Fig. 2.14, Taillight Fuse Box Diagram

Vehicle Access

2.9

3

InstrumentsInstrumentation Control Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.1

Warning and Indicator Lights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.5

Standard Instruments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.9

Optional Instruments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.12

Overhead Instrument Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.15

Instrumentation Control Unit

The ICU3 instrument cluster is a single unit that pro-vides the driver with engine and vehicle information.It is comprised of gauges, warning and indicatorlamps, an audible warning, and a liquid crystal dis-play (LCD) screen.

IMPORTANT: Vehicles that are domiciled out-side of the U.S. and Canada may not haveEPA07- or EPA10-compliant engines with anemission aftertreatment system (ATS), depend-ing upon local jurisdictional emissions guide-lines.

Figure 3.1 shows a typical ICU3 instrument clusterinstalled in EPA07- and EPA10-compliant vehicles.

Vehicles that are not EPA10-compliant do not have afuel/diesel exhaust fluid (DEF) gauge.

There can be up to eight gauges on the driver’s in-strument panel (six electronic and two mechanical).The air gauges operate mechanically.

The ICU3 also has the capability to drive up to sixindependent stand-alone gauges such as those in-stalled on the auxiliary dash panel. Figure 3.2 showsa typical dash panel layout.

Dash Message Center

The dash message center houses all of the standardand optional warning and indicator lamps, as well asthe driver display screen. The display screen has a

f610525a

1

2 3 4 5

6

7

8

12

11 10 909/10/2009

NOTE: This instrument cluster is shown with the U.S. speedometer, which shows miles per hour (mph) more prominentlythan kilometers per hour (km/h).

1. Engine Oil Pressure Gauge2. Dash Message Center3. Driver Display Screen4. Headlight High-Beam Indicator

5. Fuel/DEF Level Gauge6. Primary Air Pressure Gauge7. Mode/Reset Button8. Secondary Air Pressure Gauge

9. Speedometer (U.S. version)10. Tachometer11. Transmission Temperature Gauge12. Coolant Temperature Gauge

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

Instruments

3.1

7-character LCD that normally shows odometer read-ings and, below that, a smaller 3-character LCD thatshows voltmeter readings. Warning messages anddiagnostic fault codes will also appear in the displayscreen.

Information provided by the driver display screen in-cludes:

• odometer readings (in miles or kilometers)

• trip and total engine distance

• trip and total engine hours

• service screens

• fault code displays

• warning messages

Ignition Sequence

When the ignition is turned on, the ICU3 runsthrough the ignition sequence. See Fig. 3.3. First,the ICU3 performs a self-test, looking for active faultcodes and displays them, if any, one after the otheruntil the engine is started or the ignition switch isturned off. If there are no active fault codes, thedriver display screen displays the odometer.

When the ignition is first turned on, all the electronicgauges complete a full sweep of their dials, thewarning and indicator lamps illuminate, and the au-dible warning sounds for three seconds. On EPA10-compliant vehicles, the DEF level indicator illumi-nates all segments green, then turns them off one ata time before turning the left most segment amberthen red.

5

4

f610578

1

23

10/11/2001

NOTE: Instruments and controls, and their locations, may vary from those shown.

1. Left-Hand Control Panel2. ICU33. Right-Hand Control Panel

4. Auxiliary Dash Panel5. Climate Control Panel

Fig. 3.2, Dash Panel Layout (typical)

Instruments

3.2

NOTE: The air gauges do not sweep.

NOTE: If active fault codes are present, take thevehicle to an authorized Freightliner service fa-cility as soon as possible.

If the fault is a serious problem that requires immedi-ate attention, the engine protection system will acti-vate. In most cases, the check engine light will illumi-nate also.

If service miles or service hours has been exceeded,either Fig. 3.4 or Fig. 3.5 will come up before thefault screen (if fault codes are present). If no faultcodes are present and service hours or miles areexceeded, either Fig. 3.4 or Fig. 3.5 will stay dis-played until the parking brake is released with theengine running, or the mode/reset button is pressed.

POWER ON

PARK BRAKE

IGNITION ON

HEADLIGHTS ON

RELEASE PARK BRAKE

f04080410/26/2009

RELEASED − MOVING

FAULT CODESCREEN

IF NO FAULTSWERE DETECTED

ELECTRONIC GAUGE NEEDLESSWEEP, WARNING/INDICATORLIGHTS COME ON, BUZZER SOUNDS

IF FAULT DETECTED

ICU PERFORMS SELFTEST:

123456.7

ABS 11

ODOMETERSCREEN

123456.7

12.3 VOLTS

123456.7

12.3 VOLTS

MI

MI

MI

/ IGNITION OFF

**

**

*

* HOURS SERVICE or MI SERVICE may display

** If the key was cycled off wile displaying Trip Miles, Trip Hours, or Ambient Air Temperature, that screen will be dis-played instead of odometer miles, when the key is cycled ON without any fault codes.

Fig. 3.3, Ignition Sequence

10/26/2009

SERVICE

HOURS

f040805

Fig. 3.4, Service Hours Exceeded

10/26/2009

SERVICE

MI

f040806

Fig. 3.5, Service Miles Exceeded

Instruments

3.3

Odometer

The odometer is set to display in either miles or kilo-meters, depending on the primary scale of thespeedometer. The legend, either MI or KM, illumi-nates between the odometer and the volts displaywhen the engine is running or the headlights are on.

The odometer is a 7-digit display with a decimal pointuntil the vehicle has traveled 999,999.9 miles or kilo-meters (km). At one million miles (km), the odometerrolls over to "1000000" without the decimal point, andcan continue up to 9,999,999. The odometer onlydisplays significant figures (no leading zeros).

Mode/Reset Button

The mode/reset button (Fig. 3.6) is located on theright side of the instrument cluster. The mode/resetbutton is used to scroll through the displays on thedriver display screen, and to reset the trip distanceand trip hours values to zero.

Functions

When the parking brake is off, pressing the mode/reset button will scroll through the following screens:

i. Trip distance

ii. Trip hours

iii. Outside temperature

iv. Back to odometer

When the parking brake is set, pressing the mode/reset button will scroll through the following screens:

i. Trip distance

ii. Trip hours

iii. Outside temperature

iv. Select screen

v. Temperature alert screen

vi. Diagnostic screen

vii. Clear screen (with less than 254 miles)

viii. Engine miles

ix. Engine hours

x. Setup screen

xi. Back to odometer

Trip Miles

To reset trip miles and/or trip hours to zero, press themode/reset button for one second or longer.

Miles or Kilometers

To toggle between MI (miles) or KM (kilometers),press the mode/reset button while in the Selectscreen.

Audible Warnings

An audible warning sounds during the ignition se-quence and whenever one of the following conditionsexist:

• Engine oil pressure falls below the minimumlevel shown in Table 3.1.

• Coolant temperature rises above the maximumtemperature shown in Table 3.2.

• Air pressure falls below approximately 70 psi(483 kPa).

• Parking brake is set with the vehicle moving ata speed greater than two miles per hour.

• System voltage falls below 12.0 volts.

• Door is open and the parking brake is off.

• Occupied seat belts are not fastened and theparking brake is off.

• Outside temperature falls below 35°F (1.7°C).

Minimum Oil Pressure*

Engine ModelAt Idle Speed:

psi (kPa)

At Rated RPM:

psi (kPa)

Caterpillar 10–20 (69–138) 30–45 (207–310)

Cummins 15 (103) 35 (241)

09/25/99

PUSH−MODE

HOLD−RESET

f610340

Fig. 3.6, Mode/Reset Button

Instruments

3.4

Minimum Oil Pressure*

Engine ModelAt Idle Speed:

psi (kPa)

At Rated RPM:

psi (kPa)

Detroit Diesel 14 (97) 55 (350)

Mercedes-Benz 7 (50) 36 (250)

* Oil pressures are given with the engine at operating temperature. Withthe engine cold, oil pressure may be higher. Individual engines may varyfrom the listed pressures; observe and record pressures when the engineis new to create a guide for checking engine condition.

Table 3.1, Minimum Oil Pressure

Maximum Coolant Temperature

Engine Make Temperature: °F (°C)

Caterpillar 230 (110)

Cummins 225 (107)

Detroit Diesel 215 (101)

Mercedes-Benz 222 (105)

Table 3.2, Maximum Coolant Temperature

Warning and Indicator Lights

There can be up to 28 warning and indicator lampsinstalled in the dash message center. See Fig. 3.7for pre-EPA07 engines, Fig. 3.8 for EPA07 engines,or Fig. 3.9 for EPA10 engines.

The lamps, or telltales, in the top row are optional.The lamps on the other three rows are installed atfixed positions that do not vary. If an optional lamp isnot requested, the position is blank.

See Table 3.3 for a list of standard and commonlyused warning and indicator lamps.

Engine Protection System

If a critical engine condition exists (for example, lowengine oil pressure, low coolant level, high coolanttemperature, high diesel particulate filter soot level,or uncontrolled regeneration), the CHECK enginelamp will illuminate to alert the driver to correct thecondition as soon as possible. If the condition wors-ens, the STOP engine lamp will illuminate.

NOTE: If the CHECK engine lamp illuminatesduring vehicle operation, take the vehicle di-rectly to an authorized Freightliner service facil-ity.

WARNING

When the red STOP engine lamp illuminates,most engines are programmed to shut down au-tomatically within 30 seconds. The driver mustimmediately move the vehicle to a safe locationat the side of the road to prevent causing a haz-ardous situation that could cause bodily injury,property damage, or severe damage to the en-gine.

The STOP engine lamp illuminates when the engineprotection system is activated. The engine protectionsystem typically works as follows, depending on theengine type. Some vehicles may have a shutdown-override switch, which may be used to momentarilyoverride the shutdown sequence. See Chapter 7 formore information.

• On some engines, the engine protection sys-tem will derate the engine, allowing it to run atlower rpm and slower vehicle speed—drive thevehicle to a safe location or to a service facility.

• On other engines, the engine protection sys-tem will shut down the engine. It will first der-ate the engine, then shut it down completely30 to 60 seconds after the indicator illuminates(depending on the critical fault type) if the con-dition does not improve.

Bring the vehicle to a stop on the side of theroad before the engine shuts down. Do not at-tempt to restart the engine while the vehicle ismoving. To restart the engine, turn the ignitionswitch to OFF, leave it there a few seconds,then turn the switch to START. The engine willrun for a short period and shut down again ifthe condition does not improve.

Instruments

3.5

1 2 310 11 12

16 17 1822 23

4 5 6 7 8 913 14 15

19 20 21

26 272524 f610593a

WHEELLOCK

WASHFLUID

INTAKEHEATER

WATERIN FUEL

WHEELSPIN

LOWWATER

CHECKTRANS

ENGFAN

LOWFUEL

03/05/2002

BRAKE

Typical installation shown. Location of legends installed in the top row may vary, and other legends may be specified.

1. Wheel Lock Warning2. Low Washer Fluid Indicator3. Intake Heater On Indicator4. Water In Fuel Indicator5. Wheel Spin Indicator6. Low Coolant Warning7. Check Transmission Indicator8. Engine Fan On Indicator9. Low Fuel Warning10. Check Engine Indicator

11. Engine Protection Warning12. No Charge Indicator13. Tractor ABS Indicator14. Transmission Temperature

Indicator15. Trailer ABS Indicator (as applies)16. Low Oil Pressure Warning17. High Coolant Temperature

Warning18. Fasten Seat Belts Warning

19. Parking Brake On Indicator20. Not Used21. Air Restriction Indicator22. Left-Turn Signal23. Low Battery Voltage Warning24. Driver Display Screen25. High-Beam Headlights Indicator26. Low Air Pressure Warning27. Right-Turn Signal

Fig. 3.7, Pre-EPA07 Dash Message Center

f61085010/18/2006

1 2 3 4

8 9 1014 15

5 6 7

11 12 13

18 191716

ABS ABS

OPT OPT OPT OPT OPT OPT OPT OPT OPT

Typical installation shown. Location of legends installed in the top row may vary, and other legends may be specified.

1. Optional Indicator2. Check Engine Indicator3. Stop Engine Indicator4. Malfunction Indicator Light (MIL)5. Tractor ABS Indicator6. Transmission Temperature

Indicator7. Trailer ABS Indicator (as applies)

8. Low Oil Pressure Warning9. High Coolant Temperature

Warning10. Fasten Seat Belt Warning11. Parking Brake On Warning12. DPF Status Lamp13. High Exhaust System

Temperature (HEST) Warning

14. Left-Turn Signal15. Low Battery Voltage Warning16. Driver Display Screen17. High-Beam Headlights Indicator18. Low Air Pressure Warning19. Right-Turn Signal

Fig. 3.8, EPA07 Dash Message Center

Instruments

3.6

Common Warning and Indicator Lamps

CHECK CHECK Engine

Indicates a critical engine condition (low oil pressure, lowcoolant level, high coolant temperature, high DPF soot level,or uncontrolled DPF regeneration). Correct the condition assoon as possible. If the condition worsens, the STOP enginelamp will illuminate.

STOP STOP Engine

Indicates a serious fault which requires engine shutdownimmediately. The engine protection system will reduce themaximum engine torque and speed, and, if the conditiondoes not improve, will shut down the engine within 30 to 60seconds.

The driver must safely bring the vehicle to a stop on the sideof the road and shut down the engine as soon as the redlight is seen. If the engine shuts down while the vehicle is ina hazardous location, restart the engine after turning the keyto the OFF position for a few seconds. Move the vehicle to asafer location.

High Exhaust System Temperature(HEST)

Slow (10-second) flashing indicates a regeneration (regen) isin progress.

Solid illumination indicates high exhaust temperatures at theoutlet of the tail pipe, when speed is below 5 mph (8 km/h).It does not signify the need for service; it only alerts thevehicle operator to high exhaust temperatures when a regenis in progress.

DPF Status

Solid illumination indicates a regen is required. Change to amore challenging duty cycle (such as highway driving ) toraise exhaust temperatures for at least twenty minutes, orperform a parked regen.

Blinking indicates that a parked regen is requiredimmediately. An engine derate and shutdown will occur.

Malfunction Indicator Lamp (MIL)Indicates an emissions-related fault. See the engineoperation manual for details.

Vehicle ABS

Indicates the vehicle ABS is engaged.

When ABS is not engaged. illumination indicates a problemwith the vehicle ABS. Repair the ABS immediately to ensurefull braking capability.

Trailer ABS

Indicates the trailer ABS is engaged.

When ABS is not engaged. illumination indicates a problemwith the vehicle ABS. Repair the ABS immediately to ensurefull braking capability.

WHEELSPIN Wheel Spin

Indicates the Automatic Traction Control (ATC) is engaged.

Solid illumination indicates a problem with the ATC system.Repair the ATC system immediately to ensure full brakingcapability.

High Coolant TemperatureIndicates the coolant temperature is above the maximumallowable temperature listed in Table 3.2.

Instruments

3.7


Low Air PressureIndicates air pressure in the primary or secondary reservoiris below 70 psi (483 kPa).

WAIT

TO START Wait To StartIlluminates when starting the engine during cold conditions.Wait until the lamp goes out before turning the ignition key toSTART.

Low Engine Oil PressureIndicates the engine oil pressure is below the minimumallowable pressure listed in Table 3.1.

Water In FuelIndicates the fuel may contain water. Drain any watercollected in the fuel/water separator.

Fuel Filter Restriction Indicates the fuel filter is clogged and requires service.

Low Battery Voltage Indicates that battery voltage is 11.9 volts or less.

Check Transmission Indicates an undesirable transmission condition.

Transmission Overheat Indicates high transmission temperature.

NOCHARGE No Charge Indicates an alternator charge output failure.

Engine Brake Indicates the engine brake is engaged.

IDLE

MGMTOptimized Idle Indicates optimized idle is enabled.

Left-Turn SignalFlashing indicates the outside left-turn signal lights areactivated.

Right-Turn SignalFlashing indicates the outside right-turn signal lights areactivated.

High-Beam Headlights Indicates the high-beam headlights are on.

Instruments

3.8


Parking/Emergency Brake Indicates the parking brake is engaged.

Cruise Control Indicates the cruise control is enabled.

Unfastened Seat Belt

Activates with an audible alert when the system detects thatthe parking brake is off and the driver seat belt is notfastened on some vehicles. On other vehicles, this lampilluminates for 15 seconds when the ignition is first turnedon.

Table 3.3, Common Warning and Indicator Lamps

Standard Instruments

Standard instruments are present on every vehicle.They are listed here in alphabetical order, to makethe information easier to find.

Air Pressure Gauges

WARNING

If air pressure falls below minimum pressure, thebraking ability of the vehicle will be limited. Slowthe vehicle down and bring it to a gradual stop.Do not attempt to move the vehicle until air pres-sure has risen above the minimum level. Moving

a vehicle without adequate braking power couldcause an accident resulting in personal injury ordeath.

Air pressure gauges, as shown in Fig. 3.10, registerthe pressure in the primary and secondary air sys-tems. The gauges are labeled for the A or B reser-voir. Normal pressure with the engine running is 100to 120 psi (689 to 827 kPa) in both systems.

A low-air-pressure warning light and audible warning,connected to both the primary and secondary sys-tems, activate when air pressure in either systemdrops below 64 to 76 psi (441 to 524 kPa).

ABS ABS

BRAKE

CHECK STOP

OPT 9

11/09/2011 f611107a

*WAIT*

TO START

CHECK

TRANS

BRAKE

AIR

LOW

WATER

WHEEL

SPIN

AIR

FILTER

WASH

FLUID OPT 8

Fig. 3.9, EPA10 Dash Message Center

Instruments

3.9

When the engine is started, the warning light andaudible warning remain on until air pressure in bothsystems exceeds minimum pressure.

Coolant Temperature Gauge

NOTICE

A sudden increase in coolant temperature mayindicate engine or cooling system failure. Bringthe vehicle to a safe stop and investigate thecause to prevent further damage. Do not operatethe engine until the cause has been determinedand corrected.

During normal engine operation, the coolant tem-perature gauge, as shown in Fig. 3.11, should read175 to 195°F (79 to 91°C). If the temperature re-mains below 160°F (71°C), inspect the cooling sys-tem to determine the cause.

If coolant temperature rises above the maximumtemperature listed in Table 3.2, the CHECK enginelamp will illuminate. If the condition does not im-prove, the STOP engine lamp will also illuminate andan audible warning will sound. The engine will thenderate or shut down, depending on the type of en-gine protection system installed.

Engine Oil Pressure Gauge

NOTICE

A sudden decrease or absence of oil pressuremay indicate mechanical failure. Bring the vehicleto a safe stop and investigate the cause to pre-vent further damage. Do not operate the engineuntil the cause has been determined and cor-rected.

The engine oil pressure gauge, as shown inFig. 3.12, displays the current engine oil pressure. Ifengine oil pressure falls below the minimum levelsshown in Table 3.1, the CHECK engine lamp will illu-minate. If the condition does not improve, the STOPengine lamp will also illuminate and an audible warn-ing will sound. The engine will then derate or shutdown, depending on the type of engine protectionsystem installed.

Fuel Gauge, Pre-EPA10

Pre-EPA10-compliant vehicles have a fuel levelgauge indicating the level of diesel in the fuel tank(s).See Fig. 3.13. A single fuel gauge is standard. Ifequipped with an optional second fuel gauge, eachfuel tank level is indicated on a separate gauge.

05/14/2001 f610556

Fig. 3.10, Air Pressure Gauge (reservoir A shown)

10/09/2001 f610565

WATER

100

150 200

250

F°

Fig. 3.11, Coolant Temperature Gauge

10/09/2001

0 100

50

PSI

OIL

f610528

Fig. 3.12, Engine Oil Pressure Gauge

Instruments

3.10

Fuel/Diesel Exhaust Fluid (DEF)Gauge, EPA10

For engines that are EPA10-compliant, the fuel andDEF levels are measured in a dual purpose fuel/DEFgauge. See Fig. 3.14.

The diesel fuel level is indicated at the top of thegauge, with a low-fuel warning lamp that illuminateswhen the diesel fuel level registers 1/8th of capacity.

The DEF level is indicated in the lightbar on thelower portion of the gauge. There is a low DEF level

warning lamp that illuminates when the DEF levelreaches 10% of capacity. See Chapter 7for details ofthe DEF gauge functions.

Speedometer

Three speedometer options (see Fig. 3.15) are avail-able. The U.S. version of the speedometer registersspeed in both miles per hour (mph) and kilometersper hour (km/h), with mph in larger numbers. Themetric version of the speedometer face reverses thisarrangement, with km/h in larger numbers. Themetric-only version shows km/h exclusively.

Voltmeter

The voltmeter is a digital readout located on the bot-tom line of the dash message center whenever theignition switch is turned on.

The voltmeter indicates the vehicle charging systemvoltage when the engine is running and the batteryvoltage when the engine is off. By monitoring thevoltmeter, the driver can stay aware of potential bat-tery charging problems and have them fixed beforethe batteries discharge enough to create starting diffi-culties.

The voltmeter will normally show approximately 13.7to 14.1 volts when the engine is running. The voltageof a fully charged battery is 12.7 to 12.8 volts whenthe engine is off. Battery voltage under 12.0 volts isconsidered a low battery, and a completely dis-charged battery will produce only about 11.0 volts.The voltmeter will indicate lower voltage as the ve-hicle is being started or when electrical devices inthe vehicle are being used.

10/09/2001 f610566

E F

1/2

FUEL

Fig. 3.13, Fuel Level Gauge, Pre-EPA10

08/21/2009

1/2ULTRA LOW SULFURDIESEL FUEL ONLY

E F

DEF

FE

f611045

1

2

3

4

1. Diesel Fuel LevelIndicator

2. DEF Level Indicator3. Low DEF Warning

Lamp (amber below10% DEF)

4. Low Fuel WarningLamp (amber at 1/8tank of fuel)

Fig. 3.14, Fuel/DEF Gauge, EPA10

10/09/2001

0

5

10

1520

30

RPM5

15

25

3545

55

65

75

85

MPH

km/h

25

X100

30

50

7090

130

110

10

1 2

f610527

1. Tachometer 2. Speedometer

Fig. 3.15, Speedometer and Tachometer (U.S. version)

Instruments

3.11

If the voltmeter shows an undercharged or over-charged condition for an extended period, have thecharging system and batteries checked at an autho-rized Freightliner service facility.

On a vehicle equipped with a battery isolator system,the voltmeter measures the average voltage of all thebatteries when the engine is running. When the en-gine is off, the voltmeter shows only the isolated bat-tery voltage and does not indicate the voltage of theengine-starting batteries.

Optional Instruments

Optional instruments, typically located on the auxil-iary dash panel or right-hand control panel, are notfound on every vehicle. They are listed here in alpha-betical order, to make the information easier to find.

Air Restriction Gauge

The air intake restriction gauge measures thevacuum on the engine side of the air cleaner. Onstandard installations, it is mounted on the air intakeduct in the engine compartment.

As an option for easier viewing, the air intake restric-tion indicator (see Fig. 3.16) can be mounted on thedash, usually on the right-hand control panel.

NOTE: Rain or snow can wet the filter andcause a higher than normal reading temporarily.

Air intake restriction vacuum is measured in inchesof water (inH2O). For vehicles equipped with agraduated indicator or a restriction gauge on thedash, check the gauge with the engine off. If the yel-low signal stays locked in the red zone once the en-gine is shut down, or is at or above the valuesshown in Table 3.4, the air cleaner element needs tobe replaced.

Vehicles may be equipped with a go/no-go restrictionindicator without graduations (see Fig. 3.17) insteadof a graduated indicator.

Air Intake Maximum Restriction Values

Engine Make*Pre-EPA07

Engines (inH2O)

EPA07/EPA10Engines (inH2O)

Caterpillar 25 —

Cummins 25 25

Detroit Diesel 20 22

Mercedes-Benz 22 22

* Turbocharged engines must be checked at full load and governed en-gine speed.

Table 3.4, Air Intake Maximum Restriction Values

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Fig. 3.16, Air Intake Restriction Indicator

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Fig. 3.17, Manual-Reset Air Restriction Indicator, Go/No-Go

Instruments

3.12

Ambient Temperature Gauge

The ambient temperature gauge, shown in Fig. 3.18,displays the in-cab or outside temperature, depend-ing on the settings selected.

When the alarm is enabled, the ambient temperaturegauge will sound an audible alert and the amberlamp will illuminate when the outside or inside tem-perature (depending on the setting selected) reachesthe set temperature. Turn the alarm on and off usingthe steps below.

1. Press the IN button for in-cab temperature, orthe OUT button for outside temperature.

2. Press the SET button.

3. Press the ADJ button until the desired tempera-ture is displayed.

4. Press the ALARM button and "AL" will appear onthe display.

5. Press the SET button to return to the currenttemperature display.

NOTE: To turn the alarm off, press the ALARMbutton again and "AL" will disappear from thedisplay.

Ammeter

An ammeter, shown in Fig. 3.19, measures currentflowing to and from the battery. When the batteriesare charging, the meter needle moves to the plusside of the gauge. When the batteries are being dis-

charged, the needle moves to the minus side. A con-sistent negative reading when the engine is runningindicates a possible problem with the chargingsystem.

Digital Clock

The digital clock, shown in Fig. 3.20, displays thecurrent time, and has a 24-hour alarm with a3-minute snooze feature.

Set the clock by pressing the SET button, then se-lecting the desired time by pressing the HRS andMIN buttons. When the clock is set to PM hours, aPM indicator will appear on the display. When thePM indicator is not displayed, the clock is set to anAM hour.

SET ADJ ALARM

IN OUT

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Fig. 3.18, Ambient Temperature Gauge

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Fig. 3.19, Ammeter

SET SNOOZE ALARM

HRS MIN

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Fig. 3.20, Digital Clock

Instruments

3.13

To set the alarm, press the SET button, then pressthe ALARM button. Select the desired alarm time bypressing the HRS and MIN buttons, then press theSET button once again.

To turn the alarm on and off, press the ALARM but-ton when the current time is displayed. When thealarm sounds, pressing the SNOOZE button willdelay the sounding of the alarm for three minutes.

Drive Axle Oil Temperature Gauges

NOTICE

A sudden increase in oil temperature that is notcaused by a load increase may indicate mechani-cal failure. Bring the vehicle to a safe stop andinvestigate the cause to prevent further damage.Do not operate the vehicle until the cause hasbeen determined and corrected.

During normal operation, forward-rear and rear-rearaxle oil temperature gauges (see Fig. 3.21) shouldread between 160 and 220°F (71 and 104°C).

Under heavy loads, such as when climbing steepgrades, temperatures that exceed the normal oil tem-perature range for a short period are not unusual. Ifthe temperature returns to normal when the load de-creases, there is no problem.

Engine Oil Temperature Gauge

NOTICE

A sudden increase in oil temperature that is notcaused by a load increase may indicate mechani-cal failure. Bring the vehicle to a safe stop andinvestigate the cause to prevent further damage.Do not operate the engine until the cause hasbeen determined and corrected.

During normal operation, the optional engine oil tem-perature gauge (Fig. 3.22) should read in the follow-ing temperature ranges:

• 160 to 195°F (71 to 91°C) for Caterpillar en-gines

• 200 to 260°F (93 to 126°C) for Detroit Dieseland Cummins engines

• 177 to 203°F (81 to 95°C) for Mercedes-Benzengines


Tachometer

The tachometer, shown in Fig. 3.9, indicates enginespeed in revolutions per minute (rpm) and serves asa guide for shifting the transmission and keeping theengine in the appropriate rpm range. For low idle andrated rpm, see the engine identification plate.

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Fig. 3.21, Axle Oil Temperature Gauge

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Fig. 3.22, Engine Oil Temperature Gauge

Instruments

3.14

Transmission Fluid TemperatureGauge

The transmission fluid temperature gauge, shown inFig. 3.23, measures the transmission lubricant oper-ating temperature. Temperatures vary by application,but the transmission fluid temperature gauge readingshould not exceed 250°F (121°C).

NOTICE

A sudden increase in transmission fluid tempera-ture that is not caused by a load increase mayindicate mechanical failure. Bring the vehicle to asafe stop and investigate the cause to preventfurther damage. Do not operate the vehicle untilthe cause has been determined and corrected.


Turbocharger Boost Pressure Gauge

A turbocharger boost pressure gauge, shown inFig. 3.24, measures the pressure in the intake mani-fold, in excess of atmospheric pressure, being cre-ated by the turbocharger.

Overhead Instrument Panel

The optional overhead instrument panel, shown inFig. 3.25, may hold a citizen’s band (C/B) radio, amicrophone clip, and any switches that can not be

accommodated on the driver’s or auxiliary dashpanels.

The underside of the overhead console also holdsthe sun visors and the optional dome/reading lightassembly. For more information on the dome/readinglight assembly, see Chapter 4.

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TRANS

125 350

F

275200

Fig. 3.23, Transmission Fluid Temperature Gauge

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Fig. 3.24, Turbo Boost Pressure Gauge

Instruments

3.15

04/19/2002 f680028

1 2

1

3 4

1. Storage Area with Netting2. C/B Radio

3. Microphone Clip4. Dome/Reading Light Assembly

Fig. 3.25, Overhead Instrument Panel

Instruments

3.16

4

ControlsIgnition Switch and Key . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.1

Electrical System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.1

Lighting Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.1

Multifunction Turn Signal Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.5

Horn Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.7

Powertrain Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.7

All-Wheel-Drive Controls, Optional . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.11

Braking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.13

Adjustable Steering Column . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.13

Other Dash-Mounted Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.14

Heater/Air Conditioner Control Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.15

Seat Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.15

Ignition Switch and Key

The ignition switch (Fig. 4.1) has four positions: AC-CESSORY, OFF, ON, and START. In addition, thesame key locks and unlocks the cab doors.

In the OFF position, the key slot is vertical; the keycan be inserted and removed only in this position.The following can be operated in the off position (re-gardless of whether the key is inserted): The low-beam headlights, taillights, brake lights, road lights,dome lights, clearance lights, turn signals, hazardwarning lights, horn, CB radio, power windows, ciga-rette lighter, clock, and electric oil pan heater.

In the ACCESSORY position, the key is turned coun-terclockwise. The radio, stereo system, mirror heat,air dryer, backup lights, and all of the electrical sys-tems that are operable in the off position are oper-able in the accessory position.

In the ON position, the key is turned clockwise andall electrical systems are operable. The low air pres-sure and low oil pressure warning lights (or mes-sages) and buzzer operate until the engine is startedand pressure is built up.

Electrical System

The Business Class® M2 features a new type ofelectrical system, different from any previous vehicle.Multiple electrical signals are carried along a simpli-fied set of wires, reducing the size of wiring bundles.There are significantly fewer wires overall, meaningless chance of damage, shorts and other problems.

WARNING

Do not attempt to modify, add, splice, or removeelectrical wiring on this vehicle without authoriza-tion from Freightliner Engineering. Doing socould damage the electrical system and result ina fire that could cause serious personal injury orproperty damage.

There are two new electrical modules, a master mod-ule located near the frontwall (bulkhead module) anda slave module located between the frame rails(chassis module).

This new wiring system features intelligent controlsthat blink to show switch activity and error conditions.These controls cannot be distinguished by their ap-pearance, only by their function.

For more information about these controls, see underthe headings "Axle Switches" and "SuspensionDump Switch."

Lighting Controls

The lighting controls mentioned under this headinggenerally operate through switches located on thedash.

Two types of dash switches are used:

• Paddle switches with a single paddle located inthe center of the switch. The paddle can beraised or lowered to perform a function.

• Rocker switches that can be pressed at eitherthe upper or lower end to perform a function.Certain rocker switches are guarded to preventthem from being switched on or off acciden-tally.

When the panel lights are on, most switch legendsare backlit with a colored light, usually green. Thisallows the driver to find the switch more easily in thedark. When the switch is on, the switch icon is nor-mally backlit with a colored light, usually amber.Some switch icons are dead-fronted (not visible untilthe switch is turned on). When turned on, someswitches are illuminated from within by a red oramber LED (light-emitting diode).

Control Panels

The left-hand control panel (Fig. 4.2) contains a lou-vered window outlet for the face vents of the heating,

09/12/2001 f610509

Fig. 4.1, Ignition Switch Positions

Controls

4.1

ventilation, and air conditioning system (HVAC), andfour switches arranged in a vertical line, usually theheadlight, panel light increase/decrease, and thecruise control On/Off and Set/Resume switches.

The instrument cluster (ICU3-M2) is located right be-hind the steering wheel. No controls are installed onthe standard instrument cluster.

The right-hand control panel (Fig. 4.2) usually con-tains the transmission push-button shift selector (onvehicles with automatic or automated transmission)and the trailer brake lever (hand control valve). Onvehicles with manual transmission, a variety ofswitches are installed here. If there is a dash-mounted air-restriction indicator, it is often mountedhere.

The radio panel contains two louvered dash outletsfor the face vents of the HVAC, one on either side ofthe radio (if installed).

The auxiliary dash panel (Fig. 4.2) below the radiopanel contains the marker interrupt switch, the airbrake valve knobs, the cigarette lighter, and a varietyof switch options.

The HVAC climate control panel is on a separatepanel below the auxiliary dash panel, between thetwo cupholders.

Exterior Light Controls

Headlight/Parking Light Switch

The headlight/parking light switch (Fig. 4.3) is apaddle switch located on the left-hand control panelabove the cruise control switches. When the paddleis lowered, the parking lights illuminate (the front turnsignals, the cab marker and identification lights, andthe taillights). When the paddle is raised, the low-beam headlights illuminate, along with all the parkinglights. To turn off all lights, return the paddle to thecenter position.

NOTE: The front turn signal is the amber lens ineach headlight unit. The low-beam headlight isthe top clear lens in each headlight unit.

When the headlights or parking lights are on, thepanel lights also illuminate. An amber light in theswitch backlights either the top icon (for headlightsand parking lights) or the bottom icon (for parkinglights only).

Panel Light Increase/Decrease Switch

When the panel lights are on, they can be eitherbrightened or dimmed by using the INCR/DECRrocker switch just below the headlight switch(Fig. 4.4). To brighten the panel lights, press on theupper part of the rocker (at the INCR legend). To dim

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1

2

3

4

5

1. Left-Hand Control Panel2. Instrumentation Control Unit3. Right-Hand Control Panel4. Radio Panel5. Auxiliary Dash Panel

Fig. 4.2, Switch and Gauge Panels

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Raise the paddle to illuminate the headlights, low beam.

Lower the paddle to illuminate the parking lights.

Fig. 4.3, Headlight/Parking Light Switch

Controls

4.2

the panel lights, press on the lower part of the rocker(at the DECR legend).

When the panel lights are on, both legends are back-lit in green.

Daytime Running Lights

Switching on the ignition and releasing the parkingbrakes automatically activates the daytime runninglights, if equipped. The daytime running lights willoperate until the parking brakes are applied or theheadlights are turned on.

NOTE: Daytime running lights are standard onall Canadian vehicles.

The daytime running lights illuminate at about two-thirds of normal power.

Marker Light Interrupt Switch

The marker light interrupt (MRKR INT) paddle switchtemporarily flashes the marker lights and taillights(Fig. 4.5). With the vehicle lights on, raise the paddleto briefly turn off the marker lights and taillights. Withthe vehicle lights off, raise the paddle to briefly turnon the marker lights and taillights.

Turning off the vehicle lights automatically turns offthe marker lights. When the panel lights are on, themarker light icon and MRKR INT legend are backlitin green.

Road Light Switch, Optional

The road light (ROAD LAMP) rocker switch operatesthe optional road lights, which are recessed into thefront bumper or mounted on the lower edge of a cut-out in the center of the front bumper.

The low beam headlights must be turned on beforethe road lights can be turned on. The road lights willnot illuminate if the high beam headlights are alreadyon, and switching from low beams to high beams willswitch off the road lights.

To turn the road lights on, press on the upper part ofthe rocker (at the road light icon). See Fig. 4.6. Toturn the road lights off, press on the lower part of therocker (at the ROAD LAMP legend).

When the road lights are on, the road light icon isbacklit in amber. When the panel lights are on, theROAD LAMP legend is backlit in green.

Utility Light Switch, Optional

The utility light switch operates one of the followinglights or sets of lights:

• A single round utility light swivel-mounted inthe center of the cab roof;

f61059810/29/2001

Fig. 4.4, Panel Light Increase/Decrease Switch

05/09/2002 f610581

Raise the paddle to flash the marker lights.

Fig. 4.5, Marker Light Interrupt Switch

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Fig. 4.6, Road Light Switch

Controls

4.3

• Two round utility lights mounted in fixed posi-tions on each side of the cab roof;

• Two flush-mounted utility lights mounted on theback of the cab, one on each side.

To turn the utility light(s) on, press in on the upperpart of the utility light (UTLY LAMP) rocker switch(Fig. 4.7). To turn the utility light(s) off, press on thelower part of the rocker (at the UTLY LAMP legend).

When the utility lights are on, the diagonal light beamicon is backlit in red. When the panel lights are on,the UTLY LAMP legend is backlit in green.

Spotlight, Optional

The spotlight switch is located on the pivoting handleof the spotlight. There may be a single spotlight as-sembly mounted on the driver’s door, or one on eachdoor.

Interior Lights and Light Controls

The interior lights include dome lights, red maplights, and clear reading lights.

Dome Lights

Diffuse dome lights are installed on all cabs. Thestandard dome light has a clear lens and is installedon the back of the cab above the rear window. SeeFig. 4.8 for the rear dome light.

On cabs with an overhead console, there is an op-tional overhead dome light assembly containing adiffuse dome and a clear reading light. See Fig. 4.9for the optional dome/reading lights on the overheadconsole.

Light Replacement

Rear Dome Light

To replace the rear dome light (Fig. 4.8), do the fol-lowing steps:

1. Press in on the lens at the four mounting tabs(arrows).

2. Replace the bullet-type bulb and install the lenson the lamp base with the button at the bottom.

Overhead Console Dome/Reading Lights

To replace the overhead console dome/reading lights(Fig. 4.9), do the following steps:

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Fig. 4.7, Utility Light Switch

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To remove the lens, press in at the mounting tabs(arrows).

Fig. 4.8, Rear Dome Light

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1

2

3

1. Overhead Console2. Trimplate

3. Light Assembly

Fig. 4.9, Overhead Console Dome Lights

Controls

4.4

1. Remove the tapping screws that attach the lampassembly and trimplate to the overhead console.

2. Separate the lamp assembly from the trimplateand disconnect the wiring harness.

3. Replace the lamp assembly.

4. Snap the lamp assembly and trimplate together.

5. Connect the lamp assembly to the wiring har-ness.

6. Insert the tabs on the trimplate into the slots onthe overhead console attachment plate.

7. Center the lamp assembly in the headliner cutoutand install the center tapping screw.

8. Install the remaining tapping screws.

Dome Light Switches

In the standard cab, there is one dome light switch inthe driver’s door that turns on the diffuse dome lightwhen the driver’s door is opened. In one option, twoswitches are installed, so that the diffuse dome lightturns on when either the driver’s or passenger’s dooris opened.

Clear Reading Lights, Optional

Clear reading lights are available as a option. Theyare included only in the light assembly installed inthe overhead console, located next to the diffusedome light in the same fixture (Fig. 4.9). Like thedome lights, the reading lights are door-activated.

Multifunction Turn SignalSwitch

The multifunction turn signal switch is attached to thesteering column, just below the steering wheel, onthe left-hand side. This switch has the followingfunctions:

• The turn signals

• The windshield wipers and washers

• The headlight high beams

• The hazard warning flasher

See Fig. 4.10 for the multifunction switch and itscomponent parts.

Turn-Signal Controls

The turn signal lever (Fig. 4.11) is mounted on thesteering column. Moving the lever down turns on theleft turn signal lights; moving it up turns on the rightturn signal lights.

When one of the turn-signal lights is on, a green indi-cator arrow flashes at the far left or far right of thewarning and indicator light panel.

f820386

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11/16/2001

Press down on the upper part of the rocker to activatethe hazard warning flashers.

1. Washer Button2. Wiper Control Dial3. Turn Signal Lever4. Hazard Flasher (red rocker switch)5. Multifunction Switch Module

Fig. 4.10, Multifunction Turn Signal Switch

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Move the lever down to turn on the left turn signals.

Move the lever up to turn on the right turn signals.

Fig. 4.11, Turn Signal Controls

Controls

4.5

The lever automatically returns to the neutral position(self-cancels the switch) when the steering wheelreturns to the straight ahead position after a turn. Tocancel the signal manually, move the lever to theneutral position.

Windshield Wiper/Washer Controls

CAUTION

Do not move the wiper arms manually. Wipermotor damage will occur if the arms are moved.

The wipers are operated by a rotary switch in thewiper control dial, which is on the end of the turn sig-nal lever. See Fig. 4.12. There are five delay set-tings, marked on the dial by lines of increasinglength, and two steady speed settings, LO and HI.

Rotating the control dial forward (in a counterclock-wise direction) turns the wipers on. If they are al-ready on, rotating the handle further forward (to afaster speed setting) increases the speed of the wip-ers through the various delay settings, and to LO andthen HI.

Rotating the control dial in the opposite direction(clockwise) causes the wipers to slow down. Rotating

the control dial clockwise as far as it will go (to theOFF setting) turns the wipers off.

The washers are operated by a yellow button at thevery end of the turn signal lever. To operate thewashers, press the button in and hold it in until youwant the washers to stop.

Headlight High Beams

Push the turn signal lever forward, towards the wind-shield, to turn on the high-beam headlights. Pull theturn signal lever back to its original position to turnthem off. See Fig. 4.13.

When the high beam headlights are on, a blue lightilluminates on the instrument cluster between the ta-chometer and speedometer. For vehicles built to op-erate in the United States, switching on the highbeams will switch off the road lights.

NOTE: The ignition switch must be on for thehigh beams to work.

With the headlight low beams on, pull the lever back-ward, towards the steering wheel, to flash the highbeams (turn them on momentarily).

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10/29/2001

Rotate the control dial away from you to turn the wiperson, or speed them up.

Rotate the control dial towards you to slow the wipersdown, or turn them off.

1. Washer Button2. OFF Position3. Delay Positions4. Wipers On, Low Speed5. Wipers On, High Speed

Fig. 4.12, Wiper/Washer Controls

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1

2

Move the lever away from you to turn on the high beams.Move the lever back to its original position to turn themoff.

Move the lever towards you to flash the high beamsmomentarily.

1. Turn Signal Lever 2. Boot

Fig. 4.13, Headlight High Beams

Controls

4.6

The headlight low beams remain on continuouslyduring high beam operation. If the low beam head-lights are turned off by use of the headlight switch,the high beams turn off also.

Hazard Warning Flasher

The hazard warning light flasher (Fig. 4.10) is a redrocker switch located on the top of the multifunctionswitch module. When the flashers are activated, allof the turn signal lights (front, side, and rear) and thetwo green indicator arrows on the control panel willblink on and off.

To flash the hazard warning lights, press down onthe upper part of the rocker (towards the dash). Tostop the hazard warning lights, press down on thelower part of the rocker (towards the steering wheel).

Horn ControlsNOTE: It is possible to have both the electricand the air horn installed on one vehicle.

Electric Horn

A single electric horn is standard. Dual electric hornsare available as an option.

The button for the electric horn is located in the cen-ter of the steering wheel. To sound the horn, pressdown on the button. See Fig. 4.14.

Air Horn, Optional

Single and dual air horns are available as options.

The air horn is controlled by a wire lanyard hangingdown just inboard on the driver’s door. See Fig. 4.15.Pull downward on the lanyard to sound the air horn.

Powertrain Controls

After-Treatment System (ATS)Request/Inhibit Regen Switch

A parked regen of the ATS can be initiated with therequest/inhibit regen switch. It may also be used toinhibit the vehicle from performing an automaticregen. See Fig. 4.16.

The style and function of switch will vary with the en-gine make and model. See the engine operationmanual for operation details.

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1

To sound the electric horn, press down on the hornbutton.

1. Horn Button

Fig. 4.14, Electric Horn Control

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To sound the air horn, pull down on the lanyard (arrow).

Fig. 4.15, Air Horn Control

f61084810/02/2006

Fig. 4.16, Request/Inhibit Regen Switch

Controls

4.7

Cruise Control Switches

CAUTION

Do not attempt to shift gears without using theclutch pedal when the cruise control is engaged.Failure to follow this precaution will result in atemporarily uncontrolled increase in enginespeed; transmission damage and gear strippingcould result.

On standard models, cruise control is activated bytwo dash switches. See Fig. 4.17. On some models,cruise control can be activated by a button on thetransmission shift knob.

• The On/Off Switch—this two-position rockerswitch bears the legend SPD CNTL on thelower half of the switch. When cruise control ison, an amber light illuminates in the top part ofthe switch.

• The Set/Resume Switch—this three-positionpaddle switch bears the legend RES/ACCabove the paddle and SET/CST below thepaddle.

NOTE: For more information about cruise con-trol operation, see Chapter 7.

Engine Brake Switch, Optional

The engine brake switch controls the degree of en-gine braking. Normally there are two paddleswitches, a two-position On/Off Switch to activate theengine brake, and a two-position HI-LO Switch tocontrol the amount of engine braking.

To turn the two-position On/Off Switch on, raise thepaddle. When the two-position switch is on, anamber LED (light-emitting diode) illuminates insidethe switch.

To turn the two-position HI-LO Switch on high, raisethe paddle (at the HI-LO icon). To turn the two-position HI-LO Switch on low, lower the paddle (atthe ENG BRK legend). See Fig. 4.18.

A three-position switch is used on MBE900 enginesequipped with both the regular engine brake and theconstant-throttle (decompression) brake. It works thesame as the two-position HI-LO switch, except thatthere is a third (off) position when the switch is left atits normal position.

The engine brake turns off automatically or when theclutch pedal is pressed. On vehicles without a clutchpedal, the brake pedal can be used to deactivate theengine brake. For more information about enginebrake operation, see Chapter 7.

When the panel lights are on, the HI-LO icon is back-lit in amber on the HI-LO switch. On both switches,

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f610510

To turn cruise control on, press the upper half of the On/Off (rocker) switch. To turn cruise control off, press thelower half of the On/Off (rocker) switch.

1. Cruise Control On/Off (rocker) Switch2. Cruise Control Set/Resume (paddle) Switch

Fig. 4.17, Cruise Control Switches, Dash-Mounted

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1 2

1. On/Off Switch 2. HI-LO Switch

Fig. 4.18, Engine Brake Switches

Controls

4.8

the ENG BRK legend is backlit in green when thepanel lights are on.

Exhaust Brake Switch, Optional

The optional exhaust brake is controlled by a dash-mounted rocker switch to help slow the vehicle whenthe accelerator is released. See Chapter 7 under theheading "Exhaust Braking System, Optional" for addi-tional information.

To turn the exhaust brake on, press on the upperpart of the rocker (at the light inside the switch). Theexhaust brake turns off automatically. See Fig. 4.19or Fig. 4.20.

When the exhaust brake switch is on, an amber LEDilluminates inside the switch. When the panel lightsare on, the EXHST BRK legend is backlit in green.

Engine Fan Switch, Optional

The engine cooling fan can be turned on by the en-gine fan switch (ENG FAN legend). The fan will con-tinue to operate for a set amount of time and thenturn off unless the coolant temperature is highenough to continue the fan operation.

To turn the engine fan on, press on the upper part ofthe rocker (at the fan icon). See Fig. 4.21.

When the engine fan is running, the fan blade icon isbacklit in amber. When the panel lights are on, theENG FAN legend is backlit in green.

Transmission Controls

If so equipped, the transmission range control valveand splitter valve are attached to the gearshift knob.Transmission shift pattern labels are located insidethe cab. See Chapter 8 for complete transmissionoperating instructions.

On vehicles with standard Allison On-Highway Seriesautomatic transmission, the shift selector is lever-activated. The display mounted on the steering col-umn provides four forward ranges and one reverserange. See Fig. 4.22.

When the transmission is in D (drive), the vehicle willoperate in the overdrive (5th) gear. To shift down intothe direct drive (4th) gear, use the overdrive lockoutswitch (O/D legend). See Fig. 4.23. The transmissionwill shift into 4th gear and remain in that gear unlessa range inhibitor is active, such as engine overspeed.See Chapter 8 for more information about rangeinhibitors.

To shift to fourth gear, press on the upper part of therocker (at the LED). The LED will come on and stay

f61058911/28/2001

Fig. 4.19, Exhaust Brake Switch

f610589a03/31/2009


f61059001/04/2011

Fig. 4.21, Engine Fan Switch

Controls

4.9

illuminated until the bottom part of the rocker switchis pressed.

On vehicles with Allison MD Series automatic trans-mission or Eaton Autoshift automated transmission, apush-button shift selector provides four, five, or sixforward ranges and one reverse range. See Chap-ter 8 for more information about the push-button shiftselector.

Axle Switches

All axle switches contain a red LED (light-emittingdiode) that illuminates the switch from within whenthe switch is turned on (the upper part of the rockeris pressed). The legend under the LED, if any, is notvisible until the switch is turned on.

IMPORTANT: A guard is positioned around allaxle switches to prevent unintentional activation.

NOTE: For more information on axle switchfunction, see Chapter 8.

Differential Lock Switch

CAUTION

Differential lock should only be engaged whenthe vehicle is stopped or moving slowly at lowthrottle. This will prevent internal axle damage.

The differential lock switch is a two-position guardedrocker switch. See Fig. 4.24. It causes the wheels oneach axle governed by the switch to rotate together.It is also known as side-to-side wheel lock.

To lock the wheels together, press the upper half ofthe rocker momentarily (at the LED). To turn off dif-ferential lock, press the upper half of the rockeragain.

When the panel lights are on, the double-axle icon isbacklit in green.

IMPORTANT: The differential lock switch isguarded to prevent unintentional switch activa-tion. If the LED in the switch begins to blink dur-ing normal operation, when the switch has notbeen activated, this indicates an error condition.

01/22/2003

1

2

3

f270119

1. All Series, Standard (without park)2. 1000/2400 Series, Optional (with park)3. 2000 Series, Optional (with auto-apply parking

brake)

Fig. 4.22, Steering Column-Mounted Shift Controls

f61063801/22/2003

Fig. 4.23, Overdrive Lockout Switch

10/26/2001 f610596

Fig. 4.24, Differential Lock Switch

Controls

4.10

Bring the vehicle to an authorized Freightlinerservice facility as soon as possible.

Interaxle Lock Switch

CAUTION

The interaxle lock should not be engaged on avehicle with obviously spinning wheels. Engage-ment at high speed or power can damage theaxle(s).

The interaxle lock switch is a two-position guardedrocker switch installed on vehicles with dual driveaxles. See Fig. 4.25. It causes both axle shafts torotate together.

To lock the axles together, press the upper half of therocker momentarily (at the LED). To turn off interaxlelock, press the upper half of the rocker again.

When the panel lights are on, the double-axle icon isbacklit in green.

IMPORTANT: The interaxle lock rocker switch isguarded to prevent unintentional switch activa-tion. This switch does not have a diagnosticblink function when inactive.

Axle Shift Switch

CAUTION

To prevent transmission and axle damage, makesure the automatic transmission is in high rangewhen performing an axle shift with the vehiclemoving.

The axle shift switch is a two-position guarded rockerswitch installed on vehicles with two-speed axles.See Fig. 4.26.

To shift the axle from low speed to high speed, pressthe upper half of the rocker momentarily (at theLED). To turn the axle shift off (switch from highspeed back to low speed), press the upper half ofthe rocker again.

NOTE: On vehicles with tandem drive axles,there is an interlock that prevents a 2-speedaxle from shifting whenever the interaxle lock ison.

When the panel lights are on, the AXLE SHIFT leg-end is backlit in green.

IMPORTANT: The axle shift switch is guarded toprevent unintentional switch activation. If theLED in the switch begins to blink during normaloperation, when the switch has not been acti-vated, this indicates an error condition. Bring thevehicle to an authorized Freightliner service fa-cility as soon as possible.

All-Wheel-Drive Controls,Optional

All-wheel-drive (AWD) allows the driver to directdriveline power to all four axles, front and rear. Twoswitches are used to control AWD: an AWD operationswitch used to activate all-wheel-drive, and an AWDrange switch used to select the high or low range.AWD controls are not multiplexed.

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Fig. 4.25, Interaxle Lock Switch

10/26/2001 f610594

Fig. 4.26, Axle Shift Switch

Controls

4.11

AWD Operation Switch

The AWD operation switch is a two-position rockerswitch with a light-emitting diode (LED) that illumi-nates when AWD is engaged. The legend LOCKEDis underneath the LED on the upper half of theswitch. On the lower half is the legend AWD. SeeFig. 4.27. When the panel lights are on, the AWDlegend is backlit in green.

To engage AWD, press the upper half of the rockerswitch. The LED illuminates to indicate that AWD isengaged. To turn off AWD, press the lower half of theswitch. The LED goes out to indicate the AWD is nolonger engaged.

When AWD is engaged, the LOCKED legend isbacklit in red. In addition, a red indicator with the leg-end T-CASE ENGAGED displays on the dash mes-sage center.

AWD Range Switch

CAUTION

To prevent damage to the transfer case and thedriveline, stop the vehicle and apply the parkingbrake before using the range switch.

The AWD range switch is used under similar condi-tions to those of the axle shift switch on a two-speedrear axle. Use the high range when driving at normalspeeds under off-road conditions, or on non-pavedsurfaces. Use the low range when extra traction isneeded at lower speeds; for example, under condi-tions of mud, snow, or ice. This switch should beused only when AWD has been engaged.

In most cases, the AWD range switch is a two-position rocker switch with the legends LO RANGE

at the upper end and HIGH RANGE at the lowerend. On vehicles with a power take-off unit (PTO),the three-position switch has a neutral (N-TRL) posi-tion in the middle. See Fig. 4.28. When the panellights are on, the HIGH RANGE legend is backlit ingreen.

Two-Position Switch (no PTO)

On vehicles without a PTO, high range is consideredstandard operation. To activate the low range, pressthe upper half of the switch. When the low range isactivated, the LO RANGE legend is backlit in red. Inaddition, a red indicator with the legend T-CASE LORNG displays on the dash message center. Toswitch back to HIGH RANGE, press the lower half ofthe switch.

Three-Position Switch (with PTO)

IMPORTANT: Always use the N-TRL switch po-sition when operating the PTO.

On vehicles with a PTO, neutral is considered stan-dard operation (switch in the middle position). Anamber indicator with the legend T-CASE NTRL dis-plays on the dash message center.

To activate the high range, press the lower half of theswitch. No indicator displays on the dash messagecenter with the high range activated. Press the upperhalf to return to N-TRL.

To activate the low range, press the upper half of theswitch. A red indicator with the legend T-CASE LORNG displays on the dash message center. On theswitch, the LO N-TRL legend is backlit in red. Press

08/10/2006 f610807

LOCKED

AWD

Fig. 4.27, AWD Operation Switch

1

f610808

LO

RANGEHIGH

RANGE

LO

RANGEHIGH

N−TRL

07/21/2006

2

1. Two-Position Switch2. Three-Position Switch

Fig. 4.28, AWD Range Switches

Controls

4.12

the lower half to return to N-TRL, and then press thelower half again to select HIGH RANGE.

Braking

Parking Brake Control Valve

The yellow diamond-shaped knob (Fig. 4.29) on theauxiliary dash panel operates the parking brake con-trol valve (park brake switch). Pulling the yellow knobapplies the tractor parking brakes (spring brakes).Pushing in the knob releases the tractor parkingbrakes. Before the parking brakes can be released,the air pressure in either air brake system must be atleast 65 psi (448 kPa).

See Chapter 9 under the heading "Dual Air BrakeSystem" for further information about the parkingbrake control valve.

Trailer Air Supply Valve

The red octagonal-shaped knob (Fig. 4.29) on theauxiliary dash panel operates the trailer air supplyvalve. After the vehicle and its air hoses are con-nected to a trailer, and the pressure in the air systemis at least 65 psi (448 kPa), the red knob must bepushed in (and should stay in) to charge the trailerair supply system and release the trailer spring park-ing brakes. Before disconnecting a trailer or whenoperating a vehicle without a trailer, the red knobmust be pulled out.

See Chapter 9 under the heading "Dual Air BrakeSystem" for further information about the trailer airsupply valve.

Trailer Brake Lever

The trailer brake lever (hand control valve) is usedfor applying the trailer brakes without applying thetruck or tractor brakes. It is usually mounted on theright-hand control panel. See Fig. 4.30. See Chap-ter 9 under the heading "Dual Air Brake System" foroperating instructions.

Meritor™ WABCO® Antilock BrakingSystem (ABS)

The Meritor WABCO Antilock Braking System (ABS)has an amber tractor indicator light (TRACTOR ABSlegend) and, if equipped with automatic traction con-trol (ATC), an amber wheel spin indicator light(WHEEL SPIN legend). See Fig. 4.31.

On vehicles equipped with a compatible trailer, thereis also an amber trailer indicator light (TRAILER ABSlegend).

See the brake system operating instructions in Chap-ter 9 for more information about ABS.

Adjustable Steering Column

To tilt the steering column, press down on the footpedal located below the steering column. Tilt thesteering column up or down to the desired position.Release the foot pedal to lock the steering column inplace. See Fig. 4.32.

To telescope the steering column, press down on thefoot pedal located below the steering column. Pullthe steering wheel closer to you or push the steering

f610291

12

03/10/99

1. Trailer Air Supply Valve (red knob)2. Parking Brake Control Valve (yellow knob)

Fig. 4.29, Brake Valve Control Knobs

10/17/2001 f610591

Fig. 4.30, Trailer Brake Lever

Controls

4.13

wheel farther away from you. Release the foot pedalto lock the steering column in place.

Other Dash-Mounted Controls

Windshield-Fan Switches, Optional

Ceiling-mounted defogger fans are operated byLOW/OFF/HIGH toggle switches located in the baseof the fan.

Cigarette Lighter

Push in the lighter to heat the element. The lighterwill stay in and will automatically pop out when theelement is hot.

CB Radio Connections

An antenna connection and positive (+) and negative(–) power connections are provided for a CB radio.

Suspension Dump Switch

NOTICE

Do not operate the vehicle over uneven groundsuch as ramps, speed bumps, curbs, etc. withthe air springs deflated. Doing this may lead toair bag separation from the piston, preventing thesuspension air springs from reinflating.

NOTICE

Never exhaust air from the suspension whiledriving. When the air is exhausted, the suspen-sion will not absorb road shocks, and compo-nents may be damaged.

The suspension dump switch is a two-positionguarded rocker switch (Fig. 4.33). It allows the air inthe vehicle air suspension to be quickly exhausted,lowering the rear of the vehicle. This makes it easierto connect to, or disconnect from, a trailer.

To lower the rear of the vehicle quickly, press theupper half of the rocker momentarily (at the LED). To

2

1 3

10/12/2000 f610454

1. Tractor ABS Indicator2. Wheel Spin Indicator

(optional)

3. Trailer ABS Indicator

Fig. 4.31, ABS Indicator Lights

07/19/2006 f610799

1

2

3

4

5

1. Multifunction TurnSignal Switch

2. Headlight Switch3. Ignition Switch

4. Adjustable SteeringColumn foot Pedal

5. Steering Wheel

Fig. 4.32, Adjustable Steering Column

Controls

4.14

raise the suspension to its normal height, press theupper half of the rocker again.

When the panel lights are on, the tractor icon isbacklit in green.

IMPORTANT: The suspension dump switch isguarded to prevent unintentional switch activa-tion. This switch does not have a diagnosticblink function when inactive.

When the suspension dump switch is pressed, threeresponses are possible: a normal response, a slowresponse, and an abnormal response.

Normal Response: The LED in the switch blinkswhile the suspension is deflating or filling. When it iscompletely deflated, the LED comes on steady andstays illuminated. In normal operation, the suspen-sion may dump or fill so quickly that the blinking ofthe switch is barely noticeable.

If operation of the switch is not possible for any rea-son (vehicle is moving faster than 5 mph, ignition isturned off, etc.), the LED will stop blinking and turnoff.

Slow Response: If operation of the switch is slowedfor any reason (by cold weather, low air pressure,etc.), the switch will continue to blink until the sus-pension completes a dump or fill. As in the normalresponse, the LED comes on steady and stays illumi-nated when the suspension if fully deflated.

Abnormal Response: If the LED blinks for more than10 seconds, the suspension dump mechanism maynot be operating properly. Bring the vehicle to an au-thorized Freightliner service facility for testing.

If the ignition is turned off while the vehicle is indump mode, the power to the dump solenoid is cutoff to prevent battery drain, and the suspension sys-tem will autofill the rear air springs. The suspension

will also autofill if the vehicle is operated with thesuspension dumped, and the speed is over 5 mph(e.g. -- driver forgot to inflate the bags or there was asystem failure).

Suspension Autofill Override Valve

The suspension autofill override option is a dash airvalve, that keeps the suspension deflated when theignition is turned off. To operate it, turn off the ignitionthen push the override valve knob. See Fig. 4.34.When the ignition is turned on, the override valve willrelease automatically, and the suspension will autofill.The suspension dump switch will then operate nor-mally as described previously.

Heater/Air Conditioner ControlPanel

Standard controls (Fig. 4.35) for the heating, ventila-tion, and air-conditioning system (HVAC) consist ofan eight-speed fan switch, an air selection switch,and a temperature control switch. On vehicles withair conditioning, the panel also contains a telltaleLED and an air recirculation button. See Chapter 6for detailed operating instructions for the HVAC.

Seat Controls

Bench Seat Adjustment Controls

The standard bench seat has one control: the seatslide lever. See Fig. 4.36. The two-person bench

10/26/2001 f610597

Fig. 4.33, Suspension Dump Switch

PUSH TO

09/11/2007 f321102

Fig. 4.34, Suspension Autofill Override Valve

Controls

4.15

seat and the non-suspended passenger seat haveno controls.

Suspension Seat Adjustment Controls

All controls for adjusting air suspension seats arelocated within easy reach of the occupant.

Due to the maximum adjustability of mid- and high-back air suspension seats, it is possible to combinethe seat back recline adjustment and the seat slideadjustment so that the seat back contacts the back-wall. It is the responsibility of the driver to adjust the

seat to prevent damage to the seat and the cab inte-rior.

All adjustment controls for a suspension seat are lo-cated on the seat base. See Chapter 5 for completeinstructions.

10/03/2001

231

40

1 2 3

f831452

1. Fan Switch2. Air Selection Switch3. Temperature Control Switch

Fig. 4.35, HVAC Climate Control Panel, Standard

10/05/2001 f910481

1

2

1. Three-Person Seat2. Seat Slide Lever

Fig. 4.36, Full Bench Seat

Controls

4.16

5

Cab FeaturesWindows . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.1

Mirrors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.1

Seats . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.2

Seat Belts and Tether Belts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.7

Air Bag, Optional . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.9

Cab Amenities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.10

Windshield Washer Reservoir . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.11

Windows

Standard windows operate mechanically using ahand crank.

Power windows are optional, and can be installed onone side or both sides. One power window switch(window icon) will be installed on the dash for eachwindow. See Fig. 5.1. If your vehicle is equipped withpower windows, press up to raise the window; pressdown to lower the window. Releasing the switchcauses the window to stop.

Standard vent (wing) windows do not open. Operat-ing vent windows are optional. To open the operatingvent window, turn the latch on the window and pushthe window open. See Fig. 5.2.

Mirrors

The standard outside mirrors are mounted on thedoor frame. There is a primary rear view mirror and aconvex mirror.

Mirror Heat Switch, Optional

One or both outside door mirrors can be heated tokeep them clear of fog, frost, and ice.

To heat the mirrors, press the upper part of the mir-ror heat switch (MIRR HEAT) on the dash. SeeFig. 5.3. When the mirror heat switch is on, anamber indicator light illuminates inside the switch.

The mirror heat switch is a smart switch (fully multi-plexed).

Power Mirrors, Optional

The main outside mirrors, if heated, can be equippedwith an electrical remote control located on the driv-er’s door. See Fig. 5.4.

To select the mirrors on the left-hand side, press theleft side of the mirror select switch. To select the mir-rors on the right-hand side, press the right side of themirror select switch.

The keypad has four arrow keys, pointing up, down,left, and right. To adjust the mirror position, press thekeypad in the direction you want the mirror to move.

Down View Mirror, Optional

A down view mirror can be installed on the top of thepassenger door frame to allow the driver a view of

10/09/2001 f610522

Press up to raise the window; press down to lower thewindow. Releasing the switch causes the window to stop.

Fig. 5.1, Power Window Switch

10/05/2001 f670096

1

2

1. Latch 2. Vent Window

Fig. 5.2, Operating Vent Window (optional)

MIRRHEAT

10/09/2001 f610524

To heat the mirrors, press up; press down to turn off theheat.

Fig. 5.3, Mirror Heat Switch

Cab Features

5.1

the area adjacent to the right side of the cab. SeeFig. 5.5.

Seats

General Information

WARNING

Keep hands, tools, and other objects away fromthe scissor points under the seats. Failure to doso could cause personal injury.

Unless otherwise noted, all seat adjustments shouldbe made while seated and before the engine isstarted.

Due to the high degree of adjustability found in high-back air suspension seats, it is possible to set theseat back recline adjustment and the seat slide ad-justment in such a combination that the seat backwill come into contact with the rear wall of the cab. Itis the responsibility of the driver to adjust the seat toprevent damage to the seat and the cab interior.

The following is a description of adjustments that areavailable on one or more seats. Not all seats have allof the adjustments listed below.

1. Seat Slide (fore-and-aft): When this adjustment ismade, the entire seat moves forward or back-ward on its track (Fig. 5.6).

2. Isolator: This feature (also referred to as back-slap isolator or Chugger-Snubber®) reduces theamount of road shock by isolating the occupantfrom the motion of the vehicle, and allowing theupper seat to move in a simple pendulum mo-tion. Whenever the isolator is not desired, it canbe locked out (Fig. 5.6).

3. Lumbar Support: Lumbar support changes theshape of the seat back to give more or less sup-port to the occupant’s lumbar (lower back) area.

10/05/2001 f610523

1

2

To adjust the mirror position, press the keypad on thedoor in the direction you want the mirror to move.

1. Mirror Select Switch 2. Keypad

Fig. 5.4, Power Mirror Switch Pad

10/05/2001 f720396

1

1. Mirror

Fig. 5.5, Down View Mirror (optional)

10/05/2001 f910482

A

B

A. Seat Slide (fore-and-aft) AdjustmentB. Isolator Feature

Fig. 5.6, Seat Slide Adjustment and Isolator Feature

Cab Features

5.2

This adjustment is either mechanical or air con-trolled, depending on make and model of theseat (Fig. 5.7).

4. Headrest: When this adjustment is made, theupper part of the backrest (back cushion)changes angle to provide head and upper backsupport (Fig. 5.7).

5. Backrest Tilt: This adjustment pivots the backrestforward or backward (Fig. 5.8).

6. Seat Cushion Tilt: This adjustment raises or low-ers the front and/or back of the seat (bottom)cushion. This adjustment is easier to performwhen all weight is removed from the seat(Fig. 5.8).

7. Seat Tilt: When this adjustment is made, the seatassembly, both backrest and seat cushion, tiltsforward or backward (Fig. 5.8).

8. Ride Height Adjustment: The entire seat movesup or down when adjusting the ride height. Theadjustment is either manual or air controlled, de-pending on the make and model of the seat(Fig. 5.9).

9. Damper: When you sit on the seat, a levelingvalve places you in the center of the ride zone.When the damper is adjusted properly under nor-

mal driving conditions, the seat should not top orbottom against the limits of the vertical travel.

10. Ride Firmness: A firmer ride gives a better feelfor the road but less protection against uneven-ness in the road surface. A softer ride smoothsout the bumps.

10/05/2001

A

B

f910483

A. Lumbar Support B. Headrest Adjustment

Fig. 5.7, Lumbar Support and Headrest Adjustment

A

B

10/05/2001 f910484

A. Backrest Tilt B. Seat Cushion Tilt

Fig. 5.8, Cushion Tilt Adjustments

10/05/2001

A

f910485

A. Ride Height

Fig. 5.9, Ride Height Adjustment

Cab Features

5.3

Bench Seats

The three-person full bench seat is standard. SeeFig. 5.10.

The full bench seat has a seat slide adjustment toallow more or less leg room for the driver and pas-sengers. Release the seat slide lever and push back-wards or forwards to move the seat along its track.

High-back air suspension seats are optional for bothdriver’s and passenger’s seats. Also available are anon-suspended passenger’s seat, and a two-personbench seat with a safe or tool box located under theseat.

No adjustments are possible on the two-personbench seat or the non-suspended passenger seat.

Bostrom Seat

Seat Slide Adjustment

Move the seat slide and isolator lever (Fig. 5.11) tothe left and hold it there to slide the seat forward orbackward to the desired position.

Isolator

To engage the isolator, put the seat slide and isolatorlever in the center position. Lock out the isolator bymoving the lever to the right.

Lumbar Support

To increase lumbar support, rotate the lumbar sup-port knob forward. To decrease lumbar support, ro-tate the knob rearward.

On seats equipped with air lumbar support, press thecontrol valve upward to increase lumbar support.Press the control valve downward to decrease lum-bar support.

Seat Cushion Tilt

Rotate the seat cushion tilt knob to increase or de-crease seat cushion tilt.

Backrest Tilt

To tilt the backrest, lean forward slightly to removepressure from the cushion and hold the backrest tiltlever rearward. Lean backward slowly to the desiredposition and release the lever to lock the backrest inplace.

10/05/2001 f910481

1

2

1. Three-Person Seat2. Seat Slide Lever

Fig. 5.10, Full Bench Seat

1

23

45

6

7

10/10/96 f910131

1. Backrest Tilt Lever2. Air Lumbar Support Control Valve (optional)3. Damper Adjustment Switch4. Height Adjustment Switch5. Seat Cushion Tilt Knob6. Seat Slide and Isolator Lever7. Lumbar Support Knob (standard)

Fig. 5.11, Bostrom Seat

Cab Features

5.4

Ride Height and Damper Adjustment

To raise the seat, press the upper portion of theheight adjustment switch. To lower the seat, pressthe lower portion of the switch.

Press the damper adjustment switch to adjust thedamper.

National 2000 Series Seat


Move the seat slide lever (Fig. 5.12) to the left andhold it there to slide the seat forward or backward tothe desired position. Move the lever back to its origi-nal position to lock the seat in place.

Isolator

To use the isolator feature, turn the isolator handle tothe horizontal position. Turn the isolator handle downto lock out the isolator.

Lumbar Support

To adjust the lumbar support, use the lumbar supportswitch on the side of the seat to give more or lesssupport to your lower back.

Backrest Tilt

To tilt the backrest, turn the backrest tilt knob untilthe desired position is reached.

Seat Cushion Adjustment

To adjust the height of the front of the seat cushion,lift the front cushion height adjustment handle, andpull 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 rearcushion adjustment knob to one of three positions.

Ride Height Adjustment

To raise or lower the height of the seat, use theheight adjustment switch on the side of the seat.

Sears Seat


Push the seat slide (fore-and-aft adjustment) lever(Fig. 5.13) all the way to the left and slide the seatforward or backward, as desired. Release the leverto lock the seat in the desired position.

11/14/2000

1

234

5

f910445

6

7

1. Backrest Tilt Knob2. Lumbar Support Switch3. Height Adjustment Switch4. Seat Slide Lever5. Front Cushion Height Adjustment Handle6. Isolator Handle7. Rear Cushion Adjustment Knob

Fig. 5.12, National 2000 Series Seat10/08/2001 f910487

1

2

34

5

1. Seat Slide Lever2. Seat Cushion Tilt Adjustment3. Ride Height Knob4. Lumbar Support Lever5. Backrest Lever

Fig. 5.13, Sears Low Profile Seat

Cab Features

5.5

Isolator

To engage the isolator (if installed), move the seatslide and isolator lever (Fig. 5.14) all the way to theright. To lock out the isolator, move the isolator leverto the center position.

Lumbar Support

Move the three-position lumbar support lever upwardto increase lumbar support (firmer). Move the leverdownward to decrease lumbar support (less firm).

NOTE: This three-position lever (see inset) doesnot rotate a full 360 degrees.

For seats with air support, use the aft rocker switchon the control panel on the left-hand side of the seat(Fig. 5.15). Press up to make the seat firmer; pressdown to make the seat less firm.

Seat Cushion Tilt

To raise the seat cushion, lift upward on the front ofthe seat cushion, and then push it rearwards. Tolower the seat cushion, pull forward on the front ofthe seat cushion, and then push downwards.

Backrest Adjustment

To adjust the backrest, push downwards on the back-rest lever just below the bottom of the backrest cush-ion. With the lever down, lean forward or backwardto the desired position. Release the lever to lock thebackrest in place.

Ride Height Adjustment

Push the ride height knob inwards to inflate the aircylinder, raising the height of the seat. Pull the rideheight knob outwards to deflate the air cylinder, low-ering the height of the seat.

For seats with air support, use the forward rockerswitch on the control panel on the left-hand side ofthe seat (Fig. 5.15). Press up to raise the seat; pressdown to lower the seat.

Ride Firmness Adjustment

For a softer ride, remove the snap ring and pin fromthe shock absorber bracket (see inset). Relocate thepin in the other set of holes in the bracket and se-cure it with the snap ring.

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2

3

4

5

6

7

8

NOTE: Armrests are optional.

1. Lumbar Support Lever2. Backrest Lever3. Ride Height Knob4. Shock Absorber Bracket (ride firmness)5. Pin (ride firmness)6. Snap Ring (ride firmness)7. Seat Slide and Isolator Lever8. Seat Cushion Adjustment

Fig. 5.14, Sears Fleetmaster Seat (with isolator)

10/08/2001 f9104881 2

1. Ride Height Switch2. Air Lumbar Support Switch

Fig. 5.15, Air Controls, Sears Seat

Cab Features

5.6

Seat Belts and Tether Belts

General Information

Seat belt assemblies are designed to secure personsin the vehicle to help reduce the chance of injury orthe amount of injury resulting from accidents or sud-den stops. For this reason, Daimler Trucks NorthAmerica LLC urges that the driver and all passen-gers, regardless of age or physical condition, useseat belts when riding in the vehicle.

WARNING

Always use the vehicle’s seat belt system whenoperating the vehicle. Failure to do so can resultin severe personal injury or death.

Seat belt assemblies in Daimler Trucks NorthAmerica (DTNA) vehicles meet Federal Motor Ve-hicle Safety Standard 209, "Type 1" and "Type 2" re-quirements.

When transporting a child, always use a child re-straint system or the vehicle seat belts as appropri-ate. To determine whether a child restraint system isrequired, review and comply with applicable stateand local laws. Any child restraint used must complywith Federal Motor Vehicle Safety Standard 213,"Child Restraint Systems." When providing a childrestraint system, always carefully read and follow allinstructions pertaining to installation and usage forthe child. Make certain the child remains in the re-straint system at all times when the vehicle is in mo-tion.

In addition to seat belt assemblies, tether belts areinstalled on suspension-type seats. Tether belts helpsecure the seat to the floor and are intended to re-strain the seat and seat belt in case of an accident orsudden stop.

IMPORTANT: Seat belts have a finite life whichmay be much shorter than the life of the vehicle.Regular inspections and replacement as neededare the only assurance of adequate seat beltsecurity over the life of the vehicle.

Seat Belt Inspection

WARNING

Inspect and maintain seat belts. When any part ofa seat belt system needs replacement, the entireseat belt must be replaced, both retractor andbuckle side. Any time a vehicle is involved in anaccident, and the seat belt system was in use,the entire vehicle seat belt system must be re-placed before operating the vehicle. Do not at-tempt to modify the seat belt system; doing socould change the effectiveness of the system.Failure to replace worn or damaged seat belts, ormaking any modifications to the system, may re-sult in personal injury or death.

Inspect the seat belts and tether belts (if soequipped).

1. Check the web for fraying, cuts, extreme dirt anddust, or for severe fading from exposure to sun-light, especially near the buckle latch plate and inthe D-loop guide area.

2. Check operation of the buckle, latch, KomfortLatch or Sliding Komfort Latch (if equipped), webretractor, and upper seat belt mount on the doorpillar. Check all visible components for wear ordamage.

3. Check the seat belt and tether belt connectionpoints and tighten any that are loose.

Seat Belt Operation

Three-Point Seat Belt With Komfort Latchor Sliding Komfort Latch

WARNING

Wear three-point seat belts only as describedbelow. Three-point seat belts are designed to beworn by one person at a time. In case of an acci-dent or sudden stop, personal injury or deathcould result from misuse.

Fasten the seat belts before driving. Fastening athree-point seat belt while driving creates a haz-ard.

When engaged and used properly, the Komfort Latch(Fig. 5.16) and the Sliding Komfort Latch (Fig. 5.17)

Cab Features

5.7

introduce a small amount of slack into the seat belt,resulting in a more comfortable ride.

1. Slowly pull the latch end of the three-point seatbelt out of the retractor and pull it across your

lap (from outboard to inboard) far enough to en-gage the buckle. If the retractor locks too soon,allow the belt to retract slightly, then slowly pull itout again.

2. Fasten the three-point seat belt by pushing thelatch into the buckle. Listen for an audible click.See Fig. 5.18.

3. Tug on the seat belt to make sure it is securelyfastened. If the buckle unlatches, repeat thisstep. If the problem continues, replace the three-point seat belt.

4. Snug the seat belt to your waist.

5. Position the shoulder strap diagonally acrossyour chest with the adjustable D-loop bracket (ifequipped). If desired, engage the Komfort Latchor Sliding Komfort Latch as follows.

If equipped with a Sliding Komfort Latch, makesure that the shoulder strap is snug against yourchest. Without loosening the shoulder strap,push the Sliding Komfort Latch switch to the"ON" position. See Fig. 5.17. To activate thelatch lean forward until you hear a click. This willallow for approximately 1 inch (2.5 cm) of slackbetween your chest and the shoulder harness.Once engaged, the latch will allow you to leanforward about 5 inches (13 cm) without having toreset the latch. Leaning forward more than 5inches (13 cm) will disengage the Sliding Kom-fort Latch, requiring it to be reset.

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A B

A. Disengaged B. Engaged

Fig. 5.16, Komfort Latch

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Fig. 5.17, Sliding Komfort Latch

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Fig. 5.18, Fastening the Three-Point Belt

Cab Features

5.8

If equipped with a Komfort Latch, pull on theshoulder strap to lessen the pressure of the strapon your shoulder and chest. Allow no more than1 inch (2.5 cm) of slack between your chest andthe shoulder harness. More slack can signifi-cantly reduce the seat belt effectiveness in anaccident or a sudden stop. While holding the beltslack, press the Komfort Latch lever up, clamp-ing the seat belt webbing (Fig. 5.19 andFig. 5.20).

6. Unbuckle the three-point seat belt and releasethe Komfort Latch or the Sliding Komfort Latchas follows.

If equipped with a Sliding Komfort Latch, un-buckle the seat belt, then tug on the shoulder

belt to release the Sliding Komfort Latch, orpress the Sliding Komfort latch to the "OFF" po-sition, then unbuckle the seat belt.

If equipped with a Komfort Latch, unbuckle theseat belt, then release the Komfort Latch by giv-ing the shoulder belt a quick tug. If you lean for-ward against the shoulder belt, the Komfort Latchwill automatically release, and will need to bereset.

NOTE: Neither the Komfort Latch nor the SlidingKomfort Latch need to be manually released inan emergency situation. Each will release byitself under rough road or other abnormal condi-tions. Make sure the three-point seat belt iscompletely retracted when it is not in use.

Air Bag, Optional

Your vehicle may or may not be equipped with adriver’s air bag supplemental restraint system.

The air bag, when used with seat belts, provides ad-ditional protection to the driver in severe frontal colli-sions. The operational readiness of the air bag sys-tem is indicated by the supplemental restraint system(SRS) indicator on the dash. The SRS indicatorcomes on when the engine is started and then goesoff. The indicator will remain on if there is a problemwith the air bag system. The vehicle should be ser-viced if the SRS indicator does not come on whenthe engine is started or if the SRS indicator remainson.

WARNING

Air bags are designed to inflate only in severefrontal collisions. The driver and the passengershould always wear seat belts. For maximum pro-tection in a collision or rollover, always be in anormal seated position with your back againstthe seat back and your head upright. Fasten yourseat belt and ensure that it is properly positionedon your body as described under the "Seat BeltOperation" heading. Since the air bag inflateswith considerable speed and force, a proper seatposition will keep you a safe distance from theinflating air bag.

Do not place objects on the steering wheel or be-tween you and the steering wheel. Keep yourhands on the sides and lower portion of the

A

01/06/95 f910048a

A. 1 Inch (2.5 cm) Maximum

Fig. 5.19, Adjusting Shoulder Harness Clearance,Komfort Latch

11/02/95 f910144

Fig. 5.20, Locking the Komfort Latch

Cab Features

5.9

steering wheel. Any objects may cause harm dur-ing an accident.

Failure to follow these instructions may result indeath or personal injury.

Air Bag Safety Guidelines

The air bag system contains components that usecombustible chemicals. Because these chemicals arecombustible, care must be taken when replacing orhandling system components.

WARNING

Consider undeployed air bags to be dangerousand capable of deploying at any time. Do not at-tempt to service the air bag system unlesstrained to do so. Damaged air bag systemsshould be examined by qualified personnel be-fore any attempt is made to remove or to deploythe air bag. All intentional deployments and test-ing of the system should be performed by trainedpersonnel. Unintentional or improper air bag de-ployment could cause severe bodily injury ordeath.

Do not attempt to disassemble the air bag inflatorunit or breach the integrity of the sealed metallicinflator case. Doing so could cause severe bodilyinjury or death.

Do not allow system chemicals to contact otherliquids, combustibles, and flammable materials.Doing so could cause chemical burns or per-sonal injury.

The surface of the deployed air bag may containsmall amounts of sodium hydroxide (which is aby-product of the gas generant combustion) andmetallic sodium. Sodium hydroxide may be irri-tating to the skin and eyes. Always wear rubbergloves and safety glasses when handling a de-ployed air bag. Immediately wash your hands andexposed skin areas with a mild soap and water.Flush your eyes immediately if exposed to so-dium hydroxide.

Review and comply with the following list ofwarnings. Failure to do so could result in severeinjury or death.

• Keep all liquids, acids, halogens, heavymetals, and heavy salts away from the airbag system.

• Do not cut, drill, braze, solder, weld, strike,or probe any part of the air bag system.

• Do not expose the air bag module to elec-tricity. Never probe a circuit.

• Do not attempt to adapt, reuse, or install anair bag system in any vehicle other than thespecific vehicle for which it is designed.

• Do not cut wires or tamper with the connec-tor between the vehicle wiring harness andthe air bag module. Cutting or removing theconnector from the system will disable thesafety shunt and could cause unintentionaldeployment.

• Allow deployed air bag systems to coolafter deployment.

• Wear rubber gloves and safety glasseswhen handling a deployed air bag.

• Wash your hands and exposed skin surfaceareas immediately after handling a de-ployed system.

• Store, transport, dispose of, and recycledeployed air bag system components inaccordance with all applicable federal,state, and local regulations.

• The air bag module may contain perchlor-ate material: special handling may apply,see www.dtsc.ca.gov/hazardouswaste/perchlorate.

• Keep all heavy objects in the cab secured.

Cab Amenities

Cup Holders

There are two cup holders molded into the lower partof the auxiliary dash panel, one on either side of theHVAC control head.

Cab Storage

There are storage bins in the dash and the overheadconsole. On vehicles with optional individual driver’sand passenger seats, there is a center storage con-sole between the seats.

There is a dash storage bin located under the cupholders on the center panel. The bin has a hinged

Cab Features

5.10

cover and can be used to store sunglasses. There isalso a small storage pocket above the radio.

Overhead Storage

Vehicles without an overhead console have two stor-age bins located above the windshield.

On vehicles equipped with an overhead console,most vehicles have a storage bin located in the over-head console. See Fig. 5.21. The overhead storagebin is often removed and replaced with a CB radio.

Two map holders with netted openings are locatedoverhead, one on either side of the overheadconsole.

Center Storage Console (optional)

On vehicles with individual driver’s and passenger’sseats, a center storage console can be installed be-tween the seats.

The center storage console has a table top that canbe lifted up to deploy a writing surface. SeeFig. 5.22.

In another version, the center storage console has aprinter top with a paper slot in it. See Fig. 5.23.

Windshield Washer Reservoir

The standard location for the windshield washer res-ervoir is on the right-hand side of the cab underneaththe door, just above the trailing edge of the top cabstep. See Fig. 5.24.

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3

1. Overhead Storage Bin 2. Overhead Console 3. Map Holder Netting

Fig. 5.21, Overhead Storage

Cab Features

5.11

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2

3

4

1. Table Top2. Storage Console Cover3. Storage Area4. Storage Console Base

Fig. 5.22, Center Storage Console (with writing surface)

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2

3

1. Printer Top2. Printer/Paper Area

3. Storage Console Base

Fig. 5.23, Center Storage Console (printer option)

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12

3

1. Cab2. Washer Reservoir Fill Cap3. Top Step

Fig. 5.24, Windshield Washer Reservoir

Cab Features

5.12

6

Heater, Ventilator and AirConditioner

Climate Control Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.1

Climate Control Panel

The climate control panel allows you to control theheating, ventilating, defrosting, and air conditioningfunctions. The climate control panel without air condi-tioning is shown in Fig. 6.1. The climate controlpanel with air conditioning is shown in Fig. 6.2.

Fan Switch

The fan switch controls the fan speed and forcesfresh or recirculated air through the air outlets. Thefan switch has eight fan speeds and an off position.

To increase airflow, turn the fan switch to the right orto a higher number. To decrease the airflow, turn theswitch to the left or to a lower number.

Air Selection Switch

The air selection switch allows you to control the flowof air through the face outlets, the floor outlets, thedefrost (windshield) outlets, or a combination ofthese outlets to give you nine air selection modes ona system without air conditioning. See Fig. 6.3. Asystem with air conditioning has 11 air selection

2

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40

1 2 3

f831452a06/17/2003

1. Fan Switch 2. Air Selection Switch 3. Temperature Control Switch

Fig. 6.1, Climate Control Panel Without Air Conditioning

1 2 3

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231

40

1. Fan Switch2. Air Selection Switch

3. Temperature Control Switch4. Recirculation Button

5. Recirculation Indicator

Fig. 6.2, Climate Control Panel With Air Conditioning

Heater, Ventilator and Air Conditioner

6.1

modes, four of which are air conditioning modes. SeeFig. 6.4.

Air Selection Switch Without AirConditioning

1. Face Mode: Directs all airflow through the faceor instrument panel outlets.

2. Selection between Face Mode and Bi-LevelMode: Directs 75 percent of the airflow throughthe face outlets and 25 percent through the flooroutlets.

3. Bi-Level Mode: Directs the airflow equally to theface outlets and the floor outlets.

4. Selection between Bi-Level Mode and FloorMode: Directs 25 percent of the airflow throughthe face outlets and 75 percent through the flooroutlets.

5. Floor Mode: Directs all airflow through the flooroutlets.

6. Selection between Floor Mode and Floor/Defrost Mode: Directs 75 percent of the airflow

through the floor outlets and 25 percent throughthe defrost outlets.

7. Floor/Defrost Mode: Directs the airflow equallyto the floor outlets and the defrost outlets.

8. Selection between Floor/Defrost Mode andDefrost Mode: Directs 75 percent of the airflowthrough the defrost outlets and 25 percentthrough the floor outlets.

9. Defrost Mode: Directs all airflow through thedefrost outlets.

Air Selection Switch With AirConditioning

1. Air Conditioning Face Mode: Directs all airflowthrough the face or instrument panel outlets.

2. Selection between the Air Conditioning FaceMode and the Air Conditioning Bi-Level

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2

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7

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f831455

1. Face Mode2. Selection Between Face Mode and Bi-Level Mode3. Bi-Level Mode4. Selection Between Bi-Level Mode and Floor Mode5. Floor Mode6. Selection Between Floor Mode and Floor/Defrost

Mode7. Floor/Defrost Mode8. Selection Between Floor/Defrost Mode and Defrost

Mode9. Defrost Mode

Fig. 6.3, Air Selection Switch Without Air Conditioning

f831462

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9

10

11

06/18/2003

A

A. Air Conditioning Modes

1. Air Conditioning Face Mode2. Selection Between Air Conditioning Face Mode and

Air Conditioning Bi-Level Mode3. Air Conditioning Bi-Level Mode4. Selection Between Air Conditioning Bi-Level Mode

and Face Mode5. Face Mode6. Selection Between Face Mode and Floor Mode7. Floor Mode8. Selection between Floor Mode and Floor/Defrost

Mode9. Floor/Defrost Mode10. Selection between Floor/Defrost Mode and Defrost

Mode11. Defrost Mode

Fig. 6.4, Air Selection Switch With Air Conditioning


6.2

Mode: Directs 75 percent of the airflow to theface outlets and 25 percent to the floor outlets.

3. Air Conditioning Bi-Level Mode: Directs theairflow equally to the face outlets and the flooroutlets.

4. Selection between the Air Conditioning Bi-Level Mode and the Face Mode: Directs 25percent of the airflow to the face outlets and 75percent to the floor outlets.

5. Face Mode: Directs all airflow through the faceoutlets.

6. Selection between Face Mode and FloorMode: Directs the airflow equally through theface outlets and the floor outlets.

7. Floor Mode: Directs all airflow through the flooroutlets.

8. Selection between Floor Mode and Floor/Defrost Mode: Directs 75 percent of the airflowthrough the floor outlets and 25 percent throughthe defrost outlets.

9. Floor/Defrost Mode: Directs the airflow equallyto the floor outlets and the defrost outlets. Therecirculation button will not work in this mode.

10. Selection between Floor/Defrost Mode andDefrost Mode: Directs 75 percent of the airflowthrough the defrost outlets and 25 percentthrough the floor outlets. The recirculation buttonwill not work in this mode.

11. Defrost Mode: Directs all airflow through thedefrost outlets. The recirculation button will notwork in this mode.

Temperature Control Switch

The temperature control switch is used to select thedesired temperature. Turn the switch to the left(counterclockwise) for cool air, or to the right (clock-wise) for hot air. There are 21 positions on the tem-perature control switch ranging from full cool air tofull hot air.

Fresh Air Mode

Fresh air, or outside air, is circulated through theheating and air conditioning system unless the recir-culation mode, if equipped, is turned on.

Recirculation Mode

The recirculation mode is only available on vehicleswith air conditioning.

The recirculation mode limits the amount of outsideair entering the cab. Press the recirculation button toprevent dusty or smoky air from entering the cab.The recirculation mode can also be used to decreasethe time required to cool or heat the cab interior dur-ing extreme outside temperature conditions. Whenthe recirculation mode is on, the recirculation indica-tor will be on. See Fig. 6.2.

The recirculation mode is not available when the airselection switch is in one of the following modes:

• floor/defrost mode

• selection between floor/defrost mode and de-frost mode

• defrost mode

When the recirculation mode is turned on, it will stayon for 20 minutes, or until the recirculation button ispressed again, or the air selection switch is turned toa defrost mode.

IMPORTANT: On vehicles built before May 2,2003, the recirculation mode turns off aftertwenty minutes and can be turned back onwhen the recirculation button is pressed again.On vehicles built from May 2, 2003, the systementers a partial recirculation mode for five min-utes after being in full recirculation mode for 20minutes. This cycle repeats as long as the sys-tem is in recirculation mode.

NOTE: To prevent the buildup of fumes or odorsinside the cab on a vehicle built before May 2,2003, do not use the recirculation mode formore than 20 minutes. It is recommended thatthe recirculation mode remains off for five min-utes before it is turned back on.

Defrosting

Before using any of the defrost modes, clear thescreen at the base of the windshield if snow or ice ispresent.


6.3

Air Conditioning, Optional

There are four air conditioning modes on the air se-lection switch. The air conditioning settings on the airselection switch are blue, in addition to the selectionbetween the air conditioning bi-level mode and theface mode.

IMPORTANT: Operate the air conditioner atleast five minutes each month, even during coolweather. This helps prevent drying and crackingof the refrigerant compressor seals and reducesthe chance of refrigerant leaks in the system.

NOTE: The heating and air conditioning systemhas a brushless blower motor with a protectionor shutdown mode to prevent damage due tooverheating and overcurrent conditions. If thebrushless blower motor goes into a protectionmode, 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 themotor has cooled or the overcurrent conditionhas been resolved. It will be necessary to cyclethe fan switch off, and then on, to reset themotor. If the problem appears repeatedly, takethe vehicle to an Freightliner dealer or autho-rized service outlet for repairs.


6.4

7

EnginesAftertreatment System (ATS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.1

Engine Starting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.9

Cold-Weather Starting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.10

Starting After Extended Shutdown or Oil Change . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.10

Engine Break-In . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.10

Engine Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.10

Cruise Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.11

Power Takeoff (PTO) Governor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.13

Cold-Weather Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.13

High-Altitude Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.13

Engine Shutdown . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.14

Engine Braking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.14

Exhaust Braking Systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.15

Aftertreatment System (ATS)IMPORTANT: EPA07 and EPA10 emissionsregulations apply to vehicles domiciled inCanada and the USA at the time of printing thismanual. Vehicles that are domiciled outside ofthe USA and Canada may not have EPA07- orEPA10-compliant engines with an emission af-tertreatment system, depending upon localstatutory emissions guidelines.

EPA07 Aftertreatment System (ATS)

On-road diesel engines built after December 31,2006 are required to meet EPA07 guidelines for re-duced exhaust emissions of particulate matter andnitrogen oxides (NOx). NOx is limited to just over 1gram per brake horsepower hour (g/bhp-hr), and par-ticulate matter cannot exceed 0.01 g/bhp-hr.

EPA07-compliant engines require ultralow-sulfur die-sel (ULSD) fuel, and they should never be run onfuel with sulfur content higher than 15 ppm. In addi-tion, they require low-ash engine oil. The followingguidelines must be followed, or the warranty may becompromised.

• Use ultralow-sulfur diesel (ULSD) with 15 ppmsulfur content or less, based on ASTM D2622test procedure.

• Do not use fuel blended with used engine lubeoil or kerosene.

• Engine lube oil must have a sulfated ash levelless than 1.0 wt %, meeting the API CJ-4 indexspecifications.

IMPORTANT: Using non-specification fuels oroils can lead to shortened diesel particulate filter(DPF) cleaning or exchange intervals. For ex-ample, using CI-4+ oil with 1.3% sulfated ash(30% more ash content) may result in the needfor DPF cleaning or exchange 20 to 30% soonerthan would normally be required.

The "exhaust system" in EPA07-compliant vehicles iscalled the aftertreatment system (ATS). The ATS var-ies according to engine manufacturer and vehicleconfiguration, but instead of a muffler, an aftertreat-ment system has a device that outwardly resemblesa muffler, called the aftertreatment device (ATD).

IMPORTANT: See your engine operation manualfor complete details and operation of the after-treatment system.

Inside the ATD on Mercedes-Benz, Detroit Diesel,and Cummins engines, the exhaust first passes overthe diesel oxidation catalyst (DOC), then it passesthrough the DPF, which traps soot particles. If ex-haust temperature is high enough, the trapped sootis reduced to ash, in a process called passive regen-eration (regen). Passive regeneration occurs as thevehicle is driven normally under load; the driver isnot even aware that it is happening. The harder anEPA07 engine works, the better it disposes of soot,as the exhaust heat alone is enough to burn the sootto ash. Over the course of a workday, however, pas-sive regeneration cannot always keep the ATD filterclean, so the filter must undergo active regenera-tion.

In active regeneration, extra fuel is injected into theexhaust stream to superheat the soot trapped in theDPF and turn it to ash. Active regeneration happensonly when the vehicle is moving above a certainspeed, determined by the engine manufacturer. Con-sult manufacturers’ documentation for details. Bothactive and passive regeneration happen automati-cally, without driver input.

If conditions do not provide for at-speed active re-generation, the vehicle will need a driver-activatedparked regeneration. The vehicle must be standingstill, and the driver must initiate parked regen. Com-pleting a parked regen takes 20 minutes to an hour,depending on ambient conditions.

DANGER

During parked regeneration, exhaust tempera-tures are very high, and could cause a fire, heatdamage to objects or materials, or personal in-jury to persons near the exhaust outlet.

Before initiating a parked regeneration, make cer-tain the exhaust outlets are directed away fromstructures, trees, vegetation, flammable materi-als, and anything else that may be damaged orinjured by prolonged exposure to high heat.

There are three warning lamps in the driver messagecenter that alert the driver of the need to perform aparked regen, clean the filter, or of an engine faultthat affects the emissions.

Engines

7.1

A slow (10-second) flash of the high exhaust systemtemperature (HEST) lamp, indicates a regeneration isin progress, and the driver is not controlling the en-gine idle speed.

A solid illuminated high exhaust system temperature(HEST) lamp, alerts the operator of high exhausttemperature during the regeneration process, whenthe speed is below 5 mph (8 km/h). See Fig. 7.1.The HEST lamp does not indicate the need for anykind of vehicle or engine service; it only alerts thevehicle operator of high exhaust temperatures. Thedriver must be careful that the exhaust pipe outlet isnot directed at any person, or at any object or mate-rial that can be damaged or ignited by the heat.

WARNING

Active regeneration can occur automatically any-time the vehicle is moving. The exhaust gas tem-perature could reach 1500°F (800°C), which is hotenough to cause a fire, heat damage to objectsor materials, or personal injury to persons nearthe exhaust outlet. See Regen-Inhibit Switch laterin this chapter for instructions on preventing au-tomatic regen if necessary.

The exhaust temperature can remain high evenafter the vehicle has stopped. When stopping thevehicle shortly after an automatic regen, ensurethe exhaust outlets are directed away from struc-tures, trees, vegetation, flammable materials, andanything else that may be damaged or injured byexposure to high heat.

A steady yellow DPF lamp indicates that a parkedregen is required soon, and should be scheduled forthe earliest convenient time. See Fig. 7.2. A blinking

yellow DPF lamp indicates that a parked regen isrequired immediately, or an engine derate may occur.

A solid yellow malfunction indicator lamp (MIL) indi-cates an engine fault that affects the emissions. SeeFig. 7.3.

Diesel particulate filter servicing must be performedby an authorized service facility, and a record mustbe maintained for warranty purposes. The recordmust include:

• date of cleaning or replacement;

• vehicle mileage;

• particulate filter part number and serial number.

The request regen switch is located on the dash.See Fig. 7.4 . The function of the switch varies bythe engine make and model in the vehicle. See theengine operation manual for switch operation details.

NOTE: The regen switch can start an activeregen only when the DPF light is illuminated

09/25/2006 f610816a

Fig. 7.1, High Exhaust System Temperature (HEST)Lamp

09/25/2006 f610815a

Fig. 7.2, Diesel Particulate Filter (DPF) Status Lamp

09/25/2006 f610814a

Fig. 7.3, Malfunction Indicator Lamp (MIL)

Engines

7.2

because the engine software calls for a manualregen.

The regen-inhibit switch provides additional controlover the aftertreatment regeneration process. A drivermay decide to use this feature if they are haulingcargo that should not be exposed to possible highexhaust temperatures from an automatic regen.When activated, the inhibit switch will stop a regen-eration cycle in progress, and prevent the start of aregeneration cycle until the switch is no longer ac-tive. See Fig. 7.5.

EPA10 Aftertreatment System (ATS)

The EPA mandates that all engines built after De-cember 31, 2009 must reduce the level of emissionsexhausted by the engine to the following levels:

• Nitrogen Oxides (NOx) – 0.2 g/bhp-hr

• Particulate Matter (PM) – .01 g/bhp-hr

To meet EPA guidelines, diesel engines installed inDaimler Trucks North America (DTNA) chassis fordomicile in Canada and the USA use an aftertreat-ment system (ATS) with an aftertreatment device(ATD) and Selective Catalytic Reduction (SCR) tech-nology to reduce NOx downstream of the engine.

NOTICE

Using non-specification fluids can result in seri-ous damage to the ATS. It is extremely importantthat the following guidelines be followed for ve-hicles with EPA10-compliant engines, or damagemay occur to the ATD, and the warranty may becompromised.

• Use ultralow-sulfur diesel with 15 ppm sulfurcontent or less.


• Engine lube oil must have a sulfated ash levelless than 1.0 wt %; currently referred to asCJ-4 oil.

• Use only certified diesel exhaust fluid (DEF) inthe DEF tank.

After exhaust gasses leave the engine, they flow intothe ATS. First they flow into a two-part ATD, com-prised of a diesel oxidation catalyst (DOC), and adiesel particulate filter (DPF). The DPF traps sootparticles, then exhaust heat converts the soot to ashin the DPF, in a process called regeneration (regen).The harder an engine works, the better it disposes ofsoot. When the engine is running under load andregen occurs without input, it is called passive regen.If the engine isn’t running hot enough, the electroniccontrols may initiate an active regen, whereby extrafuel is injected into the exhaust stream before thediesel particulate filter, to superheat the soot trappedin the filter and burn it to ash. Both types of regenoccur without driver input.

WARNING

Active regeneration can occur automatically any-time the vehicle is moving. The exhaust gas tem-perature could reach 1500°F (800°C), which is hotenough to cause a fire, heat damage to objectsor materials, or personal injury to persons nearthe exhaust outlet. See Regen-Inhibit Switch later

f61084810/02/2006

Fig. 7.4, Request Regen Switch

f61094407/30/2009

Fig. 7.5, Regen-Inhibit Switch

Engines

7.3

in this chapter for instructions on preventing au-tomatic regen if necessary.

The exhaust temperature can remain high evenafter the vehicle has stopped. When stopping thevehicle shortly after an automatic regen, ensurethe exhaust outlets are directed away from struc-tures, trees, vegetation, flammable materials, andanything else that may be damaged or injured byexposure to high heat.

Operating at reduced engine load will allow soot toaccumulate in the DPF. When this occurs, the DPFlamp illuminates, indicating that a regen must be per-formed, and the driver must either bring the vehicleup to highway speed to increase the load, or parkthe vehicle and initiate a parked regen. See ParkedRegen, later in this chapter for instructions.

After the exhaust stream passes through the ATD, itflows through another canister housing the SCR de-vice. A controlled quantity of diesel exhaust fluid(DEF) is injected into the exhaust stream, where heatconverts it to ammonia (NH3) gas. This mixture flowsthrough the SCR device, where the ammonia gasreacts with the NOx in the exhaust, to produce harm-less nitrogen (N2) and water vapor (H2O), which thenexits out of the tailpipe.

ATS Warning Lamps

The malfunction indicator lamp (MIL) illuminates toindicate a fault that affects the emissions. SeeFig. 7.3.

Warning lamps in the driver’s message center alertthe driver of situations with the aftertreatment sys-tem. A decal attached to the driver’s sun visor ex-plains the aftertreatment system DPF, HEST, andDEF warning lamps. See Fig. 7.6.

• An illuminated DPF lamp indicates a regen isneeded.

• A slow, 10-second flashing of the HEST lampalerts the driver that a parked regen is inprogress, but the exhaust temperatures are stillrelatively cool. It also indicates that the high-idle speed is being controlled by the enginesoftware, not the driver.

• A steadily illuminated HEST lamp alerts theoperator of high exhaust temperatures whenvehicle speed is below 5 mph (8 km/h) while itis performing an automatic regen, and during aparked regen.

• An illuminated DEF warning lamp in the gauge,indicates that the DEF tank should be refilledat the next opportunity.

Parked Regen

DANGER

During parked regeneration, exhaust tempera-tures are very high, and could cause a fire, heatdamage to objects or materials, or personal in-jury to persons near the exhaust outlet.

Before initiating a parked regeneration, make cer-tain the exhaust outlets are directed away fromstructures, trees, vegetation, flammable materi-als, and anything else that may be damaged orinjured by prolonged exposure to high heat.

See Fig. 7.7 for an explanation the ATS warnings,and actions required to avoid further engine protec-tion sequences.

The regen switch, located on the dash, is used toinitiate a parked regen of the aftertreatment device. Itis a momentary switch, that you press and hold for 4seconds to activate. See Fig. 7.4.

NOTE: The regen switch can initiate a parkedregen only when the DPF lamp is illuminated(because the engine software is signaling for aparked regen.)

The regen-inhibit switch provides additional controlover the aftertreatment regeneration process. A drivermay decide to use this feature if they are haulingcargo that should not be exposed to possible highexhaust temperatures from an automatic regen.When activated, the inhibit switch will stop a regen-eration cycle in progress, and prevent the start of aregeneration cycle until the switch is no longer ac-tive. See Fig. 7.5.

To initiate a parked regeneration, perform the follow-ing steps.

1. Park the vehicle away from all combustible andflammable materials. Chock the tires. Start andwarm the engine until the coolant temperature isat least 150°F (66°C).

2. Set the parking brake. If the parking brake wasalready set, you must release it, then set itagain.

Engines

7.4

For manual transmissions, fully depress theclutch pedal, put the transmission in neutral, thenrelease the pedal.

If the vehicle has a two-pedal automated trans-mission, shift it into gear, then back to neutral.

IMPORTANT: The driver must remain with thevehicle during the entire regen cycle.

3. Press and hold the regen switch for 4 seconds.The engine will increase rpm and initiate theregen process.

4. After the parked regen has run for 20 to 40 min-utes, the regen cycle is completed. The engineidle speed will drop to normal, and the vehiclemay be driven normally. The HEST lamp may beilluminated, but will go out when the vehiclespeed exceeds 5 mph (8 km/h), or the systemhas cooled to normal operating temperature.

5. To stop a parked regen at any time during theprocess, engage the clutch, brake, or throttlepedal, or turn off the engine.

DPF Maintenance

Eventually ash will accumulate in the DPF and thefilter will require servicing. DPF servicing must beperformed by an authorized technician, following theengine manufacturer’s instructions. A record must bemaintained for warranty purposes, that includes:

• date of cleaning or replacement;

• vehicle mileage;

• particulate filter part number and serial number.

DEF

DEF is used in the aftertreatment system to lowerNOx in the exhaust stream. DEF is colorless and

DPF Regen Needed

Hot Exhaust

DEF Refill Needed

Diesel Particulate Filter (DPF)regeneration is needed.

If flashing, regenerate as soon aspossible. Engine derate possible.

Hot exhaust can cause fire.

Keep flammables and people awayfrom exhaust.

Diesel Exhaust Fluid (DEF) level islow. Engine derate likely.

Refill tank with certified DEF.

See operator’s manual for complete instructions.24−01656−000

IMPORTANT

DEF

11/30/2010 f080161

1

2

3

1. DPF Warning Lamp 2. HEST Warning Lamp 3. DEF Warning Lamp

Fig. 7.6, Warning-Lamp Decal, Sunvisor

Engines

7.5

close to odorless. (It may have a slightly pungentodor similar to ammonia.) It is nontoxic, nonflam-mable and biodegradable. It is mildly corrosive toaluminum, but it will not affect the strength or struc-ture of the aluminum. A white powder may be notice-able around components that the DEF comes in con-tact with. Around 12°F (-11°C) DEF freezes to slush,but is not damaged or destroyed if frozen, and is fullyusable when thawed. The DEF supply lines are elec-trically heated and are purged when the engine isshut down. The DEF in the tank is allowed to freezewhile the vehicle is non-operational. At start up, nor-mal operation of the vehicle is not inhibited if theDEF is frozen; an immersion heater with engine cool-ant flowing through it will warm the DEF once theengine is running, to allow the SCR system to oper-ate.

DEF Tank

EPA10-compliant vehicles are equipped with a DEFtank located on the driver’s side of the vehicle, usu-ally behind the battery box, or an optional locationforward of the fuel tank for day cab configurations.See Fig. 7.8, and Fig. 7.9. The DEF tank has a 19mm filler neck inlet that prevents the hose from a

diesel outlet from being inserted, and has a blue capfor easy identification.

DEF consumption will vary depending on ambientconditions and vehicle application.

f080147

EXHAUST AFTERTREATMENT SYSTEM INFORMATION

Switch.

Level 1 Level 3Level 2 Level 4

Filter RegenerationRecommended

Filter is reaching

Bring vehicle tohighway speeds to

Filter RegenerationNecessary

Filter is nowreaching maximumcapacity.

To avoid enginederate bring vehicle

Parked RegenerationRequired − EngineDerate

Filter has reachedmaximum capacity.

Vehicle must beparked and a Parked

Parked Regeneration Required −Engine Shut Down

Filter has exceededmaximum capacity

Vehicle must be parked and aParked Regeneration or Service

(Solid) (Flashing) (Flashing)

CHECK CHECK

(Flashing)

INDICATORLAMP(S)

Indicator LampMessage(s)

Diesel ParticulateFilter Condition

Required Action

capacity. .

STOP

See Engine Operator’s Manual for complete Regeneration Instructions.

allow for an AutomaticRegeneration orperform a ParkedRegeneration.

to highway speedsto allow for anAutomaticRegeneration orperform a ParkedRegeneration assoon as possible.

Regeneration mustbe performed −engine will beginderate.

Regeneration must be performed.Check engine operator’s manualfor details −engine will shut down.

For a driver performed Parked Regeneration, vehicle must be equipped with a dash mounted Regeneration Switch.

06/29/2009

24−01583−000B

WARNING

HEST (High ExhaustSystem Temperature)

Exhaust Componentsand exhaust gas areat high temperature. When stationary, keepaway from people andflammable materialsor vapors.

A regeneration is inprogress.

Flashing

Solid

Fig. 7.7, Exhaust-Aftertreatment Warnings

07/24/2009 f470542

1

2

1. Batteries 2. DEF Tank

Fig. 7.8, DEF Tank Located Behind the Battery Box

Engines

7.6

Fuel/DEF Gauge

The diesel fuel and DEF levels are measured in adual purpose gauge. See Fig. 7.10.

The diesel-fuel level is indicated at the top of thegauge. Below the fuel level, a diesel-fuel warninglamp illuminates amber when the diesel fuel leveldrops below 1/8th of the capacity.

The lower portion of the gauge has a DEF warninglamp that illuminates amber when the DEF tank isnear empty, and a lightbar that indicates the level ofDEF in the tank. The DEF light bar illuminates asfollows.

• Four bars illuminated green—Between 75%and 100% full.

• Three bars illuminated green—Between 50%and 75% full.

• Two bars illuminated green—Between 25%and 50% full.

• One bar illuminated green—Between approxi-mately 10% and 25% full.

• One bar illuminated amber—DEF very low, re-fill DEF.

• One bar flashing red—DEF empty, refill DEF.

DEF Warnings and Engine Derates

IMPORTANT: Ignoring the DEF warning lightswill result in limited engine power, with a speedlimit of 5 mph (8 km/h) eventually being applied.

DEF Level Low—Initial Warning

When the DEF level reads low the following warningsstrongly encourage the driver to refill the DEF tank:

• One bar of the DEF level indicator illuminatesamber—DEF very low, refill DEF

• DEF warning lamp illuminates solid amber

See Fig. 7.11.

The DEF tank must be filled to cancel the warningsequence.

DEF Empty

When the DEF level reads empty, the following warn-ings are activated:

• One bar of the DEF level indicator flashesred—DEF empty, refill DEF

• DEF warning lamp flashes amber

• MIL lamp illuminates

• CHECK engine lamp illuminates for CumminsISB and ISC/L engines

Detroit Diesel engines: Power is limited, with a 55mph (90 km/h) speed limit.

Cummins engines: Power is limited with progres-sively harsher engine power limits applied.

See Fig. 7.12.

The DEF tank must be filled to cancel the warningsequence.

DEF Level Empty and Ignored

If the empty warning is ignored and the DEF is notrefilled, the red STOP engine lamp illuminates in ad-dition to the DEF warning lamp, MIL, (and CHECKengine lamp if Cummins ISB or ISC/L engine.) SeeFig. 7.13.

If the DEF is not refilled, a 5 mph (8 km/h) speedlimit will be applied after the next engine shut downor while parked and idling.

07/24/2009 f470541

12

1. DEF Tank 2. Fuel Tank

Fig. 7.9, DEF Tank Located Forward of the Fuel Tank

Engines

7.7

DEF Quality or SCR Tampering

NOTICE

Once contaminated DEF or tampering has beendetected in the SCR system, the vehicle must betaken to an authorized service center to checkthe SCR system for damage, and to deactivatethe warning lights and engine limits.

If contaminated DEF or tampering is detected theDEF warning light flashes, and the MIL illuminates towarn the driver. The CHECK engine lamp also illumi-nates if the vehicle has a Cummins ISB or ISC/L en-gine. See Fig. 7.13.

Detroit Diesel engines: Power is limited, with a 55mph (90 km/h) speed limit. If the fault is not cor-rected the STOP engine light illuminates, and a 5mph (8 km/h) speed limit will be applied after thenext engine shut down, or while parked and idling.

Cummins engines: Power is limited with progres-sively harsher engine power limits applied. If the faultis not corrected the STOP engine light illuminates,and a 5 mph (8 km/h) speed limit will be applied afterthe next engine shut down, or while parked andidling.

11/08/2010 f611037

B


E F

DEF

FE


E F

DEF

FE


E F

DEF

FE

A C

12

A. Green bars—DEF level indicatorsB. One bar illuminated amber—DEF very low, refill DEF

C. One bar flashing red—DEF empty, refill DEF

1. Diesel Fuel Warning Lamp 2. DEF Warning Lamp

Fig. 7.10, Fuel/DEF Gauge

A

B

07/09/2009 f470537

A. DEF Warning Lamp (illuminated)B. DEF Lightbar (one bar amber)

Fig. 7.11, DEF Level Low Initial Warning

A

B

11/08/2010 f470539a

NOTE: MIL illuminates. CHECK engine lamp illuminatesif Cummins ISB or ISC/L engine. Engine power is lim-ited.

A. DEF Warning Lamp (flashing)B. DEF Lightbar (one bar flashing red)

Fig. 7.12, DEF Empty Warning

Engines

7.8

Engine Starting

For cold-weather starting, refer to "Cold WeatherStarting" later in this chapter.

Whenever you start an engine, watch for any signsof engine problems. If the engine vibrates, misfires,or makes unusual noises, turn the engine off as soonas possible and determine the cause of the problem.Frequently, engine damage may be avoided by aquick response to early indications of problems.

NOTICE

When starting a vehicle equipped with a manualtransmission and clutch lockout switch, theclutch pedal must be fully depressed during theentire start sequence. Failure to do so can causethe pinion to release and re-engage, which couldcause ring gear and starter pinion damage.

If a vehicle does not start on the first attempt,make sure that the engine has completelystopped rotating before reapplying the starterswitch. Failure to do so can cause the pinion torelease and re-engage, which could cause ringgear and starter pinion damage.

Moving a vehicle with the starter and/or using thestarter to bump the engine for maintenance pro-cedures is strictly prohibited. Use of these meth-ods to bump the engine over or move the vehiclecan cause the pinion to release and re-engage,which could cause ring gear and starter piniondamage.

Ring gear and starter pinion damage caused byimproper starting procedures is not warrantable.

Pre-Start

NOTE: These pre-start steps apply to all en-gines.

1. Perform the engine pretrip inspection and dailymaintenance checks in Chapter 11.

2. Set the parking brake.

3. For manual transmissions, place the transmis-sion in neutral and disengage the clutch.

For automatic transmissions, make sure thetransmission shift control is in neutral or park.

NOTE: On vehicles equipped with a neutral startswitch, the transmission must be in neutral be-fore the engine can be started. For air start sys-tems, check the air supply before starting theengine. There must be 100 psi (689 kPa) of airpressure available.

4. Turn the ignition switch to the ON position(Fig. 7.14). All the electronic gauges on the ICU(instrumentation control unit) complete a fullsweep of their dials, the warning and indicatorlights light up, and the buzzer sounds for threeseconds.

A

B

11/08/2010 f470540a

NOTE: STOP engine light illuminates. Engine powerlimited, speed limit of 5 mph (8 km/h)

A. DEF Warning Lamp (flashing)B. DEF Lightbar (one bar flashing red)

Fig. 7.13, DEF Empty and Ignored Warning

09/12/2001 f610509

Fig. 7.14, Ignition Switch Positions

Engines

7.9

Starting Precautions, All Engines

WARNING

Never pour fuel or other flammable liquid into theair inlet opening in the air intake in an attempt tostart the vehicle. This could result in a flash firecausing serious personal injury or property dam-age.

NOTICE

Do not crank the engine for more than 30 sec-onds at a time. Wait two minutes after each try toallow the starter to cool. Failure to do so couldcause starter damage.

NOTE: Some starters are equipped with op-tional overcrank protection. If overcranking oc-curs, a thermostat breaks the electrical circuit tothe starter motor until the motor has cooled.

NOTICE

Protect the turbocharger during the start-up bynot opening the throttle or accelerating the en-gine above 1000 rpm until minimum engine idleoil pressure registers on the gauge. Failure to doso could damage the turbocharger.

Cold-Weather Starting

Electronic engines do not normally require specialstarting aids. At low temperatures, oil pan heaters orwater jacket heaters are sometimes used to assist instarting. See the engine manufacturer’s operationmanual for starting aids that are approved for specificengines.

Starting After ExtendedShutdown or Oil Change

An engine in storage for an extended period of time(over winter, for example) may accumulate water inthe oil pan through normal condensation of moistureon the internal surfaces of the engine. Oil diluted bywater cannot provide adequate bearing protection atstart-up. For this reason, change the engine oil andfilters after extended storage.

NOTICE

Failure to eliminate water-diluted lubricating oilmay lead to serious engine damage at startup.

Before engine start-up, complete the engine pretripand post-trip inspections and maintenance proce-dures in Chapter 11.

Engine Break-In

Every engine is tested on a dynamometer beforeshipment, eliminating the need for a break-in period.Before running the engine for the first time, follow theinstructions in the engine manufacturer’s operationmanual.

Engine Operation

DANGER

Do not operate the engine in an area where flam-mable vapors such as gasoline or diesel fumesare present. Shut down the engine when in anarea where flammable liquids or gases are beinghandled. Failure to observe these precautionscould result in serious injury or death.

All Freightliner diesel engines comply with the re-quirements of the Federal (U.S.) Clean Air Act. Oncean engine is placed in service, the responsibility formeeting both state and local regulations is with theowner/operator.

IMPORTANT: EPA07 and EPA10 emissionsregulations apply to vehicles domiciled inCanada and the USA at the time of printing thismanual. Vehicles that are domiciled outside ofthe USA and Canada may not have EPA07- orEPA10-compliant engines with an emission af-tertreatment system, depending upon localstatutory emissions guidelines.

NOTICE

It is extremely important that the following pointsbe followed for vehicles with EPA07- or EPA10-compliant engines, or damage may occur to theaftertreatment device, and the warranty may becompromised.

Engines

7.10

• Use ultralow-sulfur diesel with 15 ppm sulfurcontent or less.


• Engine lube oil must have a sulfated ash levelless than 1.0 wt %; currently referred to asCJ-4 oil.

• Adequate maintenance of the engine and thediesel-particulate filter are the responsibility ofthe owner/operator, and are essential to keepthe emission levels low. Good operating prac-tices, regular maintenance, and correct adjust-ments are factors that will help to stay withinthe regulations.

The driver should be familiar with the vehicle warningsystem in order to bring the vehicle to a safe stop ifthe engine malfunctions. If the driver doesn’t under-stand how the warning system works, an engineshutdown could occur, causing a safety hazard. SeeChapter 3 for information.

All engines have an operating range specific to thatengine in which the engine performs most efficiently.The operating range extends from maximum torquerpm at the low end to engine rated speed at the highend. Most engines deliver best fuel economy whenoperated in the low- and mid-speed segments of theefficiency range and produce maximum horsepowerat rated speed, which is also the recommendedmaximum speed of the engine. For specifics for anyengine refer to the engine manufacturer’s operationmanual.

Prolonged idling of engines is not recommended, andis illegal in some states. The belief that idling a die-sel engine causes no engine damage is wrong. Idlingproduces sulfuric acid, that is absorbed by the lubri-cating oil, and eats into bearings, rings, valve stems,and engine surfaces. If you must idle the engine forcab heat or cooling, the high idle function of thecruise control switches should be used. An idlespeed of 900 rpm should be enough to provide cabheat in above freezing ambient temperatures.

If the engine is programmed with the idle shutdowntimer, ninety seconds before the preset shutdowntime, the CHECK ENGINE light will begin to flash ata rapid rate. If the position of the clutch pedal or ser-vice brake changes during this final ninety seconds(CHECK ENGINE lamp flashing) the idle shutdowntimer will be disabled until reset.

Cruise Control

WARNING

Do not use the cruise control system when driv-ing conditions do not permit maintaining a con-stant speed, such as in heavy traffic or on roadsthat are winding, icy, snow-covered, slippery, orroads with a loose driving surface. Failure to fol-low this precaution could cause a collision orloss of vehicle control, possibly resulting in per-sonal injury or property damage.

Dash-Mounted Switches

NOTICE

Do not attempt to shift gears without using theclutch pedal when the cruise control is engaged.Failure to follow this precaution will result in atemporarily uncontrolled increase in enginespeed; transmission damage and gear strippingcould result.

On standard models, cruise control is activated bytwo dash switches (Fig. 7.15).

• The On/Off Switch—this two-position rockerswitch bears the legend SPD CNTL on thelower half of the switch. When cruise control ison, an amber light illuminates in the top part ofthe switch.

• The Set/Resume Switch—this three-positionpaddle switch bears the legend RES/ACCabove the paddle and SET/CST below thepaddle.

1. To cruise at a particular speed, do these steps:

1.1 Press the upper half of the On/Off (rocker)switch on the instrument panel.

1.2 Hold the accelerator pedal down until thespeedometer reaches the desired speed.

1.3 Momentarily lower the paddle of the Set/Resume switch to SET/CST.

2. To disengage the cruise control, do these steps:

2.1 Press down the brake pedal (on automaticor manual transmission) or

Press down the clutch pedal (on manualtransmission only)

Engines

7.11

2.2 Press the lower half of the On/Off (rocker)switch on the instrument panel.

3. To resume a preselected cruise speed, do thesesteps:

3.1 If the On/Off (rocker) switch on the instru-ment panel is off, turn it on.

3.2 Momentarily raise the paddle of the Set/Resume switch to RES/ACC. Cruise willreturn to the last speed selected.

NOTE: If the ignition is shut off, the speedmemory will be lost.

4. To adjust cruise speed up, raise the paddle ofthe Set/Resume switch to RES/ACC and hold itthere until the vehicle accelerates to the newspeed, as desired.

5. To adjust cruise speed down, lower the paddle ofthe Set/Resume switch to SET/CST and hold itthere until the vehicle decelerates to the newspeed, as desired.

Shift Knob Controls, Optional

Cruise control can also be activated by the optionalPAUSE, RESUME, and SET buttons on the transmis-sion shift knob (Fig. 7.16).

1. To cruise at a particular speed, do these steps:

1.1 Hold the accelerator pedal down until thespeedometer reaches the desired speed.

1.2 Push the SET button on the transmissionshift knob.

2. To disengage the cruise control, do these steps:

2.1 Press down the brake pedal (on automaticand manual transmission) or

Press down the clutch pedal (on manualtransmission only)

2.2 Push the PAUSE button on the transmis-sion shift knob.

3. To resume a preselected cruise speed, push theRESUME button on the transmission shift knob.Cruise will return to the last speed selected.

NOTE: If the ignition is shut off, the speedmemory will be lost.

4. To adjust cruise speed up, push the SET buttonand hold it in until the vehicle accelerates to thenew speed, as desired.

09/13/2001

1

2

f610510

To turn cruise control on, press the upper half of the On/Off (rocker) switch. To turn cruise control off, press thelower half of the On/Off (rocker) switch.

1. Cruise Control On/Off (rocker) Switch2. Cruise Control Set/Resume (paddle) Switch

Fig. 7.15, Cruise Control Switches, Dash-Mounted

05/23/95 f260316

Fig. 7.16, Cruise Control Buttons on the TransmissionShift Knob

Engines

7.12

5. To adjust cruise speed down, push the RESUMEbutton and hold it in until the vehicle deceleratesto the new speed, as desired.

Power Takeoff (PTO) Governor

Front Engine Power Take Offs (PTO) are devicesused to tap into engine power to run auxiliary de-vices. Common uses are vehicles with hydraulicpumps which power additional equipment. The fol-lowing instructions are general guidelines for operat-ing a PTO.

1. Set the parking brake. Shift the transmission toneutral.

2. Press the dash PTO switch. Release the switchwhen the light begins to blink.

When the light comes on steadily, the PTO isengaged and ready to operate. In stationarymode, the vehicle must remain in neutral with theparking brake set.

3. To activate the mobile mode, shift from neutral toreverse, 1st, or 2nd gear. The clutch will openand the PTO will disengage for a moment.

4. Touch the throttle pedal to close the clutch andengage the PTO in mobile mode. The PTO maybe operated with the transmission in the follow-ing gears only: R-N-1-2.

NOTE: Do not attempt to change gears whilethe vehicle is moving. The transmission will ig-nore the request.

5. To end the mobile mode, bring the vehicle to astop. The clutch will open and shut off power tothe PTO.

6. To resume stationary mode, shift to neutral. ThePTO will engage.

7. To end stationary mode, press the dash switch.When the light in the switch goes out, power tothe PTO is shut off. Shut down the engine.

Cold-Weather Operation

Satisfactory performance of a diesel engine operatingin low ambient temperatures requires modification ofthe engine, surrounding equipment, operating prac-tices, and maintenance procedures. The lower thetemperature, the greater the amount of modificationrequired. For service products approved for use in

cold weather for your engine, see the engine manu-facturer’s engine operation manual, supplied in thevehicle documentation package.

If satisfactory engine temperature is not maintained,maintenance costs will increase due to greater en-gine wear. If the engine coolant temperature be-comes too low, raw fuel will wash the lubricating oiloff the cylinder walls and dilute the crankcase oil,causing all moving parts of the engine to suffer frompoor lubrication.

If the engine is in good mechanical condition and theprecautions necessary for cold-weather operation aretaken, ordinary cold weather will not cause difficultyin starting, or loss of efficiency.

The following points are important to observe whenoperating in cold weather:

• Check for cracks in the batteries, for corrosionof the terminals, and for tightness of the cableclamps at the terminals.

• Charge the batteries to full capacity. Replaceany battery that is damaged.

• If so equipped, turn off the load disconnectswitch after the engine is shut down, to preventbattery discharge.

• Have the alternator output checked at an au-thorized service provider.

• Check the condition and tension of the drivebelts.

• Refer to the engine manufacturer’s engine op-eration manual for recommended heaters, low-viscosity lubricating oils, wintergrade fuels, andapproved coolants.

A winterfront may be used to improve cab heatingwhile idling. If a winterfront is used, at least 25% ofthe grille opening should remain open in sectionedstripes that run perpendicular to the charge-air-coolertube-flow dirrection. This assures even coolingacross each tube, and reduces header to tubestress, and possible failure. Winterfronts should onlybe used when the ambient temperature remainsbelow 10°F (-12°C).

High-Altitude Operation

Engines lose horsepower when operated at high alti-tude because the air is too thin to burn as much fuelas at sea level. This loss is about three percent for

Engines

7.13

each 1000 feet (300 m) altitude above sea level for anaturally aspirated engine.

All engines used on M2 vehicles are altitude-compensated by the use of a turbocharger. This re-duces smoky exhaust at high altitudes, requires lessdownshifting, and allows the engine to make betteruse of its fuel. Nevertheless, shift gears as needed toavoid excessive exhaust smoke.

Engine Shutdown1. With the vehicle stopped, apply the parking

brakes and place the transmission in neutral.

NOTICE

Idle the engine one to two minutes before shut-ting it down. After hard operation, shutting downthe engine without idling may cause damage tothe turbocharger.

2. Allow the engine to idle one to two minutes be-fore shutting it down. This allows the lubricatingoil and the coolant to carry heat away from thecombustion chambers, bearings, shafts, andseals. The extreme heat may cause bearings toseize or oil seals to leak.

IMPORTANT: Bearings and seals in the turbo-charger are subjected to the high heat of com-bustion exhaust gases. While the engine is run-ning, this heat is carried away by oil circulation,but if the engine is stopped suddenly, the turbo-charger temperature may rise as much as 115°F(46°C).

NOTICE

Except in an emergency, do not shut down theengine when the coolant temperature is above194°F (90°C). To do so could damage the engine.

3. Turn off the ignition switch and shut down theengine.

Engine Braking

The engine brake switch controls the degree of en-gine braking. Normally there are two paddleswitches, a two-position On/Off Switch to activate theengine brake, and a two-position HI-LO Switch tocontrol the amount of engine braking.

To turn the two-position On/Off Switch on, raise thepaddle. When the two-position switch is on, anamber LED (light-emitting diode) illuminates insidethe switch.

To turn the two-position HI-LO Switch on high, raisethe paddle (at the HI-LO legend). To turn the two-position HI-LO Switch on low, lower the paddle (atthe ENG BRK legend). See Fig. 7.17.

When the panel lights are on, the Hi-Lo legend isbacklit in amber on the three-position switch. On boththe three-position switch and the two-position switch,the ENG BRK legend is backlit in green when thepanel lights are on.

Whenever vehicle braking is required on good roadconditions, the engine brake may be used in con-junction with the service brakes. There is no timelimit for operation of the engine brake. However, anengine brake does not provide the precise controlavailable from the service brakes, and is not a sub-stitute for a service braking system.

WARNING

Usage of the engine brake as the primary brakingsystem can cause unpredictable stopping dis-tances, that could result in personal injury orproperty damage. Service brakes are the primaryvehicle braking system.

Since the engine brake is most effective at rated en-gine speed, gear selection is very important. Gearingdown the vehicle, within the limits of the rated engine

10/17/2001 f610588

1 2

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

Fig. 7.17, Engine Brake Switches

Engines

7.14

speed, makes the engine brake more effective. Rec-ommended engine braking speed is above 1800 rpmand below the rated speed.

WARNING

The engine brake must be disengaged whenshifting gears using the clutch pedal. If the en-gine brake is engaged when the transmission isin neutral, the braking power of the engine brakecan stall the engine, which could result in loss ofvehicle control, possibly causing personal injuryand property damage.

NOTICE

Do not allow the engine to exceed 2500 rpm. Se-rious engine damage could result.

"Control speed" is the speed at which the enginebrake performs 100 percent of the required downhillbraking, resulting in a constant speed of descent.The control speed varies, depending on vehicleweight and the downhill grade.

For faster descent, select a higher gear than thatused for control speed. Service brakes must then beused intermittently to prevent engine overspeed andto maintain desired vehicle speed.

A driver may descend slower than control speed byselecting a lower gear, being careful not to over-speed the engine. Occasional deactivation of the en-gine brake may be necessary to maintain the desig-nated road speed under these conditions.

Below a set engine temperature when the engine iscold, the brake may be disabled depending on thebrake type.

To activate the engine brake after the engine iswarmed up and the vehicle is in motion:

• Remove your feet from both the clutch andthrottle pedals. Press the dash-mounted ENGBRK switch to toggle the engine brake ON.

The engine brake will engage at the rate lastset on the brake intensity switch.

• Move the intensity switch to the desired inten-sity. Depending on engine model, LO will pro-vide 1/3 or 1/2 of the full braking capacity ofthe engine. HI will provide maximum enginebraking.

Use the dash-mounted switch set at the LOposition when driving on flat, open stretches ofroad. If the service brakes are still required toslow down on a grade, switch to a higher set-ting on the dash switch, until there is no needfor the service brakes. Grade descent speedshould be such that the service brakes areused infrequently and that they remain cool,thus retaining their effectiveness.

• For maximum retarding, maintain the top gov-erned speed of the engine through the appro-priate selection of gears. When shifting gears,the engine brake will disengage when theclutch pedal is depressed, then engage whenthe clutch pedal is released.

• To cancel the engine brake application, togglethe ENG BRK switch OFF.

If the engine is equipped with both cruise control andan engine brake, the engine brake can operate auto-matically while in cruise control mode. If the cruisecontrol/engine brake function is turned on in theDDEC VI system programming, the engine brake willcome on "low" when the set road speed increases afew miles-per-hour (kilometers-per-hour) above thecruise set speed. The maximum amount of braking(low, medium, high) is selected with the dashswitches. When the vehicle returns to the set cruisespeed, the engine brake will turn off.

The engine brake will only operate when the accel-erator pedal is fully released. Disengaging the clutchwill prevent the engine brake from operating.

Vehicles equipped with antilock braking systems(ABS) have the ability to turn the engine brake off ifa wheel-slip condition is detected. The engine brakewill automatically turn itself back on once the wheelslip is no longer detected. The DDEC VI system willdeactivate the engine brake system when the enginespeed falls below 1000 rpm or when the vehicleslows down to a preset speed, depending on DDECprogramming. This prevents stalling the engine.

Exhaust Braking Systems

Exhaust Brake Switch

The optional exhaust brake is controlled by a dash-mounted rocker switch to help slow the vehicle whenthe accelerator is released.

Engines

7.15

To turn the exhaust brake on, press on the upperpart of the rocker (at the light inside the switch). Theexhaust brake turns off automatically. See Fig. 7.18or Fig. 7.19.

When the exhaust brake switch is on, an amber LEDilluminates inside the switch. When the panel lightsare on, the EXHST BRK legend is backlit in green.

Mercedes-Benz Exhaust Brake

An exhaust brake is an optional auxiliary braking sys-tem that assists but does not replace the servicebrake system. The exhaust brake can be used aloneor together with the constant-throttle valves for steepor long grades. The exhaust brake switch located onthe control panel, in combination with the acceleratorand clutch pedals, allows the driver to make maxi-mum use of the exhaust brake in off-highway andmountain driving as well as in traffic or high-speedhighway driving.

When only the exhaust brake is installed, a two-position switch on the dash controls the engine brak-ing system. The exhaust brake is only active whenthe engine speed is between 1100 and 2700 rpm.Depressing the accelerator or clutch pedal deacti-vates the exhaust brake. The ABS system, when ac-tive, also deactivates the exhaust brake.

The exhaust brake is a butterfly valve mounted in theexhaust pipe. When the driver’s foot is not on theaccelerator pedal and the upper half of the exhaustbrake switch is pressed in, with the amber light onthe switch illuminated, an air cylinder shuts the but-terfly valve, which restricts the flow of exhaust gasesand retards the engine. This retarding action is car-ried through the engine and drivetrain, slowing thevehicle and reducing the need for frequent servicebrake applications.

Exhaust brakes are not intended for use as the pri-mary braking system during vehicle operation.

Operating Characteristics

WARNING

Do not use the exhaust brake when driving onslippery or low-traction road surfaces. Failure tofollow this precaution could result in a loss ofvehicle control and possible personal injury orproperty damage.

Before starting the engine, make sure that the lowerhalf of the exhaust brake switch is pressed in andthe amber light is not illuminated. Do not turn the ex-haust brake on until the engine has reached normaloperating temperatures.

When you remove your feet from both the accelera-tor and clutch pedals and the upper half of the ex-haust brake switch is pressed in with the amber lightilluminated, the exhaust brake is applied. The follow-ing conditions should exist if the brake is operatingproperly:

• A slight change in the sound of the engine maybe noticed when the exhaust brake is applied.

• Exhaust smoke should appear normal.

• Engine temperature should remain in the nor-mal operating range.

• Road speed usually decreases when the ex-haust brake is applied during a descent. Whenthe vehicle is carrying a heavy load or the

f61058911/28/2001


f610589a03/31/2009


Engines

7.16

grade is extremely steep, you may need toapply the service brakes occasionally.

• Do not expect a retarding effect similar to sud-den hard application of the service brakes. Theexhaust brake retards the vehicle with asmooth braking effect.

• During a descent, the tachometer usuallyshows a drop in rpm, depending on the gradeand the vehicle load.

• Depending on the grade and vehicle load, youmay or may not feel the retarding force actingagainst your body when the brake is applied.The retarding force of the brake may not al-ways be noticed, but it is actually preventingthe vehicle from going much faster.

Make sure the exhaust brake is turned off beforeshutting down the engine.

Driving Downhill

While approaching a steep grade, make sure that theupper half of the exhaust brake switch is pressed in,with the amber light illuminated. The exhaust brakecomes on as soon as you remove your foot from theaccelerator pedal. While going down the grade, usea low enough gear to safely descend with a minimumapplication of the service brakes. As a general guide-line, use the same gear as you would to ascend thehill.

NOTICE

Do not allow the engine to exceed its governedspeed, or serious engine damage could result.

Apply the service brakes to reduce the engine rpm ormake a slower descent by using a lower gear.

Pacbrake® Exhaust Brake

The Pacbrake exhaust brake is intended as asupplement to the service brakes and will not bringthe vehicle to a complete stop. The Pacbrake willassist in the control or reduction of road speed inconjunction with, or independent of, the servicebrakes. The amount of retarding or braking force iscontrolled by the driver.

Pacbrake Operation (Caterpillar)

The Pacbrake is controlled by the exhaust brakeswitch and the throttle pedal. All applications are ad-ditionally affected, controlled, or governed by enginespeed through transmission gear selection. The Alli-son MD3060 transmission has automatic downshift-ing when the exhaust brake is requested. See theinformation on the "Allison World Transmission" laterin this chapter.

On some applications, when the Pacbrake is in use,it may be necessary to check that the cruise controlis not set and that the throttle is in the idle position.

On some applications, the engine, transmission,cruise control, and the Pacbrake exhaust brake mayelectronically interact with each other, which auto-matically operates their functions. Following aresome examples of the programmed options that maybe available with the cruise control in the on position:

• The coast mode engages the Pacbrake whenthe service brake is applied and disengageswhen the service brake is released.

• The latch mode engages the Pacbrake whenthe service brake is applied and the Pacbrakeremains on after the service brake is released.The Pacbrake is disengaged when anotherinput (depressing the throttle or clutch, enginespeed drops below 800 rpm, or the exhaustbrake switch is turned off) is supplied.

• The manual mode does not require the cruisecontrol switch to be on, and operates thePacbrake manually at the driver’s discretion.

The amount of braking power the engine will developis related to the speed (rpm) of the engine. Thehigher the engine rpm, the greater the retardingpower.

Certain conditions may require that the transmissionbe downshifted in order to generate adequate rpmfor the amount of retarding power required. Pacbrakeexhaust brakes are designed and approved for safeuse at 300 rpm above the engine’s maximum gov-erned rpm. Refer to individual engine manufacturer’sspecifications.

The Pacbrake will function best if it is used all of thetime. However, if the vehicle is used inconsistently orseasonally, it may be necessary to perform a preven-tive maintenance procedure.

Engines

7.17

1. With the engine shut down, use any oil-free ornonpetroleum-based high-heat lubricant, andspray or coat a sufficient amount on the restrictervalve shaft and the attaching locations at eachend of the actuation cylinder. See Fig. 7.20.

2. With your hands or a pair of pliers, motion thevalve several times to distribute the lubricantdown the shaft and the attaching locations.

NOTE: Starting the engine and idling for shortperiods of time is not recommended. During acold engine start-up, enough moisture is devel-oped within the engine and the exhaust systemto create a corrosion hazard that could affectthe future operation of the Pacbrake. The brakehousing may trap water in the valve shaft borecausing corrosion in an improperly functioningor nonfunctioning brake. If it is necessary to pe-riodically start the engine, it is recommendedthat normal operating temperatures be attainedbefore shutting down the engine.

Allison World Transmission

Pacbrake exhaust brakes on engines that are usedwith the Allison World Transmission MD series, areinterfaced with the transmission electronic controlmodule (ECM). An exhaust-brake-enabled transmis-sion ECM will usually provide converter lockup ingears two through six. Effective exhaust braking be-gins when the transmission automatically downshiftsinto fifth gear (62 mph or less). Once on, thePacbrake exhaust brake will control road speed

and/or slow the vehicle sufficiently that the transmis-sion will automatically downshift, if necessary, to Alli-son’s preselect mode.

The preselect mode is normally assigned to secondgear; however, the transmission can be repro-grammed by an Allison Transmission Distributor tothird or fourth gear, should the operator desire. If ad-ditional retarding power is required before the auto-matic downshifting occurs, you can select a lowertransmission gear on the Allison shift selector.

03/06/2000 f490228

AA

A

A. Lubrication Point

Fig. 7.20, Pacbrake Exhaust Brake and Air Cylinder

Engines

7.18

8

DrivetrainClutches . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.1

Allison On-Highway Transmissions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.3

Allison MD Series . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.5

Eaton® Fuller® Straight-Shift Transmissions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.8

Eaton Fuller Range-Shift Transmissions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.9

Eaton Fuller AutoShift™ . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.12

Freightliner SmartShift Shift Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.15

Eaton Fuller UltraShift . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.15

Mercedes-Benz Manual Transmissions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.22

Mercedes-Benz Automated Transmissions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.22

Meritor™ Drive Axles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.26

Clutches

Clutch Operation

Applying the Clutch Brake

The purpose of the clutch brake is to stop the trans-mission gears from rotating in order to engage thetransmission gears quickly in making an initial start.To apply the clutch brake, put the transmission inneutral and press the clutch pedal to the floor.

CAUTION

Never apply the clutch brake while the vehicle ismoving. The clutch pedal should never bepressed down fully before putting the transmis-sion in neutral. Considerable heat will be gener-ated, which will be detrimental to the frictiondiscs, release bearings, and transmission frontbearings.

Applying the clutch brake with the transmission still ingear puts a reverse load on the gear. At the sametime, it will have the effect of trying to stop or decel-erate the vehicle with the clutch brake. Rapid wear offriction discs will take place necessitating frequent re-placement.

Vehicle Overload, or Overloading theClutch

CAUTION

Overloading will not only result in damage to theclutch, but also to the entire powertrain.

Clutches are designed for specific vehicle applica-tions and loads. These limitations should not be ex-ceeded.

Riding the Clutch Pedal

Riding the clutch pedal is destructive to the clutch.Partial clutch engagement permits slippage, and gen-erates excessive heat. Riding the clutch pedal willalso put a constant thrust load on the release bear-ing, which can thin out the lubricant. Release bearingfailures can be attributed to this type of misuse.

Holding the Vehicle on an Incline With aSlipping Clutch

A slipping clutch accumulates heat faster than it canbe dissipated, resulting in early clutch failures. Neveruse the clutch to hold a vehicle on a hill.

Coasting With the Clutch Released(pedal down) and the Transmission inGear

WARNING

Do not coast with the clutch released (pedal de-pressed) and the transmission in gear. Highdriven-disc rpm could cause the clutch facing tobe thrown off the disc. Flying debris could causeinjury to persons in the cab.

If the transmission remains in a low gear and the ve-hicle gains speed, as may occur on a downgrade,the input shaft and clutch driven disc will turn atspeeds that are higher than normal. This occurs be-cause the rear wheels and the driveline become theinput for the transmission, and a higher-than-normalspeed for a given transmission gear translates to ahigher rpm value for the clutch driven disc.

Clutch driven discs are designed to allow for someamount of excess rotational speed, but the facinghas a limited burst strength. If the clutch driven discrpm increases too much, the clutch facing can bethrown off the disc(s).

Engaging the Clutch While Coasting

Engaging the clutch while coasting can result in tre-mendous shock loads and possible damage to theclutch as well as to the entire drivetrain.

Report Erratic Clutch Operation Promptly

Reporting erratic clutch operation as soon as pos-sible will give maintenance personnel a chance toinspect the clutch components.

CAUTION

Operating the vehicle with incorrect clutch pedalfree-travel could result in clutch damage. SeeGroup 25 of the Business Class® M2 WorkshopManual for free-pedal adjustment procedures andspecifications.

Drivetrain

8.1

On mechanical clutch linkages, free-pedal travelshould be included and commented on daily in thedriver’s report, since clutch free-pedal travel is thebest guide to the condition of the clutch and the re-lease mechanism.

Clutch Wear

The major reason clutches wear out too soon is ex-cessive heat. Clutches are designed to absorb anddissipate 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 orrequired 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 highenough to cause the metal to flow and the frictionfacing material to char and burn.

CAUTION

Do not allow sustained slippage of the clutch;this could severely damage the clutch disc, pres-sure plate, or flywheel. Damage caused by clutchslippage due to improper break-in is not warrant-able.

Slipping and excessive heat are practically nonexist-ent when a clutch is fully engaged. But during themoment of engagement, when the clutch is pickingup the load, it generates considerable heat. An incor-rectly adjusted or slipping clutch will rapidly generatesufficient heat to destroy itself.

The most important items that a driver should beaware of to ensure long service life of the clutch in-clude: starting in the right gear, recognizing clutchmalfunctions, and knowing when to adjust a clutch.

Clutch Adjustments

Some clutches have an internal adjustment. See theapplicable section in Group 25 of the BusinessClass® M2 Workshop Manual for clutch adjustmentprocedures and specifications.

CAUTION

Operating the vehicle with the clutch incorrectlyadjusted could result in clutch or clutch brakefailure.

Clutch Lubrication

The release bearing should be lubricated at frequentintervals. See Group 25 of the Business Class® M2Maintenance Manual for intervals and procedures.

CAUTION

Failure to lubricate the release bearing as recom-mended could result in release bearing damageand damage to the clutch.

NOTE: The Sachs hydraulic clutch does not re-quire lubrication of the release bearing.

Sachs Hydraulic Clutch

The Sachs hydraulic clutch is a 14.5-inch (365 mm)push-type clutch that is used with the Mercedes-Benz medium-duty transmissions, models MBT520and MBT660.

NOTE: All Mercedes-Benz transmission modelsrequire a hydraulic clutch system. For more in-formation on the Mercedes-Benz transmissions,see under the heading "Mercedes-Benz ManualTransmissions."

The clutch hydraulic system consists of three maincomponents:

• A pedal unit, including the pedal, master cylin-der and fluid reservoir,

• A slave cylinder at the clutch,

• A hydraulic hose that connects the master andslave cylinders.

Keep the clutch fluid reservoir full to the MAX mark.If fluid level falls below the MIN mark, have the hy-draulic system checked for leaks at an authorizedFreightliner service facility. Use only DOT 4 brakefluid to fill the reservoir.

The hydraulic clutch provides smooth, quiet, and reli-able clutch actuation with a minimum of mainte-nance.

Pressure builds up in the master cylinder when theclutch pedal is pressed. This pressure is transmittedthrough the brake fluid in the hose to the slave cylin-der, where it acts directly on the clutch release fork.

Drivetrain

8.2

Allison On-HighwayTransmissions

The Allison on-highway transmissions are fully auto-matic and include the 1000 Series™, 2000 Series™,and 2400 Series™. Refer to the Allison website foradditional information, www.allisontransmission-.com.

Safety Precautions

WARNING

Do not leave the vehicle unattended with the en-gine running. If you leave the vehicle and the en-gine is running, the vehicle can move suddenly,which could result in personal injury or propertydamage.

1000 Series

On vehicles with Allison 1000 series transmissions,do the following steps if you have to leave the cabwith the engine running (for example, when checkingthe transmission fluid):

Without Park Position

1. Bring the vehicle to a complete stop using theservice brake.

2. Ensure that the engine is at low idle rpm.

3. Put the transmission in neutral.

4. Apply the parking brake, and make sure it isproperly engaged.

5. Chock the rear tires and take any other stepsnecessary to keep the vehicle from moving.

With Park Position



3. Put the transmission in P (park).

4. Apply the parking brake (if equipped), and makesure it is properly engaged.

5. Engage the park range by slowly releasing theservice brake.


2000 Series

On vehicles with Allison 2000 series transmissions,do the following steps if you have to leave the cabwith the engine running (for example, when checkingthe transmission fluid):

Without Auto-Apply Parking Brake

Follow the instructions for vehicles with 1000 seriestransmissions, under the heading "Without Park Posi-tion."

With Auto-Apply Parking Brake



3. Put the transmission in PB (auto-apply parkingbrake).

4. Apply the parking brake (if equipped), and makesure it is properly engaged.


2400 Series

On vehicles with 2400 series transmissions, followthe instructions for vehicles with 1000 series trans-missions.

Range Inhibit Indicator, 2000 and2400 Series

A RANGE INHIBIT indicator is a standard feature ofthe 2000 series and 2400 series transmissions. TheRANGE INHIBIT indicator comes on to alert thedriver that transmission operation is being inhibitedand that the range shifts being requested by thedriver may not occur. When certain operating condi-tions are detected by the TCM (transmission controlmodule), the controls will lock the transmission in thecurrent operating range.

Shift inhibits occur under the following conditions:

• Shifts from neutral to reverse or from neutral toa forward range when the engine is above idle,greater than 900 rpm.

Drivetrain

8.3

• Forward/reverse directional shifts are typicallynot permitted if appreciable output shaft speedis 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 servicelocation. When this type of situation is de-tected, the TCM will lock the transmission in asafe gear range.

• The TCM will prevent shifts from park or neu-tral to range when auxiliary equipment, such asa power takeoff unit (PTO), is in operation.

Operating Instructions, On-HighwayTransmissions

Allison automatic transmissions are electronicallycontrolled. The shift selector provides five or six for-ward ranges and one reverse range.

P (Park, optional on 1000 and 2400Series)

Use park when turning the engine on or off, to checkvehicle accessories, to operate the engine in idle forlonger than 5 minutes, and for stationary operation ofthe power takeoff, if equipped. This position placesthe transmission in neutral and engages the parkpawl of the transmission.

NOTE: This does not apply the parking brake.

PB (Auto-Apply Parking Brake, optionalon 2000 Series)

The auto-apply parking brake places the transmis-sion in neutral and applies the parking brake.

R (Reverse)

Reverse is used to back the vehicle. When the selec-tor is in reverse, the reverse warning signal willsound. Always bring the vehicle to a complete stopbefore shifting from a forward range to reverse, orfrom reverse to a forward range.

CAUTION

Extended idling in reverse may cause transmis-sion overheating and damage.

Do not idle in reverse for more than 5 minutes. Se-lect P (park), PB (auto-apply parking brake), or N(neutral) when time at idle exceeds 5 minutes.

NOTE: The shift into reverse may not succeed ifa range inhibitor is active. Check for illuminationof the RANGE INHIBIT indicator.

N (Neutral)

The neutral position places the transmission in neu-tral. This position is used when starting the engineand for stationary operation.

WARNING

Failure to apply the vehicle parking brakes whenthe transmission is in neutral may allow the ve-hicle to move unexpectedly, possibly causingproperty damage or personal injury.

When neutral is selected, the vehicle service brakes,parking brake, or emergency brake must be applied.Selecting neutral does not apply vehicle brakes un-less an auxiliary system to apply the parking brake isinstalled.

WARNING

Do not coast in neutral. Coasting in neutral cancause an accident, possibly resulting in severepersonal injury or death.

Do not let the vehicle coast in neutral. If the vehicleis allowed to coast in neutral, the engine brake willnot work and you could lose control of the vehicle.

CAUTION

Coasting in neutral can cause severe transmis-sion damage.

D (Drive)

WARNING

When going downhill, use a combination ofdownshifting, braking, and other retarding de-vices to control vehicle speed and the engine’srated governed speed. Failure to do so could re-duce vehicle braking, possibly causing loss ofvehicle control and resulting in personal injury orproperty damage.

Drivetrain

8.4

In the drive position, the transmission will initially gointo first range when drive is selected. As vehiclespeed increases, the transmission will upshift auto-matically through each available range up to fourthrange or fifth range. As the vehicle slows, the trans-mission will downshift automatically.

When going downhill, downshift to a lower transmis-sion range to increase engine braking and to helpmaintain control. The transmission has a feature toprevent automatic upshifting above the lower rangeselected. However, during downhill operation, thetransmission may upshift to the next higher range, ifthe engine is exceeding its governed speed in thelower range.

CAUTION

Do not idle in drive for more than 5 minutes. Ex-tended idling in drive may cause transmissionoverheating and damage. Always select PB (auto-apply parking brake) or P (park) if time at idle islonger than 5 minutes.

NOTE: The shift into drive may not succeed if arange inhibitor is active. Check for illuminationof the RANGE INHIBIT indicator.

4 and 3 (Fourth and Third Ranges,optional)

Use the fourth or third range for city traffic and forbraking on steep downgrades.

3 and 2 (Third and Second Ranges,standard)

Use the third or second range for heavy city trafficand for braking on steeper downgrades.

1 (First Range)

Use first range when pulling through mud or deepsnow, when maneuvering in tight spaces, or whendriving up or down very steep grades. First rangeprovides the vehicle with its maximum driving torqueand maximum engine braking effect.

NOTE: To have the transmission select theseranges automatically, leave the selector lever inD (drive).

Allison MD Series

Refer to the Allison website for additional information,www.allisontransmission.com.

Safety Precautions

WARNING

Do not leave the vehicle unattended with the en-gine running. If you leave the vehicle and the en-gine is running, the vehicle can move suddenly,which could result in personal injury or propertydamage.

On vehicles with MD series transmissions, do thefollowing steps if you have to leave the cab with theengine running (for example, when checking thetransmission fluid):


2. Put the transmission in N (neutral).

3. Ensure that the engine is at low idle (500 to 800rpm).

4. Apply the parking brake and emergency brakes,and make sure they are properly engaged.


Operating Instructions, MD Series

The Allison MD transmission is electronically con-trolled and comes with a push-button shift controlthat provides five or six forward ranges and one re-verse range. The push-button shift selector has an R(reverse), an N (neutral), a D (drive), an up arrow, adown arrow, a mode button, and a digital display.

New shift controls — known as "fourth generation" —were introduced in mid-2006. They replaced the pre-vious units that are commonly referred to as "WTECIII". See Fig. 8.1 and Fig. 8.2.

R (Reverse)

Press the R button to select reverse. The digital dis-play will show R when reverse is selected. Alwaysbring the vehicle to a complete stop and let the en-gine return to idle before shifting from a forwardrange to reverse, or from reverse to a forward range.

Drivetrain

8.5

CAUTION

Extended idling in reverse may cause transmis-sion overheating and damage.

Do not idle in reverse for more than 5 minutes. Se-lect neutral when time at idle exceeds 5 minutes.

NOTE: The shift into reverse may not succeed ifa range inhibitor is active. When reverse is se-lected, always be sure that R is not flashing.

N (Neutral)

WARNING

When starting the engine, make sure that the ser-vice brakes are applied. Failure to apply the ser-vice brakes may result in unexpected vehiclemovement, which could cause severe personalinjury or death. Failure to apply the vehicle park-ing brakes when the transmission is in neutralmay allow the vehicle to move unexpectedly, pos-sibly causing property damage or personal injury.

Press the N button to select neutral. The digital dis-play will display N when neutral is selected. It is notnecessary to press neutral before starting the ve-hicle. The ECU (electronic control unit) or TCM(transmission control module) automatically placesthe transmission in neutral at start-up.

WARNING

Failure to apply the vehicle parking brakes whenthe transmission is in neutral may allow the ve-hicle to move unexpectedly, possibly causingproperty damage or personal injury.

When neutral is selected, the vehicle service brakes,parking brake, or emergency brake must be applied.Selecting neutral does not apply vehicle brakes un-less an auxiliary system to apply the parking brake isinstalled.

WARNING

Do not coast in neutral. Coasting in neutral cancause an accident, possibly resulting in severepersonal injury or death.

Do not let the vehicle coast in neutral. If the vehicleis allowed to coast in neutral, the engine brake willnot work and you could lose control of the vehicle.

Always select neutral before turning off the engine.Neutral is also used during stationary operation ofthe power takeoff if your vehicle is equipped with aPTO.

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D

f270113

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1. Digital Display2. Mode Identification

Label

3. Mode Indicator LED4. Mode Button

Fig. 8.1, WTEC III Push-Button Shift Selector

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f61080407/27/2006

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1. Digital Display2. Mode Identification

Label

3. Mode Indicator LED4. Mode Button

Fig. 8.2, Fourth Generation Push-Button Shift Selector

Drivetrain

8.6

D (Drive)

When the D button is pushed, the highest forwardrange will appear in the display. The transmission willnormally go into first range when drive is selected(except for those units programmed to start in sec-ond range). As vehicle speed increases, the trans-mission will upshift automatically through each range.As the vehicle slows, the transmission will downshiftautomatically.

CAUTION

Do not idle in drive for more than 5 minutes. Ex-tended idling in drive may cause transmissionoverheating and damage. Always select neutral iftime at idle is longer than 5 minutes.

NOTE: The shift into drive may not succeed if arange inhibitor is active. When drive is selected,always be sure that D is not flashing.

5, 4, 3, and 2 (Fifth, Fourth, Third, andSecond Ranges)

Occasionally, road conditions, load, or traffic condi-tions will make it desirable to restrict automatic shift-ing to a lower range. Lower ranges provide greaterbraking for going down grades. The lower the range,the greater the braking effect.

Push the up or down arrows on the push-button shiftselector to select individual forward ranges. The digi-tal display will display your choice of range. When alower range is selected, the transmission may notdownshift until the vehicle speed or engine RPM (en-gine governed speed) is reduced.

WARNING

When going downhill, use a combination ofdownshifting, braking, and other retarding de-vices to control vehicle speed and the engine’srated governed speed. Failure to do so could re-duce vehicle braking, possibly causing loss ofvehicle control and resulting in personal injury orproperty damage.

When going downhill, downshift to a lower transmis-sion range to increase engine braking and to helpmaintain control. The transmission has a feature toprevent automatic upshifting above the lower rangeselected. However, during downhill operation, if the

engine governed speed is exceeded in the lowerrange, the transmission may upshift to the nexthigher range.

1 (First Range)

Use the first range when pulling through mud ordeep snow, when maneuvering in tight spaces, orwhen driving up or down steep grades. First rangeprovides the vehicle with its maximum driving torqueand maximum engine braking effect. Push the downarrow until the first range appears on the display.

Up and Down Arrows

When a lower range is desired, after D has beenpressed, press the down arrow until the desiredrange is shown on the display. Pressing the downarrow continuously causes the range position to con-tinue to go down until the button is released or thelowest range is attained.

When the transmission is in drive and the downarrow has the transmission in a lower range position,press the up arrow to shift to a higher selector posi-tion. Pressing the up arrow continuously causes therange position to continue to rise until the button isreleased or the highest available position is attained.

Pressing the up or down arrows does not overridethe transmission automatic shifting operation. If ahigher or lower position is selected, the transmissioncontinues shifting through the ranges according tothe vehicle operating characteristics until the highestor lowest selected position is reached.

Mode Button

The MODE button starts a specialized input or outputfunction that has been previously programmed intothe ECU or TCM. Pressing the MODE buttonchanges transmission operation for a specific func-tion.

Mode Indicator LED

When the MODE button is pressed, the mode indica-tor LED illuminates. A mode identification label, lo-cated above the MODE button, identifies the functionassociated with a mode change.

Drivetrain

8.7

Digital Display

The dual digital display shows both the selectedrange (SELECT) and actual range attained (MONI-TOR). The single digital display shows the selectedrange.

Oil Level Sensor

Allison MD Series transmissions have an electronicoil level sensor to read fluid level information. Thefluid level diagnostic will display whether the oil levelis OK, too low, or too high. It will also display a de-fault code and indicate if the preconditions (of receiv-ing the fluid level information) are not met.

IMPORTANT: Maintain the the proper fluid levelat all times. If the fluid level is too low, the con-verter and clutch do not receive an adequatesupply of fluid. If the level is too high, the trans-mission may shift erratically or overheat.

To access the oil level display mode, park the vehicleon a level surface, shift to N (Neutral), apply theparking brake, and idle the engine. Then simulta-neously press both the up and down arrows once.The oil level will display at the end of a two-minutecountdown.

Diagnostic Codes

Diagnostic codes are numerical indications relating toa malfunction in transmission operation. These codesare logged in the TCM/ECU memory. The most se-vere or most recent code is listed first. A maximum offive codes (numbered d1-d5) may be listed inmemory at one time. If the mode indicator LED isilluminated, the displayed code is active. If it is notilluminated, the displayed code is not active.

NOTE: During normal operation, an illuminatedmode indicator LED signifies the specializedmode operation is in use.

To enter diagnostics mode, first park the vehicle andapply the parking brake. Then simultaneously pressboth the up and down arrows twice.

Eaton® Fuller® Straight-ShiftTransmissions

Refer to the Eaton website for additional information,www.roadranger.com.

General Information, Straight-Shift

Eaton Fuller 5-speed FS models are fully synchro-nized. They have five forward speeds and one re-verse. See Fig. 8.3 for the shift pattern.

Eaton Fuller 6-speed FS and FSO models are fullysynchronized. They have six forward speeds and onereverse. See Fig. 8.4 for the shift pattern.

Eaton Fuller 7-speed T models are not synchronized.They have seven forward speeds and one reverse.See Fig. 8.5 for the shift pattern.

These transmissions are designed for use with on-highway, fuel economy engines where a minimum ofshifting is desired and less gear reduction is accept-able.

Operation, Straight-Shift

1. Always use first gear when starting to move thevehicle forward.

IMPORTANT: Do not rest your foot on the clutchpedal while driving. This causes partial clutch

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Fig. 8.3, Shift Pattern, 5-Speed FS Models

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Fig. 8.4, Shift Pattern, 6-Speed FS and FSO Models

Drivetrain

8.8

disengagement which could cause prematureclutch wear.

2. On synchronized models, press the clutch pedalto the floor when shifting gears. Double-clutchingis unnecessary.

On unsynchronized models, press the clutchpedal to the floor to contact the clutch brake onlywhen engaging the first or reverse gears.

NOTE: If the vehicle is moving when shifting,press the clutch pedal just far enough to disen-gage the clutch. Pressing it to the floor will en-gage the clutch brake, if so equipped, causingpremature clutch brake wear.

3. To upshift, do the following steps:

3.1 Accelerate to engine governed speed.

3.2 On synchronized models, disengage theclutch and move the shift lever to secondgear.

On unsynchronized models, disengage theclutch and move the shift lever to neutral.Engage the clutch again. With the shiftlever in neutral, disengage the clutch andmove the shift lever to second gear.

3.3 Engage the clutch and note the drop inengine rpm before accelerating up to en-gine governed speed again.

3.4 Continue upshifting using the same se-quence described in the previous step.Follow the pattern on the shift lever.

4. To downshift, do the following steps:

4.1 Wait until the engine speed drops to therpm noted immediately after the upshift.

4.2 On synchronized models, disengage theclutch and move the shift lever to the nextlower gear.

On unsynchronized models, disengage theclutch and move the shift lever to neutral.Engage the clutch again. With the shiftlever in neutral, disengage the clutch andmove the shift lever to the next lowestgear.

4.3 Engage the clutch smoothly.

4.4 Use the sequence described above toshift progressively down through eachsuccessive lower gear, as driving condi-tions require.

Eaton Fuller Range-ShiftTransmissions

Refer to the Eaton website for additional information,www.roadranger.com.

General Information, Range-Shift

Eaton Fuller 9-Speed Models

Eaton Fuller 9-speed range-shift models are not syn-chronized. They have nine forward speeds and tworeverse speeds. The shift lever controls five forwardgears and one reverse gear in the transmission frontsection, and the range lever controls a LO and HIrange in the two-speed auxiliary section. The firstposition in the front section is used only as a startinggear. The other four ratios are used once in LOrange and once again in HI range. See Fig. 8.6 forthe shift patterns.

After shifting out of the first gear position, use theRoadranger® "repeat H" shift pattern. Select both LOrange and HI range with the range lever (rangeknob). It is used once during the upshift sequenceand once during the downshift sequence.

Always preselect the range shift. After preselection,the transmission will automatically make the synchro-nizer range shift as the shift lever passes throughneutral.

Eaton Fuller 10-Speed Models

Eaton Fuller 10-speed range-shift models are notsynchronized. They have ten forward speeds and

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Fig. 8.5, Shift Pattern, 7-Speed T Models

Drivetrain

8.9

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