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Driver’s Manual

CASCADIA

Part Number STI 478

Introduction

This manual provides information needed to operate

and understand the vehicle and its components.

More detailed information is contained in the Owner’s

Warranty Information for North America booklet, and

in the vehicle’s workshop and maintenance manuals.

Custom-built Freightliner vehicles are equipped with

various chassis and cab components. Not all of the

information contained in this manual applies to every

vehicle. For details about components in your ve-

hicle, refer to the chassis speciﬁcation pages in-

cluded in all new vehicles and to the vehicle speciﬁ-

cation decal, located inside the vehicle.

For your reference, keep this manual in the vehicle

at all times.

IMPORTANT: Descriptions and speciﬁcations in

this manual were in effect at the time of printing.

Freightliner Trucks reserves the right to discon-

tinue models and to change speciﬁcations or

design at any time without notice and without

incurring obligation. Descriptions and speciﬁca-

tions contained in this publication provide no

warranty, expressed or implied, and are subject

to revisions and editions without notice.

Environmental Concerns and

Recommendations

Whenever you see instructions in this manual to dis-

card materials, you should ﬁrst attempt to reclaim

and recycle them. To preserve our environment, fol-

low appropriate environmental rules and regulations

when disposing of materials.

Event Data Recorder

This vehicle is equipped with one or more devices

that record speciﬁc vehicle data. The type and

amount of data recorded varies depending on how

the vehicle is equipped (such as the brand of engine,

if an air bag is installed, or if the vehicle features a

collision avoidance system, etc.).

This vehicle is equipped with an event data recorder

(EDR). The main purpose of an EDR is to record

data in certain crash or near-crash situations, such

as air bag deployment or hitting a road obstacle, that

will assist in understanding how a vehicle’s systems

performed. The EDR is designed to record data re-

lated to vehicle dynamics and safety systems for ap-

proximately 60 seconds. This data can help provide

a better understanding of the circumstances in which

crashes and injuries occur. Data recorded includes

the following items:

•how various systems in the vehicle were oper-

ating

•engine system information

•how far (if at all) the driver was depressing the

accelerator

•if the driver was depressing the brake pedal

•how fast the vehicle was traveling

NOTE: Data is not recorded by the EDR under

normal driving conditions. Personal data such

as name, gender, age, and crash location are

not recorded. However, other parties such as

law enforcement could combine the EDR data

with the type of personally identifying data rou-

tinely acquired during a crash investigation.

To read data recorded by an EDR, special equipment

is required, and access to the vehicle or the EDR is

needed. In addition to the vehicle manufacturer, other

parties that have the special equipment, such as law

enforcement, can read the information if they have

access to the vehicle or the EDR.

Emissions and Fuel Efficiency

Compliance

This vehicle must be regularly inspected and main-

tained as indicated in the Cascadia Maintenance

Manual, and in the Pre- and Post-Trip Inspections

and Maintenance chapter in this manual, in order to

continue satisfactory performance and ensure cover-

age of the vehicle under the manufacturer’s warranty.

Many maintenance procedures ensure that the ve-

hicle and engine continue to comply with applicable

emissions standards. Maintenance procedures, using

components engineered to comply with greenhouse

gas emissions and fuel efficiency regulations, may be

performed by an authorized Daimler Trucks North

America dealer, an independent outlet, or the vehicle

owner or operator.

The vehicle owner is responsible for determining the

suitability of replacement components to maintain

Foreword

STI-478-6 (11/14)

Part Number STI 478

Printed in U.S.A.

compliance with federal and local jurisdictional regu-

lations. Components including, but not limited to,

tires, cab/sleeper side extenders, chassis fairings,

bumper, hood, vehicle speed limiters, and idle reduc-

tion timers are speciﬁcally designed and manufac-

tured to exacting standards for regulatory fuel effi-

ciency and greenhouse gas emissions compliance. It

is important that these components are always re-

placed with components that meet or exceed the per-

formance of the originally installed components.

Customer Assistance Center

Having trouble ﬁnding service? Call the Customer

Assistance Center at 1-800-385-4357 or 1-800-FTL-

HELP. Call night or day, weekdays or weekends, for

dealer referral, vehicle information, breakdown coor-

dination, or Fleetpack assistance. Our people are

knowledgeable, professional, and committed to fol-

lowing through to help you keep your truck moving.

Reporting Safety Defects

If you believe that your vehicle has a defect which

could cause a crash or could cause injury or

death, you should immediately inform the National

Highway Traffic Safety Administration (NHTSA) in

addition to notifying Daimler Trucks North America

LLC.

If the NHTSA receives similar complaints, it may

open an investigation, and if it ﬁnds that a safety

defect exists in a group of vehicles, it may order a

recall and remedy campaign. However, NHTSA

cannot become involved in individual problems

between you, your dealer, or Daimler Trucks North

America LLC.

To contact NHTSA, you may call the Vehicle

Safety Hotline toll-free at 1-888-327-4236 (TTY:

1-800-424-9153); go to www.safercar.gov;or

write to: Administrator, NHTSA, 1200 New Jersey

Avenue, SE, Washington, DC 20590. You can also

obtain other information about motor vehicle safety

from www.safercar.gov.

Canadian customers who wish to report a safety-

related defect to Transport Canada, Defect Investi-

gations and Recalls, may telephone the toll-free

hotline 1-800-333-0510, or contact Transport

Canada by mail at: Transport Canada, ASFAD,

Place de Ville Tower C, 330 Sparks Street, Ot-

tawa, Ontario, Canada K1A 0N5.

For additional road safety information, please visit

the Road Safety website at: www.tc.gc.ca/

roadsafety.

company.

No part of this publication, in whole or part, may be translated, reproduced, stored in a retrieval system, or transmitted

in any form by any means, electronic, mechanical, photocopying, recording, or otherwise, without the prior written per-

mission of Daimler Trucks North America LLC. For additional information, please contact Daimler Trucks North

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

www.Daimler-TrucksNorthAmerica.comand www.FreightlinerTrucks.com.

Foreword

Contents

Chapter Page

Introduction, Environmental Concerns and Recommendations,

Event Data Recorder, Emissions and Fuel Efficiency Compliance,

Customer Assistance Center, Reporting Safety Defects .................... Foreword

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

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

3Electrical System ........................................................ 3.1

4Instruments ............................................................. 4.1

5Driver Controls .......................................................... 5.1

6Driver Assistance Features ................................................ 6.1

7Seats and Restraints ..................................................... 7.1

8Climate Control .......................................................... 8.1

9Cab Features ........................................................... 9.1

10 Engine Starting, Operation, and Shutdown ................................... 10.1

11 Optional Engine Systems ................................................. 11.1

12 Emissions and Fuel Efficient Components ................................... 12.1

13 Brake Systems ......................................................... 13.1

14 Manual Transmissions and Hydraulic Clutch ................................. 14.1

15 Automated Transmissions ................................................ 15.1

16 Drive Axles ............................................................ 16.1

17 Steering System ........................................................ 17.1

18 Fifth Wheels ........................................................... 18.1

19 Trailer Couplings ........................................................ 19.1

20 Pre- and Post-Trip Checklists ............................................. 20.1

21 Pre- and Post-Trip Inspections and Maintenance .............................. 21.1

22 Cab Appearance ........................................................ 22.1

23 Headlight Aiming ........................................................ 23.1

24 In an Emergency ....................................................... 24.1

25 Natural Gas Vehicles .................................................... 25.1

26 Speciﬁcations .......................................................... 26.1

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

Vehicle Identiﬁcation

Component Information Label ....................................................... 1.1

Component GWR Label ............................................................ 1.1

Federal Motor Vehicle Safety Standard Labels .......................................... 1.1

Canadian Motor Vehicle Safety Standard Labels ........................................ 1.1

Emissions Labels ................................................................. 1.1

Component Information Label

NOTE: Labels shown in this chapter are ex-

amples only. Actual speciﬁcations may vary from

vehicle to vehicle.

The component information label lists the vehicle

model, identiﬁcation number, and major component

models. It also lists the major assemblies and instal-

lations shown on the chassis speciﬁcation sheet.

One copy of the component information label is at-

tached to the inside of the glove box; another copy is

inside the rear cover of the Owner’s Warranty Infor-

mation for North America booklet. An illustration of

the label is shown in Fig. 1.1.

Component GWR Label

The component GWR label is located on the

passenger-side B-pillar. The label provides maximum

GWR ratings for each component.

See Fig. 1.2 for a typical component GWR label.

Federal Motor Vehicle Safety

Standard Labels

NOTE: Due to the variety of Federal Motor Ve-

hicle Safety Standard (FMVSS) certiﬁcation re-

quirements, not all of the labels shown will apply

to your vehicle.

Tractors with or without ﬁfth wheels purchased in the

U.S. are marked as certiﬁed by means of an FMVSS

certiﬁcation label. See Fig. 1.3. This label is attached

to the driver-side B-pillar, as shown in Fig. 1.4.

The tire and rim portion of the FMVSS certiﬁcation

label certiﬁes suitable tire and rim combinations that

can be installed on the vehicle, for the given gross

axle weight rating. Tires and rims installed on the

vehicle at the time of manufacture may have a higher

load capacity than that certiﬁed by the tire and rim

label. If the tires and rims currently on the vehicle

have a lower load capacity than that shown on the

tire and rim label, then the tires and rims determine

the load limitations on each of the axles.

Trucks built without a cargo body that are intended

for service in the U.S. have an incomplete vehicle

certiﬁcation label attached by the ﬁnal-stage manu-

facturer. See Fig. 1.5. This label will be attached to

the incomplete vehicle document included with the

vehicle, and certiﬁes that the vehicle conforms to all

applicable FMVSS regulations in effect on the date of

completion.

Canadian Motor Vehicle Safety

Standard Labels

In Canada, tractors with ﬁfth wheels are marked as

certiﬁed by means of a statement of compliance label

with the Canadian National Safety Mark attached to

the driver-side door frame B-pillar. See Fig. 1.6.

Trucks built without a cargo body and tractors built

without a ﬁfth wheel that are intended for service in

Canada have an incomplete vehicle certiﬁcation label

attached to the driver-side B-pillar. After completion

of the vehicle, a complete certiﬁcation label must be

attached by the ﬁnal-stage manufacturer to certify

that the vehicle conforms to all applicable Canada

Motor Vehicle Safety Standard (CMVSS) regulations

in effect on the date of completion.

Emissions Labels

Aftertreatment System Indicators

Label

Engines and vehicles manufactured after December

31, 2006 and domiciled in the U.S. or Canada are

required to meet all EPA regulations effective as of

the vehicle build date, and are equipped with an

emission aftertreatment system (ATS). Vehicles do-

miciled outside of the U.S. and Canada may not

have aftertreatment equipment, depending upon local

statutory emissions guidelines. See Table 1.1.

02/20/2012 f080176

Fig. 1.1, Component Information Label

Vehicle Identiﬁcation

1.1

A warning label on the driver-side visor contains im-

portant warning indicators in the instrument cluster

that pertain to the ATS. See Fig. 1.7 or Fig. 1.8.

It is a violation of U.S. federal law to alter exhaust

plumbing, ATS, or other components in any way that

would bring the engine/vehicle out of compliance with

certiﬁcation requirements [Ref: 42 U.S.C. S7522(a)

(3)]. It is the owner’s responsibility to maintain the

vehicle so that it conforms to EPA regulations.

02/20/2012 f080178

Fig. 1.2, Component GWR Label

02/20/2012 f080177

Fig. 1.3, Vehicle Certiﬁcation Label

02/28/2012 f080182

1. EPA Noise Emission Control Label

2. FMVSS Certiﬁcation Label

Fig. 1.4, Label Locations

f080180

02/28/2012

Fig. 1.5, Incomplete Vehicle Certiﬁcation Label

f08002410/10/2006

Fig. 1.6, Canadian National Safety Mark

Vehicle Identiﬁcation

1.2

Applicable Emissions System Based on Build Date and EPA Regulations

Build Date Regulation: Emissions Components

January 1, 2007–December 31,

2009

EPA07 (reduce nitrogen oxides (NOx) emissions to 1.1 g/bhp-hr, and reduce

particulate matter emissions to 0.01 g/bhp-hr): Aftertreatment device (ATD) containing

a diesel particulate ﬁlter that traps soot and ash.*

January 1, 2010–December 31,

2012

EPA10 (reduce NOx emissions to 0.2 g/bhp-hr): EPA07-type ATD, with additional

selective catalyst reduction (SCR) technology that utilizes diesel exhaust ﬂuid (DEF)

to convert NOx to nitrogen and water vapor.

From March 5, 2012

GHG14: Aerodynamic and fuel efficiency components including, but not limited to,

tires, cab/sleeper side extenders, chassis fairings, bumper, hood, vehicle speed

limiters, and idle reduction timers speciﬁcally designed to meet regulatory fuel

efficiency and greenhouse gas emissions standards.

*Cummins, Detroit, and Mercedes-Benz ATD’s are also equipped with a diesel oxidation catalyst to break down pollutants.

Table 1.1, Applicable Emissions System Based on Build Date and EPA Regulations

EPA Noise Emission Control Label

A vehicle noise emission control label (Fig. 1.9)is

located on the driver-side B-pillar as shown in

Fig. 1.4. It is the owner’s responsibility to maintain

the vehicle so that it conforms to EPA regulations.

IMPORTANT: Certain Freightliner incomplete

vehicles may be produced with incomplete noise

control hardware. Such vehicles will not have a

vehicle noise emission control information label.

For such vehicles, it is the ﬁnal-stage manufac-

turer’s responsibility to complete the vehicle in

conformity to U.S. EPA regulations (40 CFR Part

205) and label it for compliance.

f080156

EXHAUST AFTERTREATMENT SYSTEM INFORMATION

Switch.

Level 1 Level 3Level 2 Level 4

Filter Regeneration

Recommended.

Filter is reaching

Bring vehicle to

highway speeds to

Filter

Regeneration

Filter is now

reaching maximum

capacity

To avoid engine

derate, bring vehicle

Parked Regeneration

Required − Engine

Derate

Filter has reached

maximum capacity

Vehicle must be

parked, and a Parked

Service Regeneration Required.

Engine Derate To Idle Only.

Filter has exceeded maximum

capacity.

Vehicle must be parked, and a

Service Regeneration must be

(Solid)

(Flashing) (Flashing)

CHECK

INDICATOR

LAMP(S)

Indicator Lamp

Message(s)

Diesel Particulate

Filter Condition

Required Action

capacity

STOP

allow for an

Automatic

Regeneration or

perform a Parked

to highway speeds

to allow for an

Automatic

Regeneration, or

perform a Parked

Regeneration as

soon as possible.

Regeneration must

be performed.

Engine will begin

derate.

performed. Check engine

operator’s manual for details.

Engine will shut down.

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

02/20/2009

ARNING

HEST (High Exhaust

System Temperature)

Exhaust components

and exhaust gas are at

high temperature. When

stationary, keep away

from people and

flammable materials or

vapors.

A regeneration is in

progress.

Flashing

Solid

Regeneration.

Necessary

Fig. 1.7, ATS Indicators, EPA07

Vehicle Identiﬁcation

1.3

Vehicle Emission Control Information

Label

Model year 2013 and later vehicles meet additional

requirements as speciﬁed by federal greenhouse gas

and fuel efficiency regulations (GHG14). These ve-

hicles are equipped with components that increase

fuel efficiency and reduce GHG emissions. Compo-

nents may include, but are not limited to, low-rolling

resistance tires; aerodynamic devices such as hood,

cab side extenders, and fuel tank fairings; vehicle

speed limiters; and idle shutdown timers.

A Vehicle Emission Control Information Label is lo-

cated on the driver-side door. See Fig. 1.10.Itisthe

owner’s responsibility to maintain the vehicle so that

it conforms to EPA and NHTSA regulations.

Certiﬁed Clean Idle Label

The California Air Resources Board (CARB) requires

model year 2008 and newer heavy-duty diesel en-

gines to be equipped with a non-programmable en-

gine shutdown system that automatically shuts down

the engine after ﬁve minutes of idling in order to limit

emissions of particulate matter and NOx.

DPF Regen Needed

Hot Exhaust

DEF Refill Needed

Diesel Particulate Filter (DPF)

regeneration is needed.

If flashing, regenerate as soon as

possible. Engine derate possible.

Hot exhaust can cause fire.

Keep flammables and people away

from exhaust.

Diesel Exhaust Fluid (DEF) level is

low. Engine derate likely.

Refill tank with certified DEF.

24−01656−000

IMPORTANT

DEF

11/30/2010 f080162

See operator’s manual for complete instructions.

Fig. 1.8, ATS Indicators, EPA10 and Newer

10/06/98 f080026

24−00273−020

VEHICLE NOISE EMISSION CONTROL INFORMATION

FREIGHTLINER CORPORATION

THIS VEHICLE CONFORMS TO U.S. EPA REGULATIONS FOR NOISE EMISSION

APPLICABLE TO MEDIUM AND HEAVY TRUCKS.

THE FOLLOWING ACTS OR THE CAUSING THEREOF BY ANY PERSON ARE PROHIBITED BY

THE NOISE CONTROL ACT OF 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. 1.9, Vehicle Noise Emission Control Label

f080181

02/29/2012

MANUFACTURED BY:

VIN:

VEH FAMILY CD:

GVWR−KG

GVWR−LBS

REGULATORY CLASS:

EMISSION CONTROL IDENTIFIERS:

DATE OF MANUFACTURE:

VEHICLE EMISSION CONTROL INFORMATION

THIS VEHICLE COMPLIES WITH U. S. EPA REGULATIONS FOR XXXX HEAVY DUTY VEHICLES.

SEE OWNER’S MANUAL FOR PROPER MAINTENANCE OF THIS VEHICLE. U PART NO. 24−01177−060 REV A

Fig. 1.10, Vehicle Emission Control Information Label

Vehicle Identiﬁcation

1.4

Certiﬁed vehicles are equipped with a label placed

near the bottom edge of the driver-side door. See

Fig. 1.11.

CERTIFIED

CLEAN IDLE

02/20/2012 f080179

Fig. 1.11, CARB Clean Idle Label

Vehicle Identiﬁcation

1.5

Vehicle Access

Cab Door Locks and Handles ....................................................... 2.1

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

Cab-to-Sleeper Access ............................................................. 2.3

Sleeper Door ..................................................................... 2.3

Sleeper Luggage Door ............................................................. 2.4

Back-of-Cab Access ............................................................... 2.4

Hood Opening and Closing ......................................................... 2.5

Cab Door Locks and Handles

One common key operates the ignition switch and all

of the door locks.

IMPORTANT: Each key is numbered. Record

the number so a duplicate key can be made, if

needed.

To unlock the driver’s door from outside the cab, in-

sert the key in the lockset and turn it one-quarter turn

clockwise. See Fig. 2.1. To remove the key, turn it

counterclockwise to the original position. Pull out on

the door 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-quarter

turn counterclockwise. Turn the key clockwise to the

original position to remove it.

NOTE: The cab door locks can be operated

when the doors are open.

To lock a door from outside the cab, insert the key in

the lockset and turn it in the direction opposite to the

unlocking direction (counterclockwise for the driver’s

door, clockwise for the passenger’s door). Close the

door if it is open.

To lock either door from inside the cab, push the lock

button downwards. See Fig. 2.2.

To open the door from the inside, lift up on the door

lever. This will unlatch the door whether or not it is

locked.

To unlock the door without unlatching it, pull the lock

button upwards.

Grab Handles and Access

Steps

WARNING

Wet or dirty shoe soles greatly increase the

chance of slipping or falling. If your soles are wet

or dirty, be especially careful when climbing

onto, or down from, the back-of-cab area.

Always maintain three-point contact with the

back-of-cab access supports while entering and

exiting the back-of-cab area. Three-point contact

means both feet and one hand, or both hands

and one foot, on the grab handles, steps, and

deck plates. Other areas are not meant to sup-

port back-of-cab access, and grabbing or step-

ping in the wrong place could lead to a fall, and

personal injury.

Be careful not to get hands or feet tangled in

hoses or other back-of-cab equipment. Careless-

ness could cause a person to trip and fall, with

possible injury.

10/22/2001 f720397

1. Key

2. Lockset

3. Door Pull Handle

Fig. 2.1, Exterior Door Handle

06/22/2006

3f720639

1. Lock Button

2. Integral Door Upper Grab Handle

3. Door Lever

Fig. 2.2, Door Interior

Vehicle Access

2.1

Entering the Driver Side

When entering the cab from the driver side, use the

grab handle and access steps as follows:

1. Open the driver side door, and place anything

that you are carrying in the cab.

2. Using both hands, grasp the grab handle that is

on the B-pillar, or use your left hand on the inte-

gral door lower grab handle. See Fig. 2.3. Reach

up as far as is comfortable.

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

yourself up. Move your left hand to the integral

door upper grab handle.

4. Place your left foot on the top step.

5. Grasp the steering wheel with your left hand, and

step up.

6. Step into the cab with your right foot ﬁrst, and

grasp the steering wheel with your right hand.

Exiting the Driver Side

Exit the cab from the driver side as follows:

IMPORTANT: Do not attempt to exit the cab

while carrying any items in your hands.

1. Grasp the steering wheel with both hands, place

your left foot on the top step, then stand on the

threshold facing into the cab.

2. Using your right hand, grasp the grab handle,

located on the B-pillar.

3. Move your right foot to the bottom step.

4. Move your left hand to the integral door lower

grab handle.

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

Entering the Passenger Side

When entering the cab from the passenger side, use

the grab handles and access steps as follows:

1. Open the passenger-side door, and place any-

thing that you are carrying in the cab.

2. Using your left hand, grasp the grab handle

that’s on the rear of the door opening. See

Fig. 2.4.

3. Using your right hand, grasp the integral door

lower grab handle.

4. Place your right foot on the bottom step, and

step up to the upper step with your left foot.

5. Place your right foot on the top step, and step

up.

6. Move your right hand to the upper grab handle

on the windshield post.

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

Exiting the Passenger Side

Exit the cab from the passenger side as follows:

IMPORTANT: Do not attempt to exit the cab

while carrying any items in your hands.

11/30/2006 f602271

1. Steering Wheel

2. B-Pillar Grab Handle

3. Bottom Step

4. Top Step

5. Integral Door Lower

Grab Handle

Fig. 2.3, Driver-Side Steps and Grab Handle

Vehicle Access

2.2

1. Using both hands, grasp the grab handle thats

on the windshield post, and place your right foot

on the top step while standing up from the seat

facing inward.

2. Place your left foot on the bottom step.

3. Move your left hand to the lower grab handle

located at the rear edge of the door opening.

See Fig. 2.4.

4. Move your right hand to the integral door lower

grab handle.

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

Cab-to-Sleeper Access

To open the sleeper access on vehicles with vinyl

sleeper curtains, unzip the sleeper curtains. If de-

sired, unsnap the curtains all the way around the

sides and top, and remove the curtains.

To open the sleeper access on vehicles with velour

sleeper curtains, unfasten the snaps at one side,

then push the curtain to the opposite side.

Sleeper Door

The sleeper door (Fig. 2.5, Ref. 1) is not intended for

entry or exit. The door is intended only as a conve-

nient means to stow or remove personal belongings

in and from the sleeper area. To open the sleeper

door from the inside, push down on the lever handle

located inside the sleeper compartment aft of the

door, or pull out on the upper lever located inside the

cab door opening; see Fig. 2.6. To open the sleeper

door from outside, open the cab door, then pull out

on the upper lever located inside the cab door open-

ing. To close the door, pull on the strap attached to

the inside of the door, or push it closed from the out-

side, until it latches.

IMPORTANT: The sleeper doors are two-stage

latching. When closing the doors, ensure that

they are completely latched to prevent wind

noise and water intrusion.

01/03/2007 f720643

1. Lower Grab Handle

2. Upper Grab Handle

3. Integral Door Lower Grab Handle

4. Top Step

Fig. 2.4, Passenger-Side Steps and Grab Handles

04/20/2007

f602302

1. Sleeper Door

2. Luggage Compartment Door

Fig. 2.5, Sleeper Doors

Vehicle Access

2.3

Sleeper Luggage Door

To open the sleeper luggage door, pull out on the

lower lever located inside the cab door opening. See

Fig. 2.6. To close the door, push it closed until it

latches.

Back-of-Cab Access

WARNING

External surfaces of the exhaust system remain

hot after the engine has been shut down. When

accessing the back of the cab or sleeper, do not

touch any part of the exhaust system, or severe

burns could occur.

When trailer air and electrical connections cannot be

reached conveniently from the ground, Federal Motor

Carrier Safety Regulations require commercial carri-

ers to provide back-of-cab access.

Optional grab handles are mounted either on both

cab sidewalls, or on the left sidewall only. See

Fig. 2.7. Steps are mounted either on the fuel tank(s)

or on metal brackets. When a deck plate is neces-

sary, it is mounted across the top of the frame rails.

IMPORTANT: Climb onto, and down from, back-

of-cab access facing in toward the vehicle, as

you would on a ladder. Do not climb up or down

facing out away from the vehicle.

WARNING

Wet or dirty shoe soles greatly increase the

chance of slipping or falling. If your soles are wet

or dirty, be especially careful when climbing

onto, or leaving, the back-of-cab area.

Always maintain three-point contact with the

back-of-cab access supports while entering and

exiting the back-of-cab area. Three-point contact

means both feet and one hand, or both hands

and one foot, on the grab handles, steps, and

deck plates. Other areas are not meant to sup-

port back-of-cab access, and grabbing or step-

ping in the wrong place could lead to a fall, and

personal injury.

03/22/2007 f720661

1. Sleeper Door Lever

2. Luggage Door Lever

Fig. 2.6, Sleeper Door Levers

09/24/2007 f602335

1. Steps

2. Grab Handle

3. Deck Plate

Fig. 2.7, Back-of-Cab Access

Vehicle Access

2.4

Be careful not to get hands or feet tangled in

hoses or other back-of-cab equipment. Careless-

ness could cause a person to trip and fall, with

possible injury.

Entering Back-of-Cab

When climbing onto the deck plate, do the following:

1. Grasp the sidewall grab handle with both hands.

Reach up as far as is comfortable.

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

self up.

3. Place your other foot on the top step.

4. Move your lower hand to a higher position on the

grab handle.

5. Step onto the deck plate.

Climbing Down from Back-of-Cab

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

1. Grasp the sidewall grab handle with both hands.

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

3. Move your upper hand to a lower position on the

grab handle.

4. Move one foot to the bottom step.

5. Move your upper hand to a lower position on the

grab handle.

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

Hood Opening and Closing

A grab handle at the front of the hood provides a

hand-hold for hood tilting. Two tilt-assist struts help to

tilt the hood open, and to return it to the operating

position. A damper controls the closing rate of the

hood and hood straps prevent the hood from over-

travel. In the operating position, the hood is secured

by a hold-down latch on each side of the hood.

To Tilt the Hood

1. Apply the parking brakes.

2. Release both hood hold-down latches by pulling

the ends outward.

CAUTION

Do not let the hood free-fall to the full-open posi-

tion. To do so could cause damage to the hood

or hood straps.

3. Using the bumper step and grab handle, slowly

tilt the hood until the straps support it. See

Fig. 2.8.

To Return the Hood

1. Grasp the grab handle, and lift the hood a just-

over-center position.

2. As the hood goes over center, the hood damper

controls the rate of descent to the operating posi-

tion.

3. Make sure the hood is ﬂush with the cowl, then

secure the hood by engaging both hood hold-

down latches.

IMPORTANT: Make sure that both hold-down

latches are fully engaged before operating the

vehicle.

03/22/2007 f880788

Fig. 2.8, Hood Tilting

Vehicle Access

2.5

Electrical System

Electrical Power Distribution ........................................................ 3.1

Emergency Power Supply .......................................................... 3.3

Progressive Low Voltage Disconnect ................................................. 3.4

Electrical Power Distribution

Electrical power distribution provides battery power to

the electrical and electronic systems. See Fig. 3.1 for

power distribution component locations.

The following components make up the power distri-

bution system:

•MEGA Fuse Junction Block (MFJB), EPA07

only

•Powertrain Power Distribution Module

(PT-PDM)

•Powernet Distribution Box (PNDB), EPA10 and

newer

•Cab Load Disconnect Switch

•Auxiliary PDM

MEGA Fuse Junction Block, EPA07

On EPA07 vehicles, the MFJB distributes battery

power to the alternator, SAM cab, SAM chassis, and

powertrain PDM. Battery power may also be routed

to an inverter and a trailer PDM. The MFJB houses

up to ﬁve MEGA fuses, and is located on the left

frame rail in front of the batteries. See Fig. 3.2.

Powernet Distribution Box, EPA10

and Newer

The PNDB distributes battery power to the SAM cab,

SAM chassis, powertrain PDM, and other keep-alive

circuits.

The PNDB is mounted in the engine compartment on

the frontwall near the steering column. The label on

the PNDB fuse cover identiﬁes typical circuits. See

Fig. 3.3.

Power Distribution Modules

Powertrain PDM

The powertrain PDM contains fuses and relays that

provide battery and ignition power to the engine, af-

tertreatment device, transmission, and other

powertrain-related circuits. It is mounted in the en-

gine compartment, above the driver-side inner

fender.

Auxiliary PDM

The optional auxiliary PDM is used when additional

circuit protection is needed for optional features. For

example, if a beacon light is added to the Cascadia,

it may require an auxiliary PDM. The auxiliary PDM

may contain fuses and relays for these devices. It is

mounted in the cab, behind the doghouse cover.

Trailer PDM

The optional trailer PDM, mounted on the frame rail,

is used to supply trailer power to the chassis-

mounted trailer receptacles. The SAM chassis sup-

plies control signals to the relays in the trailer PDM.

SAM Cab

The SAM cab is located behind the glove box inside

the vehicle cab. See Fig. 3.4. The SAM cab contains

fuses and relays in addition to solid state circuit pro-

tection devices that will trip when a circuit is over-

loaded.

Refer to Chapter 25 for fuse and relay locations.

SAM Chassis

The SAM Chassis is located in the engine compart-

ment on the driver-side frontwall. See Fig. 3.3. The

SAM chassis contains fuses and relays in addition to

solid state circuit protection devices that will trip

when a circuit is overloaded.

Refer to Chapter 25 for fuse and relay locations.

Circuit Protection Features

The SAM chassis and SAM cab may be equipped

with self-resetting circuit breakers instead of fuses.

Self-resetting circuit breakers are tripped when they

reach 170°F (77°C), then self-reset once the tem-

perature drops sufficiently. When the circuit overload

is removed, this circuit protection will self-reset.

Some of these circuits require the ignition switch to

be cycled off then back on again for the self-reset to

occur.

Some ECU’s are equipped with a self-resetting circuit

breaker removal tool.

WARNING

Always wear heat-protective gloves when han-

dling a self-resetting circuit breakers, which can

Electrical System

3.1

reach extremely high temperatures. Failure to use

appropriate heat protection can lead to serious

injury.

NOTICE

Self-resetting circuit breakers can be perma-

nently damaged if improperly handled. Use the

guidelines below to handle them safely.

•Disconnect the batteries before removing a

self-resetting circuit breaker.

•Use a circuit breaker removal tool to remove a

self-resetting circuit breaker. See Fig. 3.5. Use

of any other tool, including pliers, may damage

the circuit breaker.

•Never attempt to probe a self-resetting circuit

breaker while installed on the SAM Cab or

SAM Chassis. Remove the circuit breaker ﬁrst,

or use a non-contact infrared thermometer to

measure temperature.

f001175a

02/27/2012

1. SAM Cab

2. Powertrain PDM (PT-PDM)

3. Powernet Distribution Box (PNDB)

4. SAM Chassis

5. Main Ground Junction Block

6. MEGA Fuse Junction Block

7. Cab Load Disconnect Switch (optional location)

8. Cab Load Disconnect Switch (optional location)

9. Trailer PDM

Fig. 3.1, Component Locations

Electrical System

3.2

Cab Load Disconnect Switch

WARNING

Turning the cab load disconnect switch (CLDS) to

the off position does not disconnect the connec-

tion between the battery and the starter. To work

on the vehicle safely, the negative leads must be

disconnected from the battery.

IMPORTANT: The ignition should be turned off

before turning the CLDS to on or off.

The CLDS is used to avoid excessive draw on the

battery when the vehicle is parked for an extended

period of time by disconnecting (or opening) the con-

nection between the battery and the most of the ve-

hicle electrical system.

The CLDS may be mounted:

•inside the cab on the outboard side of the

driver’s seat;

•at the battery box;

•outboard on the left frame rail.

See Fig. 3.6 for an EPA07 CLDS; see Fig. 3.7 for an

EPA10 and newer switch.

If the CLDS is turned to the off position while the ve-

hicle is running, the emergency power system will

activate. The powertrain PDM will receive power from

the emergency power feed, but the batteries will not

be charging. See the Emergency Power Supply

heading below for details.

Emergency Power Supply

The Cascadia electrical system has an emergency

power circuit that supplies battery power for exterior

lighting. This assists vehicle visibility in the event a

MEGA fuse is open circuit. The emergency power

circuit is live even when the CLDS is turned off.

The emergency power supply feature allows for the

vehicle to be driven off the highway and for the exte-

rior lighting to remain on in the event of a SAM Cab

or SAM Chassis failure. The emergency power sup-

ply will cause certain exterior lamps to ﬂash (depend-

ing on if it is the SAM Cab or SAM Chassis that

failed), indicating that the vehicle is disabled.

06/15/2007 f545073

1. MEGA Fuse Junction Block

2. Main Ground Junction Block

Fig. 3.2, EPA07 MEGA Fuse Junction Block

02/27/2012 f545682a

1. Powertrain PDM (PT-PDM)

2. Inline Fuse, Auxiliary PDM

3. SAM Chassis

4. Powernet Distribution Box (PNDB)

Fig. 3.3, Engine Compartment Power Distribution

Components

Electrical System

3.3

SAM Cab Fault

If the emergency power supply system activates, do

not shut down the engine until the vehicle is in a safe

position to do so. It will not be able to be restarted

until the problem is corrected. If emergency power

mode is due to a SAM Cab fault, the gauges will be-

come unresponsive but the engine will remain run-

ning until it is turned off.

When the ignition is in the ON position, the emer-

gency power supply will cause the following lamps to

ﬂash:

•dash panel lights

•clearance lights

•front marker lights

•side marker lights

•trailer taillights

•rear stop lights

SAM Chassis Fault

The engine may be able to be restarted when the

SAM Chassis fails. When the ignition is in the ON

position, the emergency power supply will cause the

following lamps to ﬂash:

•dash panel lights

•identiﬁcation lights

•front marker lights

•turn-signal indicators in the ICU (alternately)

•side marker lights

•rear turn-signal lights

•trailer taillights

If the ignition switch is turned ON while the load dis-

connect switch is in the OFF position, the emergency

power supply feature will activate the following

lamps:

•clearance lights (ﬂashing)

•side marker lamps (ﬂashing)

•low beam headlights

Progressive Low Voltage

Disconnect

The progressive low voltage disconnect (PLVD) fea-

ture protects the batteries from excessive discharge

by disconnecting certain circuits from battery power

supply. This allows the batteries to maintain accept-

able charge to restart the vehicle.

When battery voltage drops below a predetermined

value, loads designated as comfort loads (priority

f544945

02/07/2007

Fig. 3.4, SAM Cab Location

Electrical System

3.4

level I) are shut down ﬁrst. Then loads designated as

house loads (priority level II) are shut down. If neces-

sary, basic loads (priority level III) are shut down last.

PLVD allows the driver to continue using critical

loads, while noncritical loads are temporarily unavail-

able. Calculations for disconnecting loads are based

on battery voltage, ignition switch status, and engine

rpm. Also, a time delay is implemented for the shut-

down and reactivation of loads to avoid unnecessary

cycling of loads when battery voltage is close to

shutdown thresholds.

One minute before the comfort loads or house loads

are shut down, the alarm in the instrument cluster

beeps. No alarm sounds before basic loads are shut

down.

If the interior lights have been shut down by PLVD,

pressing one of the interior light switches (if

equipped) brings the interior lights back on.

See Table 3.1 for the type of loads shut down under

speciﬁc conditions.

See Table 3.2 for the loads that are designated com-

fort, house, and basic load status.

Type of Loads Shut Down Under Speciﬁc Conditions

Key Switch Position Engine On, Voltage less than

12.5 Volts

Engine Off, Voltage less than

12.3 Volts

Engine Off, Voltage less than

12.1 Volts

Off N/A Priority level I, II loads Priority level I, II, and III loads

Accessory N/A Priority Level I loads Priority level I, II loads

02/20/2012 f545876

1. Circuit Breaker

Removal Tool

2. Self-Resetting Circuit

Breaker

Fig. 3.5, Self-Resetting Circuit Breaker Removal

06/19/2007 f545071

Fig. 3.6, Cab Load Disconnect Switch, EPA07

05/13/2009 f545527

Fig. 3.7, Cab Load Disconnect Switch, EPA10 and

Newer

Electrical System

3.5

Type of Loads Shut Down Under Speciﬁc Conditions

Key Switch Position Engine On, Voltage less than

12.5 Volts

Engine Off, Voltage less than

12.3 Volts

Engine Off, Voltage less than

12.1 Volts

On Priority level I loads Priority Level I loads Priority level I, II loads

Start N/A N/A N/A

Table 3.1, Type of Loads Shut Down Under Speciﬁc Conditions

Designated Loads

Type of Load Function

Priority Level I

12V power receptacle 6 (sleeper, refrigerator)

Ampliﬁer power, accessory

General sleeper light

Foot well light

Reading light 1 (dimmer/theater)

Reading light 2 (dimmer/theater)

Rear baggage compartment light

12V power receptacle 5 (sleeper, cigar), battery

Auxiliary circulation fan-sleeper, battery

12V power receptacle 4 (sleeper, cigar), battery

Reading light 4 (switched locally), battery

Priority Level II

Heated seats, ignition*

Sleeper HVAC controller, accessory*

Cabin HVAC controller, accessory*

Radio, accessory (clamp 15R)

Power feed spare output I, battery

Power feed spare output III, battery

Mirror heating, passenger*

Mirror heating, driver*

Power feed spare output IV, battery

Power feed spare output II, battery

Fuel/water separator heater element, ignition*

Air dryer (pneumatic, electrically heated), accessory*

Auxiliary circulation fan-windshield, accessory*

Accessory heater power

Utility light

Dome light rear

Area lighting (lower bunk and sleeper work surface),

battery

Dome light cab, battery

Overhead compartment lights, battery

12V power receptacle 3 (sleeper, cigar), battery

Stand-alone HVAC, battery

Advertising light, accessory*

Dome light passenger

Dome light driver/forward overhead

Electrical System

3.6

Designated Loads

Type of Load Function

Priority Level III

CB radio, battery†

Fleet management system, battery†

Trailer power, battery or ignition

12V power receptacle 2 (dash, phone), battery

12V power receptacle 1 (dash, cigar), battery

*When the vehicle has Optimized Idle, these functions will not operate with the ignition switch in the accessory

position. Optimized Idle may also turn these functions off to reduce stress on the batteries. Refer to the Opti-

mized Idle section in Chapter 11 for more information.

†May or may not shut down depending on how an additional parameter is set at the factory or dealership.

Table 3.2, Load Designation

Electrical System

3.7

Instruments

Instrumentation Control Units ....................................................... 4.1

Warning and Indicator Lights ........................................................ 4.3

Instruments ...................................................................... 4.7

Driver Message Center ........................................................... 4.11

Overhead Instrument Panel ........................................................ 4.24

Instrumentation Control Units

The instrumentation control unit (ICU) provides the

driver with engine and vehicle information. It is com-

prised of standard and optional gauges, an audible

warning, a driver message center, and a lightbar con-

taining warning and indicator lamps (also known as

telltales). Warning and indicator lamps illuminate in

red (danger), amber (caution), green (status advi-

sory), or blue (high-beam headlights active).

Cascadia vehicles are equipped with an ICU3, ICU4,

ICU4M, or ICU4Me. See Fig. 4.1,Fig. 4.2, and

Fig. 4.3 for typical ICU layouts.

The following headings in this chapter provide addi-

tional information and operating instructions for ICU

components:

•"Warning and Indicator Lights"

•"Instruments"

•"Driver Message Center"

Ignition Sequence

When the ignition is turned on, the ICU runs a self-

check. See Fig. 4.4. Observing the ignition sequence

is a good way to ensure the ICU is functioning prop-

erly.

IMPORTANT: Do not crank the engine until the

ICU self-check is complete.

NOTE: Air gauges do not complete a sweep of

their dials during the ignition sequence.

When the ignition is turned on, the following actions

should occur:

•electronic gauges complete a full sweep of

their dials

09/10/2009 f610864a

1. Transmission Temperature Gauge

2. Coolant Temperature Gauge

3. Engine Oil Pressure Gauge

4. Driver Message Center

5. Fuel/DEF Level Gauge

6. Primary Air Pressure Gauge

7. Secondary Air Pressure Gauge

8. Speedometer

9. Tachometer

10. High Beam Indicator

11. Driver Display Screen

12. Mode/Reset Switch

13. Satellite Gauges

Fig. 4.1, ICU3 Instrument Cluster (EPA10 shown)

Instruments

4.1

•warning and indicator lamps illuminate, then

are extinguished

•audible alert sounds for approximately four

seconds or until sufficient air pressure builds

up in the primary and secondary air systems

•DEF level indicator illuminates all segments

green, then turns them off one at a time before

turning the leftmost segment amber and then

red

•Freightliner logo displays on the ICU4Me driver

message center for two seconds.

•software revision level of the ICU is displayed

on the driver message center, followed by any

active faults

IMPORTANT: If any red or amber warning and

indicator lamps do not illuminate during the ICU

self-check or do not go out after the self-check

completes, take the action outlined in Table 4.1,

or take the vehicle to an authorized Freightliner

service facility as soon as possible.

NOTE: If active faults are present, take the ve-

hicle to an authorized Freightliner service facility

as soon as possible.

If the ICU receives active fault codes, it displays

them one after the other until the parking brake is

released or the ignition is turned off. Once the park-

ing brake is completely released, the ICU displays

the odometer. If there are no active faults, the ICU

displays the odometer after the self-check completes.

When the self-check is complete on an ICU4M, the

fasten seat belt screen displays if the engine is off. If

the engine is running, the idle hours screen displays.

Audible Alerts

An audible alert sounds during the ignition sequence

and whenever one of the following conditions exists:

•Engine oil pressure falls below the minimum

preset value.

•Coolant temperature rises above the maximum

preset value.

f610865b

11 12

13 14

09/10/2009

NOTE: The ICU4 and ICU4M are nearly identical, with the exception of the driver message center (Item 7).

1. Battery Voltage Gauge

2. Lightbar

3. Engine Oil Pressure Gauge

4. Coolant Temperature Gauge

5. Engine Oil Temperature Gauge

6. Turbo Boost Air Pressure Gauge

7. Driver Message Center

8. Tachometer

9. Speedometer

10. Primary Air Pressure Gauge

11. Fuel/DEF Level Gauge

12. Secondary Air Pressure Gauge

13. Pyrometer

14. Rear Axle Temperature Gauge

Fig. 4.2, ICU4M Instrument Cluster (EPA10 shown)

Instruments

4.2

•Air pressure falls below approximately 70 psi

(483 kPa).

•Parking brake is set with the vehicle moving

faster than two miles per hour.

•System voltage falls below 11.9 volts.

•Door is open or the headlights are on, with the

parking brake off.

•Driver seat belt is not fastened with the parking

brake off (optional).

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

(optional).

Warning and Indicator Lights

The ICU lightbar has three or four rows of warning

and indicator lights with icon symbols, depending on

the ICU. The positions of the lights may vary for the

different ICU’s, but the telltales are standard for all

applications. See Table 4.1 for a listing of standard

and commonly used warning and indicator lamps.

06/27/2012 f611164

456

1. Engine Oil Temperature Gauge

2. Front Axle Temperature Gauge

3. Rear Axle Temperature Gauge

4. Speedometer and Coolant

Temperature Gauge

5. Fuel/DEF Level Gauge

6. Tachometer and Engine Oil

Pressure Gauge

7. Primary Air Pressure Gauge

8. Secondary Air Pressure Gauge

9. Transmission Oil Temperature

Gauge

10. Driver Message Center

Fig. 4.3, ICU4Me Instrument Cluster

IGNITION SWITCH

PARKING BRAKE

RELEASED

IF NO FAULTS

WERE DETECTED

IF FAULT DETECTED

APU 190

123456.7

12.3 VOLTS

123456.7

12.3 VOLTS

01/18/2012 f040420c

PARKING BRAKE

RELEASED

TURNED TO ON

ICU PERFORMS

SELF−TEST

Fig. 4.4, ICU Ignition Sequence

Instruments

4.3

Warning and indicator lamps illuminate in red (dan-

ger), amber (caution), green (status advisory), or

blue (high-beam headlights active).

IMPORTANT: Depending upon local jurisdic-

tional emissions guidelines, vehicles and/or en-

gines that are domiciled outside of the U.S. and

Canada may not be compliant with EPA07,

EPA10, or GHG14 regulations. Noncompliant

vehicles may not be equipped with all of the

lamps shown in Table 4.1.

Common Warning and Indicator Lamps

Lamp Description Color

STOP

STOP Engine*

Indicates a serious fault that requires engine shutdown

immediately. The engine protection system will reduce the

maximum engine torque and speed, and, if the condition

does not improve, will shut down the engine within 30 to 60

seconds.

Safely bring the vehicle to a stop on the side of the road

and shut down the engine as soon as the red light is seen.

If the engine shuts down while the vehicle is in a

hazardous location, turn the key to the OFF position for

a few seconds, then restart the engine and move the

vehicle to a safer location.

Red

High Coolant Temperature Indicates the coolant temperature is above the maximum

allowable temperature. Red

Low Air Pressure (EPA07) Indicates air pressure in the primary or secondary reservoir

has dropped below approximately 70 psi (483 kPa). Red

Low Air Pressure (EPA10

and Newer)

Indicates air pressure in the primary or secondary reservoir

has dropped below approximately 70 psi (483 kPa). Red

Low Engine Oil Pressure Indicates the engine oil pressure is below the minimum

allowable pressure. Red

Transmission Overheat Indicates high transmission temperature. Red

Transmission Fluid Level Indicates low transmission ﬂuid level. Safely bring the

vehicle to a stop as soon as possible. Red

BRAKE Parking Brake (EPA07)

Indicates the parking brake is engaged, or hydraulic brake

ﬂuid pressure is low. An audible alert activates when the

vehicle is moving over 2 mph (3 km/h) with the parking

brake set.

Red

Parking Brake (EPA10

and Newer) Indicates the parking brake is engaged. Red

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

Instruments

4.4

Common Warning and Indicator Lamps

Lamp Description Color

Unfastened Seat Belt

Activates with an audible alert when the system detects that

the parking brake is off and the driver seat belt is not

fastened on some vehicles. On other vehicles, this lamp

illuminates for 15 seconds when the ignition is ﬁrst turned

on.

Red

Check ECAS Indicates Electronically Controlled Air Suspension (ECAS)

active fault. Red

CHECK

CHECK Engine*

Indicates an engine condition (low oil pressure, low coolant

level, high coolant temperature, high DPF soot level, or

uncontrolled DPF regeneration) that requires correction.

Correct the condition as soon as possible. If the condition

worsens, the STOP engine lamp will illuminate.

Amber

High Exhaust System

Temperature (HEST)*

Slow (10-second) ﬂashing indicates a regeneration (regen)

is in progress.

IMPORTANT: When the HEST lamp is illuminated, do

not park the vehicle near ﬂammable material.

Solid illumination indicates high exhaust temperatures at the

outlet of the tail pipe when speed is below 5 mph (8 km/h).

Amber

Diesel Particulate Filter

(DPF) Status

Solid illumination indicates a regen is required. Change to a

more challenging duty cycle (such as highway driving ) to

raise exhaust temperatures for at least twenty minutes, or

perform a parked regen.

Blinking indicates that a parked regen is required

immediately. An engine derate and shutdown will occur.

Amber

Malfunction Indicator

Lamp (MIL)

Indicates an emissions-related fault. See the engine

operation manual for details. Amber

Vehicle ABS

Momentary illumination indicates the vehicle ABS is

engaged.

Solid illumination indicates a problem with the vehicle ABS.

Repair the ABS immediately to ensure full braking

capability.

Amber

Trailer ABS

Momentary illumination indicates the trailer ABS is engaged.

Solid illumination indicates a problem with the trailer ABS.

Repair the ABS immediately to ensure full braking

capability.

Amber

CHARGE No Charge Indicates the alternator is not properly powering the

electrical system. Amber

Water in Fuel Indicates the fuel may contain water. Drain any water

collected in the fuel/water separators. Amber

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

Instruments

4.5

Common Warning and Indicator Lamps

Lamp Description Color

IDLE

MGMT

Optimized Idle Indicates optimized idle is enabled. Amber

Check Transmission Indicates an undesirable transmission condition. Amber

WAIT

TO START

Wait To Start (EPA07/

EPA10)

Indicates that the system is preventing the starter from

cranking. This can occur when the ignition switch is turned

to START before the gauge sweep has completed, or if the

starter has overheated.

Turn the ignition switch back to ON, wait for the lamp to go

out, then turn the ignition switch to START again.

Amber

START

BLOCKED

Start Blocked (GHG14)

Indicates that the system is preventing the starter from

cranking. This can occur when the ignition switch is turned

to START before the gauge sweep has completed, or if the

starter has overheated.

NOTE: Illumination of the Start Blocked lamp does not

indicate a problem with the starter.

Turn the ignition switch back to ON, wait for the lamp to go

out, then turn the ignition switch to START again.

Amber

WHEEL

SPIN Wheel Spin

Flashing indicates the ATC system is active, or the ATC

button has been pressed to allow wheel slip.

Solid illumination indicates a problem with the ATC system.

Repair the ATC system immediately to ensure full braking

capability.

Amber

Roll Stability

Momentary illumination indicates that a stability event has

occurred.

On vehicles that are also equipped with ATC, ﬂashing

indicates the ATC button has been pressed to allow wheel

slip.

Amber

Hill Start Aid (HSA)

Override

Indicates the HSA switch has been pressed to override the

hill start assist feature. Amber

Outside Normal Ride

Height

Indicates the current rear suspension height is not at the

normal ride height. This light will turn off once the vehicle

returns to normal ride height.

Amber

Engine Brake Indicates the engine brake is enabled. Green

Left-Turn Signal Flashing indicates the outside left-turn signal lights are

activated. Green

Right-Turn Signal Flashing indicates the outside right-turn signal lights are

activated. Green

Instruments

4.6

Common Warning and Indicator Lamps

Lamp Description Color

Cruise Control

Indicates the cruise control is enabled.

NOTE: The ICU4Me does not have a green cruise control

telltale.

Green

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

*See Fig. 4.5 for an explanation of the aftertreatment system (ATS) warning indicators, and actions required to avoid further engine protection steps.

Table 4.1, Common Warning and Indicator Lamps

Engine Protection System

WARNING

When the red STOP engine lamp illuminates,

most engines are programmed to shut down au-

tomatically within 30 seconds. The driver must

immediately move the vehicle to a safe location

at the side of the road to prevent causing a haz-

ardous situation that could cause bodily injury,

property damage, or severe damage to the en-

gine.

See Fig. 4.5 for an explanation of the aftertreatment

system (ATS) warning indicators, and actions re-

quired to avoid further engine protection steps.

The STOP engine lamp illuminates when the engine

protection system is activated in one of two ways. On

some engines, the engine protection system will der-

ate the engine, allowing it to run at lower rpm and

slower vehicle speed. Drive the vehicle to a safe lo-

cation or to a service facility.

IMPORTANT: Safely bring the vehicle to a stop

on the side of the road and shut down the en-

gine as soon as the red light is seen. If the en-

gine shuts down while the vehicle is in a haz-

ardous location, turn the key to the OFF position

for a few seconds, then restart the engine and

move the vehicle to a safer location.

On other engines, the engine protection system will

shut down the engine. It will ﬁrst derate the engine,

then shut it down completely 30 to 60 seconds after

the indicator illuminates (depending on the critical

fault type) if the condition does not improve. Bring

the vehicle to a stop on the side of the road before

the engine shuts down.

Some vehicles may have a shutdown-override

switch, which may be used to momentarily override

the shutdown sequence. See Chapter 11 for detailed

information regarding the shutdown process.

IMPORTANT: Do not attempt to restart the en-

gine while the vehicle is moving. Bring the ve-

hicle to a safe stop, then restart the engine.

To restart the engine, turn the ignition to OFF, leave

it there a few seconds, then turn the ignition to

START. The engine will run for a short period and

shut down again if the condition does not improve.

Instruments

Standard instruments are present on every vehicle.

They are listed here in alphabetical order to make

the information easier to ﬁnd.

Optional instruments, typically located on the auxil-

iary dash panel or right-hand control panel, are not

found on every vehicle. They are listed here in alpha-

betical order, to make the information easier to ﬁnd.

Air Intake Restriction Gauge

The air intake restriction gauge indicates the vacuum

on the engine side of the air cleaner. On standard

installations, it is mounted on the air intake duct in

the engine compartment. As an option for easier

viewing, the air intake restriction indicator (see

Fig. 4.6) can be mounted on the dash, usually on the

right-hand control panel.

NOTE: Rain or snow can wet the ﬁlter and

cause a temporary high reading.

Air intake restriction vacuum is measured in inches

of water (inH

O). For vehicles equipped with a

graduated indicator or a restriction gauge on the

Instruments

4.7

dash, check the gauge with the engine off. If the yel-

low signal stays locked in the red zone once the en-

gine is shut down, or is at or above the values

shown in Table 4.2, the air cleaner element needs to

be replaced.

Vehicles may be equipped with a go/no-go restriction

indicator without graduations (see Fig. 4.7) instead of

agraduated indicator.

Air Intake Maximum Restriction Values (inH

Engine Make Pre-EPA07

Engines

EPA07 and

Newer Engines

Cummins 25 25

Detroit 20 22

Mercedes-Benz 22 22

Table 4.2, Air Intake Maximum Restriction Values

Application Air Pressure Gauge

An application air pressure gauge registers the air

pressure being used to apply the brakes, and should

be used for reference only. The gauge will not regis-

ter air pressure until the foot brake pedal is de-

pressed or the trailer hand brake is applied.

f080156

EXHAUST AFTERTREATMENT SYSTEM INFORMATION

Switch.

Level 1 Level 3Level 2 Level 4

Filter Regeneration

Recommended.

Filter is reaching

Bring vehicle to

highway speeds to

Filter

Regeneration

Filter is now

reaching maximum

capacity

To avoid engine

derate, bring vehicle

Parked Regeneration

Required − Engine

Derate

Filter has reached

maximum capacity

Vehicle must be

parked, and a Parked

Service Regeneration Required.

Engine Derate To Idle Only.

Filter has exceeded maximum

capacity.

Vehicle must be parked, and a

Service Regeneration must be

(Solid)

(Flashing) (Flashing)

CHECK

INDICATOR

LAMP(S)

Indicator Lamp

Message(s)

Diesel Particulate

Filter Condition

Required Action

capacity

STOP

allow for an

Automatic

Regeneration or

perform a Parked

to highway speeds

to allow for an

Automatic

Regeneration, or

perform a Parked

Regeneration as

soon as possible.

Regeneration must

be performed.

Engine will begin

derate.

performed. Check engine

operator’s manual for details.

Engine will shut down.

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

02/20/2009

ARNING

HEST (High Exhaust

System Temperature)

Exhaust components

and exhaust gas are at

high temperature. When

stationary, keep away

from people and

flammable materials or

vapors.

A regeneration is in

progress.

Flashing

Solid

Regeneration.

Necessary

Fig. 4.5, ATS Warning Lamps

10/10/2001 f610568

Fig. 4.6, Air Intake Restriction Indicator

Instruments

4.8

Coolant Temperature Gauge

NOTICE

A sudden increase in coolant temperature may

indicate engine or cooling system failure. Bring

the vehicle to a safe stop and investigate the

cause to prevent further damage. Do not operate

the engine until the cause has been determined

and corrected.

During normal engine operation, the coolant tem-

perature gauge should read 175 to 195°F (79 to

91°C). If the temperature remains below 160°F

(71°C), inspect the cooling system to determine the

cause.

If coolant temperature rises above the maximum

temperature listed in Table 4.3, the CHECK engine

lamp will illuminate. If the condition does not im-

prove, the STOP engine lamp will also illuminate and

an audible warning will sound. The engine will then

derate or shut down, depending on the type of en-

gine protection system installed.

Maximum Coolant Temperature

Engine Make Temperature: °F (°C)

Cummins 225 (107)

Detroit 215 (101)

Mercedes-Benz 221 (105)

Table 4.3, Maximum Coolant Temperature

Drive Axle Oil Temperature Gauges

NOTICE

A sudden increase in oil temperature that is not

caused by a load increase may indicate mechani-

cal failure. Bring the vehicle to a safe stop and

investigate the cause to prevent further damage.

Do not operate the vehicle until the cause has

been determined and corrected.

During normal operation, drive axle oil temperature

gauges should read as follows:

•160 to 220°F (71 to 104°C) for Detroit™and

Meritor™drive axles

•180 to 200°F (82 to 93°C) for Dana Spicer®

drive axles

Under heavy loads, such as when climbing steep

grades, temperatures that exceed the normal oil tem-

perature range for a short period are not unusual. If

the temperature returns to normal when the load de-

creases, there is no problem.

Engine Oil Pressure Gauge

NOTICE

A sudden decrease or absence of oil pressure

may indicate mechanical failure. Bring the vehicle

to a safe stop and investigate the cause to pre-

vent further damage. Do not operate the engine

until the cause has been determined and cor-

rected.

The engine oil pressure gauge displays the current

engine oil pressure. If engine oil pressure falls below

the minimum levels shown in Table 4.4, the CHECK

engine lamp will illuminate. If the condition does not

improve, the STOP engine lamp will also illuminate

and an audible warning will sound. The engine will

then derate or shut down, depending on the type of

engine protection system installed.

Minimum Oil Pressure*

Engine Model At Idle Speed:

psi (kPa)

At Rated RPM:

psi (kPa)

Cummins 15 (103) 35 (241)

Detroit 14 (97) 55 (350)

04/08/2005 f090431

Fig. 4.7, Manual-Reset Air Restriction Indicator, Go/

No-Go

Instruments

4.9

Minimum Oil Pressure*

Engine Model At Idle Speed:

psi (kPa)

At Rated RPM:

psi (kPa)

Mercedes-Benz 7 (50) 36 (250)

*Oil pressures are given with the engine at operating temperature. With

the engine cold, oil pressure may be higher. Individual engines may vary

from the listed pressures; observe and record pressures when the engine

is new to create a guide for checking engine condition.

Table 4.4, Minimum Engine Oil Pressure

Engine Oil Temperature Gauge

NOTICE

A sudden increase in oil temperature that is not

caused by a load increase may indicate mechani-

cal failure. Bring the vehicle to a safe stop and

investigate the cause to prevent further damage.

Do not operate the engine until the cause has

been determined and corrected.

During normal operation, the optional engine oil tem-

perature gauge should read:

•200 to 260°F (93 to 126°C) for Detroit and

Cummins engines

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

engines

Under heavy loads, such as when climbing steep

grades, temperatures that exceed the normal oil tem-

perature range for a short period are not unusual. If

the temperature returns to normal when the load de-

creases, there is no problem.

Fuel Gauge, Pre-EPA10

The fuel gauge indicates the level of fuel in the fuel

tank(s). A single fuel gauge is standard. If equipped

with an optional second fuel tank, each fuel tank

level is indicated on a separate gauge.

Fuel/Diesel Exhaust Fluid (DEF)

Gauge, EPA10 and Newer

For engines that are EPA10-compliant or newer, the

fuel and DEF levels are measured in a dual purpose

fuel/DEF level gauge. See Fig. 4.8.

The diesel fuel level is indicated at the top of the

gauge, with a low-fuel warning lamp that illuminates

amber when the diesel fuel level registers 1/8th of

capacity.

The DEF level is indicated in the lightbar on the

lower portion of the gauge. There is a low DEF level

warning lamp that illuminates amber when the DEF

level reaches 10% of capacity. See Chapter 12 for

details of the DEF gauge functions.

Primary and Secondary Air Pressure

Gauges

WARNING

If air pressure falls below minimum pressure, the

braking ability of the vehicle will be limited. Slow

the vehicle down and bring it to a gradual stop.

Do not attempt to move the vehicle until air pres-

sure has risen above the minimum level. Moving

a vehicle without adequate braking power could

cause an accident resulting in property damage,

personal injury, or death.

Air pressure gauges register the pressure in the pri-

mary and secondary air systems. Normal pressure,

with the engine running, is 100 to 120 psi (689 to

827 kPa) in both systems.

A low-air-pressure warning light and audible alert,

connected to both the primary and secondary sys-

tems, activate when air pressure in either system

drops below approximately 70 psi (483 kPa).

08/21/2009

1/2

ULTRA LOW SULFUR

DIESEL FUEL ONLY

DEF

f611045

1. Diesel Fuel Level Indicator

2. DEF Level Indicator

3. Low DEF Warning Lamp (amber below 10% DEF)

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

Fig. 4.8, Fuel/DEF Gauge, EPA10 and Newer

Instruments

4.10

When the engine is started, the warning light and

audible warning remain on until air pressure in both

systems exceeds minimum pressure.

Speedometer

Two speedometer options are available. The U.S.

version of the speedometer registers speed in both

miles per hour (mph) and kilometers per hour (km/h),

with mph in larger numbers. The metric version of

the speedometer face reverses this arrangement,

with km/h in larger numbers.

Tachometer

The tachometer indicates engine speed in revolutions

per minute (rpm) and serves as a guide for shifting

the transmission and keeping the engine in the ap-

propriate rpm range. For low idle and rated rpm, see

the engine identiﬁcation plate.

Transmission Fluid Temperature

Gauge

The transmission ﬂuid temperature gauge indicates

the transmission lubricant operating temperature.

Temperatures vary by application, but the transmis-

sion ﬂuid temperature gauge reading should not ex-

ceed 250°F (121°C).

NOTICE

A sudden increase in transmission ﬂuid tempera-

ture that is not caused by a load increase may

indicate mechanical failure. Bring the vehicle to a

safe stop and investigate the cause to prevent

further damage. Do not operate the vehicle until

the cause has been determined and corrected.

Under heavy loads, such as when climbing steep

grades, temperatures that exceed the normal oil tem-

perature range for a short period are not unusual. If

the temperature returns to normal when the load de-

creases, there is no problem.

Turbocharger Boost Pressure Gauge

A turbocharger boost pressure gauge indicates the

pressure in the intake manifold, in excess of atmos-

pheric pressure, being created by the turbocharger.

Voltmeter

The voltmeter indicates the vehicle charging system

voltage when the engine is running and the battery

voltage when the engine is off. By monitoring the

voltmeter, the driver can stay aware of potential bat-

tery charging problems and have them ﬁxed before

the batteries discharge enough to create starting diffi-

culties. Cascadia vehicles are equipped with either a

voltmeter gauge, or a digital voltmeter readout lo-

cated on the bottom line of the dash message center.

The voltmeter will normally show approximately 13.7

to 14.1 volts when the engine is running. The voltage

of a fully charged battery is 12.7 to 12.8 volts when

the engine is off. Battery voltage under 12.0 volts is

considered a low battery, and a completely dis-

charged battery will produce only about 11.0 volts.

If the voltmeter shows an undercharged or over-

charged condition for an extended period, have the

charging system and batteries checked at an autho-

rized Freightliner service facility.

On a vehicle equipped with a battery isolator system,

the voltmeter measures the average voltage of all the

batteries when the engine is running. When the en-

gine is off, the voltmeter shows only the isolated bat-

tery voltage and does not indicate the voltage of the

engine-starting batteries.

Driver Message Center

ICU3/ICU4

The driver message center is controlled using the

mode/reset switch, located on the right side of the

ICU, and the +and –buttons mounted in the right-

hand pod of the steering wheel (Fig. 4.9). See

Fig. 4.1 and Fig. 4.9. Tap the mode/reset switch or

the +switch to advance one screen; press and hold

either switch to select a menu choice or reset the

display. When the display resets, an audible chirp

sounds.

Four driving screens are accessible when the parking

brake is off. All screens and menus are accessible

when the parking brake is on (parked screens).

Driving Screens

The following screens are available when the parking

brake is off (when the vehicle is mobile) and no ac-

tive fault codes are found. Use the +and –switches

on the steering wheel, or the mode/reset switch, to

Instruments

4.11

scroll through the screens. To reset any values,

press and hold the +switch or the mode/reset

switch. The driving screens appear in the following

order:

i. Odometer

ii. Trip distance

iii. Trip hours

iv. Outside temperature

Parked Screens/Menus

The following screens and menus are available when

the parking brake is on (when the vehicle is parked)

and no active fault codes are found. Use the +and –

switches on the steering wheel, or the mode/reset

switch, to scroll through the driving screens. To reset

any values, press and hold the +switch or the mode/

reset switch. See Fig. 4.10. The parked screens ap-

pear in the following order:

i. Odometer

ii. Trip distance

iii. Trip hours

iv. Outside temperature

v. Temperature alert

vi. Diagnostics

vii. Clear screen (on vehicles with less than 255

miles on the odometer)

viii. Engine miles/hours

ix. Setup

Temperature Alert

When the outside temperature drops to 35°F (1.7°C)

or less, the ICU displays a caution text at one-

second intervals for ﬁve seconds, and an audible

alert sounds. Tap the +or –switch on the steering

wheel, or the mode/reset switch, to acknowledge the

message. The audible alert will not sound again un-

less the temperature cycles above 37°F (4°C) and

back to 35°F (1.7°C) or less. This warning only oc-

curs while the ignition is on and the parking brake is

released.

The temperature alert message allows the driver to

enable or disable the ambient temperature warning.

Press and hold the mode/reset switch to toggle be-

tween on and off. Release the mode/reset switch,

then tap it to select the displayed choice.

Diagnostics

When the DIAG screen is displayed, press and hold

the mode/reset switch to access the various diagnos-

tic screens. See Fig. 4.11 for a diagram of the diag-

nostic screens.

The diagnostic screens are used by trained techni-

cians to retrieve fault codes and other diagnostic in-

formation pertaining to the vehicle. If active fault

codes display during start-up or at any other time,

make a note of the fault code and take the vehicle to

an authorized Freightliner service facility

If fault codes are displayed, press and hold the

mode/reset switch to view the next fault code until

reaching the DIAG screen.

Engine Miles/Hours

When the engine miles/hours screen is displayed,

press and hold the mode/reset switch to access the

engines screen submenu. See Fig. 4.11 for a dia-

gram of the engine screens.

MRKR

INT

ENG

BRK

−

02/06/2007 f462061

NOTE: To reset values in the ICU4M and ICU4Me driver

message centers, press and hold the +switch.

Fig. 4.9, Steering Wheel-Mounted Switches

Instruments

4.12

Setup

The setup menu allows the driver to manage ICU

parameters. The setup screen submenu allows the

driver to enable and change service intervals. See

Fig. 4.12.

If service intervals are enabled and service distance

or time has been exceeded, the text SERVICE

HOUR/MI (KM) will display at start-up to indicate ve-

hicle service is required.

For each parameter, press and hold the mode/reset

switch to navigate to the parameter change screen.

In each change screen, tap the mode/reset switch to

toggle between options.

Use the last screen in the setup menu, RESET EE,

to reset the parameters the ICU learns back to the

default settings. Press and hold the mode/reset

switch to reset the following learned parameters:

•automated transmission display

•seat belt switch learning

•engine oil level

•other electronic devices that have been re-

moved from the vehicle (e.g. Qualcomm)

ICU4M

Functions

ICU4M settings and the driver message center are

controlled with the +and –switches and the MY

INFO switch, mounted on the dash. See Fig. 4.13.

Tap the MY INFO switch to drill down from each

main screen to the submenus contained within it.

Use the +and –switches to scroll through screens

and select options. Tap the MY INFO switch again to

exit each change screen.

With the parking brake off, only the odometer and

alert messages can be displayed. Park the vehicle

and set the parking brake to access the parked

screens and menus.

01/30/2012 f040754

123456.7

TRIP MI

12.3 VOLTS

Tap

123456.7

12.3 VOLTS

Tap

123456.7

TRIP HOURS

12.3 VOLTS

ALrt

123456.7

HOURS

ENGINE

oiL

*Lo

SEtUP

**MI **HOURS

**no

To reset trip miles

Press & Hold

To reset trip hours

Press & Hold

Display service

interval screens

Press & Hold

Tap

To toggle ON

*Lo = Oil Level Low

HI = Oil Level High

Blank = Oil Level OK

− − = No Message

**MI = Miles Interval Mode

**HOURS = Hours Interval Mode

**no = Service Interval Inactive

dIAG

MI HOURS

Display diagnostics

Press & Hold

n = Number of Active Fault Codes

MI = Miles Interval Mode

HOURS = Hours Interval Mode

°t

ENGINE

Tap

12.3 VOLTS

56°F

OFF

Odometer

To display total

engine miles/hours

Note: The engine oil level screen displays for Mercedes-Benz engines only (if equipped and enabled).

Fig. 4.10, ICU3 Parked Screens

Instruments

4.13

Alert Messages

The driver message center displays alert messages

when certain conditions occur. They are warnings,

cautions, or other messages that require the driver’s

attention, but not all of them are critical to the opera-

tion of the vehicle.

NOTE: If there is more than one alert message

to display, tap the +switch or the MY INFO

switch to access the next message, and so on,

until all messages have been viewed.

More important messages take priority over less im-

portant messages. The order of priority is:

1. parking brake set (with the vehicle moving)

2. parking brake off (with the door open)

3. low oil pressure or high coolant temperature

4. hard brake warnings (if equipped with roll stabil-

ity advisor)

5. low battery voltage

6. ambient temperature below 35°F (1.7°C)

7. turn signal on

8. incoming instant or Qualcomm messages

9. service warnings

f040802

From Temp Alert Screen

Press & Hold

Tap

Press & Hold

Tap

Press & Hold

Tap

n = Number of

Active Fault Codes

dlAG

*FAULT

*If fault goes inactive,

display "noFault 1"

*FAULT

*If fault goes inactive,

display "noFault n"

To Setup Screen (or Oil

Level Screen, if equipped)

Press & Hold

AbS 11 ECU 0

Tap Tap

Press & Hold

123456

Tap Tap

Press & Hold

FAIL 03 FAIL 00

Tap Tap

SPN SPN

123456

01/31/2012

Fig. 4.11, ICU4 Diagnostic Screens

Instruments

4.14

10. no datalink activity Incoming Message

On vehicles with a Qualcomm onboard communica-

tions system, a notiﬁcation appears on the driver

message center whenever a message is received.

Selection?

To toggle

HOURS

NOTE:

* Flash screen text

**Display active mode

Select NO

to disable

Service Intervals

Press & Hold to reset all

Service Interval counters

To toggle

Tap

To toggle

HRS

Tap

TapTap

Tap Tap Tap

Tap

TapTap

Press & Hold

Press & Hold Press & Hold Press & Hold

Press & HoldPress & Hold

Press & Hold

SET UP SELECT

*MI

SET UP

WARN°T

*on

LCD LMP

*on

**MI **HOURS

**no

RESET

**MI **HOURS

*no

SELECT

*MI *HOURS

*no

SERVICE SERVICE SERVICE

*12345

SERVICE

*12345

HOURS

SERVICE

RESET

DONE

f040755

01/30/2012

OFF

ON OFF

To Odometer

From Engine

Miles/Hours Screen

Fig. 4.12, ICU4 Setup Screens

Instruments

4.15

NOTE: The incoming message screen also dis-

plays during the ignition sequence if a message

is available.

This message displays for a preset time period, then

returns after a preset interval until it is dismissed by

the +and –switches or the MY INFO switch.

Parking Brake On

This warning message and an audible warning come

on whenever the parking brake is applied and the

vehicle is moving faster than 2 mph (3 km/h). See

Fig. 4.14. The screen and audible warning go away

only when the parking brake is released, or speed is

reduced below 2 mph.

Low Oil Pressure

This warning message and an audible warning come

on whenever the oil pressure falls below the mini-

mum oil pressure, whether the vehicle is idling or in

motion. Tap the +and –switches or the MY INFO

switch to dismiss the message.

If low oil pressure is detected during the ignition se-

quence, it displays as an active fault instead of an

alert message. After 30 seconds, the message dis-

plays again.

High Coolant Temp

This message and an audible warning come on

whenever the engine coolant temperature exceeds

the maximum allowable temperature.

If high coolant temperature is detected during the

ignition sequence, it displays as an active fault in-

stead of an alert message. After 30 seconds, the

message displays again.

Low Voltage

On some vehicles, this optional message and an au-

dible warning come on whenever a low voltage con-

dition is detected.

Turn Signal On

This warning message and audible warning come on

whenever the turn signal remains on for four minutes

or ﬁve miles of travel. To dismiss this message, ei-

ther turn off the turn signal or tap the +and –

switches or the MY INFO switch.

Air Temperature

When the outside air temperature drops below 35°F

(1.7°C), a warning text is displayed at one-second

intervals for ﬁve seconds, and an audible warning will

sound. Tap the +and –switches or the MY INFO

switch to acknowledge the warning. The alert mes-

sage will not occur again unless the temperature

cycles above 37°F (4°C) and back below 35°F

(1.7°C). This warning only occurs while the ignition is

on and the parking brake is off.

Service Warnings

Service warning alerts display during the ignition se-

quence and indicate if a service interval has been

reached or exceeded and maintenance is required.

The messages may indicate the number of miles

(KM) or hours until the next required service or, once

passed, the number of miles (KM) or hours since

maintenance should have been performed.

Automated Transmission Display

The ICU4M can display current gear information for

vehicles with an automated transmission. The last

three digits at the far right on the lower line of the

driver message center are reserved for this informa-

tion.

02/22/2007

INFO

f610887a

Fig. 4.13, MY INFO Switch

f601414

WARNING

PARK BRAKE ON

06/21/2007

Fig. 4.14, Parking Brake On Alert Message

Instruments

4.16

When a shift request is made by the driver, an up or

down arrow is also displayed, depending on the shift

direction.

For more information about speciﬁc models of auto-

mated transmissions, see Chapter 15.

Driving Screens

The following screens are available when the parking

brake is off (when the vehicle is mobile).

Tap the MY INFO switch to drill down from each

main screen to the submenus contained within it.

Use the +and –switches to scroll through screens

and select options. Tap the MY INFO switch again to

exit each change screen. See Fig. 4.15.

i. Fasten seat belt (rpm<100)

ii. Fuel economy (rpm>100)

iii. Odometer

iv. Trip distance/hours

v. Trip advisory

vi. Leg distance/hours

vii. Leg advisory

viii. Fuel used/average MPG (KM/L)

ix. Outside air temperature

Favorite Screen

The driver can set a favorite driving screen using the

MY INFO switch. Press and hold the lower half of the

MY INFO switch for just over one second to set the

current screen as the favorite screen. A chirp will

sound to verify the screen has been set.

Tap the lower half of the MY INFO switch to access

the favorite screen. Tap the MY INFO switch again to

leave the favorite screen.

NOTE: Only driving screens can be set as the

favorite screen.

Parked Screens/Menus

Tap the MY INFO switch to drill down from each

main screen to the submenus contained within it.

Use the +and –switches to scroll through screens

and select options. Tap the MY INFO switch again to

exit each change screen. Press and hold the +

switch or the upper half of the MY INFO switch to

reset the counters for trip and fuel information.

The following screens are available when the parking

brake is on (when the vehicle is parked). See

Fig. 4.16.

i. Odometer

ii. Trip information including trip miles/hours, idle

hours, average speed, leg miles/hours

iii. Fuel information including fuel used, fuel

economy, idle/PTO fuel usage

iv. Engine information including engine miles/hours,

engine/PTO gallons, oil level

v. Diagnostic information

vi. Service information including mileage or time to

next service

vii. Setup information

−

−0%III +

10.5 MPG 23456.7 MI

TRIP MILES 123456.7

TRIP HR 1234:56

TRIP ADVISORIES

123 ROLL 456 BRK

LEG MILES 123456.7

LEG HR 1234:56

LEG ADVISORIES

123 ROLL 456 BRK

FUEL USED 12345.6

AVG MPG 12:34

OUTSIDE AIR

TEMPERATURE 56F

01/30/2012 f545600a

dto

et.

KEY

LEA

onf

mat

een

ill

ght afte

the f

tho

My Info

Odometer

Fig. 4.15, ICU4M Driving Screens

Instruments

4.17

viii. Vehicle information including Datalink status, ICU

serial number, software version

ix. Outside air temperature

x. Fasten seat belt warning

Trip Information

Trip Information displays the trip miles, trip adviso-

ries, idle hours, leg miles, and leg advisories, in that

order.

Fuel Information

Fuel information displays total fuel usage since the

last reset, fuel mileage, and fuel consumed while

idling or running the PTO, in that order.

Engine Information

Engine information displays engine mileage and

hours, and total fuel consumption, in that order.

Diagnostic Information

If active fault codes are displayed on the diagnostic

information screens, make a note of the fault code

and text message, then take the vehicle to an autho-

rized Freightliner service facility See Fig. 4.17 for a

diagram of the diagnostic information screens.

Service Information

The Service Information menu displays the next ser-

vice interval, expressed in either miles or hours. See

Fig. 4.17. Service intervals can also be deactivated.

For programming service intervals, see Setup Infor-

mation, below.

NOTE: If the vehicle has exceeded the service

interval, the miles(km)/hours remaining screen

is replaced by the service was due screen, fol-

lowed by the number of miles(km)/hours since

the service was due.

IDLE HOURS 1234:56

12.3 GAL 123456.7 MI

−

− −

−

− − −

TRIP

INFORMATION

FUEL

INFORMATION

ENGINE

INFORMATION

TRIP MILES 123456.7

TRIP HR 1234:56

TRIP ADVISORIES

123 ROLL 456 BRK

IDLE HOURS 1234:56

AVG MPH 12.3

LEG MILES 123456.7

LEG HR 1234:56

LEG ADVISORIES

123 ROLL 456 BRK

FUEL USED 12345.6

AVG MPG 12:34

IDLE GALLONS 12345.6

PTO GAL 12345.6

ENG MILES 1234567.8

ENG HOUR 1234:56

ENG GALLONS 123456.7

PTO GAL 123456.7

OIL LVL

*Lo

f545600b

−

01/30/2012

−

ENGINE

PER

*Lo ENGINE

dto

et.

KEY

LEA

onf

mat

een

ill

ght afte

the f

tho

My Info

Odometer

To Diagnostic Information Screen

Fig. 4.16, ICU4M Idle Hours, Trip Information, Fuel Information, and Engine Information Screens

Instruments

4.18

Setup Information

The Setup Information menu allows the driver to pro-

gram various features of the ICU4M. See Fig. 4.18.

The setup features include:

1. Service intervals (OFF/MILES/HOURS)

2. Outside temperature warning (ON/OFF)

3. Target MPG

4. LCD lamp (ON/OFF)

5. Driver message center brightness

6. Language (English/French/Spanish)

7. Units of measurement (English/Metric)

8. Driver select (ON/OFF)

9. Reset parameters to original settings

Vehicle Information Screens

The vehicle information screens display hardware

and software information, including the Freightliner

part number and switch ID of the ICU. See Fig. 4.19.

ICU4Me

Functions

ICU4Me settings and the driver message center are

controlled using the ICU4Me control switch located

on the dash, and the +and –switches mounted in

the right-hand pod of the steering wheel. See

Fig. 4.20 and Fig. 4.9.

The driver message center is divided into four sec-

tions. The odometer and cruise control status ﬁeld

are displayed along the bottom of the message cen-

ter. When cruise control is active, the cruise control

123456.7

SA(

)SA

(

)

LAST OCCUR 123456.7

1234 TI

FIRST OCCUR 123456.7

1234 TI

faults when odo

eter is

254

LES

VAL

SSE

LES

HOLD

TO CLEAR

DASH FAULTS

LES AGO

SA(

)SA

####

(

)

2SecTi

eout

This will also clear other vehicle ECU’s inactive

If overdue:

dto

et.

KEY

LEA

onf

mat

een

ill

ght afte

the f

tho

−−

−

−−

−

−− −

12345

12345 12345

f54560101/30/2012

My Info

From Engine Information Screen

To Setup Screen

Fig. 4.17, ICU4M Diagnostic Information and Service Information Screens

Instruments

4.19

status ﬁeld displays relevant cruise control icons and the set speed. If the vehicle is equipped with a

01/30/2012

SETUP

INFORMATION

−

PUSH KEY TO

Note: If parking brake is released while in stationary screens,

the display will return to the bar graph screen.

* = Indicates flashing text

= My Info

Press to toggle between selections

Miles or Hours

Press to set service interval

Press to toggle On Off

Press to toggle Yes No

Press to increase target MPG

Press to decrease target MPG

Press to increase brightness

Press to decrease brightness

Press to toggle between selections

Off

SERVICE INTERVAL

PUSH KEY TO

CHANGE SERV MI

PUSH KEY TO

CHANGE TEMP WARN

PUSH KEY TO

CHANGE TARGET MPG

PUSH KEY TO

INTERVAL *2000 MILES

− LESS MORE +

TEMPERATURE WARNING

− OFF * ON +

LCD LAMP

− OFF * ON +

TARGET MPG *8.5

− LESS MORE +

CHANGE LCD LAMP

CHANGE BRIGHTNESS

CHANGE LANGUAGE

DISPLAY BRIGHTNESS

− DARK LIGHT +

LANGUAGE: *ENGLISH

FRENCH / SPNISH

CHANGE UNITS

CHANGE DRIVER SEL

RESET PARAMETERS

UNITS

*ENGLISH / METRIC

DRIVER SELECT

− OFF * ON +

RESET PARAMETERS

− *NO YES +

f544963a

OFF/*MILES/HOURS

CHANGE SERVICE

Vehicle Information

Screen

−

Fig. 4.18, ICU4M Setup Information Screens

Instruments

4.20

manual transmission, time and temperature are dis-

played in the top left corner of the driver message

center. The message ﬁeld displays the driving

screens and alert messages. See Fig. 4.21.

If the vehicle is equipped with an automated trans-

mission, the gear display is located in the top left

corner of the driver message center. Time and tem-

perature are displayed in the message ﬁeld, unless

an alert message is active or a driving screen has

been selected. The odometer and cruise control sta-

tus ﬁeld are displayed along the bottom of the mes-

sage center. See Fig. 4.22. For information about

transmission display options, see Chapter 15.

Alert Messages

Alert messages are displayed in the message ﬁeld to

notify the driver when certain conditions occur. They

include warnings, cautions, and other messages that

require the driver’s attention. Not all alert messages

are critical to the operation of the vehicle. More im-

portant messages take priority over less important

messages.

NOTE: All alert messages follow the format

shown in Fig. 4.23.

Press the +switch to acknowledge alert messages

and revert to the previously displayed driving screen.

−−

VEHICLE

INFORMA

TION

DASH

123

−

12345

−

123

SW VER

Setup Information

Outside

Air

emp

03/30/2010 f040803

Fig. 4.19, ICU4M Vehicle Information Screens

f61117304/03/2012

Back

Fig. 4.20, ICU4Me Control Switch

06/26/2012 f611166

5555555 mi

1/7

77° F

Trip MPG: 5.6

015

65 mph

1. Temperature and Compass

2. Message Field

3. Cruise Control Status Field

4. Odometer

Fig. 4.21, Driver Message Center Without Gear Display,

ICU4Me

1/7

77 °F

06/26/2012 f611165

A econ

5555555 mi

65 mph

1. Gear Display

2. Temperature and Compass

3. Cruise Control Status Field

4. Odometer

Fig. 4.22, Driver Message Center with Gear Display,

ICU4Me

Park Brake On!

06/12/2012 f611192

A econ

5555555 mi

Fig. 4.23, Parking Brake Alert Message

Instruments

4.21

The following alert messages will repeat intermittently

until the condition is eliminated:

•turn signal on

•low voltage

•no datalink

•low transmission air pressure (Detroit transmis-

sions only)

Driving Screens

With the parking brake off, only the driving screens

are available. Use the +and –switches on the steer-

ing wheel to scroll through the driving screens; see

Fig. 4.24. To reset any values, press and hold the +

switch.

•Temperature

•MPG information

•Trip information

•Leg information

•Gauge display (if selected)

•Predictive Cruise Control (optional)

•Enter parked menus

Parked Screens/Menus

Park the vehicle and set the parking brake to access

the parked menus and submenus. See Fig. 4.25.To

reset values in any of the menus, press and hold the

+switch.

•Trip information

•Fuel information

•Engine information

•Diagnostics

•Service information

•Settings

•ICU Information

A small numerical fraction is displayed in the upper

right-hand corner of each screen to indicate the num-

ber of available screens or options to scroll through.

See Fig. 4.26. Press the upper half of the ICU4Me

control switch to select a menu choice. Press the

lower half of the control switch to back out of a se-

lected menu or submenu. Use the +switch to scroll

up, and the –switch to scroll down.

Time &

Temperature

MPG

Information

−

Trip

Information

Enter to

Stationary

−

Gauge

Display

Screens

Leg

Information

Predictive

Cruise

Control (opt)

−

06/21/2012 f040823

−

(if selected)

Use the +and –switches on the steering wheel to

navigate through the driving screens.

Fig. 4.24, Driving Screen Navigation, ICU4Me

−

06/26/2012 f040824

Trip Info

Fuel Info

Engine Info Diagnostics Service

Settings

ICU Info

Use the +and –switches on the steering wheel to

navigate through the parked menus.

Fig. 4.25, Parked Menus, ICU4Me

Instruments

4.22

When navigating the parked menus, the left side of

the driver message center displays a "breadcrumb

menu" to show the order of menus and submenus

that have been selected during the current naviga-

tion.

Trip Information

The ICU can record data for one trip segment and

one leg segment. When trip information is reset, all

the leg information is reset as well.

Fuel Information

Using this menu, the driver can view the total fuel

used since the last reset, the total idle gallons used

since the last reset, and the average MPG since the

last reset.

Engine Information

Using this menu, the driver can view engine miles,

engine hours, gallons used, PTO hours, and PTO

gallons. Engine oil level is optional for Detroit en-

gines. The information contained in the Engine Infor-

mation screens cannot be reset.

Diagnostics

Active and historical faults are displayed in the diag-

nostics menu. See Fig. 4.27. If there are any active

faults, the total number of faults is displayed in pa-

renthesis next to the affected controller. To view spe-

ciﬁc active faults, press the upper half of the ICU4Me

control switch on the dash. Press the upper half of

the ICU4Me control switch to toggle between the text

description and the failure code for each selected

fault.

Service Information

Using this menu, the driver can enable, disable, and

set service intervals for engine miles or engine

hours. After enabling service intervals, select interval

unit (miles or hours), and the interval duration.

Settings

The settings menu contains the controls for the fol-

lowing settings:

•Display (includes brightness, contrast, display

light, and night mode settings)

•Gauge select

•Language

•Self-test

•Temperature warning enable/disable

•Units

The Gauge Select submenu allows the driver to se-

lect certain gauge values for display in the message

ﬁeld while driving. See Fig. 4.28. Use the +and –

switches on the steering wheel to scroll through the

list of available gauges, then press the upper half of

the ICU4Me control switch to select a desired gauge.

The ICU4Me control switch can also be used to un-

check boxes if necessary.

1/3

Miles:

Gallons:

BACK

Avg. MPG:

Trip Info

Trip

123456.7

123.4

1/2

Trip

Leg

BACK

Trip Info

1/7

Trip Info

Fuel Info

Engine Info

BACK

Indicates when to press

the MENU BACK switch

Indicates when to press

the ENTER switch

06/21/2012 f611193

Fig. 4.26, Parked Menu Navigation, ICU4Me

Instruments

4.23

ICU Information

The ICU Information screen displays the part num-

bers for the instrument cluster and software.

Overhead Instrument Panel

The optional overhead instrument panel may hold a

citizen’s band (C/B) radio and any switches that can

not be accommodated on the driver’s or auxiliary

dash panels.

The underside of the overhead console also holds

the sun visors and the optional dome/reading light

asssembly. See Chapter 5 for more information on

the dome/reading light assembly.

1/3

Accelerator Pedal

Problem Detected

Diagnostics

BACK

Active

Engine (3)

1/3

ABS (1)

Engine (3)

BACK

1/2

Active (12)

Historic (0)

BACK

Indicates when to press

the MENU BACK switch

Indicates when to press

the ENTER switch

05/30/2012 f611194

Diagnostics

MSF (1)

Diagnostics

Active

Fig. 4.27, Diagnostics Menu Navigation, ICU4Me

06/26/2012 f611195

1/6

Axle Temp

Air Pressure

Engine Oil Temp

Settings

Gauge Disp. x

Fig. 4.28, Selecting Gauges to Display, ICU4Me

Instruments

4.24

Driver Controls

Ignition Switch and Key ............................................................ 5.1

Lighting Controls .................................................................. 5.2

Horn Controls .................................................................... 5.7

Powertrain Controls ............................................................... 5.7

Cruise Control ................................................................... 5.11

Dash-Mounted Brake Controls ...................................................... 5.14

Windshield Wiper/Washer Controls .................................................. 5.15

Suspension/Trailer Connection Controls .............................................. 5.16

Climate Controls ................................................................. 5.17

Seat Controls ................................................................... 5.19

Adjustable Steering Column Controls ................................................ 5.20

Ignition Switch and Key

The ignition switch is located on the left-hand dash,

below the headlight switch. See Fig. 5.1.

The ignition switch has four positions: OFF, ACC (ac-

cessory), ON, and START. See Fig. 5.2.

In the OFF position, the ignition switch is vertical.

The key can be inserted and removed only in the

OFF position.

The following functions are operable when the igni-

tion switch is in the OFF position (regardless of

whether the key is inserted):

•low-beam headlights

•taillights

•brake lights

•road lights

•dome lights

•clearance lights

•hazard warning lights

•utility lights

•baggage compartment lights

•spotlights

•electric horn

•clock

•refrigerator

•CB radio

•power mirrors

•power receptacle

•fuel heater

•electric oil pan heater

•electric or diesel-ﬁred engine coolant pre-

heater

Turn the key counterclockwise to reach the ACC po-

sition. In addition to all the functions that are oper-

able in the OFF position, the following functions are

operable when the switch is in the ACC position:

•radio/stereo system

•heater and A/C fan

•mirror defog

•windshield fan

•ether start system

•air dryer

•backup lights

Turn the key clockwise past the OFF position to

reach the ON position. With the switch in the ON po-

sition, all electrical systems become operable and

04/30/2007

f610916

1. Headlight Switch 2. Ignition Switch

Fig. 5.1, Left-Hand Dash

07/19/2006 f610805

Fig. 5.2, Ignition Switch

Driver Controls

5.1

the warning and indicator lamps illuminate. Wait for

three seconds before starting the engine.

The SAM Cab vehicle controller automatically cycles

all exterior lights off and then on when the head-

lamps are on and the park brake is released, or set.

This rapid ﬂash of the exterior lights is a self-test to

detect any bulb that is not operational. Drivers may

notice all lights ﬂash simultaneously during this pro-

cess. This is the normal operating sequence. A fault

code is set for any bulb that is out.

IMPORTANT: Do not crank the engine until the

ICU self-check is complete.

Turn the key clockwise past the ON position to reach

the START position to start the engine. Release the

key the moment the engine starts. Do not operate

the starter longer than thirty seconds, then allow the

starter to cool between attempts. If the starter over-

heats, the starter protection system will prevent op-

eration of the starter until it has cooled. Release the

key the moment the engine starts.

The ignition key also locks and unlocks the cab

doors, the baggage door(s) and if equipped, the bunk

door(s).

Lighting Controls

IMPORTANT: Unless otherwise noted below,

press the upper half of the switch to activate the

desired light(s). Press the lower half of the

switch to turn the light(s) off.

Exterior Lighting Controls

Exterior light controls are listed here in alphabetical

order. See Fig. 5.3 for exterior light locations.

Auxiliary High Beam Lights

Auxiliary high-beam lights may be located in the front

bumper. To activate the auxiliary high beam lights,

press the upper part of the dash switch. The auxiliary

high beam lights will illuminate only when the high-

beam headlights are on. They will switch off tempo-

rarily when the low-beam headlights are on, until the

high beams are on again. Press the lower half of the

switch to deactivate it. See Fig. 5.4.

Backup Lights

Backup lights activate only when the vehicle is in re-

verse, and are designed to be used while backing up

at night.

Daytime Running Lights

The daytime running lights (DRL), if equipped, are

automatically activated when the ignition is switched

on and the parking brake is released. The DRL turn

off when the engine falls below 400 rpm, the parking

brake is applied, or the headlights are turned on.

Daytime running lights are mandatory for vehicles

domiciled in Canada. Vehicles domiciled in any other

location may have an optional override switch

(Fig. 5.4, ref. 2). This is a momentary switch that en-

ables the driver to deactivate the DRL. Press the

upper half of the switch brieﬂy to activate or deacti-

vate the DRL.

Fog Lights

Fog lights are designed to reduce glare in foggy con-

ditions. The low-beam headlights must be on in order

to turn the fog lights on. Pull the headlight switch out-

ward to activate the fog lights.

Hazard Warning Lights

The hazard warning light switch is located on the

dash in what is referred to as the master module.

See Fig. 5.5. The hazard lights can be activated re-

gardless of the ignition switch position.

To activate the hazard lights, press the center of the

switch once. The switch will blink at the same rate

that the hazard lights ﬂash. Press the switch again to

turn them off. All the turn signals on the vehicle and

trailer, as well as the turn signal indicators in the

ICU, ﬂash simultaneously when the hazard lights are

activated.

Headlights

The headlight switch is a rotary switch located to the

left of the steering column, above the ignition switch.

See Fig. 5.6.

If the Follow Me Home feature is activated, the low-

beam headlights will remain on for nine seconds

after the vehicle is parked, if the headlights were on

prior to engine shutdown. This feature provides tem-

porary lighting in the path of the headlights while

walking to a building or other destination. If a vehicle

Driver Controls

5.2

door is opened or closed while this feature is active,

the timer will add an additional 10 seconds of light-

ing. This feature can be temporarily disabled by turn-

ing the ignition switch on, or by cycling the headlight

switch from the off position to one of the other two

positions.

High-Beam Headlights

To activate the high-beam headlights, press the turn

signal lever forward towards the windshield while the

low-beam headlights are on. Return the turn-signal

lever back to its neutral position to deactivate the

high beams, and return to low beam headlights.

When the high-beam headlights are on, a blue light

illuminates on the instrument cluster. For vehicles

with fog lights, switching on the high beams will

switch off the fog lights. The headlight low beams

remain on continuously during high-beam operation.

02/03/2012 f544971

234

1. High-Beam Headlight

2. Fog Light, or Auxiliary High-Beam Light

3. Low-Beam Headlight

4. Marker Light

5. Turn Signal

6. Side Turn Signal and Marker Light

7. Clearance Light

8. Stop Light, Taillight, and Turn Signal

9. Back-Up Light

10. Identiﬁcation Light

Fig. 5.3, Exterior Lights

Driver Controls

5.3

NOTE: The ignition switch must be on for the

high beams to work.

Marker Lights

Turn the headlight switch clockwise to past the off

position. See Fig. 5.6.

Marker Interrupt

The marker interrupt switch, located in the right-hand

switch pod of the steering wheel, temporarily ﬂashes

the marker lights. See Fig. 5.7.

AUX

HIGH

DRL

OVRD

UTLY

LAMP

FOOT

WELL DOME

DOME REAR

DOME

REAR

DOME

LWR

LAMP

LWR

LAMP

01/05/2012 f611155

1 2 3 4 5 6

7 8 9 10 11

1. Auxiliary High Beam Light Switch

2. DRL Override Switch

3. Utility Light Switch

4. Cab Foot Well Light Switch

5. Panel Lights Switch

6. Rear Cab Dome Light Switch

7. Rear Cab Dome Light Switch

(mounted in sleeper)

8. Sleeper Rear Dome Light Switch,

Driver Side

9. Sleeper Rear Dome Light Switch,

Passenger Side

10. Sleeper Reading Light Switch,

Driver Side

11. Sleeper Reading Light Switch,

Passenger Side

Fig. 5.4, Dash-Mounted and Sleeper-Control Light Switches

03/20/2007 1f610855

1. Hazard Warning

Switch

2. Panel Lights Dimmer

Switch

Fig. 5.5, Master Module

Driver Controls

5.4

Spotlight

The spotlight switch is located on the pivoting handle

of the spotlight. There may be a single spotlight as-

sembly mounted above the driver’s door, or one

above each door.

Turn Signals

The turn-signal lever is on the left side of the steer-

ing column. See Fig. 5.8.

NOTE: The optional self-canceling turn signal

lever will automatically return to the neutral posi-

tion when the steering wheel returns to the

straight-ahead position after a turn.

Move the turn signal lever downward to turn the left-

turn signal on; move it upward to turn the right-turn

signal on. To manually cancel the signal, move the

lever to the neutral position.

When a turn signal is activated, a green indicator

light ﬂashes on the instrument cluster.

Turn-Tip Feature

The turn-tip feature is advantageous in lane change

situations when the steering wheel does not travel far

enough to cancel a conventional turn signal request.

Pushing the turn-signal lever halfway to the normal

turning position to activate the turn-tip feature. The

signal will ﬂash for a few seconds, then cancel. Acti-

vation of the turn-tip feature is immediately canceled

when a request for the turn signal in the opposite

direction is made.

Utility Lights

Utility lights can be swivel-mounted on upper half of

the cab, mounted on the exhaust support, or ﬂush-

mounted on the back of the cab or sleeper. Press the

upper half of the switch to activate it. Press the lower

f610806

01/05/2012

1. Fog Lights (optional)—Activate by pulling the switch

out when the marker lights or headlights are on.

2. Off

3. Marker Lights

4. Headlights

Fig. 5.6, Headlight Switch

05/24/2007 f462049

ON/

OFF

ACC

RES CNCL

DEC/

SET

MRKR

INT

ENG

BRK

Fig. 5.7, Steering Wheel-Mounted Controls

07/19/2006 f820427

1. Wiper Control Dial 2. High-Beam Icon

Fig. 5.8, Multifunction Turn Signal Lever

Driver Controls

5.5

half of the switch to turn it off. When activated, a red

indicator light in the switch is illuminated. See

Fig. 5.4.

Interior Lighting Controls

Interior light controls are listed here in alphabetical

order.

The interior lights include panel lights, dome lights,

red map lights, clear reading lights, and courtesy

lights. Vehicles come pre-set from the factory with

theater lighting, which ramps up lights from low

power to full power when activated.

Sleepers have rear dome lights, bunk reading lights,

sleeper ﬂoor lights, and baggage compartment lights.

Baggage Compartment Lights

Baggage compartment lights are located on the un-

derside of the lower bunk, on both sides. Both lights

turn on when either baggage compartment door is

opened to illuminate the baggage compartment. The

lights also come on when the lower bunk is raised.

Foot Well Lights

When the driver or passenger doors are opened, red

lights illuminate both foot wells. These lights can also

be activated with the foot well light switch. See

Fig. 5.4. Press the upper half of the switch to turn

the foot well lights on, press the lower half of the

switch to turn them off.

Overhead Console Lights

The overhead console includes a clear reading light,

a clear dome light, and a red map light. See Fig. 5.9.

The dome lights illuminate when a door opens, then

stay on for a short time after both doors are closed.

Press the lens of the reading light, dome light, or

map light to activate each one independently of the

others.

Panel Lights

The panel lights illuminate when the headlights are

turned on. To adjust the brightness of the panel

lights, use the panel lights switch, usually located in

the master module next to the hazard ﬂasher switch.

See Fig. 5.4. The panel lights brighten and dim in

5% increments, depending on whether the upper half

or the lower half of the switch is pressed. When the

headlights are turned on, the panel lights setting will

default to the intensity that was last set.

Rear Dome Light

A rear cab dome light is located on the roof, between

the bunk and the cab on sleeper vehicles. See

Fig. 5.10. The rear cab dome light will activate with

the dome lights when a door is opened, then stay on

for a short time after both doors are closed.

Use the dash-mounted switch or the switch in the

sleeper panel to activate the rear cab dome light.

See Fig. 5.4.

11/21/2006 f544907

1. Clear Reading Lamp

2. Clear Dome Lamp

3. Red Map Lamp

Fig. 5.9, Overhead Console Lights

11/21/2006 f544908

Fig. 5.10, Rear Cab Dome Light

Driver Controls

5.6

Sleeper Dome Light

Two dome lights are mounted on the sleeper roof,

close to the outside walls.

There are two switches in the sleeper that control the

sleeper dome lights. The passenger-side switch will

activate both dome lights. The driver-side switch op-

erates the driver-side light only. Press the upper half

of the switch to turn the sleeper dome light on, press

the lower half of the switch to turn it off.

Sleeper Foot Well Lights

The sleeper foot well switch is located in the lower

switch module in the sleeper. It looks identical to the

cab foot well switch. See Fig. 5.4. When the switch

is activated, two lights illuminate the sleeper ﬂoor.

Sleeper Reading Lights

Clear reading lights are mounted above the lower

bunk in the rear corners of the sleeper. There are

two switches in the sleeper control panel for the

reading lights. To turn a reading light on, press the

upper half of the switch. Press the lower half of the

switch to turn it off. See Fig. 5.4.

The reading lights can also be activated by pressing

the lens.

Horn Controls

Air Horn

Air horn(s) may be mounted on the roof of day cabs,

or under the driver-side ﬂoor for sleeper cabs. The

air horn is controlled by a wire lanyard that hangs

down inboard by the driver’s door. See Fig. 5.11.

Pull downward on the lanyard to sound the air horn.

Electric Horn

The button for the electric horn on a vehicle without

an airbag is located in the center of the steering

wheel. See Fig. 5.12. To sound the horn, press down

on the button.

The electric horn on a vehicle with an airbag is acti-

vated by pressing down on the top of the steering

wheel center pad. See Fig. 5.13.

The horn will sound for the duration that the button is

pressed, up to 60 seconds. The electric horn will op-

erate regardless of the position of the ignition key.

Powertrain Controls

Aftertreatment System Regen

Switches

NOTE: See Chapter 12 for detailed information

about the operation of the regeneration (regen)

switches and the aftertreatment system (ATS).

06/13/2007 f602322

1. Lanyard

Fig. 5.11, Air Horn Control

02/05/2007

f544961

1. Horn Button

Fig. 5.12, Steering Wheel, No Airbag

Driver Controls

5.7

IMPORTANT: Depending upon local jurisdic-

tional emissions guidelines, vehicles that are

domiciled outside of the U.S. and Canada may

not have engines and/or emissions aftertreat-

ment systems that are compliant with EPA07,

EPA10, or GHG14 regulations.

The regen request switch, located on the dash, is

used to initiate a parked regen. See Fig. 5.14.To

access the regen request switch, lift the guard and

press the yellow button.

Some vehicles may be equipped with a regen inhibit

switch. See Fig. 5.14. To stop a regen in progress or

prevent the start of a regen, press the lower half of

the switch. Regen will be delayed until the switch is

no longer active.

Axle Switches

Some vehicles are equipped with an interaxle differ-

ential lock switch and/or a switch for each driver-

controlled differential lock (DCDL). See Fig. 5.15. For

more information about differential locks and using

them for traction control, see Chapter 16.

Engine Brake Switch

The Hi/Med/Lo engine brake 3-position switch con-

trols the amount of engine braking. See Fig. 5.16.

Press the lower third of the switch for low, center for

medium, and upper third for high.

01/13/2012 f462236

Press down on the top of the steering wheel center pad

to activate the horn.

Fig. 5.13, Steering Wheel With Airbag

f61115702/08/2012

RGEN

1. Regen Request

Switch

2. Regen Inhibit Switch

Fig. 5.14, Regen Request and Inhibit Switches

01/05/2012 f611158

1. Interaxle Differential Lock Switch

2. Fifth Wheel Slide Switch

3. Driver-Controlled Differential Lock (DCDL) Switch

4. Air Suspension Dump Control Switch

Fig. 5.15, Axle and Suspension Switches

Driver Controls

5.8

There is also an engine brake switch located in the

right-hand switch pod on the steering wheel. See

Fig. 5.7. Press the ENG BRK switch once to engage

or disengage the engine brake. Refer to Chapter 13

for instructions on using the engine brake.

Engine Fan Switch

The engine cooling fan can be turned on by the en-

gine fan switch.

To turn the engine fan on, press the upper half of the

switch. The fan will continue to operate for a set

amount of time and then turn off unless the coolant

temperature is high enough to continue fan opera-

tion. To turn the fan off before the set time period

ends, press the lower half of the switch. See

Fig. 5.17.

Hill Start Aid Override Switch

Some vehicles are equipped with a Hill Start Aid

(HSA) feature to prevent the vehicle from rolling

while on steep grades and to allow for a controlled

launch. HSA is "on" by default. It can be turned off

by pressing and releasing the HSA override switch

on the dash (see Fig. 5.18).

PTO Switch

To activate the PTO function, press the upper half of

the switch. Press the lower half of the switch to de-

activate the PTO function. See Fig. 5.19.

WARNING

To avoid injury, do not install a PTO that is not

Detroit Diesel approved onto a Detroit™Trans-

mission. Use of a non-Detroit Diesel approved

PTO with a Detroit Transmission could result in

unintended operation which could lead to severe

personal injury.

Transmission Controls

Detroit™Automated Transmissions

NOTE: See Chapter 15 for complete Detroit

automated transmission operating instructions.

Vehicles with Detroit transmissions use the multifunc-

tion control shown in Fig. 5.20. This control moves in

two directions and has two switches. It is used to

request manual shifts, change shift mode, set engine

brake levels, and control specialty engine brake func-

tions during cruise control operation.

ENG

BRK

f61090505/02/2007

Fig. 5.16, Engine Brake Switch

ENG

FAN

f61089902/26/2007

Fig. 5.17, Engine Fan Switch

HSA

OVRD

f61118604/30/2012

Fig. 5.18, Hill Start Aid Override Switch

Driver Controls

5.9

Eaton Automated Transmissions

NOTE: See Chapter 15 for complete automated

transmission operating instructions.

The SmartShift electronic transmission control is in-

stalled with the Eaton® Fuller® UltraShift™and

Eaton Fuller AutoShift™transmissions. The Smart-

Shift control is operated by the ﬁngers of the driver’s

right hand, allowing both hands to remain on the

steering wheel.

A two-position driving mode slide switch is mounted

on the body of the control lever just before the

paddle widens out. The slide switch allows the driver

to choose automatic (AUTO) or manual (MAN) mode.

See Fig. 5.21.

Manual Transmissions

NOTE: See Chapter 14 for complete manual

transmission operating instructions.

If so equipped, the transmission range control and

splitter valves are attached to the gear shift knob.

The range-preselection lever allows the selection of

the low or high range for each transmission ratio. It is

used once during an upshift sequence and once dur-

ing a downshift sequence.

Dependent on the transmission model, some ratios

can be split using the splitter-control button.

Allison Automatic Transmissions

Automatic transmissions have up to six forward

speeds and one reverse speed. These transmissions

have electronic shift controls that can be pro- grammed to allow the use of different geared

speeds. See Fig. 5.22.

f61089402/23/2007

PTO

Fig. 5.19, PTO Switch

( + )

( − )

05/30/2012 f270163a

A. Front View

B. Shift Requests

C. Four positions for engine brake settings

1. Engine Brake Symbol

2. D/N/R Switch

3. Mode Switch

4. Gear Shift Symbol

Fig. 5.20, Detroit Multifunction Control

Driver Controls

5.10

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 roads

that are winding, icy, snow-covered, slippery, or

roads with a loose driving surface. Failure to fol-

low this precaution could cause a collision or

loss of vehicle control, possibly resulting in per-

sonal injury or property damage.

NOTICE

When the cruise control is engaged, do not at-

tempt to shift gears without using the clutch

pedal. Failure to follow this precaution will result

in a temporarily uncontrolled increase in engine

speed. Transmission damage and gear stripping

could result.

IMPORTANT: On vehicles equipped with

VORAD Collision Warning System with Smart-

Cruise, see Chapter 6 before operating the

cruise control.

NOTE: If the vehicle is equipped with a Detroit

multifunction control, setting the cruise control

with the engine brake on will activate Descent

Control Mode. Moving the lever to the top posi-

tion will resume the set cruise speed. Moving

the lever down to engage the engine brake after

the cruise control has been set will activate De-

celeration Mode. See "Descent Control and De-

celeration Modes, Detroit™Automated Transmis-

sions" in this chapter.

The cruise control is operated by four buttons

mounted in the left-hand button pod of the steering

wheel. See Fig. 5.7.

•ON/OFF Button—Press to turn cruise control

on or off. When cruise control is on, a green

telltale illuminates in the ICU. The speed

memory will be retained until the cruise control

is disabled with the ON/OFF button, or the igni-

tion is turned off.

01/24/2003

11 12

f270120

To upshift manually, pull the lever back (towards the

driver). To downshift manually, push the lever forward

(away from the driver).

1. SmartShift Control Lever

2. Slide Switch (forward driving mode switch)

3. MAN Mode (of slide switch)

4. AUTO Mode (of slide switch)

5. Upshift Direction

6. Reverse Position (of selector switch)

7. Selector Switch

8. Neutral Lock Button

9. Neutral Position (of selector switch)

10. Drive Position (of selector switch)

11. Low Position (of selector switch)

12. Downshift Direction

Fig. 5.21, SmartShift Control (Eaton Fuller UltraShift

and AutoShift transmissions)

10/31/94 f600369a

1. Indicator Panel 2. Mode ID

Fig. 5.22, Allison Push-Button Shift Selector

Driver Controls

5.11

•DEC/SET Button—Press to set the cruise

speed while the vehicle is traveling at the de-

sired speed. Press and hold to decrease the

set cruise speed.

•CNCL Button—Press to pause the cruise con-

trol, while retaining the speed setting in

memory. The cruise control can also be disen-

gaged, while retaining the speed memory, by

depressing the brake or clutch pedals.

•ACC/RES Button—Press to resume the set

speed. Press and hold to accelerate the set

cruise speed.

1. To cruise at a particular speed:

1.1 Press the ON/OFF button to turn cruise

control on.

1.2 Depress the accelerator pedal until the

speedometer reaches the desired speed.

NOTE: Cruise control is cancelled if the

brake or clutch pedal is depressed, or ve-

hicle speed drops below the minimum cruise

control speed.

1.3 Press the DEC/SET button to set the de-

sired speed.

NOTE: The speed memory is lost whenever the

ignition switch is turned to OFF, or cruise control

is turned off.

2. To disengage the cruise control, do one of the

following:

•Press the CNCL button.

•Depress the brake pedal.

•Depress the clutch pedal (on a manual

transmission only).

3. To resume a preselected cruise speed:

3.1 Ensure cruise control is on.

3.2 Press the ACC/RES button. Cruise will

return to the last set speed.

NOTE: If vehicle speed drops below the

minimum cruise control speed, cruise control

will disengage. To resume to the preselected

cruise speed, increase vehicle speed to

above minimum cruise control speed and

press the ACC/RES button.

4. To increase cruise speed, press the ACC/RES

button until the vehicle accelerates to the desired

speed.

5. To decrease cruise speed, press the DEC/SET

button until the vehicle decelerates to the desired

speed.

Run Smart Predictive Cruise™

Predictive Cruise Control (PCC) is an optional fuel

savings application that adjusts vehicle speed predic-

tively, based on the approaching road. Using 3D digi-

tal map technology and GPS, PCC evaluates the up-

coming road grade about a mile in advance to

determine the most fuel-efficient vehicle speed. Ve-

hicles equipped with PCC have a sticker on the

dash. See Fig. 5.23.

The 3D digital map database contains proﬁle infor-

mation for over 200,000 highway miles (322,000 km)

in the 48 contiguous United States. PCC will vary the

set cruise speed by up to 6% depending on the ap-

proaching road grade. If the engine brake is enabled,

PCC will automatically engage the engine brake

when actual vehicle speed exceeds the cruise set

speed by 6%. This is different from conventional

cruise control, which maintains the speed set by the

driver.

WARNING

Apply the brakes and downshift as necessary

when driving on downhill grades. PCC does not

adequately control vehicle speed on steep down-

hill grades. Failure to use normal braking tech-

niques when PCC is active could result in per-

sonal injury and vehicle damage.

IMPORTANT: PCC adjusts the vehicle set speed

to achieve maximum fuel economy, but it does

04/15/2009 f100149

Fig. 5.23, Run Smart Predictive Cruise Control Sticker

Driver Controls

5.12

not account for traffic ﬂows or surrounding ve-

hicles.

Driver interaction with PCC is the same as conven-

tional cruise control, using the standard cruise control

buttons. In the event of a problem with PCC, or when

driving on a road with no proﬁle information avail-

able, the system reverts to conventional cruise

control.

Cruise Control ("CC") Limiter

On vehicles equipped with a CC Limiter (or CC

Band) switch (see Fig. 5.24 or Fig. 5.25), the cruise

control limiter allows the vehicle to exceed the set

cruise control speed before engine braking is ap-

plied. The CC limiter switch provides more ﬂexibility

to the existing cruise control limit function, allowing

the driver to tune the cruise function to better suit

driving preferences and conditions. To select a limit,

use the three-position CC Limiter switch on the dash.

See Table 5.1 for switch settings.

CC Limiter Switch Settings

Position Approximate Overrun Setting

Topin 3mph(5km/h)

Middle 6 mph (9 km/h)

Bottom in Unlimited

Table 5.1, CC Limiter Switch Settings

Descent Control and Deceleration

Modes, Detroit™Automated

Transmissions

On vehicles equipped with a Detroit multifunction

control (Fig. 5.26), the functions of the lever posi-

tions for engine brake control change when cruise

control is set. Two distinct modes can be activated:

•Descent Control Mode—engine braking keeps

the speed below cruise set speed; throttle is

not automatically applied.

•Deceleration Mode—engine braking activates

to reduce vehicle speed (with no lower limit) at

a constant rate.

Descent Control Mode

Descent Control Mode keeps the vehicle speed

below the set cruise speed on a downhill.

To activate Descent Control Mode, set the cruise

control speed with the engine brake on (Fig. 5.26,

positions 1, 2, or 3). In this mode, all three levels of

engine braking will be employed to to keep the

speed below the set cruise speed. This mode will not

keep the speed above the lower limit of the set

speed, so it is possible to eventually coast to a stop,

unless the lever is moved to "engine brake off" (posi-

tion 0), or throttle is applied. After throttle application,

the Descent Control Mode is resumed.

Moving the lever to "engine brake off" (position 0)

cancels Descent Control Mode and resumes cruise

speed. To reactivate Descent Control Mode, reset the

cruise control speed with the lever in position 1, 2, or

Deceleration Mode

Deceleration Mode reduces the vehicle speed at a

constant rate.

With the cruise control speed set, activate Decelera-

tion Mode by moving the lever to engine brake on

LIMIT

f61120302/19/2013

Fig. 5.24, CC Limiter Switch

BAND

f61119105/08/2012

Fig. 5.25, CC Band Switch

Driver Controls

5.13

(Fig. 5.27, position 1, 2, or 3). This mode engages

one of the engine brake levels, depending on the

lever position. The vehicle will decelerate at a con-

stant rate until the vehicle comes to a stop, unless

throttle applied to override the deceleration, or the

lever is moved to "engine brake off" (position 0).

Moving the lever to position 0 resumes the previously

set cruise control speed.

Dash-Mounted Brake Controls

NOTE: See Chapter 13 for detailed information

about brake systems.

Parking Brake Control Valve

NOTICE

Do not step on the service brake pedal while the

parking brakes are applied. To do so can cause

damage to the brake mechanisms.

The yellow diamond-shaped knob operates the park-

ing brake valve. See Fig. 5.28. Pull the knob out to

apply both the tractor and the trailer spring parking

brakes. Push the knob in to release the tractor spring

parking brakes. Before the spring parking brakes can

be released, the air pressure in either air brake sys-

tem must be at least 65 psi (447 kPa).

If the trailer is not equipped with spring parking

brakes, pull the parking brake valve out to apply the

tractor parking brakes and the trailer service brakes.

Trailer Air Supply Valve

The red octagonal-shaped knob operates the trailer

air supply valve, which charges the trailer air supply

system and releases the trailer spring parking

brakes. See Fig. 5.28.

After the vehicle and its air hoses are connected to a

trailer and the pressure in the air system is at least

65 psi (447 kPa), push the trailer air supply valve

knob in (and leave it in) to charge the trailer air sup-

ply system and release the trailer spring parking

brakes. Pull the trailer air supply valve out before

02/19/2013 f270164a

0. Resume cruise control set speed.

1, 2, 3. Descent Control maintains set speed.

Fig. 5.26, Descent Control Mode Positions, Detroit

Multifunction Control

02/19/2013 f270164a

0. Resume cruise control

set speed.

1. Low

2. Medium

3. High

Fig. 5.27, Deceleration Mode Positions, Detroit

Multifunction Control

f610291

1 2

03/10/99

1. Trailer Air Supply Valve (red knob)

2. Parking Brake Control Valve (yellow knob)

Fig. 5.28, Brake Valve Control Knobs

Driver Controls

5.14

disconnecting a trailer or when operating a vehicle

without a trailer.

Trailer Brake Lever

The trailer brake lever is used to apply the trailer ser-

vice brakes without applying the truck or tractor ser-

vice brakes. It is usually mounted on the right-hand

control panel. See Fig. 5.29. The valve can be par-

tially or fully applied, but in any partially on position it

will be overridden by a full application of the service

brake pedal. Move the lever down to apply the trailer

brakes; move the lever up to release the trailer

brakes. The lever will automatically return to the up

position when it is released.

Antilock Braking System

The Meritor™WABCO® Antilock Braking System

(ABS) passively monitors vehicle wheel speed at all

times, and controls wheel speed during emergency

stops or wheel lock situations.

During emergency or reduced-traction stops, fully

depress the brake pedal until the vehicle comes to a

safe stop. Do not pump the brake pedal. With the

brake pedal fully depressed, the ABS will control all

wheels to provide steering control and a reduced

braking distance.

The ABS is designed to communicate with a trailer

ABS, if they are compatible. Compatibility will result

in the illumination of the trailer ABS lamp during ve-

hicle start-up and fault detection. The trailer ABS

lamp will not illuminate unless a compatible trailer is

connected to the tractor.

Vehicles with ABS may have Automatic Traction Con-

trol (ATC). On these vehicles, the ATC system auto-

matically limits wheel spin during reduced-traction

situations. In normal braking applications, the stan-

dard air brake system is in effect.

ATC includes a deep snow and mud option to in-

crease available traction on extra-soft surfaces like

snow, mud, or gravel. A switch labeled ATC will be

located on the dash. See Fig. 5.30. Press the switch

to temporarily allow more drive wheel spin. The acti-

vation of the deep snow and mud option is indicated

by a ﬂashing WHEEL SPIN lamp. Press the switch

again to cycle the system back to normal operation.

NOTICE

The deep snow and mud option is intended to be

used under speciﬁc slippery conditions that re-

quire momentary increased wheel spin. Using

this option for an extended period of time may

damage the brake system.

Windshield Wiper/Washer

Controls

The multifunction turn signal lever is attached to the

left-hand side of the steering column, just below the

steering wheel. See Fig. 5.8.

NOTICE

Do not attempt to manually move the windshield

wiper arms. Wiper motor damage will occur if the

arms are forcibly moved.

10/17/2001 f610591

Fig. 5.29, Trailer Brake Lever

f61090706/15/2007

ATC

Fig. 5.30, ATC Switch

Driver Controls

5.15

The wipers are operated by a rotary switch in the

wiper control dial, which is on the end of the turn sig-

nal lever. There are ﬁve intermittent settings, marked

on the dial by lines of increasing length, and two

steady speed settings: LO and HI.

Turn the wipers on by rotating the control dial coun-

terclockwise. Rotate the control dial further to in-

crease the speed of the wipers through the various

intermittent settings, then to LO and HI.

Rotate the control dial clockwise to slow the wipers

down. Rotate the control dial clockwise as far as it

will go to turn the wipers off.

The windshield washer button is located at the end

of the turn signal lever. Momentarily press the wind-

shield washer button to initiate a single wipe without

activating the washer pump. The wipers will swipe

one full cycle and return to the inactive position.

To operate the windshield washers, press and hold

the button in. After a short delay, the washer will

pump windshield washer ﬂuid onto the windshield for

as long as the washer button is pressed. The wind-

shield wipers will turn on at low speed while the

washer button is pressed. After the button is re-

leased, the wipers will continue to operate for one to

several wipe cycles, depending on how long the

wash button was pressed initially.

Suspension/Trailer Connection

Controls

Air Suspension Dump Control Switch

NOTICE

Do not operate the vehicle over uneven ground

such as ramps, speed bumps, curbs, etc. with

the air springs deﬂated. Doing this may lead to

air bag separation from the piston, preventing the

suspension air springs from re-inﬂating.

The air suspension height control switch may be

used to aid in connecting or disconnecting from a

trailer. See Fig. 5.15. When the switch is set to

LOWER, the air-suspension dump valve deﬂates the

air springs to lower the rear of the vehicle. In the

AUTO position, the automatic ride-control valves op-

erate for normal driving.

NOTICE

Never exhaust air from the suspension while

driving. When the air is exhausted, the suspen-

sion will not absorb road shocks, and compo-

nents may be damaged.

A red LED in the switch is illuminated when the sus-

pension is deﬂated.

ECAS Remote Control Unit (ECAS

only)

Some vehicles equipped with Electronically Con-

trolled Air Suspension (ECAS) have a remote control

unit to lower and raise the rear suspension. See

Table 5.2 for keys and functions.

If the suspension is outside normal ride height

(amber lamp on), the ECAS system will automatically

return the suspension to normal ride height when

vehicle speed reaches or exceeds a set speed (usu-

ally set to 5 mph).

ECAS Remote Control Keys and Functions

08/16/2013 f611211

Key Function

Remote Control On/Off. The middle

light will remain lit while the remote is

active.

Driver Controls

5.16

ECAS Remote Control Keys and Functions

Memory keys. Pressing the Stop key

and a memory key simultaneously will

store the current height. Once stored,

pressing the key will adjust the

vehicle to the stored height.

Normal height key. This key will

return the vehicle to normal ride

height.

Lift and lower keys. These keys will

raise or lower the rear suspension

height.

The Stop key. Pressing the Stop key

will interrupt and stop all adjustments

being made by the remote control.

When the key is off, holding the Stop

key for 2 seconds will cancel the 1

hour Standby mode.

Table 5.2, ECAS Remote Control Keys and Functions

ECAS Standby Mode

Once the key is turned off, the ECAS will enter

Standby Mode, remaining powered and adjusting to

level and load changes for 1 hour. To cancel Standby

mode, hold the STOP button on the remote for 2

seconds.

Fifth Wheel Slide Control Switch

NOTICE

Do not activate the ﬁfth wheel slide control valve

while the vehicle is in motion. To do so could

cause damage to the ﬁfth wheel member, the

kingpin, the cab or trailer, and ultimately to the

drivetrain.

The ﬁfth wheel air slide valve allows repositioning of

the sliding ﬁfth wheel from inside the cab. See

Fig. 5.15. Move the air slide control valve switch to

the LOCK position to lock the ﬁfth wheel to the base-

plate. Move the switch to the UNLOCK position to

unlock the ﬁfth wheel slide mechanism, allowing

changes to the total length of the tractor-trailer and

changes to axle loads to comply with state or provin-

cial laws.

For detailed operating instructions for ﬁfth wheel

slide, refer to Chapter 18. A red indicator light illumi-

nates whenever the ﬁfth wheel slide is unlocked.

Trailer Auxiliary Switch

Trailers that are equipped with pneumatic brakes and

used in North America or South America are gener-

ally equipped with power for the trailer lights. The

connection is passed from the vehicle to the trailer

via the primary receptacle, controlled by a dash

switch.

Press the top of the switch to activate the trailer aux-

iliary function. Press the bottom of the switch to turn

trailer auxiliary function off. See Fig. 5.31.

Climate Controls

NOTE: See Chapter 8 for detailed climate con-

trol panel operating instructions.

Cab Climate Control

The climate control panel allows you to control the

heating, ventilating, defrosting, and air conditioning

(A/C) functions. The cab climate control panel has

three switches to control the functions of the cab

temperature system; see Fig. 5.32:

•fan switch with recirculation button

•temperature control switch with A/C button

•air selection switch (with bunk-override button

on sleeper cab only)

The fan switch controls the fan speed, and forces

fresh or recirculated air through the air outlets. To

increase airﬂow, turn the switch clockwise to a higher

number. To decrease airﬂow, turn the switch counter-

clockwise to a lower number.

TRLR

AUX

f610888

02/23/2007

Fig. 5.31, Trailer Auxiliary Switch

Driver Controls

5.17

Recirculation mode limits the amount of outside air

that enters the cab. Press the recirculation button to

prevent dusty or smoky air from entering the cab.

NOTE: To prevent the buildup of odors and/or

oxygen depletion inside the cab, the system

switches from full recirculation mode to partial

recirculation mode after 20 minutes.

The temperature control switch is used to select the

desired temperature. Turn the switch clockwise to the

red area for warm air. Turn the switch counterclock-

wise to the blue area for cool air.

The A/C cools and dehumidiﬁes the air inside the

cab. Press the A/C button, located in the center of

the temperature control switch, to turn the A/C on

and off.

The air selection switch allows the control of air ﬂow

through the face outlets, the ﬂoor outlets, the defrost

(windshield) outlets, or a combination of these out-

lets. See Fig. 5.33.

Bunk-Override Button

The bunk-override button is located in the center of

the cab air-selection switch (sleeper-cabs only). See

Fig. 5.33.

Press the bunk-override button to make the cab con-

trols override the settings on the sleeper temperature

control panel; the sleeper temperature will mimic the

cab settings. An amber LED in the button is illumi-

nated when the bunk-override mode is activated.

When the override switch is not activated, the cab

climate control panel can be adjusted without affect-

ing the sleeper settings.

Sleeper Climate Control

The sleeper temperature can be controlled from the

sleeper climate control panel or from the cab climate

control panel if the bunk-override button is activated.

The fan switch controls the sleeper temperature fan

speed. To increase airﬂow, turn the switch clockwise

to a higher number. To decrease the airﬂow, turn the

switch counterclockwise to a lower number. See

Fig. 5.34.

The temperature control switch is used to select the

desired temperature in the sleeper. Turn the switch

clockwise to the red area for warm air. Turn the

switch counterclockwise to the blue area for cool air.

Press the button in the center of the temperature

control switch to activate the A/C.

07/20/2006 f831701

12 3

1. Fan Switch with Recirculation Button

2. Temperature Control Switch with Air Conditioning

Button

3. Air Selection Switch with Bunk-Override Button

Fig. 5.32, Cab Climate Control Panel

06/08/2007 f610948

1. Face Mode

2. Selection Between Face Mode and Bi-Level Mode

3. Bi-Level Mode

4. Selection Between Bi-Level Mode and Floor Mode

5. Floor Mode

6. Selection Between Floor Mode and Defog Mode

7. Defog Mode

8. Selection Between Defog Mode and Defrost Mode

9. Defrost Mode

10. Bunk-Override Button (on sleeper-cabs only)

Fig. 5.33, Air Selection Switch With Bunk-Override

Button

Driver Controls

5.18

Cancel bunk-override mode, if activated, by changing

the sleeper fan speed or temperature setting. The

system will then operate from the sleeper controls.

Seat Controls

NOTE: See Chapter 7 for detailed information

about seat controls and adjustments.

WARNING

Keep hands, tools, and other objects away from

the scissor points under the seats. Failure to do

so could cause personal injury.

The following is a description of adjustments that can

be made to various seats. Not all seats have all of

the adjustments listed below. See Fig. 5.35.

•Backrest tilt

•Lumbar support

•Isolator

•Height adjustment

•Bottom cushion angle (fore-and-aft bottom

cushion height)

•Fore-and-aft seat slide (seat track adjustment)

•Seat tilt

•Headrest adjustment

06/08/2007 f610949

1. Fan Switch

2. Temperature Control

3. Air Conditioning

Button

Fig. 5.34, Sleeper Climate Control Panel

10/26/2000 f910149a

567

1. Backrest Tilt

2. Lumbar Support

3. Isolator Feature

4. Height Adjustment

5. Bottom Cushion Angle (fore-and-

aft cushion height)

6. Fore-and-Aft Seat Slide (seat

track adjustment)

7. Seat Tilt

8. Upper Backrest Adjustment

Fig. 5.35, General Seat Adjustments

Driver Controls

5.19

Adjustable Steering Column

Controls

To adjust the steering column, depress the foot pedal

located below the steering column. See Fig. 5.36. Tilt

the steering column to the desired angle. Telescope

the steering column closer or further away by push-

ing or pulling it. Release the foot pedal to lock the

steering column in place.

07/19/2006 f610799

1. Multifunction Turn

Signal Switch

2. Headlight Switch

3. Ignition Switch

4. Tilt Steering Column

Lever

5. Steering Wheel

Fig. 5.36, Steering Column and Left Panel Controls

Driver Controls

5.20

Driver Assistance Features

VORAD VS-400 System ........................................................... 6.1

OnGuard™Collision Safety System ................................................... 6.7

Lane Departure Warning Controls ................................................... 6.10

Roll Stability System .............................................................. 6.11

Enhanced Stability Control ......................................................... 6.13

VORAD VS-400 System

WARNING

The VORAD VS-400 System is intended solely as

an aid for an alert and conscientious professional

driver. It is not intended to be relied upon to op-

erate a vehicle. Use the system in conjunction

with rearview mirrors and other instruments to

safely operate the vehicle. Operate a vehicle

equipped with the VS-400 System in the same

safe manner as if the CWS were not present.

The VS-400 System is not a substitute for safe,

normal driving procedures, nor will it compen-

sate for any driver impairment such as drugs,

alcohol, or fatigue.

The VS-400 System may provide little or no warn-

ing of hazards such as pedestrians, animals, on-

coming vehicles, or cross traffic.

Failure to drive safely and use the system prop-

erly could result in personal injury and/or death

and severe property damage.

The VORAD VS-400 system is an on-board radar

system that monitors traffic conditions, warning the

driver of potentially hazardous driving situations.

The collision warning system (CWS) tracks objects

ahead of the vehicle, warning the driver with visual

and audible indicators whenever following distances

become unsafe.

SmartCruise® adjusts the vehicle’s cruise speed in

order to match the speed of traffic ahead, allowing

the driver to maintain a safe following distance while

cruise control is engaged.

The optional side object detection system warns of

unsafe lane changes by detecting vehicles that may

be difficult to see in adjacent lanes.

The VORAD VS-400 system performs in fog, rain,

snow, dust, smoke, and darkness. The VS-400 sys-

tem becomes active whenever the ignition key is

switched to ON.

Driver Interface Unit

The driver interface unit (DIU) provides visual and

audible alerts, along with system status information.

The DIU also provides an interface for changing sys-

tem settings. Menu selections are made by pressing

the up and down arrow buttons, and the OK button.

See Fig. 6.1.

The following warning and indicator lights illuminate

on the DIU:

•Red: illuminates with the collision alert

•Yellow: illuminates with 3-, 2-, and 1-second

following distance alerts

•Orange: illuminates when a system failure oc-

curs

•Blue: illuminates when information is available

Immediately after the ignition switch is turned to ON,

the DIU initializes a self-test routine. During the ini-

tialization, the VORAD screen displays and all lamps

illuminate for approximately three seconds, along

with a power-up tone. When the initialization is com-

plete, the DIU displays the VS-400 system conﬁgura-

tion screen. See Fig. 6.2.

Menu Selections

IMPORTANT: The display of a menu item is

overridden whenever conditions require an alert

or collision warning to be displayed.

After initialization, the menu screen is displayed.

Scroll to the desired menu item by pressing an arrow

button, then press the OK button to select the item.

See Fig. 6.3. If the driver does not make a selection

within 30 seconds, or the vehicle begins to move, the

DIU reverts to the system status display.

f610919a

02/03/2012

1. Fault Indicator

2. Info Indicator

3. Following Distance

Lights

4. Ambient Light Sensor

5. Collision Alert Lights

6. User Interface Keypad

7. Graphic Display

Fig. 6.1, Driver Interface Unit (DIU)

Driver Assistance Features

6.1

The display of any menu item is overridden when-

ever conditions require an alert or collision warning

to be displayed.

Demo (vehicle must be stationary)

When the vehicle is stationary and Demo mode is

selected, the DIU will demonstrate the meaning of all

LED and screen displays, including alert messages

and sound warnings. Scroll through the demo

screens by pressing the down arrow. Pressing any

other key exits Demo mode.

Volume

The minimum adjustable volume is 50% of the maxi-

mum volume. If the DIU volume is not adjustable, the

display screen shows a grayed bar graph whenever

volume adjustment is selected. See Fig. 6.4. After

each ignition switch cycle, the volume will default

back to 100%.

NOTE: Headway and collision alert tones may

be suppressed when the brake is applied if the

system is conﬁgured to do so.

SmartCruise Headway Range

Headway range adjustment is only available with

SmartCruise. Headway range is adjustable between

3.25 and 2.25 seconds. The headway range setting

will default to 3.25 seconds after each ignition power

cycle.

If headway range adjustment is disabled, only the

3.25 sec screen is displayed. See Fig. 6.5 for the

various headway range screens. Press the OK but-

ton to exit the menu.

VORAD started

Collision Warn

SmartCruise

f610921a

VORAD started

Collision Warn

02/03/2012

A. Conﬁgured for CWS only

B. Conﬁgured for CWS and SmartCruise

Fig. 6.2, System Conﬁguration Screens

f610922a

System Status

Volume

Demo

02/03/2012

Fig. 6.3, Menu Screen

f610925a

Volume

02/03/2012

A. Adjustable Volume

B. Non-Adjustable Volume

Fig. 6.4, Volume Screen

Driver Assistance Features

6.2

NOTE: If the headway range is adjusted to

three seconds or below and SmartCruise is ac-

tive, the 3-second collision warning headway

alert will not display. All other alerts are not

suppressed.

Brightness

Use the up and down arrows to change the DIU

backlight and warning LED brightness. Press the OK

button to exit the brightness screen.

The ambient light sensor reading determines if the

DIU is in daytime or nighttime mode. Menu-adjusted

brightness is applied only to the mode the DIU is in

at the time of adjustment. The previous brightness

settings are repeated after each ignition cycle. How-

ever, the graphic display and the warning LED bright-

ness range are constrained such that they are al-

ways visible regardless of how low the brightness is

adjusted in all driving conditions. Press the OK but-

ton to exit the menu.

Unit Adjustment Screen

The unit adjustment screen allows the driver to select

either km/h or mph units for display of SmartCruise

set speed. Press OK to exit the mph selection

screen.

System Status

System status shows the status of each system, indi-

cating if the system is operating normally. If a system

is not operating normally, the system displays Failed

beside the system name. Failed indicates that a fault

is preventing the system from operating and it cannot

be used until the fault is corrected or acknowledged.

Depending on the VS-400 system installed, one of

the screens shown in Fig. 6.6 will appear unless a

system fault is active. Press OK to exit the system

status menu.

Diagnostics

The DIU displays fault codes currently active when

this screen is selected and the vehicle is stationary.

f610927a

3.25 sec

SmartCruise

Range

SmartCruise

Range

2.25 sec

3.25 sec

SmartCruise

Range

fixed

02/03/2012

A. Minimum headway adjustment

B. Maximum headway adjustment

C. Headway range disabled

Fig. 6.5, Headway Range Screen

f610923a

Collision warn

SmartCruise

VORAD

status

Press OK for Menu

Collision warn

VORAD

status

Press OK for Menu

02/03/2012

A. Status display for CWS and SmartCruise

conﬁguration

B. Status display for CWS conﬁguration

Fig. 6.6, System Status Screens

Driver Assistance Features

6.3

See Fig. 6.7. Contact an authorized Freightliner ser-

vice center if fault codes display.

Collision Warning System

The CWS may require a warm-up period of up to

one minute if the outside air temperature is below

32°F (0°C). The DIU will display a warm-up message

until the system reaches operating temperature. See

Fig. 6.8.

The alerts given by the VS-400 system are based on

the distance to the object ahead, whenever vehicle

speed is 10 mph (16 km/h) or faster. The VS-400

CWS identiﬁes and tracks the nearest object in the

lane of travel. This object is classiﬁed by the range,

and assigned a message described under the follow-

ing headings.

Object Detected

When a vehicle is detected in the same lane of travel

within 350 ft (107 m) but farther than a 3-second fol-

lowing distance, the DIU will display OBJECT DE-

TECTED. See Fig. 6.9.

3-Second Headway Alert

When a vehicle is detected to be within a 3-second

following distance, a single yellow indicator will illumi-

nate and the DIU will display 3 seconds. See

Fig. 6.10.

f610929a

DIU DIAGNOSTICS

SPN: 00886 FMI:012

OK OK

02/03/2012

Fig. 6.7, DIU Diagnostic Screen

f610924a

Do not use

Radar Warming Up

SmartCruise

Please wait

02/03/2012

A. CWS with

SmartCruise

B. CWS Only

Fig. 6.8, CWS Warm-Up Screens

f610930a

Object Detected OK

02/03/2012

Fig. 6.9, Object Detected Alert

f610931a

3 seconds OK

02/03/2012

Fig. 6.10, 3-Second Alert

Driver Assistance Features

6.4

2-Second Headway Alert

When the following distance to the object ahead in

the same lane of travel decreases to within two sec-

onds, a second yellow indicator will illuminate, the

DIU will display 2 seconds, and a single tone will

sound. See Fig. 6.11.

1-Second Headway Alert

When the following distance to the object ahead in

the same lane of travel decreases to within one sec-

ond, a third yellow indicator will illuminate, the DIU

will display 1 sec, and two tones will sound. See

Fig. 6.12.

Collision Alert: ½-Second Headway

When the following distance to the object ahead in

the same lane of travel decreases to 0.5 second, the

red indicators all illuminate across of the DIU, the

DIU will display COLLISION ALERT, and a tone will

sound repeatedly. See Fig. 6.13.

SmartCruise

When approaching slower moving traffic with the ve-

hicle’s cruise control engaged, SmartCruise adapts

the engine cruise speed to that of the closest vehicle

ahead, allowing the vehicle to maintain a safe follow-

ing distance without disengaging the cruise control.

The DIU will display the SmartCruise status screen

indicating the vehicle’s current set cruise speed.

Once the speed of traffic ahead increases beyond

the adapted engine cruise speed, the original cruise

control set speed re-engages.

When SmartCruise is engaged, depressing the accel-

erator pedal will override the SmartCruise and will

cause the vehicle to accelerate. Depressing the

brake or clutch pedals will deactivate SmartCruise.

When approaching a slow moving or stopped vehicle

ahead, SmartCruise will attempt to maintain the mini-

mum following distance by reducing the engine

cruise speed and engaging the engine brake, if nec-

essary. If SmartCruise is unable to maintain the mini-

mum following distance, the driver will be alerted by

the CWS headway alerts until the driver takes control

or conditions clear.

Side Object Detection

The optional side object detection system may be

installed on one or both sides of the vehicle. The

radar sensor(s) are located on the side of the ve-

hicle, while the sensor display unit is mounted on the

A-pillar. See Fig. 6.14.

The side sensor display unit uses two lights to dis-

play the status of the side sensor(s). The yellow light

indicates the system is active, but no objects are de-

tected. The red light indicates that the side sensor

detects an object. If the vehicles turn signal is active

f610932a

seconds

02/03/2012

Fig. 6.11, 2-Second Alert

f610933a

sec

02/03/2012

Fig. 6.12, 1-Second Alert

f610934a

COLLISION

ALERT OK

02/03/2012

Fig. 6.13, Collision Alert

Driver Assistance Features

6.5

and the sensor detects an object alongside the ve-

hicle, an audible warning tone will sound.

Special Road Situations

Certain road situations may affect the system’s ability

to detect objects. These situations include the effects

of curves, dips, and hills which can provide an unex-

pected result.

NOTE: A warning may sound when an object is

detected in front of the vehicle even though the

driver intends to turn away or stop before reach-

ing the object.

•When an object is detected in a very sharp

right- or left-hand turn, the audible alarm will

not sound.

•When approaching a curve, alarms may sound

and lights illuminate, because of an object off

the road directly in line with your vehicle. This

will not occur when the brakes are applied.

•When approaching a roadway descending to a

lower elevation, elevated obstacles such as

overpasses and overhead signs may be de-

tected.

•Vehicles cannot be detected on the other side

of a hill. An alarm will not sound until the object

is within the antenna assembly’s ﬁeld of view.

•On approaching a steep hill, objects above the

beam cannot be detected. Generally, the beam

hitting the road surface does not cause an

alarm.

•The side sensor only detects objects within its

ﬁeld of view, next to the tractor. A vehicle be-

hind the ﬁeld of view will not be detected.

•The side sensor range is set to detect

average-sized vehicles 2 to 10 feet (0.5 to 3

meters) away in the adjacent lane.

•The radar beam will detect near range cut-ins

of approximately 30 feet (9 meters) or less,

depending on the angle of entrance into the

lane in front of your vehicle.

•A continuous ﬁxed object on the right side of

the vehicle such as a guard rail, wall, tunnel, or

bridge may cause the side sensor alert light to

stay on.

WARNING

Heavy rain or water spray at the side sensor may

cause both the yellow and red lights on the side

sensor display to illuminate at the same time.

Under these conditions the system is temporarily

unable to provide adequate warnings.

Failure to drive safely and use the system prop-

erly could result in personal injury and/or death

and severe property damage.

Maintenance

Keep the antenna and side sensor free of buildup of

mud, dirt, ice, or other debris that might reduce the

system’s range.

Failure Display Mode/Fault Codes

The VS-400 performs internal diagnostics at power-

up, then continuously monitors system components

thereafter.

If a failure is detected, depending on what features

are affected, the DIU displays a screen similar to

Fig. 6.15, blinks the orange fault light, and sounds a

tone. Press the OK button to acknowledge the fault.

After the fault has been acknowledged, the DIU will

attempt to return to normal operations. The orange

LED is continuously illuminated while the fault per-

sists. If the fault disappears, the VS-400 transmits a

f610935b

02/06/2012

1. Volume Adjust

2. Red LED–Object Detected

3. Ambient Light Sensor

4. Yellow–No Object Detected

Fig. 6.14, Side Sensor Display Unit

Driver Assistance Features

6.6

message to indicate that the fault status has

changed to a previously active fault.

In the event the CWS antenna becomes blocked

while the vehicle is moving (e.g., snow, mud, ice,

tampering, etc.), the system sounds a tone and dis-

plays the fault screen shown in Fig. 6.16.

Contact an authorized Freightliner dealer to review

and clear previously active fault codes.

OnGuard™Collision Safety

System

Meritor WABCO OnGuard is a forward-looking radar-

based adaptive cruise control and collision safety

system with active braking. The system includes a

collision warning system (CWS), adaptive cruise con-

trol (ACC) with active braking, and a collision mitiga-

tion system (CMS).

The system performs in fog, rain, snow, dust, smoke,

and darkness. To be detected, objects must be within

the radar ﬁeld of view and provide a surface area

that can reﬂect the radar.

The front-looking antenna assembly transmits radar

signals to, and receives them back from, objects

ahead of the vehicle. This allows the determination of

the distance, speed, and angle of the object ahead.

The system uses this information to warn the driver

of potentially dangerous situations.

WARNING

The Meritor WABCO OnGuard™Collision Safety

System is intended solely as an aid for an alert

and conscientious professional driver. It is not

intended to be relied upon to operate a vehicle.

Use the system in conjunction with rearview mir-

rors and other instruments to safely operate the

vehicle. Operate a vehicle equipped with the On-

Guard in the same safe manner as if the CWS

were not present.

The OnGuard Collision Safety System is not a

substitute for safe, normal driving procedures,

nor will it compensate for any driver impairment

such as drugs, alcohol, or fatigue.

The OnGuard Collision Safety System may pro-

vide little or no warning of hazards such as pe-

destrians, animals, oncoming vehicles, or cross

traffic.

Failure to drive safely and use the system prop-

erly could result in personal injury and/or death

and severe property damage.

OnGuard Display Unit

The OnGuard system controls are located in the dis-

play unit. The display provides visual and audible

warnings and messages, as well as veriﬁcation of

correct system operation and faults. Menu selections

are made by pressing the up and down arrows, and

the MODE button. See Fig. 6.17.

The display includes:

•an internal speaker

•a graphic display

•buttons to scroll and select options

Collision Warning System (CWS)

The CWS generates audible and visual alerts when

the vehicle’s following distance may result in a colli-

sion. The CWS provides only a warning, and will not

control vehicle speed.

f610936a

VORAD fault

Collision warn FAILED

02/03/2012

Fig. 6.15, VORAD Fault Display

f610937a

VORAD fault

Radar Blocked

02/03/2012

Fig. 6.16, Antenna Blocked Display

Driver Assistance Features

6.7

The CWS cannot be disengaged or turned off, and is

always active at vehicle speeds above 15 mph (25

km/h).

Standby

When no object is detected, the display shows that

the CWS is on and the radar is searching. See

Fig. 6.17.

Object Detected

When an object is detected in the lane ahead, the

display shows that the CWS is on and the radar is

tracking an object at the speed shown. See

Fig. 6.18.

If the following distance between the vehicle and the

object is too close, the CWS will emit an audible alert

and the display background will turn yellow. The alert

will end when vehicle speed drops below the object

speed and the following distance is increased.

Collision Warning

If the object is traveling slower than the driver’s ve-

hicle, the CWS warns of an impending collision by

emitting an urgent audible alert and displaying the

collision warning symbol with a red background. See

Fig. 6.19.

Adaptive Cruise Control (ACC)

ACC is a radar-based system that works in conjunc-

tion with conventional cruise control to maintain the

set cruise speed when no vehicle is being tracked,

and maintains a minimum following distance when an

object is being tracked. The minimum following dis-

tance is maintained by automatically decelerating the

vehicle using throttle, engine, and service brakes

without driver intervention. When the object is no lon-

ger being tracked, the set cruise control speed re-

sumes automatically.

Standby

When no object is detected, OnGuard ACC operates

similarly to conventional cruise control. The cruise

control set speed is shown on the OnGuard display

unit. See Fig. 6.20.

Object Detected

When an object is detected in the lane ahead, the

display shows that ACC is on and the radar is track-

ing an object at the speed shown. See Fig. 6.21.

08/30/2011 f545826

Fig. 6.17, OnGuard Display Unit

CWS

10/31/2014 f611143

55 MPH

230FT

Fig. 6.18, CWS Object Detected

10/31/2014 f611144

CWS 15 MPH

15 FT

Fig. 6.19, CWS Collision Warning

Driver Assistance Features

6.8

If the driver uses the accelerator pedal to override

the cruise control and approach a vehicle too closely,

the ACC will emit an audible alert and the display

background will turn yellow. The alert will end when

vehicle speed drops below the object’s speed and

the following distance is increased.

NOTE: The following distance alert does not

operate at speeds below 15 mph (25 km/h).

Collision Warning

If the object is traveling more slowly than the driver’s

vehicle, the CWS warns of an impending collision by

emitting an urgent audible alert and displaying the

collision warning symbol with a red background. See

Fig. 6.22.

The braking control will activate and slow the vehicle.

The driver must also initiate braking.

Collision Mitigation System (CMS)

The CMS provides the driver with audible and visual

alerts when the vehicle’s following distance could

result in a rear-end collision. If a potential rear-end

collision is developing and the driver does decelerate

the vehicle, OnGuard’s active braking automatically

applies the engine and service brakes to provide

braking power. The active braking application is in-

tended only to provide early braking as the driver is

recognizing and reacting to the situation.

IMPORTANT: CMS and active braking are not

operational at vehicle speeds below 15 mph (25

km/h).

Error Screens

IMPORTANT: The OnGuard collision safety sys-

tem is not operational when an error screen is

displayed.

If a system fault is detected, the OnGuard display

unit will immediately display an error screen like the

one shown in Fig. 6.23. The ﬁrst error code transmit-

ted will be displayed ﬁrst; additional faults (if any)

can be viewed using the up or down buttons. The

display does not show stored fault codes.

10/31/2014 f611145

Set: 60 MPH

Fig. 6.20, ACC Standby

10/31/2014 f611146

Set: 60 MPH 55 MPH

230 FT

Fig. 6.21, ACC Object Detected

10/31/2014 f611147

Set: 60 MPH 15 MPH

15 FT

Fig. 6.22, ACC Collision Warning

10/31/2014 f611148

ACC1 Link Error

DATA ERROR

Fig. 6.23, OnGuard Error Screen

Driver Assistance Features

6.9

If a fault occurs or OnGuard fails to properly track a

vehicle, take the vehicle in for service as soon as

possible. Standard cruise control will not function

with an active OnGuard system fault.

Refer to the OnGuard Collision Safety System Main-

tenance Manual MM-0951 for a full list of faults (ww-

w.Meritor.WABCO.com).

IMPORTANT: If the system fails to track an ob-

ject, look for signs of damage to the radar as-

sembly.

Additional Features

Press the MODE button to access the OnGuard dis-

play unit additional features from the CWS or ACC

main operating screen. Press the up and down ar-

rows to scroll through each menu, then press the

MODE button to select the value to be changed. In

edit mode, press the up or down arrows to change a

value setting, then press the MODE button to save

the setting. Pressing MODE in each feature screen

advances the display to the next feature.

The Display Control menu allows adjustment of the

alarm volume, LCD brightness, LCD contrast, and

U.S./metric unit conversion. See Fig. 6.24.

The component test menu provides veriﬁcation of

system component operation and acts as a valuable

OnGuard system diagnostic tool. The header will dis-

play either COMPONENT TEST or ACC FUNCTION,

depending on the software release version of the On-

Guard system. The component test screen shown in

Fig. 6.25 provides access to the following compo-

nents (press the up or down arrows to scroll through

the menu):

•brake pedal position

•EBS brake switch

•CCVS brake switch

•clutch switch

•park brake switch

•accelerator pedal position

•driveline engaged

•cruise control enable

•cruise control set speed switch

•cruise control coast switch

•cruise control resume switch

•cruise control accelerate switch

•cruise control pause switch

Lane Departure Warning

Controls

The Lane Guidance lane departure warning system

monitors the vehicle’s position within the roadway

lane markings and sounds a warning in the cab

when the vehicle is about to stray outside its lane,

provided the turn signal is not on and the vehicle is

traveling at least 37 mph (60 km/h). The system in-

cludes a digital camera mounted high near the center

of the windshield inside the cab and speakers that

emit a sound similar to a rumble strip. The sound is

made on the side of the vehicle it’s straying toward,

prompting the driver to respond and steer away from

the sound and back into the center of the correct

lane.

10/31/2014 f611149

DISPLAY CONTROL

Alarm Volume

Alarm Tone

LCD Intensity

Fig. 6.24, Display Control Menu

10/31/2014 f611151

COMPONENT TEST

CCVS Brake Switch

Brake Pedal Position

37%

EBS Brake Switch

Fig. 6.25, Component Test Menu

Driver Assistance Features

6.10

WARNING

The lane departure warning system is intended

only as an aid for a conscientious and alert

driver. The system may not indicate lane depar-

tures under certain conditions. Read carefully the

information in this manual to understand the cir-

cumstances under which this system may not

provide adequate lane departure warnings. Do

not rely solely on the system to safely operate

the vehicle. The system does not warn of all pos-

sible hazards. For example, the system cannot

prevent an accident if the driver is impaired or

not driving safely.

The lane departure warning system is not a sub-

stitute for safe driving procedures.

Failure to drive safely and use the system prop-

erly could result in personal injury and/or death

and severe property damage.

The lane departure warning system powers up each

time the ignition is turned to ON. The system con-

ducts a self test, and initiates test tones from the left

speaker and then the right speaker. Once the vehicle

is started and the system is ready, the LED in the

switch illuminates.

Press the LANE ALERT switch to temporarily disable

the lane departure warning system. See Fig. 6.26.

Some vehicles are equipped with a timer that auto-

matically re-enables the warning system after 15

minutes. On all other vehicles, the warning system

will remain disabled until the driver enables the sys-

tem by pressing the LANE ALERT switch again, or

the ignition is cycled off and then on.

When the vehicle approaches the lane markings on

either side, the system sense the activation of a turn

signal. If a turn signal has not been activated, the

system initiates the audible warning to alert the driver

that the vehicle is departing its current lane of travel.

The LANE SRCHNG warning light illuminates to indi-

cate the system is not fully functional. When the

warning light is on, the system audible alert may not

indicate a lane departure. Conditions that can cause

the warning light to illuminate include:

•The system is unable to detect lane markings.

•Vehicle speed is less than 37 mph (60 km/h).

•A system problem is detected.

Roll Stability System

The roll stability system may include the roll stability

advisor (RSA) only, or it may also include the roll sta-

bility control (RSC).

A decal (Fig. 6.27) on the auxiliary dash panel, and

an amber-colored dash indicator light (Fig. 6.28), in-

dicate that the vehicle is equipped with roll stability

system components.

LANE

ALERT

f61115601/05/2012

Fig. 6.26, Lane Departure Warning System Disable

Switch

lamp indicates traction

OR roll control event.

Follow instructions in

driver’s manual.

24−01204−000

07/11/2003 f080125

SAFETY INSTRUCTIONS

Fig. 6.27, Roll Stability Decal

06/26/2003 f602128

Fig. 6.28, Roll Stability Indicator Lamp

Driver Assistance Features

6.11

Roll Stability Advisor

IMPORTANT: This is not an advance warning

system. The roll stability advisor displays a mes-

sage only after the driving maneuver is com-

pleted.

The roll stability system uses a lateral-acceleration

sensor that monitors rollover risk. Shortly after a

curve, lane change, or other driving maneuver that

results in a rollover-risk detection, a dash warning

light illuminates, an audible tone sounds, and a driver

advisory message is displayed in the driver message

center. The purpose is to advise the driver that the

previous maneuver produced a rollover risk.

The roll stability advisor displays different text mes-

sages depending on the severity of the risk of each

occurrence of risky driving. From the highest risk

level to the lowest risk level, the system will sound

an audible alert, and display a message, as shown in

Fig. 6.29.

NOTE: The system will calculate and recom-

mend a speed reduction value. It may be differ-

ent than the values shown here.

Bring the vehicle to an authorized service facility if a

system failure message is displayed.

Roll Stability Control

WARNING

The Roll Stability Control system is intended only

as an aid for a conscientious and alert driver.

Carefully read the information in this manual to

understand this system and its limitations. The

Roll Stability Control system is not a substitute

for safe driving procedures. Failure to drive

safely, and use the system properly, could result

in personal injury and/or death and property

damage.

The roll stability control system automatically reduces

engine power, applies the engine brake, and/or ap-

plies the tractor and trailer brakes when the accelera-

tion sensor detects that the vehicle is at risk of rolling

over. The control can intervene even before an advi-

sory message is displayed.

The dash indicator light illuminates whenever the roll

stability control system intervenes.

Message to Display

MessageMSG

No.

System Fault1WARNING

RAC SYSTEM FAIL

ACTIVE SLOWING

ROLLOVER RISK

4 NoneRSC2

VERY HIGH RISK OF

ROLLOVER DETECTED

REDUCE SPEED

AT LEAST 11 KPH

REDUCE SPEED

AT LEAST 7 MPH

or in metric

19.6 10RSA Level 33

HIGH RISK OF

ROLLOVER DETECTED

REDUCE SPEED

AT LEAST 11 KPH

REDUCE SPEED

AT LEAST 7 MPH

or in metric

14 5RSA Level 24

ROLLOVER RISK

DETECTED

REDUCE SPEED

AT LEAST 11 KPH

or in metric

REDUCE SPEED

AT LEAST 7 MPH

8.4 2RSA Level 15

HARD BRAKING WITH

ABS ACTIVATED

LOOK AHEAD

BRAKE SOONER

14 0.5HBED Level 36

HARD BRAKING

DETECTED

LOOK AHEAD

BRAKE SOONER

14 0.5HBED Level 27

LOSS OF TRACTION

ABS ACTIVATED

ROAD SURFACE

MAY BE POOR

14 0.5HBED Level 18

07/25/2008 f040769

Display

Time:

Seconds

Buzzer

Time:

Seconds

Fig. 6.29, Roll Stability and Hard-Braking Warnings

Driver Assistance Features

6.12

Hard-Braking Advisor

The hard-braking advisor uses the information from

the ABS wheel speed sensors to determine when

braking is severe enough to produce lockup at one

or more wheels on the tractor, and/or very rapid ve-

hicle deceleration. Shortly after a hard-braking event

occurs, an advisory message is displayed in the

driver message center, indicating that the braking

behavior was too aggressive for the current road sur-

face conditions. This system is not a replacement for

a driver’s good judgment. Sometimes it is necessary

to brake hard.

From the highest risk level to the lowest risk level,

the system will sound an audible alert, and display a

message, as shown in Fig. 6.29.

Trip/Leg Totals

The driver message center records the number of

messages received, and displays the number of

messages as counts. Roll stability advisor (RSA) and

hard-braking event data (HBED) counts can be

viewed in the trip advisory screen, and the leg advi-

sory screen.

Counts can be reset using the + key on the steering

wheel. Clearing RSA and HBED leg counts will also

reset the leg miles and leg hours. Clearing RSA and

HBED trip counts will also reset trip miles, trip hours,

leg miles, leg hours, and leg advisory counts. In ad-

dition, resetting leg miles will clear leg counts. Clear-

ing trip miles will reset miles, hours, and counts in

both the leg and trip screens.

The TRIP and LEG advisor screens count both the

roll stability advisories (ROLL) and hard-braking

events (BRK). For example, if during a TRIP, the

driver message center recorded the events in

Table 6.1, the message center would display as

shown in Fig. 6.30.

RSA/HBED Count

Message Received Message Counts

RSA Level 3 2

RSA Level 2 3

RSA Level 1 7

HBED Level 3 5

HBED Level 2 1

HBED Level 1 8

Table 6.1, RSA/HBED Count

If the count reaches more than 9 occurrences an up-

arrow symbol will appear, to indicate to the driver

that the count has exceeded 9 counts. See

Fig. 6.31.

Enhanced Stability Control

WARNING

Enhance Stability Control (ESC) is intended only

as an aid for a conscientious and alert driver.

Carefully read the information in this manual to

understand this system and its limitations. ESC

is not a substitute for safe driving procedures.

Failure to drive safely, and use the system prop-

erly, could result in personal injury and/or death

and property damage.

ESC offers the full capability of RSC (shown above)

with the added capability of complete directional sta-

bility (yaw control) in oversteer and understeer condi-

tions to reduce the likelihood of drift-out or jackknife.

The system determines where the driver is attempt-

ing to steer the vehicle and how much brake demand

is required in order to more precisely control the ve-

hicle in an emergency situation.

07/25/2008

TRIP ADVISORIES

237 ROLL 518 BRK

f040770

ABC DEF

A. RSA lev. 3 Count (2)

B. RSA lev. 2 Count (3)

C. RSA lev. 1 Count (7)

D. HBED lev. 3 Count (5)

E. HBED lev. 2 Count (1)

F. HBED lev. 1 Count (8)

Fig. 6.30, Trip Advisor Message Screen

07/25/2008

TRIP ADVISORIES

23 ROLL 518 BRK

f040771

A. RSA Lev. 1 has more than 9 counts.

Fig. 6.31, Trip Advisor Message Screen (more than 9

counts)

Driver Assistance Features

6.13

ESC works by constantly comparing the driver’s in-

tention with the vehicle’s actual behavior. The system

does this by monitoring systems such as wheel

speed, steering angle, yaw rate, lateral acceleration,

throttle position, and brake application. A central mi-

crocomputer analyzes the collected data and triggers

a response to keep the vehicle on course when an

unstable condition is detected.

When the system detects that the vehicle is at risk of

oversteering or understeering, it applies individual

tractor wheel end brakes and trailer brakes, activates

the engine retarder (if equipped), and/or cuts engine

power, depending on the severity. As a result, the

driver has full control over the vehicle until the sys-

tem detects a potential risk and intervenes accord-

ingly. ESC operates automatically; the driver does

not monitor or activate the system.

Driver Assistance Features

6.14

Seats and Restraints

Seats, General Information ......................................................... 7.1

Cascadia 2.0 High-Back Seat ....................................................... 7.2

Cascadia High-Back Seat .......................................................... 7.3

Sears Atlas Seat .................................................................. 7.4

Seat Belts and Tether Belts ......................................................... 7.5

Steering Wheel Air Bag ............................................................ 7.8

RollTek Rollover Protection System .................................................. 7.9

Seats, General Information

Unless otherwise noted, all seat adjustments should

be made while seated and before the engine is

started.

Due to the high degree of adjustability of mid- and

high-back air suspension seats, it is possible to com-

bine the seat back recline adjustment and the seat

slide adjustment so that the seat back contacts the

back wall. Use care when adjusting the seat to pre-

vent damage to the seat and the cab interior.

WARNING

Keep hands, tools, and other objects away from

the scissor points under the seats. Failure to do

so could cause personal injury.

The following is a description of adjustments that can

be made to various Freightliner-installed seats. Not

all seats have all of the adjustments listed below.

See Fig. 7.1.

•Backrest Tilt enables the backrest to pivot for-

ward or backward.

•Lumbar Support changes the shape of the

backrest to give more or less support to the

occupant’s lumbar (lower back) area. This ad-

justment is either mechanical or air controlled,

depending on the seat model.

•Fore/Aft Isolator feature reduces the amount of

road shock by isolating the occupant from the

motion of the vehicle, and allowing the upper

seat to move in a simple pendulum motion. A

lockout feature is used whenever the isolator is

not desired.

•Height Adjustment moves the entire seat up or

down. The adjustment is either manually- or

air-controlled, depending on the seat model.

•Bottom Cushion Angle (fore-and-aft bottom

cushion height) enables the occupant to raise

or lower the front or back of the bottom cush-

ion. This adjustment is easier to perform when

all weight is removed from the seat.

•Fore/Aft Seat Slide (seat track adjustment)

moves the entire seat forward or backward on

its track.

10/26/2000 f910149a

567

1. Backrest Tilt

2. Lumbar Support

3. Fore/Aft Isolator

4. Height Adjustment

5. Bottom Cushion Tilt (fore-and-aft

cushion height)

6. Fore/Aft Seat Slide (seat track

adjustment)

7. Seat Tilt

8. Headrest Adjustment

Fig. 7.1, General Seat Adjustments

Seats and Restraints

7.1

•Seat Tilt allows the seat assembly (back and

bottom cushions) to tilt forward or backward.

•Headrest Adjustment changes the angle of the

upper part of the backrest to provide head and

upper back support.

Cascadia 2.0 High-Back Seat

See Fig. 7.2 for seat adjustment controls. Not all

models of the Cascadia 2.0 Hi-Back seat have all the

adjustments listed below.

Recline

Pull the recline handle to adjust the backrest tilt.

Seat Heating/Ventilation

Use the forward switch to turn the seat heater and

ventilation ON or OFF. To turn on the heat, push the

top of the switch. To turn on the ventilation, push the

bottom of the switch. To turn off the heat or ventila-

tion, move the switch to the middle position. To ad-

just the heat or ventilation, Use the rear button to

adjust seat heating or ventilation. Three settings are

available: low, medium, and high. See Fig. 7.3.

NOTICE

Do not install seat covers on seats with heating

and ventilation. Do not cover the seat with blan-

kets, clothing, or pillows. Blocking the air ﬂow

through the cushions can overheat and damage

the seat.

IMPORTANT: Turn off seat heating/ventilation

when the seat is unoccupied.

Lumbar Support

Press the forward button to adjust lower lumbar sup-

port, the middle button to adjust upper lumbar sup-

port, and the rear button to adjust side support.

Height Adjustment

Pull or push the lever to adjust seat height.

Shock Absorber Adjustment

Move the lever down to increase damping on rough

roads, or up to decrease damping on ﬂat roads.

Fore/Aft Isolator

Rotate the isolator knob to the left to lock the isola-

tor, or to the right to allow movement.

05/11/2012 f910682

1. Recline Handle

2. Heat/Ventilation Adjustment Switch

3. Heat/Ventilation ON/OFF Switch

4. Lumbar and Side Support Switches

5. Height Adjustment Lever

6. Shock Absorber Adjustment Lever

7. Fore/Aft Isolator Lever

8. Bottom Cushion Extension Lever

9. Seat Fore/Aft Slide Lever

10. Seat Tilt Lever

Fig. 7.2, Cascadia 2.0 Hi-Back Seat

Seats and Restraints

7.2

Bottom Cushion Extension

Pull the lever to move the seat cushion forwards or

backwards. The cushion moves 2-3/8 inches (60

mm) in 3/8-inch (10-mm) increments.

Seat Fore/Aft Slide

Lift the lever to slide the seat forward or backward.

Release the lever to lock the seat in position.

Seat Tilt

Pull the lever and lean back to tilt the seat back-

wards. Three positions are available.

Armrest Angle

To adjust the armrest angle, tilt the armrest to the

highest position, then down to the lowest position,

then to the desired position.

Cascadia High-Back Seat

See Fig. 7.4 for seat adjustment controls.

Backrest Tilt

To tilt the backrest, lean forward slightly to remove

pressure from the cushion, then turn the knob for-

ward or rearward to achieve the desired position.

Lumbar Support

To adjust the lumbar support, use the lumbar support

switches on the side of the seat.

Height Adjustment

To raise or lower the height of the seat, use the

height adjustment switch on the side of the seat.

Bottom Cushion Extension

To adjust the fore-and-aft position of the seat cush-

ion, remove your weight from the seat, then lift up

and pull forward on the cushion adjustment handle.

To return the cushion to the aft position, lift up and

push rearward.

Fore/Aft Seat Slide

To adjust the fore-and-aft position of the entire seat,

move the fore-and-aft seat adjustment lever to the

left and slide the seat forward or backward to the

desired position. Move the lever back to its original

position to lock the seat in place.

Fore/Aft Isolator

To engage the isolator, turn the isolator knob rear-

ward to the unlocked position. Turn the isolator knob

forward to the locked position when the isolator fea-

ture is not desired.

Shock Absorber

To adjust the amount of damping the shock absorber

provides, move the lever up to increase damping;

move the lever down to decrease damping.

Front Cushion Height

To adjust the height of the front of the cushion, re-

move your weight from the seat, then turn the adjust-

ment knob toward the front of the seat (clockwise) to

increase cushion height. To lower the cushion height,

turn the adjustment knob toward the rear of the seat

(counterclockwise).

Rear Cushion Height

To adjust the height of the rear of the seat cushion,

remove your weight from the seat and turn the rear

cushion adjustment knob to one of three positions.

05/08/2012 f910683

1. Ventilation ON

2. Heat/Ventilation OFF

3. Heat ON

4. Heat/Ventilation ON/OFF Switch

5. Heat/Ventilation Adjustment Switch

Fig. 7.3, Cascadia 2.0 Hi-Back Seat Heat/Ventilation

Controls

Seats and Restraints

7.3

Heater

To turn on the heat option, press the button. To turn

off the heat option, press the button again. If the ve-

hicle has Optimized Idle, seat heating will not oper-

ate with the key in accessory mode. Optimized Idle

may also turn seat heating off to reduce stress on

the batteries. Refer to Chapter 11 for more informa-

tion.

Sears Atlas Seat

See Fig. 7.5 for seat adjustment controls.

Backrest Tilt

Pull upward on the recliner handle, move the back-

rest to the desired position and release the handle.

Lumbar Support

Rear rocker switch: Push forward to inﬂate the lower

lumbar bag; push rearward to deﬂate the bag. Center

rocker switch: Push forward to inﬂate the upper lum-

bar bag; push rearward to deﬂate the bag.

Fore/Aft Seat Slide

To adjust the fore-and-aft position of the entire seat,

squeeze the fore/aft slide lock against the adjustment

bail, and lift the bail up. See Fig. 7.6. Slide the seat

f910576

07/18/2007

1. Rear Cushion Height Adjustment

Knob

2. Fore/Aft Isolator

3. Front Cushion Height Adjustment

Knob

4. Bottom Cushion Extension Handle

5. Fore/Aft Seat Slide Lever

6. Backrest Tilt Knob

7. Heater Button

8. Shock Absorber Lever

9. Height Adjustment Switch

10 Lumbar Support Switches

Fig. 7.4, Cascadia Hi Back Seat

Seats and Restraints

7.4

forward or backward to the desired position. Release

the bail and fore/aft slide lock, to its original position,

to lock the seat in place.

Bottom Cushion Tilt

Lift the handle upward and move the seat cushion to

the desired position. Three positions are available.

Armrest Angle

Rotate the control knob, located on the underside of

the armrest, to set the desired angle of the armrest.

Isolator

Position the handle to the left to allow isolation

movement. Position the handle to the right to lock-

out isolation movement.

Suspension Inﬂation/Deﬂation

Push forward on the gray rocker switch to inﬂate and

raise the suspension; push rearward to deﬂate and

lower the suspension.

Seat Extension

Rotate the handle upward to disengage, then move

the seat cushion to the desired position and release

the lever. Three positions are available.

Seat Belts and Tether Belts

Seat belt assemblies are designed to secure persons

in the vehicle to help reduce the chance of injury, or

the amount of injury, resulting from accidents or sud-

den stops. For this reason, Daimler Trucks North

America LLC (DTNA) urges that the driver and all

passengers, regardless of age or physical condition,

use seat belts when riding in the vehicle.

10/15/2007 f910597

1. Isolator Lever

2. Fore/Aft Seat Slide

Lever

3. Bottom Cushion Tilt

Handle

4. Seat Extension Lever

5. Backrest Tilt Lever

6. Lumbar Support

Switches

7. Suspension Inﬂation/

Deﬂation Switch

Fig. 7.5, Sears Atlas Seat

10/15/2007 f910599

A. Squeeze the fore-and-aft slide lock against the

adjustment bail.

B. Lift up the adjustment bail.

Fig. 7.6, Fore/Aft Slide Adjustment, Sears Atlas Seat

Seats and Restraints

7.5

WARNING

Always use the vehicle’s seat belt system when

operating the vehicle. Failure to do so can result

in severe personal injury or death.

Seat belt assemblies in DTNA vehicles meet Federal

Motor Vehicle Safety Standard 209, "Type 1" and

"Type 2" requirements.

When transporting a child, always use a child re-

straint system or the vehicle seat belts as appropri-

ate. To determine whether a child restraint system is

required, review and comply with applicable state

and local laws. Any child restraint used must comply

with Federal Motor Vehicle Safety Standard 213,

"Child Restraint Systems." When providing a child

restraint system, always carefully read and follow all

instructions pertaining to installation and usage for

the child. Make certain the child remains in the re-

straint system at all times when the vehicle is in

motion.

In addition to seat belt assemblies, tether belts are

installed on suspension-type seats. Tether belts help

secure the seat to the ﬂoor and are intended to re-

strain the seat and seat belt in case of an accident or

sudden stop.

IMPORTANT: Seat belts have a ﬁnite life which

may be much shorter than the life of the vehicle.

Regular inspections and replacement as needed

are the only assurance of adequate seat belt

security over the life of the vehicle.

Seat Belt Inspection

WARNING

Inspect and maintain seat belts. When any part of

a seat belt system needs replacement, the entire

seat belt must be replaced, both retractor and

buckle side. Any time a vehicle is involved in an

accident, and the seat belt system was in use,

the entire vehicle seat belt system must be re-

placed before operating the vehicle. Do not at-

tempt to modify the seat belt system; doing so

could change the effectiveness of the system.

Failure to replace worn or damaged seat belts, or

making any modiﬁcations to the system, may re-

sult in personal injury or death.

Inspect the seat belts and tether belts (if so

equipped).

1. Check the web for fraying, cuts, extreme dirt and

dust, or for severe fading from exposure to sun-

light, especially near the buckle latch plate and in

the D-loop guide area.

2. Check operation of the buckle, latch, Komfort

Latch or Sliding Komfort Latch (if equipped), web

retractor, and upper seat belt mount on the door

pillar. Check all visible components for wear or

damage.

3. Check the seat belt and tether belt connection

points and tighten any that are loose.

Seat Belt Operation

WARNING

Wear three-point seat belts only as described

below. Three-point seat belts are designed to be

worn by one person at a time. In case of an acci-

dent or sudden stop, personal injury or death

could result from misuse.

Fasten the seat belts before driving. Fastening a

three-point seat belt while driving creates a haz-

ard.

When engaged and used properly, the Komfort Latch

(Fig. 7.7) and the Sliding Komfort Latch (Fig. 7.8)

introduce a small amount of slack into the seat belt,

resulting in a more comfortable ride.

1. Slowly pull the link end of the seat belt out of the

retractor and pull it across your lap (from out-

board to inboard) far enough to engage the

buckle. If the retractor locks too soon, allow the

belt to retract slightly, then slowly pull it out

again. See Fig. 7.9.

2. Fasten the seat belt by pushing the latch into the

buckle. Listen for an audible click.

3. Tug on the seat belt to make sure it is securely

fastened. If the buckle unlatches, repeat this

step. If the problem continues, replace the seat

belt.

4. Snug the seat belt to your waist.

Seats and Restraints

7.6

WARNING

Before activating the Komfort Latch or the Slid-

ing Komfort Latch, make sure the amount of

slack in the shoulder strap is set as described

below. Excess slack in the shoulder strap re-

duces the effectiveness of the seat belt, and in-

creases the risk of injury or death in an accident.

5. Position the shoulder strap diagonally across

your chest with the adjustable D-loop bracket (if

equipped). The shoulder strap must be centered

on your shoulder and chest, away from your face

and neck. See Fig. 7.10. If desired, engage the

Komfort Latch or Sliding Komfort Latch as fol-

lows.

If equipped with a Sliding Komfort Latch, make

sure that the shoulder strap is snug against your

chest. Without loosening the shoulder strap,

push the Sliding Komfort Latch switch to the

"ON" position. See Fig. 7.8. To activate the latch

lean forward until you hear a click. This will allow

03/11/2010 f910620

A. Disengaged B. Engaged

Fig. 7.7, Komfort Latch

11/18/2010 f910621a

Fig. 7.8, Sliding Komfort Latch

07/02/2007 f910578

1. Latch 2. Buckle

Fig. 7.9, Three-Point Seat Belt Operation

Seats and Restraints

7.7

for approximately 1 inch (2.5 cm) of slack be-

tween your chest and the shoulder harness.

Once engaged, the latch will allow you to lean

forward about 5 inches (13 cm) without having to

reset the latch. Leaning forward more than 5

inches (13 cm) will disengage the Sliding Kom-

fort Latch, requiring it to be reset.

If equipped with a Komfort Latch, pull on the

shoulder strap to lessen the pressure of the strap

on your shoulder and chest. Allow no more than

1 inch (2.5 cm) of slack between your chest and

the shoulder harness. More slack can signiﬁ-

cantly reduce the seat belt effectiveness in an

accident or a sudden stop. While holding the belt

slack, press the Komfort Latch lever up, clamp-

ing the seat belt webbing (Fig. 7.11 and

Fig. 7.12).

6. Unbuckle the seat belt and release the Komfort

Latch or the Sliding Komfort Latch as follows.

If equipped with a Sliding Komfort Latch, un-

buckle the seat belt, then tug on the shoulder

belt to release the Sliding Komfort Latch, or

press the Sliding Komfort latch to the "OFF" po-

sition, then unbuckle the seat belt.

If equipped with a Komfort Latch, unbuckle the

seat belt, then release the Komfort Latch by giv-

ing the shoulder belt a quick tug. If you lean for-

ward against the shoulder belt, the Komfort Latch

will automatically release, and will need to be

reset.

NOTE: Neither the Komfort Latch nor the Sliding

Komfort Latch need to be manually released in

an emergency situation. Each will release by

itself under rough road or other abnormal condi-

tions. Make sure the seat belt is completely re-

tracted when it is not in use.

Steering Wheel Air Bag

Operation

NOTE: Only vehicles with the letters "SRS"

molded into the steering wheel center pad are

equipped with a steering wheel air bag.

The air bag, when used with seat belts, provides ad-

ditional protection to the driver in severe frontal colli-

sions. Steering wheel air bags are designed to inﬂate

only in severe frontal collisions. The driver and the

08/09/2010 f910634

ABC

A. Correct—Belt is centered on your shoulder and

chest, away from your face and neck.

B. Wrong—Belt must not rub against face or neck.

C. Wrong—Belt must not hang off shoulder.

Fig. 7.10, Proper Shoulder Strap Fit

01/06/95 f910048a

A. 1 Inch (2.5 cm) Maximum

Fig. 7.11, Adjusting Shoulder Harness Clearance,

Komfort Latch

11/02/95 f910144

Fig. 7.12, Locking the Komfort Latch

Seats and Restraints

7.8

passenger should always wear seat belts. The steer-

ing wheel air bag will activate during a collision even

if the seat belts are not fastened, but the system is

designed to provide protection to the occupant only

when the seat belts are fastened.

WARNING

Keep all heavy objects in the cab secured. Do not

place objects on the steering wheel or between

you and the steering wheel. Any such objects

may cause harm during an accident. Keep your

hands on the sides and lower portion of the

steering wheel. Failure to follow these instruc-

tions may result in death or personal injury.

For maximum protection in a collision, always be in a

normal seated position with your back against the

seat back and your head upright. Fasten your seat

belt and ensure that it is properly positioned on your

body as described under the "Seat Belt Operation"

heading. Since the air bag inﬂates with considerable

speed and force, a proper seat position will help

keep you a safe distance from the inﬂating air bag.

Inspection and Service

WARNING

Do not attempt to service or modify the air bag

system. Unintentional or improper air bag deploy-

ment could cause severe bodily injury or death.

Contact an authorized Freightliner service facility

for all service and maintenance.

The air bag system contains components that

use combustible chemicals. Do not cut, drill,

braze, solder, weld, strike, or probe the air bag

components. Keep all liquids and chemicals

away from air bag components.

The surface of the deployed air bag may contain

small amounts of sodium hydroxide (which is a

by-product of the gas generant combustion) and

metallic sodium. Sodium hydroxide may be irri-

tating to the skin and eyes. Immediately wash

your hands and exposed skin areas with a mild

soap and water. Flush your eyes immediately if

exposed to sodium hydroxide.

The operational readiness of the air bag system is

indicated by the supplemental restraint system (SRS)

indicator on the dash. The SRS indicator illuminates

for several seconds when the ignition is turned on,

and then it goes off. The indicator will remain on if

there is a problem with the air bag system. The ve-

hicle should be serviced if the SRS indicator does

not illuminate when the ignition is turned on, or if the

SRS indicator remains on.

The air bag module may contain perchlorate mate-

rial; for information, see www.dtsc.ca.gov/

hazardouswaste/perchlorate. Special handling may

apply; follow appropriate rules and regulations when

disposing of materials.

For all service and maintenance, contact an autho-

rized Freightliner service facility.

RollTek Rollover Protection

System

Identiﬁcation

Only seats with the RollTek module under the seat

and the molded side-roll air bag cover on the upper

side of the seat back are equipped with the RollTek

rollover protection system; see Fig. 7.13. RollTek

may be installed in one of the following conﬁgura-

tions:

•driver seat only or driver and passenger seats

•driver seat only, with an optional steering

wheel frontal air bag

•driver and passenger seats, with an optional

steering wheel frontal air bag

Operation

The RollTek system, when used with seat belts, pro-

vides additional protection to the driver and passen-

ger (if equipped with a passenger-side system) in

rollover accidents. The RollTek system provides a

signiﬁcant increase in seat stability during a rollover.

Vehicles equipped with RollTek rollover protection

have a sensor mounted in the seat base that acti-

vates the side-roll air bag and seat pull-down device

during a rollover.

When the RollTek module senses a rollover, the

module triggers gas cylinders mounted in the base of

the seat. The gas cylinders activate the power

cinches that then tighten the lap and shoulder belts

against the occupant of the seat and lower the seat

suspension, moving the occupant down and away

from the steering wheel and ceiling. The side-roll air

Seats and Restraints

7.9

bag deploys from the outboard side of the seat as

the seat is pulled down to its lowest position. See

Fig. 7.14.

WARNING

Always use the seat belts when operating the ve-

hicle. Failure to do so can result in severe per-

sonal injury or death. Do not place infants and

children in seats equipped with the RollTek sys-

tem. The RollTek system is designed for adults

only. Doing so could result in severe bodily in-

jury or death. Keep all heavy objects in the cab

secured. Do not place objects on the seat back

or block the side-roll air bag. Objects that block

the side-roll air bag may prevent proper inﬂation

and could result in serious injury or death.

The RollTek system will activate during a rollover

even if the seat belts are not fastened, but the

RollTek system is only designed to provide protection

to the occupant when the seat belts are fastened.

For vehicles with the RollTek system(s) only, de-

vice(s) deploy as follows:

•Rollover Crash—occupant seat belt pretension-

ing, seat pretensioning, and side-roll air bag at

the proper time

•Frontal Crash—no devices deployed

10/15/2007 f910598

1. RollTek Module

2. Side-Roll Air Bag Cover

Fig. 7.13, RollTek Protection System Components

07/03/2007

f910579

A. Side-roll air bag contained in seat.

B. Side-roll air bag deployed.

Fig. 7.14, Side-Roll Air Bag

Seats and Restraints

7.10

For vehicles with the RollTek system(s) and frontal

steering wheel air bag, device(s) deploy as follows:

•Rollover Crash—occupant seat belt pretension-

ing, seat pretensioning, and side-roll air bag at

the proper time

•Frontal Crash—steering wheel air bag, occu-

pant seat belt pretensioning, seat pretension-

ing, and the side-roll air bag at the proper time

Inspection and Service

WARNING

Keep hands and tools away from the scissor

points under the seats.

The RollTek system contains components that

use combustible chemicals. Do not cut, drill,

braze, solder, weld, strike, or probe any part of

the RollTek system. Keep all liquids and chemi-

cals away from the RollTek components.

Do not attempt to service or modify the RollTek

system. Unintentional or improper deployment of

the RollTek system could cause severe bodily

injury or death. Contact an authorized Freight-

liner service facility for all service and mainte-

nance.

IMPORTANT: The RollTek system must be re-

placed after being activated. Damaged seat

belts and tethers, or seat belts and tethers that

were worn in an accident, must be replaced,

and their anchoring points must be checked.

The operational readiness of the RollTek system is

indicated by the supplemental restraint system (SRS)

indicator on the dash. The SRS indicator illuminates

for several seconds when the ignition is turned on,

and then it goes off. The indicator will remain on if

there is a problem with the air bag or RollTek sys-

tem. The vehicle must be serviced if the SRS indica-

tor does not illuminate when the ignition is turned on,

or if the SRS indicator remains on.

The air bag module may contain perchlorate mate-

rial; for information, see www.dtsc.ca.gov/

hazardouswaste/perchlorate. Special handling may

apply; follow appropriate rules and regulations when

disposing of materials.

For all service and maintenance, contact an autho-

rized Freightliner service facility.

Seats and Restraints

7.11

Climate Control

Cab Climate Control Panel ......................................................... 8.1

Sleeper Climate Control Panel ...................................................... 8.2

ParkSmart™HVAC System ......................................................... 8.3

Accessory Heaters ................................................................ 8.5

Cab Climate Control Panel

The standard cab climate control panel has a fan

switch with a recirculation button, temperature control

switch with an A/C button, and a mode control

switch. See Fig. 8.1. Sleeper cabs are also equipped

with a bunk override button.

Fan Switch

The fan switch activates the fan, which forces fresh

air or recirculated air through the air outlets. The fan

switch has eight fan speed settings and an OFF po-

sition. See Fig. 8.2.

To operate the fan switch, turn the fan switch clock-

wise to increase airﬂow; turn the fan switch counter-

clockwise to decrease airﬂow.

There is a two-second delay between the time the

engine is started and the blower is operational. It can

take an additional four seconds for the blower to

reach high speed. The blower motor performs a self-

test immediately after the engine is started, which

causes the delay. If the vehicle has Optimized Idle,

the fan will not operate with the key in accessory

mode. Optimized Idle may also turn the fan off to

reduce stress on the batteries. Refer to Chapter 11

for more information.

Recirculation

Recirculation mode limits the amount of outside air

entering the cab. Press the recirculation button to

prevent dusty or smoky air from entering the cab.

See Fig. 8.2. Recirculation mode can also decrease

the time required to cool or heat the cab interior dur-

ing extreme outside temperature conditions. When

the recirculation mode is turned on, the amber indi-

cator on the recirculation button will illuminate.

The recirculation button will not work when the mode

control switch is in either defog or defrost modes.

NOTE: To prevent the buildup of odors or oxy-

gen depletion inside the cab, the system

switches from full recirculation mode to partial

recirculation mode after 20 minutes. In ex-

tremely dusty or smoky conditions, the partial

recirculation mode can be overridden by press-

ing the recirculation button twice to obtain full

recirculation mode. This resets the 20-minute

timer.

Temperature Control Switch

The temperature control switch is used to select the

desired temperature in the cab. Turn the switch

counterclockwise for cool air, or clockwise for hot air.

See Fig. 8.3.

Air Conditioning Button

The air conditioner (A/C) cools and dehumidiﬁes the

air inside the cab. Press the A/C button, located in

the center of the temperature control switch, to turn

the air conditioner on and off. See Fig. 8.3.

A/C will be automatically disabled when:

07/20/2006 f831701

12 3

1. Fan Switch

2. Temperature Control Switch

3. Mode Control Switch

Fig. 8.1, Cab Climate Control Panel

06/08/2007 f610946

1. Recirculation Button

Fig. 8.2, Fan Switch

Climate Control

8.1

•outside air temperature is low enough to make

the A/C ineffective;

•engine is running at extremely low rpm;

•conditions exist that result in the climate con-

trol system going into protection mode.

Mode Control Switch

The mode control switch allows the driver to control

the ﬂow of air through the face outlets, the ﬂoor out-

lets, the defrost (windshield) outlets, or a combination

of these outlets. See Fig. 8.4.

•Face Mode: Directs all airﬂow through the face

or instrument panel outlets.

•Bi-Level Mode: Directs the airﬂow equally to

the face outlets and the ﬂoor outlets.

•Floor Mode: Directs all airﬂow through the ﬂoor

outlets.

•Floor/Defrost Mode: Directs the airﬂow equally

to the ﬂoor outlets and the defrost outlets.

•Defrost Mode: Directs all airﬂow through the

defrost outlets.

Bunk Override Button

The bunk override button, equipped on sleeper cabs

only, allows the driver to control the sleeper heat and

A/C settings from the cab. See Fig. 8.4.

Press the bunk override button to turn the sleeper

heat or A/C on. An amber indicator will illuminate

when bunk override mode is activated.

Press the bunk override button again to turn bunk

override mode off. Adjusting the sleeper climate con-

trols at any time will also cause the bunk override

mode to cancel.

Sleeper Climate Control Panel

The standard sleeper climate control panel has a fan

switch and a temperature control switch with an A/C

button.

If the bunk override button has been activated, the

override mode can be canceled by changing the

sleeper fan speed or temperature setting. The cli-

mate control system will then operate from the

sleeper controls.

Fan Switch

The fan switch activates the fan, which forces air

through the air outlets. The fan switch has eight fan

speeds and an OFF position. See Fig. 8.5.

To operate the fan switch, turn the switch clockwise

to increase airﬂow; turn the fan switch counterclock-

wise to decrease airﬂow. If the vehicle has Optimized

06/08/2007 f610947

1. Air Conditioning Button

Fig. 8.3, Temperature Control Switch

06/08/2007 f610948

1. Face Mode

2. Selection Between Face Mode and Bi-Level Mode

3. Bi-Level Mode

4. Selection Between Bi-Level Mode and Floor Mode

5. Floor Mode

6. Selection Between Floor Mode and Defog Mode

7. Defog Mode

8. Selection Between Defog Mode and Defrost Mode

9. Defrost Mode

10. Bunk Override Button (on sleeper-cabs only)

Fig. 8.4, Mode Control Switch With Bunk Override

Button

Climate Control

8.2

Idle, the fan will not operate with the key in acces-

sory mode. Optimized Idle may also turn the fan off

to reduce stress on the batteries. Refer to Chap-

ter 11 for more information.

NOTE: When the cab air conditioner (A/C) is on,

the sleeper fan will operate at low speed even if

the sleeper fan switch is in the off position. This

is necessary to protect the evaporator in the

sleeper heater and air conditioner system from

freezing. In lower fan speed settings, a slight

increase in airﬂow levels may appear at times,

as the control acts to regulate the evaporator

temperature.

Temperature Control Switch

The temperature control switch is used to select the

desired temperature in the sleeper. Turn the switch

counterclockwise for cool air, or clockwise for hot air.

Air Conditioning Button

The A/C cools and dehumidiﬁes the air inside the

sleeper. Press the air conditioning button, located in

the center of the temperature control switch, to turn

the A/C on and off.

ParkSmart™HVAC System

There are two variations of the ParkSmart vehicle

conﬁguration. The standard conﬁguration is the most

common, and includes all vehicles without Detroit

Diesel Optimized Idle (O/I). The second variation in-

cludes vehicles equipped with Detroit Diesel Opti-

mized Idle (O/I). Both conﬁgurations are operated in

the same way, the differences are in how the batter-

ies and charging system are conﬁgured. Refer to

"Standard Vehicle Conﬁguration" or "Vehicles with

Detroit Diesel Optimized Idle" below for more infor-

mation on your vehicle.

Standard Vehicle Conﬁguration

The ParkSmart™climate control panel replaces the

standard sleeper control panel in ParkSmart-

equipped sleeper cabs. The ParkSmart HVAC sys-

tem is designed to maintain a comfortable tempera-

ture inside the sleeper, and can operate in

combination with the cab climate control system

when the vehicle is running, or independently when

the vehicle is parked. It uses a set of four dedicated

batteries mounted aft of the starting batteries, either

between the frame rails behind the cab or outside

the frame rail.

The ParkSmart climate controls operate similarly to

the standard sleeper climate controls. The tempera-

ture settings range from 60°F (15°C) to 85°F (29°C),

with 74°F (23°C) at the very center of the range. The

fan switch activates the fan. The fan switch has eight

fan speeds. Zero (0) is the OFF position. See

Fig. 8.6. To operate the fan switch, turn the switch

clockwise to increase airﬂow; turn the fan switch

counterclockwise to decrease airﬂow.

The ParkSmart HVAC system operates both when

the engine is running and when the engine is off.

When the engine is running, the air conditioning

(A/C) is powered by the vehicle electrical system,

while the auxiliary heater core is supplied with engine

06/08/2007 f610949

1. Fan Switch

2. Temperature Control Switch

3. Air Conditioning Button

Fig. 8.5, Sleeper Climate Control Panel

f610949c

05/24/2011

1. Fan Switch

2. Temperature Control

Switch

3. PARK Mode Control

Button

Fig. 8.6, ParkSmart Climate Control Panel

Climate Control

8.3

coolant. While the engine is running, the ParkSmart

batteries are also being recharged by the vehicle

electrical system.

When the engine is off with the key in the ACC or

ON positions, A/C mode is powered by the

ParkSmart batteries. The cab fan will also circulate

air in the cab using power from the main vehicle bat-

teries. The available power for other vehicle-supplied

accessories (house loads) will be affected when run-

ning in this mode. If there is no Low Voltage Discon-

nect (LVD) control on the main electrical system, the

ability to start the vehicle could also be compromised

if this mode is activated for an extended time period.

When the engine is off with the ignition switch in the

OFF position, the ParkSmart system runs the

battery-operated A/C or diesel-operated coolant

heater, depending on the temperature requested,

and power is drawn from the batteries. The main bat-

teries and the ParkSmart batteries will both be used

until the system voltage drops to 12.5 volts, then the

system will switch to the ParkSmart batteries only.

The ParkSmart system will run until the dedicated

batteries reach 11.3 volts.

Before operating the ParkSmart system, bring the

sleeper interior temperature to the desired tempera-

ture with the engine running and the bunk curtain

open. The ParkSmart system is designed to maintain

an established comfortable bunk temperature, in

parked mode, for up to 12 hours with the bunk cur-

tain closed. See Table 8.1 for recommended settings

for comfort while the vehicle is parked. Table 8.2

shows the temperature knob setting for desired tem-

peratures.

To use the ParkSmart control panel, select a fan

speed (other than off) and push the PARK button.

Adjust the temperature control knob to the desired

temperature. Refer to Table 8.1 or Table 8.2, de-

pending what mode is being used.

Start the fuel-operated heater once per month and

allow it to run for 15 minutes. Periodically running the

heater will keep fresh fuel in the lines and ensure the

heater is ready to perform when needed.

IMPORTANT: Wait three minutes after shutting

down the ParkSmart system before turning the

cab load disconnect switch (CLDS) to OFF.

NOTE: The Espar Hydronic 5 water heater can

use biodiesel blends up to 10% (B-10). Consult

the engine manufacturer’s manual to conﬁrm the

lowest allowable blend (engine or heater) is not

being exceeded.

IMPORTANT: The condition and charge of the

auxiliary batteries will directly affect run time of

the ParkSmart system. If the vehicle run-time

between discharges is less than eight hours, or

if additional loads are added to the auxiliary bat-

teries, the ParkSmart run-time will be less than

expected.

Parked HVAC Comfort Guide

Rest Hours Desired

Weather Setting Guide

Outdoor Temperature

Less Than or Equal

to: °F (°C)

Sunshine Less Than

or Equal to:

Maximum Blower

Speed

Minimum

Temperature Knob

Setting

4 105 (40) Light Sun 8 Full Cold

95 (35) Full Sun 8 Mid

90 (32) Light Sun 8 Full Cold

100 (38) Night Time 8 Full Cold

110 (43) Full Sun 6 3 O’clock

875 (24) Night Time 6-8 Full Cold

95 (35) Light Sun 6 10 O’clock

85 (30) Light Sun 6 10 O’clock

100 (38) Light Sun 6 Mid

95 (35) Night Time 6 10 O’clock

105 (40) Night Time 6 Mid

Climate Control

8.4

Parked HVAC Comfort Guide

Rest Hours Desired

Weather Setting Guide

Outdoor Temperature

Less Than or Equal

to: °F (°C)

Sunshine Less Than

or Equal to:

Maximum Blower

Speed

Minimum

Temperature Knob

Setting

12 90 (32) Night Time 6 10 O’clock

100 (38) Night Time 6 Mid

Table 8.1, Parked HVAC Comfort Guide

Temperature Control Knob Position to Requested

Output Temperature

Temperature Control

Knob Position (Clicks)

Requested Sleeper

Temperature: °F (°C)

1 60 (16)

2 60 (16)

3 62 (17)

4 64 (18)

5 66 (19)

6 68 (20)

7 70 (21)

8 71 (22)

9 72 (22)

10 73 (23)

11 74 (23)

12 75 (24)

13 76 (24)

14 77 (25)

15 78 (25)

16 79 (26)

17 80 (27)

18 82 (38)

19 84 (29)

20 85 (29)

21 Full Hot

Table 8.2, Temperature Control Knob Position to

Requested Output Temperature

Vehicles with Detroit Diesel Optimized

Idle

If a Cascadia vehicle is equipped with Detroit Diesel

optimized idle (O/I), it will affect the way the

ParkSmart operates. When the driver initiates the

O/I, the ParkSmart will operate in O/I mode as fol-

lows.

•The ParkSmart runs unless the ParkSmart fan

speed control knob is turned to the "OFF" posi-

tion. See Fig. 8.6. The fan speed control knob

must be set at "1" or higher.

•The engine will periodically start and run for at

least two hours to maintain battery voltage

then shut off. The ParkSmart will continue to

operate during this time.

•If the O/I shuts down due to a fault in the O/I

system, the ParkSmart will continue to operate

until it is shut off by the driver or one of the

automated failsafes.

•The ParkSmart ON/OFF button and LED indi-

cator on the parked HVAC control module do

not function when the vehicle is in O/I mode.

When the vehicle is not in O/I mode, the

ParkSmart ON/OFF button and LED indicator

operate normally.

All other functions are the same as the standard sys-

tem.

Accessory Heaters

Optional accessary heaters are available from the

factory in several conﬁgurations. Familiarize yourself

with the equipment on your speciﬁc vehicle, and fol-

low the manufacturer’s operating and maintenance

instructions.

WARNING

Do not operate fuel-operated heaters in an area

where ﬂammable vapors, including gasoline or

diesel fumes, are present, such as at ﬁlling sta-

tions and tank farms. Turn off a fuel-operated

heater and allow it shut down completely before

entering an area where ﬂammable gases or liq-

uids are present. Heaters continue to operate for

up to three minutes after being turned off.

Climate Control

8.5

Failure to observe these precautions could cause

an explosion or ﬁre, resulting in serious property

damage, and personal injury or death.

NOTICE

Always ensure that air inlet and outlet grilles are

not restricted. Restriction of any air inlet or outlet

ports could result in damage to the auxiliary

heater.

IMPORTANT: To maintain reliable performance,

run the accessory heater for at least 15 minutes

every month to prevent fuel from degrading.

Accessory heaters function when the ignition switch

is in the off position and the cab load disconnect

switch is on, if equipped.

IMPORTANT: Wait three minutes after shutting

down an accessory heater before turning the

cab load disconnect switch (CLDS) to OFF.

NOTE: The low voltage disconnect (LVD) control

prevents a heater from draining the batteries

below starting voltage.

Espar Heater

Refer to the Espar website, www.espar.com, for ad-

ditional information.

Espar Mini-Controller

To turn the heat on, press the heat button. See

Fig. 8.7. The red indicator will illuminate when heat

mode is activated. Adjust the desired temperature

with the control knob; rotate the temperature control

knob clockwise for warmer air, or counterclockwise

for cooler air. To turn the heat off, press the off but-

ton.

To turn the fan on, press the fan button. The blue

indicator will illuminate when ventilation mode is acti-

vated. To turn the fan off, press the off button.

Espar Digi-Controller

Vehicles built after December 8, 2011 with the Digi-

Controller and D2 air heaters are equipped with an

internal LVD in the Digi-Controller that prevents the

heater from draining battery voltage below 12.0 volts.

To turn heat mode on, press the heat button and the

heater will begin its start-up cycle. See Fig. 8.8.ON

will display brieﬂy followed by the ambient tempera-

ture, and the green indicator will illuminate. Ambient

display temperature range is 41°F to 90°F.

To adjust the desired temperature, press the up or

down arrow buttons. The desired temperature will

display brieﬂy, followed by the ambient temperature.

The desired temperature will remain in the modulator

memory when the heater is not in operation. Tem-

perature adjustment range is from 41°F to 90°F.

To turn heat mode off, press the heat button again.

The heater will initiate a 3-minute cooling cycle.

To turn the fan on, press and hold the fan button until

the blue indicator illuminates and the display shows

active rotating digits. To turn the fan off, press the

fan button again.

NOTE: The Digi-Controller also has a program-

mable run timer that will automatically shut the

heater off after the set time limit. The default

time limit setting is 10 hours.

02/06/2012 f611161

1. Temperature Control Knob

2. Fan Button

3. Fan Indicator (blue)

4. Off Button

5. Heat Indicator (red)

6 Heat Button

Fig. 8.7, Espar Mini-Controller

Climate Control

8.6

Webasto Heater

To turn the heater on, rotate the heater control knob

clockwise until the indicator light illuminates. See

Fig. 8.9. The Webasto heater requires one to two

minutes to warm up before warm air is delivered.

To set the desired temperature, rotate the heater

control knob clockwise for warmer air, or counter-

clockwise for cooler air.

To turn the heater off, rotate the heater control coun-

terclockwise until it clicks and the indicator light is

extinguished. The heater will initiate a two-minute

cooling cycle.

Refer to the Webasto website, techwebasto.com,

for additional information.

02/06/2012 f611160

Espar

1. Ambient Temperature Sensor

2. Down Arrow Button

3. Fan Button

4. Fan Indicator (blue)

5. Heat Indicator (green)

6 Heat On/Off Button

7. Up Arrow Button

8. Ambient Temperature Display

Fig. 8.8, Espar Digi-Controller

10/24/2014 f611162

1. Off Position

2. Heater On Indicator Light

Fig. 8.9, Webasto Heater Control Knob

Climate Control

8.7

Cab Features

Windows ........................................................................ 9.1

Mirrors .......................................................................... 9.1

Cab Amenities ................................................................... 9.1

Sleeper Amenities ................................................................. 9.2

Windows

Power windows are standard on Cascadia™vehicles.

The driver’s door has two switches mounted in the

top of the door, that control the driver and passenger

windows separately. See Fig. 9.1. The passenger

door has a switch mounted in the top of the door that

controls the passenger-side power window.

WARNING

There is no anti-pinch protection when the win-

dow is almost closed. Be sure to clear all objects

from the window before closing.

The window switches have three positions: lower

window, neutral, and raise window. Press forward on

the switch to lower the window. Hold the switch down

in the forward position for approximately one second

to activate the express function; the window will con-

tinue to roll down after the switch is released. Press

the switch in the rearward position (bump) to raise

the window.

Mirrors

The standard outside mirrors are mounted on the

door frame. The power mirrors are controlled with a

left-hand or right-hand mirror selector switch, and a

directional switch. Select the left (driver) mirror, or

the right (passenger) mirror using the selector switch.

The mirror can then be adjusted by pressing the di-

rectional switch arrow for the direction the mirror

should be adjusted.

The outside door mirrors can be heated to keep

them clear of fog, frost, and ice. To heat the mirrors,

press the upper part of the mirror heat switch on the

dash. See Fig. 9.2. When the mirror heat switch is

on, an amber indicator light illuminates inside the

switch. If the vehicle has Optimized Idle, mirror heat-

ing will not operate with the key in accessory mode,

or if the Optimized Idle feature turns mirror heating

off to reduce stress on the batteries. Refer to Chap-

ter 11 for more information.

Cab Amenities

Cascadia vehicles are available with many optional

features. The following are some of those options.

Cup Holders

Two cup holders and a storage tray are molded into

the center dash. See Fig. 9.3.

Lighting

See Chapter 5 for detailed information regarding

lighting controls.

Power Outlets

Power outlets that supply 12V power for accessories

are located on either side of the cup holders. An op-

tional ashtray/coin holder may be located in the cen-

ter dash. See Fig. 9.3.

06/13/2007 f602318

1. Passenger-Side Window Switch

2. Driver-Side Window Switch

3. Mirror Directional Switch

4. Left-Hand or Right-Hand Mirror Selector Switch

Fig. 9.1, Door Switches (driver-side shown)

MIRR

HEAT

f61090402/26/2007

Fig. 9.2, Mirror Heat Switch

Cab Features

9.1

Radio and CB

The radio and CB are typically installed in the over-

head console. An optional hot mount may be in-

stalled on the dash for ﬂeet CB radios.

Storage

Storage compartments/grab handles are molded into

the lower portion of the driver and passenger doors.

The glove box is located in front of the passenger

seat. To lock the latch, insert the key in the lock, and

turn it 1/2-turn clockwise. Remove the key. To unlock

the latch, insert the key in the lock, and turn it 1/2-

turn counterclockwise. The glove box door is hinged

at the bottom. To open the unlocked door, push the

button in with your thumb and pull gently on the

tang-style latch. The door will swing downwards, then

stop in the open position. To close the door, swing it

upwards, and put gentle pressure on the latch. The

door will be secured, but not locked.

Storage pockets are located in the overhead console,

above the driver and passenger seats. A glove box is

located in the center of the overhead console. See

Fig. 9.4.

Sleeper Amenities

Cascadia sleepers are available with many optional

features. The following are some of those options.

NOTE: See Chapter 8 for detailed information

regarding sleeper climate controls.

Baggage Compartment Doors

The baggage compartment doors are intended as a

convenient means to stow or remove items under the

bunk. The baggage compartment doors can be

opened using the pull cable located near the aft edge

of the cab door opening on the sidewall behind the

seat. Pull the cable handle labeled BAGGAGE for-

ward to open the door.

IMPORTANT: The baggage compartment doors

are two-stage latching. When closing the doors,

ensure that they are completely latched to pre-

vent wind noise and water intrusion.

Lighting

See Chapter 5 for detailed information regarding

lighting controls.

Power Outlets

Power outlets are located underneath the lower

bunk.

Sleeper Access Door

The sleeper access door is not intended for entry or

exit. The door is intended only as a convenient

means to stow or remove personal belongings in the

sleeper area. The sleeper access door can be

opened using two different methods. The primary

method is the pull cable located near the lower rear

edge of the cab door opening on the sidewall behind

ENG

SHDN

ATC

ENG

BRK

MIRR

HEAT

UTLY

LAMP DOME

POWER

OUTLET

12V−10A

IS IN MOTION

SUSP

AIR

LOWER

AUTO

POWER

OUTLET

12V−10A

TRLR

AUX

OVRD

06/14/2007 f610950a

1. Power Outlets

2. Cup Holders and Storage Tray

Fig. 9.3, Center Dash

02/25/2014 f602319a

1. Cargo Storage with Netting

2. Overhead Storage Compartment

3. Storage Pocket

4. Glove Box

Fig. 9.4, Overhead Storage

Cab Features

9.2

the seat. Pull the cable handle labeled ACCESS for-

ward to open the sleeper door. The secondary

method is the black knob located at the upper rear

edge of the sleeper door opening. Pull the knob

down to open the sleeper door.

IMPORTANT: The sleeper access doors are

two-stage latching. When closing the doors, en-

sure that they are completely latched to prevent

wind noise and water intrusion.

Sliding Side Window

The lower section of the sliding side window moves

vertically and may be locked in multiple positions to

suit. Two spring-loaded tabs are located at the top of

the sliding section. To adjust the window, pull both

tabs toward the center of the glass and move the

sliding section to the desired height. Release the

tabs to lock the sliding section.

Cab Features

9.3

Engine Starting, Operation,

and Shutdown

Engine Starting .................................................................. 10.1

Engine Operation ................................................................ 10.2

Engine Shutdown ................................................................ 10.4

Engine Starting

This engine chapter is to serve as a guide for best

practices only. Each engine model may have operat-

ing characteristics that are unique to that particular

engine, and will be documented in the engine manu-

facturer’s literature. Always refer to speciﬁc instruc-

tions and recommendations from the engine manu-

facturer.

NOTE: Before starting the engine, read Chap-

ter 4,Instruments,and Chapter 5,Driver

Controls. Read the engine manufacturer’s oper-

ating instructions before starting the engine.

WARNING

Never pour fuel or other ﬂammable liquid into the

air inlet opening in the air intake in an attempt to

start the vehicle. This could result in a ﬂash ﬁre

causing serious personal injury or property

damage.

IMPORTANT: Cascadia vehicles are equipped

with starter interlocks to enhance reliability and

safety. Anti-grinding, starter pinion, and thermal

protection logic limit the amount of time and

conditions for starter engagement. Cranking

may be limited from 5 to 15 seconds, with a 30-

second cool-down period, as determined by the

protection logic. If the engine is turning, the

starter will not engage. Depending on the trans-

mission option, the starter will not engage if the

clutch is not fully depressed, or if the transmis-

sion is not in neutral.

IMPORTANT: The starter can not be used for

priming the fuel system. If the fuel/water separa-

tor ﬁlter is replaced, and the fuel system needs

to be primed, see the engine manufacturer’s

operating instructions.

1. Before engine start-up, complete the pre- and

post-trip inspections and maintenance proce-

dures in Chapter 21.

2. Set the parking brake.

3. Place the transmission in neutral. On vehicles

with manual transmissions, fully depress the

clutch pedal.

NOTE: Depending on local jurisdictional emis-

sions regulations, vehicles and/or engines that

are domiciled outside of the U.S. and Canada

may not be equipped with the WAIT TO START

or START BLOCKED lamp.

4. Turn the ignition switch to the ON position and

allow the gauge sweep to complete. See

Fig. 10.1. The audible alert will sound for ap-

proximately four seconds.

During cold conditions, the WAIT TO START

lamp may illuminate. Wait until the lamp goes out

before turning the ignition key to START.

NOTE: The length of time the WAIT TO START

lamp remains illuminated depends on the ambi-

ent temperature. The lower the ambient tem-

perature, the longer the lamp will be illuminated.

NOTE: If the ignition switch is turned to START

before the gauge sweep has completed or if the

starter has overheated, the START BLOCKED

lamp may illuminate. Turn the ignition switch

back to ON, wait for the lamp to go out, then

turn the ignition switch to START again.

5. Once the gauge sweep has completed, turn the

ignition key to the START position. Release the

key the moment the engine starts.

NOTICE

Do not rev the engine if the oil pressure gauge

indicates no oil pressure. Shut down the engine

07/19/2006 f610805

Fig. 10.1, Ignition Switch

Engine Starting, Operation, and Shutdown

10.1

if oil pressure does not build within approxi-

mately ten seconds. Check to determine the

cause of the problem. Operating the engine with

no oil pressure will damage the engine.

6. It is not necessary to idle the engine before en-

gaging or starting the operation, but load should

be applied gradually during the warm-up period

until the oil temperature reaches 140°F (60°C).

7. Apply load gradually during the warm-up period.

NOTICE

If the oil pressure gauge indicates no oil pres-

sure, shut down the engine within approximately

ten seconds to avoid engine damage.

8. Check the oil pressure gauge for any drop in lu-

bricating oil pressure or mechanical malfunction

in the lubricating oil system. Minimum oil pres-

sure at idle is 7 psi (50 kPa).

Cold-Weather Starting

See the engine manufacturer’s operation manual for

starting aids that are approved for speciﬁc engines.

Starting After Extended Shutdown

Before engine start-up, complete the engine pretrip

inspections in Chapter 21.

NOTICE

Failure to eliminate water-diluted lubricating oil

may lead to serious engine damage at startup.

An engine in storage for an extended period of time

(over winter, for example) may accumulate water in

the oil pan through normal condensation of moisture

on the internal surfaces of the engine. Oil diluted by

water cannot provide adequate bearing protection at

start-up. For this reason, change the engine oil and

ﬁlters after extended storage.

Engine Operation

Safety and Environmental

Considerations

WARNING

Do not operate the engine in an area where ﬂam-

mable vapors such as gasoline or diesel fumes

are present. Shut off the engine when in an area

where ﬂammable liquids or gases are being

handled. Failure to observe these precautions

could result in serious injury or death.

All engines on Freightliner vehicles comply with the

requirements of the Federal (U.S.) Clean Air Act.

Once an engine is placed in service, the responsibil-

ity for meeting both state and local regulations is with

the owner/operator.

IMPORTANT: Depending upon local jurisdic-

tional emissions guidelines, vehicles that are

domiciled outside of the U.S. and Canada may

not have engines and/or emissions aftertreat-

ment systems that are compliant with EPA07,

EPA10, or GHG14 regulations.

NOTICE

It is extremely important that the following guide-

lines be followed for engines that comply with

EPA07 or newer regulations, or damage may

occur to the aftertreatment device, and the war-

ranty may be compromised.

•Use ultralow-sulfur diesel with 15 ppm sul-

fur content or less.

•Do not use fuel blended with used engine

lube oil or kerosene.

•Use only engine lube oil with a sulfated ash

level less than 1.0 wt%; currently referred

to as CJ-4 oil.

Adequate maintenance of the engine and the diesel

particulate ﬁlter (DPF) are the responsibility of the

owner/operator, and are essential to keep the emis-

sion levels low. Good operating practices, regular

maintenance, and correct adjustments are factors

that will help keep emissions within the regulations.

The driver should be familiar with the vehicle warning

system in order to bring the vehicle to a safe stop if

Engine Starting, Operation, and Shutdown

10.2

the engine malfunctions. If the driver doesn’t under-

stand how the warning system works, an engine

shutdown could occur, causing a safety hazard. See

Chapter 11 for more information.

Engine Break-In

Each engine must pass a full-load operating test on

a dynamometer before shipment, thereby eliminating

the need for a break-in. Before running the engine

for the ﬁrst time, follow the instructions in the manu-

facturer’s engine operation manual.

Normal Operation

WARNING

Do not operate the engine in an area where ﬂam-

mable vapors such as gasoline or diesel fumes

are present. Shut off the engine when in an area

where ﬂammable liquids or gases are being

handled. Failure to observe these precautions

could result in serious injury or death.

Every engine has an operating range in which it per-

forms most efficiently. The operating range extends

from maximum torque rpm at the low end, to engine

rated speed at the high end. Most engines deliver

best fuel economy when operated in the low- and

mid-speed segments of the efficiency range and pro-

duce maximum horsepower at rated speed, which is

also the recommended maximum speed of the en-

gine. For further engine-speciﬁc information, refer to

the engine manufacturer’s operation manual.

Prolonged idling of engines is not recommended, and

is illegal in some states. Idling produces sulfuric acid

that is absorbed by the lubricating oil, and eats into

bearings, rings, valve stems, and engine surfaces. If

you must idle the engine for cab heating or cooling,

use the high idle function of the cruise control

switches. An idle speed of 900 rpm should be

enough to provide cab heat in ambient temperatures

that are above freezing.

If the engine is programmed with an idle shutdown

timer, 90 seconds before the preset shutdown time,

the CHECK engine light will begin to ﬂash at a rapid

rate. If the position of the clutch pedal or service

brake changes during this ﬁnal 90 seconds the idle

shutdown timer will be disabled until reset.

Cold-Weather Operation

Satisfactory performance of a diesel engine operating

in low ambient temperatures requires modiﬁcation of

the engine, surrounding equipment, operating prac-

tices, and maintenance procedures. The lower the

temperature, the greater the amount of modiﬁcation

required. For service products approved for use in

cold weather for your engine, see the engine manu-

facturer’s engine operation manual.

If satisfactory engine temperature is not maintained,

maintenance costs will increase due to greater en-

gine wear. If the engine coolant gets too cold, raw

fuel will wash the lubricating oil off the cylinder walls

and dilute the crankcase oil, causing all moving parts

of the engine to suffer from poor lubrication.

If the engine is in good mechanical condition and the

precautions necessary for cold-weather operation are

taken, ordinary cold weather will not cause difficulty

in starting or loss of efficiency.

The following points are important to observe when

operating in cold weather.

•Check for cracks in the battery cases, for cor-

rosion of the terminals, and for tightness of the

cable clamps at the terminals.

•Charge the batteries to full capacity. Replace

damaged batteries.

•If equipped, turn off the load disconnect switch

after the engine is shut down to prevent battery

discharge.

•Have the alternator output checked at an au-

thorized Freightliner service provider.

•Check the condition and tension of the drive

belts.

•Refer to the engine manufacturer’s operation

manual for recommended heaters, low-

viscosity lubricating oils, winter-grade fuels,

and approved coolants.

•Periodically check the coolant mixing ratio

(concentration of antifreeze in the coolant). Add

more if necessary.

•At outside temperatures below -4°F (-20°C), a

coolant preheater is recommended.

Engine Starting, Operation, and Shutdown

10.3

NOTICE

For Detroit engines (EPA07 and newer), use of a

winterfront is not recommended, as it can cause

false fault codes with the engine and aftertreat-

ment system, and possible emission component

failures.

If using a winterfront, leave at least 25% of the grille

opening exposed in sectioned stripes that run per-

pendicular to the charge-air-cooler tube-ﬂow direc-

tion. This assures even cooling across each tube,

and reduces header-to-tube stress, and possible

chance of component failure. For engine-speciﬁc

guidelines, see below:

Cummins and Mercedes-Benz engines: A winterfront

may be used to improve cab heating while idling, and

only when the ambient temperature remains below

10°F (-12°C).

Detroit engines (EPA07 and newer): Use of a winter-

front is not recommended. Using a winterfront can

cause excessive fan run time, increased fuel con-

sumption, and failure of the DEF system heaters to

operate correctly, resulting in fault codes, poor per-

formance, and power reduction. A winterfront should

only be used temporarily in the following situations:

•To improve cab heating while idling in an ex-

tremely cold ambient temperature;

•When the ambient temperature remains below

-22°F (-30°C) and the engine is unable to

maintain a running coolant temperature of

175°F (80°C) during normal over-the-road

operation.

High-Altitude Operation

Engines lose horsepower when operated at high alti-

tude because the air is too thin to burn as much fuel

as at sea level. This loss equals about three percent

for each 1000 ft (300 m) altitude above sea level for

a naturally aspirated engine.

All engines used on Freightliner vehicles are altitude-

compensated by the use of a turbocharger. This re-

duces smoky exhaust at high altitudes, requires less

downshifting, and allows the engine to make better

use of its fuel. Nevertheless, shift gears as needed to

avoid excessive exhaust smoke.

Engine Shutdown

1. With the vehicle stopped, set the parking brake

and place the transmission in neutral.

NOTICE

Idle the engine one to two minutes before shut-

ting it down. After hard operation, shutting down

the engine without idling may cause damage to

the turbocharger.

2. Allow the engine to idle one to two minutes be-

fore shutting it down. This allows the lubricating

oil and the coolant to carry heat away from the

combustion chambers, bearings, shafts, and

seals.

NOTICE

Except in an emergency, do not shut down the

engine when the coolant temperature is above

194°F (90°C). To do so could damage the engine.

3. Turn off the ignition switch and shut down the

engine.

Engine Starting, Operation, and Shutdown

10.4

Optional Engine Systems

Engine Protection—Warning and Shutdown ........................................... 11.1

Engine Idle Limiting .............................................................. 11.2

Power Takeoff (PTO) Governor ..................................................... 11.2

Optimized Idle® ................................................................. 11.2

Engine Protection—Warning

and Shutdown

NOTE: The engine warning and shutdown sys-

tem is present on EPA07-compliant and newer

vehicles.

The driver should be familiar with the vehicle warning

system in order to bring the vehicle to a safe stop if

necessary. If the driver doesn’t understand how the

warning system works, the driver may not be able to

utilize the advantage of the advance warning system

to pull over appropriately.

The engine will begin a warning and derate and/or

shutdown process if the engine coolant temperature,

coolant level, engine oil pressure, or exhaust after-

treatment system (ATS) reach preset levels. On

some engines, the warning process will begin when

the engine oil temperature, engine coolant tempera-

ture, or the intake air temperature reach preset lev-

els. Detroit™engines may also begin the warning

and shutdown process if water is detected in the fuel.

See the engine manufacturer’s operation manual for

speciﬁc details for your vehicle. See Chapter 12 for

the warning and shutdown modes associated with

the ATS.

Electronic engine protection can be speciﬁed as ei-

ther SHUTDOWN or WARNING and DERATE.

WARNING

When the STOP engine or CHECK engine lamp

illuminates, most engines are programmed to

shut down automatically within 30 seconds. The

driver must immediately move the vehicle to a

safe location at the side of the road to prevent

causing a hazardous situation that could cause

bodily injury, property damage, or severe damage

to the engine.

In SHUTDOWN mode, the red STOP engine lamp

will illuminate when the problem is serious enough to

reduce power or speed. See Fig. 11.1. Engine power

will ramp down, then the engine will shut down if the

problem continues while in derate mode. The driver

has 30 or 60 seconds (depending on the critical fault

type) after the STOP engine lamp illuminates to

move the vehicle safely off the road. If the vehicle

cannot be moved to a safe location within that time,

turn the ignition switch to OFF for at least ﬁve sec-

onds, then restart the engine. Repeat this action until

the vehicle is safely off the road.

Do not operate the vehicle further until the problem

causing the shutdown has been corrected.

Some vehicles may have a shutdown override

switch, which can be used to momentarily override

the shutdown sequence. This switch resets the shut-

down timer, restoring power to the level before the

derate. The switch must be pressed again after ﬁve

seconds to obtain a subsequent override. See

Fig. 11.2.

NOTICE

When the derate process begins, immediately get

the vehicle serviced in order to prevent severe

damage to the engine.

Detroit engines may begin a warning and derate pro-

cess if water is detected in the fuel, or for high en-

gine coolant temperature. In WARNING and DER-

ATE mode, the CHECK engine, STOP engine, or MIL

07/09/2009 f611036

123

CHECK STOP

1. Malfunction Indicator Lamp (MIL)

2. CHECK Engine Lamp

3. STOP Engine Lamp

Fig. 11.1, Engine Warning Lamps

ENG

SHDN

f61090002/26/2007

OVRD

Fig. 11.2, Shutdown Override Switch

Optional Engine Systems

11.1

lamp will illuminate to indicate an engine problem

that requires service and the engine controls will

begin a derate of engine output. Continuing to run

the engine while it is in derate mode could cause

severe damage to the engine.

Engine Idle Limiting

Idle Shutdown Timer

This feature is an optional 1- to 100-minute idle shut-

down system. Its purpose is to conserve fuel by

eliminating excessive idling, and allowing a turbo-

charger cool-down period. Idle shutdown timing and

parameters are programmable. See the engine

manufacturer’s operation manual for speciﬁc details

for your vehicle.

The idle shutdown system requires that the transmis-

sion be in neutral with the parking brake set.

California Engine Idle Limiting

In order to meet the California Air Resources Board

(CARB) engine idle limit, vehicles are equipped with

an engine idle shutdown feature. The automatic shut-

down feature is required on all California-certiﬁed

engines (with the exception of engines used in spe-

ciﬁc vehicle types that are exempt from the require-

ment). Owners that wish to have the shutdown fea-

ture disabled on vehicles operating in California

should consult with California authorities to determine

if their vehicle qualiﬁes for the exemption.

When the CARB engine idle limiting feature is en-

abled, the engine will typically shut down after ﬁve

minutes of continuous idling with the transmission in

neutral or park, and the parking brake set. It will also

shut down after 15 minutes with the transmission in

neutral or park, and the parking brake off. See the

engine manufacturer’s operation manual for speciﬁc

details for your vehicle.

Changing the position of the brake pedal, clutch

pedal, accelerator pedal, shutdown override switch,

or parking brake during the ﬁnal 30 seconds will

cause the shutdown timer to reset. After an auto-

matic shutdown, the engine may be restarted and

operated normally.

Power Takeoff (PTO) Governor

WARNING

To avoid injury, do not install a PTO that is not

Detroit Diesel approved onto a Detroit™Trans-

mission. Use of a non-Detroit Diesel approved

PTO with a Detroit Transmission could result in

unintended operation which could lead to severe

personal injury.

Engine power takeoffs (PTO) tap into engine power

to run auxiliary devices, such as hydraulic pumps

that power additional equipment. The following are

general guidelines for operating a PTO.

1. Set the parking brake and put the transmission in

neutral.

2. Press the dash PTO switch. Release the switch

when the light begins to blink.

When the light illuminates steadily, the PTO is

engaged and ready to operate. In stationary

mode, the vehicle must remain in neutral with the

parking brake set.

3. To activate mobile mode, shift from neutral to

reverse, 1st, or 2nd gear. The clutch will open

and the PTO will disengage for a moment.

4. Touch the accelerator pedal to close the clutch

and engage the PTO in mobile mode. The PTO

may be operated with the transmission in neutral

or reverse, and 1st and 2nd gears only.

NOTE: Do not attempt to change gears while

the vehicle is moving. The transmission will ig-

nore the request.

5. To deactivate mobile mode, bring the vehicle to a

stop. The clutch will open and shut down power

to the PTO.

6. To resume stationary mode, shift to neutral. The

PTO will engage.

7. To deactivate PTO, press the PTO switch again.

When the light in the switch goes out, power to

the PTO is shut off.

Optimized Idle®

Optimized Idle reduces engine idle time by running

the engine only when required. Optimized Idle auto-

matically shuts down and restarts the engine as

Optional Engine Systems

11.2

needed to ensure engine oil temperature remains

within factory preset limits, the batteries stay

charged, and cab/sleeper temperature remains at the

thermostat setting. The beneﬁts of the system in-

clude reduced engine idle time, fuel savings, reduc-

tion of exhaust emissions and noise, increased

starter and engine life, and reduced chance of dead

batteries.

Vehicles equipped with Optimized Idle have a label

on the dash, and a telltale (OPT IDLE) in the ICU.

See Fig. 11.3 for the dash label detail. If equipped, a

thermostat is located above the sleeper bunk. See

Fig. 11.4.

Optimized Idle operates in two modes:

•Engine mode: Keeps the battery charged and

engine oil temperature between 60 and 104°F

(16 to 40°C).

•Thermostat mode (activated when the optional

thermostat is turned on): Keeps the cab and

sleeper at a constant preset temperature, in

addition to all functions available in engine

mode.

Thermostat mode controls the set point, which is the

desired temperature of the cab and sleeper, and the

comfort zone, which is the allowed temperature de-

viation from the set point before the engine starts.

The thermostat display defaults to show the tempera-

ture of the sleeper, but changes accordingly as the

buttons are pressed.

The button functions are as follows:

•Up arrow: Increases the set point and comfort

zone (allowed temperature variation).

•Down arrow: Decreases the set point and com-

fort zone.

•Cool/Heat: Sets either cooling or heating op-

eration.

•MODE: Scrolls through the various functions. It

can also be used to set desired temperature

values.

If a vehicle has Optimized Idle, the following func-

tions will not operate with the key in accessory

mode. Optimized Idle may also turn these functions

off to reduce stress on the batteries.

•Cab climate control fan

•Sleeper climate control fan

•Mirror heat

•Fuel/water separator heat

•Seat heat

•Advertising light

•Auxiliary circulation fan (windshield)

•Air dryer

1. To activate Optimized Idle (engine mode):

1.1 Set the parking brake.

1.2 If it is open, close and secure the hood.

11/13/96 f080062

TO AVOID

UNINTENTIONAL

VEHICLE MOVEMENT,

DO NOT MOVE SHIFT

LEVER OR RANGE

SELECTOR WHEN

OPTIMIZED IDLE IS ON

OPTIMIZED IDLETM

TO USE:

− IDLE ENGINE

− CLOSE HOOD

− ENGAGE PARKING BRAKES

− PUT TRANSMISSION IN

NEUTRAL AND

HI RANGE (IF EQUIPPED)

− THEN, MOVE CRUISE SWITCH

FROM OFF TO ON

− IF DESIRED, TURN CAB

THERMOSTAT ON (IF EQUIPPED)

Fig. 11.3, Optimized Idle Dash Label

MODE

°F

°C

11/08/96

3 4 5

10 f601250

1. Down Arrow Button

2. Up Arrow Button

3. Upper/Lower

Temperature Icon

4. Temperature Display

5. Degrees Fahrenheit

Indicator

6. MODE Button

7. Cooling Icon

8. Cool/Heat Selection

Button

9. Heating Icon

10. Degrees Celsius

Indicator

Fig. 11.4, Optimized Idle Thermostat

Optional Engine Systems

11.3

1.3 Start the engine and let it idle.

1.4 Put the transmission in neutral.

1.5 Turn on the cruise control.

The OPT IDLE lamp will blink, indicating

that Optimized Idle is active. The system

is now in engine mode and after an initial

phase, in which the idle speeds up to

1000 rpm, the engine will stop and start

automatically to keep the battery charged

and the engine oil warm.

IMPORTANT: The cruise control must be

turned on once the engine is idling. If it was

previously turned on, turn the cruise control

off, then turn it on again.

2. Activate thermostat mode, if equipped.

NOTE: When the system is in thermostat

mode, it is also in engine mode. It will con-

tinue to operate in engine mode even if ther-

mostat mode is turned off.

2.1 With the system in engine mode, set the

cab and sleeper heater or air conditioner

controls to the highest setting.

2.2 Turn on the thermostat by touching any of

the four buttons. See Fig. 11.4.

The display will ﬂash the current sleeper

temperature and the previous mode (cool-

ing or heating) selected. If the cab needs

to be cooled or heated, the cool/heat icon

will ﬂash.

2.3 Choose either cool or heat by pressing the

Cool/Heat button. Make sure the selection

matches that of the cab controls.

IMPORTANT: If the heat or cool selection of

the thermostat does not match that of the

cab controls, the system will idle and cycle

excessively.

2.4 Select Fahrenheit or Celsius by pressing

and holding the MODE button until either

the "F" or "C" is displayed.

2.5 Select the temperature set point by press-

ing the up or down arrows, as applicable.

Holding the button will cause the display

to scroll up or down rapidly. When the de-

sired set point is displayed, release the

button. The set point is stored in memory.

2.6 Select the temperature comfort zone by

pressing the MODE button until the upper

and lower temperature limit icon is dis-

played. Then use the up or down arrow to

select one of the three comfort zones: 4°F

(2°C), 7°F (4°C), or 10°F (6°C).

3. To deactivate thermostat mode and return to just

engine mode, press and hold the MODE button

for three seconds.

4. To shut down Optimized Idle completely, either

turn off the ignition or use the drive away feature.

The drive away feature allows the use of all the

engine features. Use the drive away feature as

follows:

4.1 If the engine is running: Release the park-

ing brakes or put the transmission in gear.

If the engine is not running: Start the en-

gine. Release the parking brakes or put

the transmission into gear.

4.2 Let the engine return to base idle. The

active light will turn off. Optimized Idle is

now disabled.

Optional Engine Systems

11.4

Emissions and Fuel Efficient

Components

Greenhouse Gas Emissions and Fuel Consumption Standards ........................... 12.1

EPA-Regulated Emissions Aftertreatment Systems ..................................... 12.1

Diesel Exhaust Fluid and Tank, EPA10 and Newer Engines .............................. 12.3

Greenhouse Gas Emissions

and Fuel Consumption

Standards

Vehicles and/or engines manufactured after Decem-

ber 31, 2006 and domiciled in the U.S. or Canada

are required to meet all EPA and NHTSA regulations

effective as of the vehicle build date. Engines manu-

factured between January 1, 2007 and December 31,

2009 meet EPA07 requirements. Engines manufac-

tured between January 1, 2010 and December 31,

2012 meet EPA10 requirements. Engines manufac-

tured from January 1, 2013 meet NHTSA and EPA

2014 fuel efficiency and greenhouse gas emission

standards (GHG14) requirements.

Model year 2013 and later vehicles meet additional

requirements as speciﬁed by GHG14 requirements.

These vehicles are equipped with components that

increase fuel efficiency and reduce GHG emissions.

Components may include, but are not limited to, low-

rolling resistance tires; aerodynamic devices such as

hood, cab/sleeper extenders, and fuel tank fairings;

vehicle speed limiter; and idle shutdown timer. If re-

placement of any drag-reducing component is re-

quired, the replacement component must meet or

exceed the drag reduction performance of the origi-

nally installed component in order to maintain compli-

ance with GHG14 requirements.

EPA-Regulated Emissions

Aftertreatment Systems

IMPORTANT: Depending on local jurisdictional

guidelines, vehicles that are domiciled outside of

the U.S. and Canada may not have emissions

aftertreatment systems (ATS) that are compliant

with EPA regulations.

NOTICE

Follow these guidelines for engines that comply

with EPA07 or newer regulations, or damage may

occur to the aftertreatment device (ATD) and the

warranty may be compromised.

•Use ultralow-sulfur diesel with 15 ppm sul-

fur content or less.

•Do not use fuel blended with used engine

lube oil or kerosene.

•Engine lube oil must have a sulfated ash

level less than 1.0 wt %; currently referred

to as CJ-4 oil.

IMPORTANT: Using non-speciﬁcation fuels or

oils can lead to shortened diesel particulate ﬁlter

(DPF) cleaning or replacement intervals. For

example, using CJ-4+ oil with 1.3% sulfated ash

(30% more ash content) may result in the need

for DPF cleaning or replacement 20 to 30%

sooner than would normally be required.

IMPORTANT: See the engine manufacturer’s

operation manual for complete details and op-

eration of the ATS.

EPA07 Engines

Engines built between January 1, 2007 and Decem-

ber 31, 2009 are required to meet EPA07 guidelines

for reduced exhaust emissions of particulate matter

and nitrogen oxides (NOx). NOx is limited to just

over 1 gram per brake horsepower hour (g/bhp-hr),

and particulate matter cannot exceed 0.01 g/bhp-hr.

The EPA07 ATS varies according to engine manufac-

turer and vehicle conﬁguration, but the exhaust muf-

ﬂer is replaced by an aftertreatment device (ATD).

Inside the ATD, the exhaust ﬁrst passes over the die-

sel oxidation catalyst (DOC), then passes through

the diesel particulate ﬁlter (DPF), which traps soot

particles. The soot is burned to ash during a process

called regeneration (regen).

EPA10 and Newer Engines

The EPA mandates that all engines built after De-

cember 31, 2009 must reduce the level of emissions

exhausted by the engine to the following levels:

•Nitrogen Oxides (NOx) – 0.2 g/bhp-hr

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

To meet EPA guidelines, engines that are compliant

with EPA10 and newer regulations use an ATS that

has, in addition to a DOC/DPF device like that used

in an EPA07 ATD, a Selective Catalytic Reduction

(SCR) device to reduce NOx downstream of the en-

gine. After exhaust gases leave the DPF, a controlled

quantity of diesel exhaust ﬂuid (DEF) is injected into

the exhaust stream. In the presence of heat, DEF is

converted to ammonia gas, which reacts with NOx in

the selective catalyst chamber to yield nitrogen and

water vapor, which exit through the tailpipe.

Emissions and Fuel Efficient Components

12.1

Regeneration

The harder an engine works, the better it disposes of

soot. If the exhaust temperature is high enough, a

process called passive regeneration (regen) occurs

as the vehicle is driven normally. However, if the en-

gine isn’t running hot enough, the electronic controls

may initiate an active regen, whereby extra fuel is

injected into the exhaust stream to superheat and

reduce the soot trapped in the DPF to ash. Active

regen happens only when the vehicle is moving

above a certain speed, determined by the engine

manufacturer. See your engine operation manual for

complete details. Both active and passive regen hap-

pen automatically, without driver input.

WARNING

Active regeneration can occur automatically any-

time the vehicle is moving. The exhaust gas tem-

perature could reach 1500°F (800°C), which is hot

enough to cause a ﬁre, heat damage to objects

or materials, or personal injury to persons near

the exhaust outlet. The exhaust temperature can

remain high even after the vehicle has stopped.

When stopping the vehicle shortly after an auto-

matic regen, ensure the exhaust outlets are di-

rected away from structures, trees, vegetation,

ﬂammable materials, and anything else that may

be damaged or injured by exposure to high heat.

See Regen Switches, below, for instructions on

preventing automatic regen if necessary.

When operating conditions do not allow for ATD ﬁlter

cleaning by active or passive regen, the vehicle may

require a driver-activated parked regen. When this

occurs, the DPF lamp illuminates, indicating that a

regen is required. The driver must either bring the

vehicle up to highway speed to increase the load

(thus starting an active regen), or park the vehicle

and initiate a parked regen. See Regen Switches,

below, for instructions on initiating a parked regen.

Regen Switches

The regen request switch, located on the dash, is

used to initiate a parked regen. See Fig. 12.1.To

access the regen request switch, lift the guard and

press the yellow button.

Some vehicles may be equipped with a regen inhibit

switch. See Fig. 12.1. To stop a regen in progress or

prevent the start of a regen, press the lower half of

the switch. Regen is then delayed until the switch is

no longer active.

NOTE: The regen switch can initiate a parked

regen only when the DPF lamp is illuminated.

WARNING

During parked regen, exhaust temperatures are

very high and could cause a ﬁre, heat damage to

objects or materials, or personal injury to per-

sons near the exhaust outlet.

Before initiating a parked regeneration, make cer-

tain the exhaust outlets are directed away from

structures, trees, vegetation, ﬂammable materi-

als, and anything else that may be damaged or

injured by prolonged exposure to high heat.

To initiate a parked regen, perform the following

steps.

1. Park the vehicle away from all ﬂammable materi-

als, put the transmission in neutral, and set the

parking brake.

2. Start and warm the engine until the coolant tem-

perature is at least 150°F (66°C).

3. Lift the regen request switch guard and press

and hold the yellow button for ﬁve seconds. As

the regen process is initiated, engine rpm in-

creases and the HEST lamp illuminates to indi-

cate extremely high exhaust temperatures.

IMPORTANT: The driver must remain with the

vehicle during the entire regen cycle.

f61115702/08/2012

RGEN

1. Regen Request

Switch

2. Regen Inhibit Switch

Fig. 12.1, Regen Request and Inhibit Switches

Emissions and Fuel Efficient Components

12.2

4. The regen cycle will ﬁnish after 20 to 60 minutes,

at which time engine idle speed drops to normal

and the vehicle can be driven normally. The

HEST lamp is extinguished when vehicle speed

exceeds 5 mph (8 km/h) or the system has

cooled to normal operating temperature.

5. To stop a parked regen at any time during the

process:

•depress the clutch pedal, brake pedal, or

accelerator pedal;

•press and hold the regen inhibit switch until

idle returns to normal;

•shut down the engine.

ATS Warning Lamps

There are three warning lamps that alert the driver of

high exhaust temperature, the need to perform a

parked regen or service the DPF, or of an engine

fault that affects emissions. A decal attached to the

driver’s sun visor explains the ATS warning lamps.

Fig. 12.2.

See Fig. 12.3 for an explanation of the ATS warn-

ings, and actions required to avoid engine protection

sequences.

Malfunction Indicator Lamp (MIL)

A steadily illuminated yellow malfunction indicator

lamp (MIL) indicates an engine fault that affects

emissions. See Fig. 12.4.

DPF Status Lamp

When soot accumulates in the DPF and the DPF sta-

tus lamp illuminates, see Fig. 12.5, perform a parked

regen or bring the vehicle up to highway speed to

increase the load (thus starting an active regen).

If the DPF status lamp blinks while the CHECK en-

gine lamp is illuminated, initiate a parked regen im-

mediately in order to prevent an engine derate.

If the red STOP engine lamp illuminates with the

blinking DPF lamp and the CHECK engine lamp,

begin a parked regen in order to prevent an engine

shutdown. Park the vehicle and perform a parked

regen.

High Exhaust System Temperature

(HEST) Lamp

Slow (10-second) ﬂashing of the high exhaust sys-

tem temperature (HEST) lamp indicates that a

parked regen is in progress, and the engine’s high

idle speed is being controlled by the engine software,

not the vehicle driver.

Steady illumination of the HEST lamp alerts the

driver of high exhaust temperature during the regen

process if the vehicle speed is below 5 mph (8 km/

h), or during a parked regen. See Fig. 12.6.

Maintenance

Authorized service facilities must perform any DPF

service. For warranty purposes, maintain a record

that includes:

•date of cleaning or replacement;

•vehicle mileage;

•particulate ﬁlter part number and serial number.

Diesel Exhaust Fluid and Tank,

EPA10 and Newer Engines

Diesel Exhaust Fluid

Diesel exhaust ﬂuid (DEF) is used in the ATS to

lower NOx in the exhaust stream. DEF is colorless

and close to odorless (it may have a slightly pungent

odor similar to ammonia). It is nontoxic, nonﬂam-

mable, and biodegradable. It is mildly corrosive to

aluminum, but does not affect the strength or struc-

ture of the aluminum.

White crystals may be noticeable around compo-

nents that come into contact with DEF. The crystals

are easily removed with water.

DEF consumption varies depending on ambient con-

ditions and vehicle application.

Freezing Conditions

DEF freezes to slush at around 12°F (-11°C). It is not

damaged or destroyed if frozen, and is fully usable

when thawed. The DEF in the tank is allowed to

freeze while a vehicle is non-operational. At start-up,

normal operation of the vehicle is not inhibited if the

DEF is frozen; an immersion heater with engine cool-

ant ﬂowing through it warms the DEF once the en-

gine is running, allowing the SCR system to operate.

Emissions and Fuel Efficient Components

12.3

Pre-2013 DEF supply lines are electrically-heated

and are purged when the engine is shut down; com-

plete purging of the DEF lines requires approximately

ﬁve minutes after the engine is shut down.

DEF supply lines with engine model year 2013 and

newer are designed to survive freezing conditions

while containing DEF, so purging is not required.

DEF Tank

Engines that are compliant with EPA10 and newer

regulations are equipped with a DEF tank located on

the driver’s side of the vehicle behind the battery box

or forward of the fuel tank. See Fig. 12.7 and

Fig. 12.8. The DEF tank has a 19 mm ﬁller neck inlet

that prevents the hose from a diesel outlet from

being inserted, and has a blue cap for easy

identiﬁcation.

Fuel/DEF Gauge

The diesel fuel and DEF levels are measured in a

dual-purpose gauge. See Fig. 12.9.

Fuel level is indicated at the top of the gauge. Below

the fuel level, a low fuel warning lamp illuminates

amber when the fuel level drops below 1/8th of the

capacity.

The lower portion of the gauge has a DEF warning

lamp that illuminates amber when the DEF tank is

near empty, and a lightbar that indicates the level of

DEF in the tank. The DEF light bar illuminates as fol-

lows.

•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

DPF Regen Needed

Hot Exhaust

DEF Refill Needed

Diesel Particulate Filter (DPF)

regeneration is needed.

If flashing, regenerate as soon as

possible. Engine derate possible.

Hot exhaust can cause fire.

Keep flammables and people away

from exhaust.

Diesel Exhaust Fluid (DEF) level is

low. Engine derate likely.

Refill tank with certified DEF.

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

IMPORTANT

DEF

11/30/2010 f080161

Fig. 12.2, Warning Lamp Decal, Sun Visor

Emissions and Fuel Efficient Components

12.4

•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 Limits

IMPORTANT: Ignoring the DEF warning lights

results in limited engine power, with the applica-

tion of a 5 mph (8 km/h) speed limit.

DEF Level Low—Initial Warning

When the DEF level is low, the following lamps notify

the driver. See Fig. 12.10. Reﬁll the DEF tank in

order to cancel the warning sequence.

•One bar of the DEF level indicator illuminates

amber—DEF very low, reﬁll DEF.

•The DEF warning lamp illuminates solid amber.

f080147

EXHAUST AFTERTREATMENT SYSTEM INFORMATION

Switch.

Level 1 Level 3Level 2 Level 4

Filter Regeneration

Recommended

Filter is reaching

Bring vehicle to

highway speeds to

Filter Regeneration

Necessary

Filter is now

reaching maximum

capacity

To avoid engine

derate bring vehicle

Parked Regeneration

Required − Engine

Derate

Filter has reached

maximum capacity

Vehicle must be

parked and a Parked

Parked Regeneration Required −

Engine Shut Down

Filter has exceeded

maximum capacity

Vehicle must be parked and a

Parked Regeneration or Service

(Solid)

(Flashing) (Flashing)

CHECK CHECK

(Flashing)

INDICATOR

LAMP(S)

Indicator Lamp

Message(s)

Diesel Particulate

Filter Condition

Required Action

capacity

. .

STOP

See Engine Operator’s Manual for complete Regeneration Instructions.

allow for an Automatic

Regeneration or

perform a Parked

Regeneration.

to highway speeds

to allow for an

Automatic

Regeneration or

perform a Parked

Regeneration as

soon as possible.

Regeneration must

be performed −

engine will begin

derate.

Regeneration must be performed.

Check engine operator’s manual

for 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

ARNING

HEST (High Exhaust

System Temperature)

Exhaust Components

and exhaust gas are

at high temperature.

When stationary, keep

away from people and

flammable materials

or vapors.

A regeneration is in

progress.

Flashing

Solid

Fig. 12.3, ATS Warning Lamps

09/25/2006 f610814a

Fig. 12.4, Malfunction Indicator Lamp (MIL)

09/25/2006 f610815a

Fig. 12.5, DPF Status Lamp

Emissions and Fuel Efficient Components

12.5

DEF Empty

When the DEF level reads empty, the following

lamps notify the driver. See Fig. 12.11.

•One bar of the DEF level indicator ﬂashes

red—DEF empty, reﬁll DEF.

•The DEF warning lamp ﬂashes amber.

•The MIL lamp illuminates.

Pre-2013 Detroit engines: Power is limited, with a 55

mph (90 km/h) speed limit.

Cummins and 2013 Detroit engines: Power is limited

with progressively harsher engine power limits

applied.

DEF Tank Empty and Ignored

If the empty warning is ignored and the DEF tank is

not reﬁlled, the red STOP engine lamp illuminates in

addition to the MIL lamp and CHECK engine lamp

(on vehicles with a Cummins ISB or ISC/L engine.)

See Fig. 12.12.

If the DEF is not reﬁlled, a 5 mph (8 km/h) speed

limit is applied after the next engine shutdown, while

parked and idling, or if a fuel reﬁll is detected.

DEF Contamination or SCR Tampering

NOTICE

Once contaminated DEF or tampering has been

detected, the vehicle must be taken to an autho-

rized service facility to check the SCR system for

damage and to deactivate the warning lights and

engine limits.

If contaminated DEF or tampering with the ATS is

detected, the DEF warning light ﬂashes and the MIL

lamp illuminates to warn the driver. The CHECK en-

gine lamp also illuminates on vehicles with a Cum-

mins ISB or ISC/L engine. See Fig. 12.12.

•Detroit engines: Engine power is limited with

progressively harsher limits applied. If the fault

09/25/2006 f610816a

Fig. 12.6, HEST Lamp

07/24/2009 f470542

1. Batteries 2. DEF Tank

Fig. 12.7, DEF Tank Located Behind the Battery Box

07/24/2009 f470541

1. DEF Tank 2. Fuel Tank

Fig. 12.8, DEF Tank Located Forward of the Fuel Tank

Emissions and Fuel Efficient Components

12.6

is not corrected, the STOP engine light illumi-

nates and a 5 mph (8 km/h) speed limit is ap-

plied after the next engine shutdown, while

parked and idling, or if a fuel reﬁll is detected.

•Cummins engines: Engine power is limited with

progressively harsher limits applied. If the fault

is not corrected, the STOP engine light illumi-

nates and a 5 mph (8 km/h) speed limit is ap-

plied after the next engine shutdown, or while

parked and idling.

11/08/2010 f611037

1/2

ULTRA LOW SULFUR

DIESEL FUEL ONLY

DEF

1/2

ULTRA LOW SULFUR

DIESEL FUEL ONLY

DEF

1/2

ULTRA LOW SULFUR

DIESEL FUEL ONLY

DEF

A C

A. Green bars—DEF level indicators

B. One bar illuminated amber—DEF very low, reﬁll DEF

C. One bar ﬂashing red—DEF empty, reﬁll DEF

1. Low Fuel Warning Lamp 2. DEF Warning Lamp

Fig. 12.9, Fuel/DEF Gauge

07/09/2009 f470537

A. DEF Warning Lamp (illuminated)

B. DEF Lightbar (one bar amber)

Fig. 12.10, DEF Level Low Initial Warning

11/08/2010 f470539a

NOTE: MIL illuminates. CHECK engine lamp illuminates

if Cummins ISB or ISC/L engine. Engine power is lim-

ited.

A. DEF Warning Lamp (ﬂashing)

B. DEF Lightbar (one bar ﬂashing red)

Fig. 12.11, DEF Empty Warning

Emissions and Fuel Efficient Components

12.7

11/08/2010 f470540a

NOTE: STOP engine light and MIL illuminate, engine

power is limited, speed limit of 5 mph (8 km/h)

A. DEF Warning Lamp (ﬂashing)

B. DEF Lightbar (one bar ﬂashing red)

Fig. 12.12, DEF Empty and Ignored Warning

Emissions and Fuel Efficient Components

12.8

Brake Systems

Air Brake System ................................................................ 13.1

Meritor WABCO® Antilock Braking System ........................................... 13.3

Engine Brake ................................................................... 13.5

Air Brake System

Brake System General Information

A dual air brake system consists of two independent

air systems that use a single set of brake controls.

Each system has its own reservoirs, plumbing, and

brake chambers. The primary system operates the

service brakes on the rear axle; the secondary sys-

tem operates the service brakes on the front axle.

Service brake signals from both systems are sent to

the trailer.

WARNING

Do not operate the vehicle with the front brakes

backed off or disconnected. Backing off or dis-

connecting the front brakes will not improve ve-

hicle handling and may lead to loss of vehicle

control, resulting in property damage or personal

injury.

Brake System Components

The warning light and buzzer come on if air pressure

drops below approximately 70 psi (483 kPa) in either

system. If this happens, check the air pressure

gauges to determine which system has low air pres-

sure. Although the vehicle’s speed can be reduced

using the foot brake control pedal, either the front or

rear service brakes will not be operating at full ca-

pacity, causing a longer stopping distance. Bring the

vehicle to a safe stop and have the air system re-

paired before continuing.

IMPORTANT: In the event of a total loss of ser-

vice brakes with full system air pressure, use

the parking brake control valve (yellow knob) to

bring the vehicle to a complete stop in the saf-

est location possible.

Before a vehicle with insufficient system air pressure

can be moved, the spring parking brakes must be

released by applying an external air source at the

gladhands, or by manually caging the parking brake

springs.

WARNING

Do not release the spring parking brakes and

then drive the vehicle. There would be no means

of stopping the vehicle, which could result in se-

rious personal injury or vehicle damage. Before

releasing the spring parking brakes, make the

connection to a towing vehicle or chock the tires.

After correcting the brake system problem, uncage

the spring parking brakes before resuming normal

vehicle operation.

Primary Air Brake System

Loss of air pressure in the primary air system causes

the rear service brakes to become inoperative. The

secondary air system will continue to operate the

front brakes and the trailer brakes (if equipped).

Secondary Air System

Loss of air pressure in the secondary air system

causes the front axle brakes to become inoperative.

The primary air system will continue to operate the

rear service brakes and the trailer brakes (if

equipped).

Brake System Operation

Before driving your vehicle, allow time for the air

compressor to build up a minimum of 100 psi (689

kPa) pressure in both the primary and secondary

systems. Monitor the air pressure system by observ-

ing the air pressure gauges and the low-air-pressure

warning light and buzzer. The warning light and

buzzer shut off when air pressure in both systems

reaches approximately 70 psi (483 kPa).

IMPORTANT: Before driving the vehicle, secure all

loose items in the cab so that they will not ﬂy forward

during a full brake application. Make sure all passen-

gers are wearing seat belts.

During normal brake stops, depress the foot brake

control pedal until braking action slows down the ve-

hicle. Increase or decrease the pressure on the

pedal so that the vehicle comes to a smooth, safe

stop. Apply the spring parking brakes if the vehicle is

to be parked.

IMPORTANT: An air brake proportioning system

may be used in tractor air brake systems when

the vehicle is not equipped with antilock braking

system (ABS). When operating in bobtail mode,

the rear brake chambers (on which the axle

load has been greatly reduced) receive reduced

(proportional) air pressure, while the front axle

brake chambers receive full (normal) air pres-

sure. This results in a different brake pedal

"feel," as the pedal seems to require more travel

Brake Systems

13.1

and/or effort to slow or stop the vehicle. How-

ever, the air brake proportioning system actually

improves vehicle control when the tractor is in

bobtail mode. When the tractor is towing a

trailer, the rear brake chambers will receive full

(normal) application air pressure.

When parking a vehicle attached to a trailer that

does not have spring parking brakes, apply the trac-

tor parking brakes. Chock the trailer tires before dis-

connecting the vehicle from the trailer.

WARNING

If a trailer or combination vehicle is not equipped

with spring parking brakes, do not park it by pull-

ing out only the trailer air supply valve knob.

This would apply only the trailer service brakes.

If air were to bleed from the trailer brake system,

the trailer brakes would release, possibly causing

an unattended runaway vehicle.

NOTICE

Never apply the service and spring parking

brakes simultaneously. To do so transmits exces-

sive input force to the brake components, which

could damage or cause eventual failure of brake

actuating components.

Brake Controls

The trailer brake lever (hand control valve) is used

for applying the trailer brakes without applying the

truck or tractor service brakes. It is usually mounted

on the right-hand control panel. See Fig. 13.1. The

valve can be partially or fully applied, but in any par-

tially on position it will be overridden by a full applica-

tion of the service brake pedal. Moving the lever

down applies the trailer brakes, while moving it up

releases the trailer brakes. The lever will automati-

cally return to the up position when it is released.

WARNING

Do not use the trailer service brakes for parking;

they are not designed for this purpose. If air

bleeds out of the trailer air tank during parking,

the vehicle could roll, causing serious personal

injury or property damage.

The red octagonal-shaped knob in the control panel

actuates the trailer air supply valve. See Fig. 13.2.

After the vehicle’s air hoses are connected to a

trailer and the pressure in both air systems is at least

65 psi (448 kPa), the trailer air supply valve must be

pushed in. It should stay in to charge the trailer air

supply system and to release the trailer spring park-

ing brakes.

Pull the trailer air supply valve out before disconnect-

ing a trailer or when operating a vehicle without a

trailer. If pressure in both air systems drops to 35 to

45 psi (242 to 310 kPa), the trailer air supply valve

automatically pops out, exhausting the trailer air sup-

ply, and applying the trailer service or spring parking

brakes.

The yellow diamond-shaped knob in the control

panel actuates the parking brake valve. See

Fig. 13.2. Pulling out the parking brake valve applies

both the tractor and trailer spring parking brakes and

10/17/2001 f610591

Fig. 13.1, Trailer Brake Lever

f610291

1 2

03/10/99

1. Trailer Air-Supply-Valve Knob

2. Parking-Brake-Valve Knob

Fig. 13.2, Brake Valve Knobs

Brake Systems

13.2

automatically causes the trailer air supply valve to

pop out.

NOTICE

Do not use the spring parking brakes if the ser-

vice brakes are hot, such as after descending a

steep grade. To do so could damage the brakes.

Allow hot brakes to cool before using the spring

parking brakes.

Do not use the spring parking brakes during

freezing temperatures if the service brakes are

wet. To do so could cause them to freeze. If the

brakes are wet, drive the vehicle in low gear and

lightly apply the brakes to heat and dry them.

If the trailer is not equipped with spring parking

brakes, pulling out the parking brake valve applies

the tractor spring parking brakes and the trailer ser-

vice brakes. When the tractor and trailer parking

brakes (or trailer service brakes) are both applied,

the trailer brakes are released by pushing in the

trailer air supply valve, leaving the tractor parking

brakes applied. Air pressure in the primary or sec-

ondary reservoir must be at least 65 psi (447 kPa)

before the tractor spring parking brakes, or the trailer

service or spring parking brakes, can be released.

Automatic Slack Adjusters

Automatic slack adjusters should never be manually

adjusted except during routine maintenance of the

foundation brakes (e.g., replacing shoes), during

slack adjuster installation, or in an emergency situa-

tion.

When the brake pushrod stroke exceeds the legal

brake adjustment limit on a vehicle, there is likely a

mechanical problem with the foundation brake com-

ponents or the adjuster is improperly installed.

Visit a repair facility as soon as possible when

brakes equipped with automatic slack adjusters are

determined to be out of adjustment.

WARNING

Manually adjusting an automatic slack adjuster to

bring the pushrod stroke within legal limits is

likely masking a mechanical problem. Adjustment

is not a repair. Before adjusting an automatic

slack adjuster, troubleshoot the foundation brake

system and inspect it for worn or damaged com-

ponents. Improperly maintaining the vehicle brak-

ing system may lead to brake failure, resulting in

property damage, personal injury, or death.

Meritor WABCO® Antilock

Braking System

The Meritor WABCO Antilock Braking System (ABS)

is an electronic wheel speed monitoring and control

system that works with the standard air brake sys-

tem. ABS passively monitors vehicle wheel speed at

all times, and controls wheel speed during emer-

gency stops.

IMPORTANT: For proper ABS system operation,

do not change tire sizes. The sizes of the tires

installed during production are programmed into

the electronic control unit. Installing different-

sized tires could result in a reduced braking

force, leading to longer stopping distances.

ABS includes signal-generating tone wheels and sen-

sors located in the wheel hubs of each sensed

wheel. The sensors transmit vehicle wheel speed

information to an electronic control unit (located be-

hind the center dash). The control unit’s main circuit

interprets the speed sensor signals and calculates

wheel speed, wheel retardation, and a vehicle refer-

ence speed. If the calculations indicate wheel lockup,

the main circuit signals the appropriate modulator

valve to reduce braking pressure. During emergency

braking, the modulator valve alternately reduces, in-

creases, or maintains air pressure supply in the

brake chamber to prevent front and rear wheel

lockup.

The electronic control unit (ECU) also has a safety

circuit that constantly monitors the wheel sensors,

traction control valve (if equipped), modulator valves,

and the electrical circuitry.

The Meritor WABCO ABS combines one front-axle

control channel with one rear-axle control channel to

form one control circuit. For example, the sensor and

modulator valve on the left-front axle form a control

circuit with the sensor and modulator valve on the

right-rear axle. If, during vehicle operation, the safety

circuit senses a failure in any part of the ABS, the

tractor warning lamp (TRACTOR ABS) illuminates

and the control circuit where the failure occurred is

switched to normal braking action. The remaining

control circuit will retain the ABS effect. Even if the

ABS is completely inoperative, normal braking ability

Brake Systems

13.3

is maintained. An exception would be if a modulator

valve (or combination modulator valve) is damaged

and inoperative. As these components are an integral

part of the air brake system, normal braking may be

impaired or inoperative.

During emergency or reduced-traction stops, fully

depress the brake pedal until the vehicle comes to a

safe stop. Do not pump the brake pedal. With the

brake pedal fully depressed, the ABS will control all

wheels to provide steering control and a reduced

braking distance.

Although the ABS improves vehicle control during

emergency braking situations, the driver still has the

responsibility to change driving styles depending on

existing traffic and road conditions. For example, the

ABS cannot prevent an accident if the driver is

speeding or following too closely.

Trailer ABS Compatibility

The Meritor WABCO ABS is designed to communi-

cate with a trailer ABS, if they are compatible. Com-

patibility will result in the illumination of the TRAILER

ABS lamp during vehicle start-up and fault detection.

The TRAILER ABS lamp will not illuminate unless a

compatible trailer is connected to the tractor. The

dash-mounted lamp will operate as follows when a

compatible trailer is properly connected to the tractor:

•When the ignition key is turned to the ON posi-

tion, the TRAILER ABS lamp will illuminate mo-

mentarily, then turn off.

•If the lamp illuminates momentarily during ve-

hicle operation, then shuts off, a fault was de-

tected and corrected.

•If the lamp illuminates and stays on during ve-

hicle operation, there is a fault with the trailer

ABS. Repair the trailer ABS system immedi-

ately to ensure full antilock braking capability.

IMPORTANT: If a compatible trailer is con-

nected, and the lamp is not illuminating momen-

tarily when the ignition key is turned to the ON

position, it is possible that the lamp is burnt out.

Automatic Traction Control

Vehicles with electronic engines and ABS may have

Automatic Traction Control (ATC). On these vehicles,

the ATC system automatically limits wheel spin dur-

ing reduced-traction situations. In normal braking ap-

plications, the standard air brake system is in effect.

An additional solenoid valve is installed. During

reduced-traction situations, the ATC solenoid valve

controls air pressure to the modulator valves and

they in turn increase, hold, or reduce pressure to the

appropriate brake chambers to provide better traction

whenever wheel spin occurs.

When the ATC system is in the NORMAL mode, it

will apply gentle braking to the spinning wheel, to

feed power to the wheel(s) with better traction. If

both wheels are spinning, the system will signal the

engine to reduce power.

ATC includes a deep snow and mud option to in-

crease available traction on extra soft surfaces like

snow, mud, or gravel. A rocker switch labeled ATC

will be located on the dash. Pressing the switch will

temporarily allow more drive wheel spin. The activa-

tion of the deep snow and mud option is indicated by

a ﬂashing WHEEL SPIN lamp. Pressing the switch

again will cycle the system back to normal operation.

NOTICE

The deep snow and mud option is intended to be

used under speciﬁc slippery conditions that re-

quire momentary increased wheel spin. Using

this option for an extended period of time may

damage the vehicle brake system.

After the ignition switch is turned on, the TRACTOR

ABS lamp and the WHEEL SPIN indicator lamp

come on for about three seconds. After three sec-

onds, the warning lights go out if all of the tractor’s

ABS components are working.

IMPORTANT: If any of the ABS warning lights

do not work as described above, or come on

while driving, repair the ABS immediately to en-

sure full antilock braking capability.

ECAS Automatic Load Transfer

(ECAS only)

On those vehicles equipped with Electronically Con-

trolled Air Suspension (ECAS), ECAS works in con-

junction with ABS. When wheel slippage is detected

by the ABS, the ECAS system transfers weight from

the tag axle to the drive axle by changing air pres-

sures in the suspension air bellows, increasing drive

wheel traction.

Brake Systems

13.4

Engine Brake

Each engine manufacturer uses a speciﬁc engine

brake for their engine. Regardless of the manufac-

turer, the engine brake is operated with the principles

outlined in here. Refer to the engine manufacturer’s

operation manual for details of their particular engine

brake product.

WARNING

To avoid injury from loss of vehicle control, do

not activate the engine brake system under the

following conditions:

•on wet or slippery pavement, unless the

vehicle is equipped with antilock braking

system (ABS) and you have had prior expe-

rience driving under these conditions;

•when driving without a trailer or pulling an

empty trailer;

•if the tractor drive wheels begin to lock, or

there is ﬁshtail motion after the engine

brake is activated.

NOTE: When the engine brake is enabled, the

engine brake lamp illuminates in the ICU. See

Fig. 13.3, Item 1.

Whenever vehicle braking is required on good road

conditions, the engine brake may be used in con-

junction with the service brakes. There is no time

limit for operation of the engine brake. However, an

engine brake does not provide the precise control of,

and is not a substitute for, service brakes.

WARNING

Usage of the engine brake as the primary braking

system can cause unpredictable stopping dis-

tances, that could result in personal injury or

property damage. Service brakes are the primary

vehicle braking system.

Since the engine brake is most effective at rated en-

gine speed, gear selection is very important. Gearing

down the vehicle within the limits of the rated engine

speed makes the engine brake more effective. Rec-

ommended engine braking speed is above 1800 rpm

and below the rated speed.

WARNING

The engine brake must be disengaged when

shifting gears using the clutch pedal. If the en-

gine brake is engaged when the transmission is

in neutral, the braking power of the engine brake

can stall the engine, which could result in loss of

vehicle control, possibly causing personal injury

and property damage.

"Control speed" is the speed at which the engine

brake performs 100 percent of the required downhill

braking, resulting in a constant speed of descent.

The control speed varies, depending on vehicle

weight and the downhill grade.

For faster descent, select a higher gear than that

used for control speed. Service brakes must then be

used intermittently to prevent engine overspeed and

to maintain desired vehicle speed.

For slower descent, select a lower gear, being care-

ful not to overspeed the engine. Occasional deactiva-

tion of the engine brake may be necessary to main-

tain the designated road speed under these

conditions.

If the engine is equipped with both cruise control and

an engine brake, the engine brake can operate auto-

matically while cruise control is activated. The maxi-

mum amount of braking is selected with the engine

brake control. When the vehicle returns to the set

cruise speed, the engine brake will turn off.

The engine brake will only operate when the accel-

erator and clutch pedals are fully released.

Vehicles equipped with ABS have the ability to turn

the engine brake off if wheel slip is detected. The

engine brake will automatically turn back on once

wheel slip is no longer detected.

Engine Brake Operation

NOTICE

Do not allow the engine to exceed its governed

speed, or serious engine damage could result.

NOTE: Depending on the brake type, the engine

brake may be disabled when engine tempera-

ture falls below a set level.

Brake Systems

13.5

The engine brake control depends on vehicle con-

ﬁguration. On some vehicles, there is an engine

brake (ENG BRK) switch located in the right-hand

pod on the steering wheel that is used to turn the

engine brake on and off, and an engine brake level

switch on the dash used to set the intensity—high,

medium, or low. See Fig. 13.4 and Fig. 13.5.

On vehicles equipped with a column-mounted Detroit

multifunction control, the engine brake is controlled

by the lever position, as shown in Fig. 13.6. At the

top position, the engine brake is off, and at the three

lower positions, the engine brake is on and the inten-

sity (low, medium, high) increases with each step

down.

NOTE: On vehicles equipped with a Detroit mul-

tifunction control, setting the engine brake with

the cruise control set activates Deceleration

Mode. Setting the cruise control while the en-

gine brake is on activates Descent Control

Mode. For information on these modes, see

"Cruise Control" in Chapter 5.

On vehicles equipped with an engine brake switch in

the right-hand pod on the steering wheel, operate the

engine brake after the engine is warmed up and the

vehicle is in motion, as follows:

1. Remove feet from both the clutch and accelera-

tor pedals.

2. Press the upper half of the on/off switch (see

Fig. 13.4) to turn the engine brake on. The en-

gine brake will engage at the rate last set on the

engine brake intensity switch and the engine

brake lamp will illuminate.

ABS ABS

CHECK STOP

OPT 2 OPT 4 OPT 5 OPT 6 OPT 9

05/07/2012 f611094

6 7 8 9 10 11

12 13 14 15 16 17

18 19 21 22 24 2520 23

234 5

IDLE

MGMT

BRAKE

1. Engine Brake

2. Optional

3. Wait To Start

4. Check Transmission

5. Optimized Idle

6. CHECK Engine

7. STOP Engine

8. Malfunction Indicator Lamp (MIL)

9. Vehicle ABS

10. Transmission Overheat

11. Trailer ABS

12. Low Engine Oil Pressure

13. High Coolant Temperature

14. Unfastened Seat Belt

15. Park Brake On

16. Diesel Particulate Filter (DPF)

Status

17. High Exhaust Temperature

(HEST)

18. Left-Turn Signal

19. Low Battery Voltage

20. Water In Fuel

21. Driver Message Center

22. High Beams On

23. Brake Air

24. Cruise Control On

25. Right-Turn Signal

Fig. 13.3, ICU3 Message Center (typical)

Brake Systems

13.6

3. Press the upper or lower half of the intensity

switch (see Fig. 13.5) to select the desired brak-

ing intensity.

Use the intensity switch set at the LOW position

when driving on ﬂat, open stretches of road. If

the service brakes are still required to slow down

on a grade, switch to a higher setting on the

dash switch to maintain constant speed of de-

scent. Grade descent speed should be such that

the service brakes are used infrequently and re-

main cool, thus retaining their effectiveness.

4. For maximum retarding, maintain the top gov-

erned speed of the engine through the appropri-

ate selection of gears. When shifting gears, the

engine brake will disengage when the clutch

pedal is depressed, then engage when the clutch

pedal is released.

5. To cancel the engine brake application, press the

lower half of the on/off switch.

06/15/2007

ON/

OFF

ACC/

RES

CNCL

DEC/

SET

MRKR

INT

ENG

BRK

−

f462049a

Fig. 13.4, Steering Wheel Switches

ENG

BRK

f61090505/02/2007

Fig. 13.5, Engine Brake Level Switch

02/19/2013 f270164a

0. Off

1. Low

2. Medium

3. High

Fig. 13.6, Engine Brake Positions, Detroit Multifunction

Control

Brake Systems

13.7

Manual Transmissions and

Hydraulic Clutch

Eaton Fuller 13-Speed and 18-Speed Splitter and Range-Shift Transmissions ............... 14.1

Eaton Fuller 10-Speed Range-Shift Transmissions ..................................... 14.4

Clutch ......................................................................... 14.5

Eaton Fuller 13-Speed and 18-

Speed Splitter and Range-Shift

Transmissions

Refer to the Eaton website for additional information,

www.roadranger.com.

General Information, Eaton Fuller

Splitter and Range-Shift

Combination splitter and range-shift transmissions

allow the choice of two splitter ratios in each lever

position as well as the additional ratio provided in

each lever position after shifting to the other range.

IMPORTANT: Not all lever positions are used in

each range and the shift patterns vary between

transmissions. Be sure to read the shift pattern

decal on the dash for the operating instructions

for the speciﬁc transmission installed in your ve-

hicle.

13-Speed RTLO Models

Eaton Fuller 13-speed transmissions have thirteen

forward speeds and two reverse speeds. Each trans-

mission consists of a 5-speed front section, and a

3-speed auxiliary section. The auxiliary section con-

tains low- and high-range ratios, plus an overdrive

splitter gear. See Fig. 14.1 for the shift pattern.

All of the 13 speeds are controlled with one shift

lever. A range preselection lever and a splitter control

button are built into the shift knob. The range prese-

lection lever controls range selection and the splitter

control button (located on the side of the shift knob)

controls gear splits.

Low gear in the front section is used only as a start-

ing ratio. The remaining four forward positions are

used once in the low range and once in the high

range. However, each of the four high range gear

positions can be split with the underdrive ratio (RT

models), or overdrive ratio (RTO models) of the split-

ter gear. Ratios cannot be split while the transmis-

sion is in low range.

18-Speed RTLO Splitter and Range-Shift

Models

Eaton Fuller 18-speed transmissions have 18 forward

speeds and four reverse speeds. These transmis-

sions consisting of a 5-speed front section and a

3-speed auxiliary section. The auxiliary section con-

tains low and high range ratios, plus an overdrive

splitter gear.

One ratio in the front section (low) is used as a start-

ing ratio; it is never used when the transmission is in

high range. Low gear can be split to provide both a

direct and an overdrive ratio.

The other four ratios in the front section are used

once in low range and once again in high range;

however, each of the ﬁve ratios (low–1–2–3–4) in low

range and each of the four ratios (5–6–7–8) in high

range can be split with the overdrive splitter gear.

All of the 18 speeds are controlled with one shift

lever. A range preselection lever and a splitter control

button are built into the shift knob. The range prese-

lection lever controls range selection and the splitter

control button (located on the side of the shift knob)

controls gear splits.

Operation, Eaton Fuller Splitter and

Range-Shift

IMPORTANT: The shifter knob has an interlock

feature that prevents the splitter control button

from being moved forward when the range pre-

selection lever is down (in low range); when in

high range and the splitter control button is in

the forward position, the range preselection

lever cannot be moved down.

R1 3

LOW

Dir OD

Dir OD Dir OD

66 8 8

03/13/96 f260044a

A. High Range

B. Low Range

C. Overdrive (forward)

D. Direct Drive (rearward)

1. Splitter Control Button

Fig. 14.1, Eaton Fuller 13-Speed Transmission Shift

Pattern

Manual Transmissions and Hydraulic Clutch

14.1

1. When operating off-road, or under adverse condi-

tions, always use low gear when starting to move

the vehicle forward.

When operating on-highway, with no load, or

under ideal conditions, use 1st gear when start-

ing to move the vehicle forward.

For all conditions, use the highest gear that is

still low enough to start the vehicle moving with

the engine at or near idle speed, and without

slipping the clutch excessively.

2. Use the clutch brake to stop gear rotation when

shifting into low (or 1st) or reverse when the ve-

hicle is stationary. The clutch brake is actuated

by depressing the clutch pedal all the way to the

ﬂoor.

For normal upshifts and downshifts, only a partial

disengagement of the clutch is necessary to

break engine torque.

3. Use double-clutching between all upshifts and

downshifts that require movement of the shift

lever. Splitting of the high range gears does not

require movement of the shift lever.

4. Never move the shift lever into low gear while in

high range.

5. Never move the splitter control button while in

neutral.

6. Do not preselect with the splitter control button;

after moving the control button, complete the

shift immediately.

7. Except when downshifting from 5th direct to 4th

gear, never push the range preselection lever

down into low range while operating in high

range—the splitter will become inoperative.

8. Do not shift from high range to low range at high

vehicle speeds.

9. Do not make range shifts with the vehicle moving

in reverse gear.

10. Never attempt to move the range preselection

lever with the gear shift lever in neutral while the

vehicle is moving. Preselection with the range

preselection lever must be made prior to moving

the shift lever out of gear into neutral.

11. After your shifting ability improves, you may want

to skip some of the ratios. This may be done

only when operating conditions permit, depend-

ing on the load, grade, and road speed.

Upshifting

1. Position the gear shift lever in neutral. Start the

engine, and bring the air system pressure up to

100 to 120 psi (689 to 827 kPa).

2. Position the range preselection lever down, into

low range. See Fig. 14.2.

3. Make sure the splitter control button is in the di-

rect (rearward) position. See Fig. 14.2.

4. For 13-speed transmissions:

Press the clutch to the ﬂoor, shift into low or 1st

gear; then engage the clutch, with the engine at

or near idle speed, to start the vehicle moving.

Accelerate to 80 percent of engine governed

speed.

For 18-speed transmissions:

Press the clutch to the ﬂoor, shift into low; then

engage the clutch, with the engine at or near idle

speed, to start the vehicle moving.

To shift from low direct to low overdrive, move

the splitter control button into the overdrive (for-

ward) position, then immediately release the ac-

celerator. Press and release the clutch pedal.

After releasing the clutch, accelerate again.

5. For 13-speed transmissions:

Shift upward from low to 1st gear, 2nd, etc. until

4th gear, double-clutching between shifts, and

Dir

Dir 5

OD 3

Dir

Dir 7

Dir

Dir 6

OD 4

Dir

Dir 8

LOW

Dir

LOW

03/13/96 f260157a

A. High Range

B. Low Range

C. Overdrive (forward)

D. Direct Drive (rearward)

1. Splitter Control Button

Fig. 14.2, Eaton Fuller 18-Speed Transmission Shift

Pattern

Manual Transmissions and Hydraulic Clutch

14.2

accelerating to 80 percent of engine governed

speed. See Fig. 14.1.

For 18-speed transmissions:

Shift upward from low overdrive to 1st direct by

ﬁrst moving the splitter control button into the

direct (rearward) position (Fig. 14.2). Move the

shift lever, double-clutching, to the 1st gear posi-

tion.

Continue upshifting through the shift pattern.

Double-clutch during lever shifts (1st to 2nd to

3rd to 4th); single-clutch during split shifts (1st

direct to 1st overdrive, etc.).

6. When in 4th gear (13-speed transmissions) or

4th overdrive (18-speed transmissions) and

ready to shift up to 5th gear, use the range shift

lever as follows:

For 13-speed transmissions:

While in 4th gear, pull the range shift preselec-

tion lever up, into high range. The transmission

will automatically shift from low to high range as

the shift lever passes through neutral. Then, dis-

engage the clutch; double-clutch through neutral;

move the shift lever to 5th gear; engage the

clutch, and accelerate the engine.

For 18-speed transmissions:

While in 4th overdrive, pull the range shift prese-

lection lever up, into high range. The transmis-

sion will automatically shift from low to high

range as the shift lever passes through neutral.

Move the shift lever, double-clutching, to the 5th

gear position. Just before making ﬁnal clutch en-

gagement, move the splitter control button to the

direct (rearward) position; then engage the clutch

and accelerate. Do not move the control button

while the shift lever is in neutral.

7. Shift up through the high range gears as follows:

For 13-speed transmissions:

To shift from 5th direct to 5th overdrive, move the

splitter control button (Fig. 14.1) into the over-

drive (forward) position, then immediately release

the accelerator. Press and release the clutch

pedal. After releasing the clutch, accelerate

again.

Continue upshifting through the shift pattern.

Double-clutch during lever shifts (6th to 7th to

8th); single-clutch during split shifts (6th direct to

6th overdrive, etc.).

For 18-speed transmissions:

To shift from 5th direct to 5th overdrive, move the

splitter control button (Fig. 14.2) into the over-

drive (forward) position, then immediately release

the accelerator. Press and release the clutch

pedal. After releasing the clutch, accelerate

again.

Continue upshifting through the shift pattern.

Double-clutch during lever shifts (6th to 7th to

8th); single-clutch during split shifts (6th direct to

6th overdrive, etc.).

Downshifting

1. Downshift from 8th overdrive to 8th direct without

moving the shift lever. Flip the splitter control but-

ton to the direct (rearward) position, then imme-

diately release the accelerator, and disengage

the clutch. Engage the clutch, and accelerate the

engine only after the transmission has shifted.

2. Start the downshift from 8th direct to 7th over-

drive by ﬂipping the splitter control button to the

overdrive (forward) position; then, immediately

double-clutch through neutral, moving the shift

lever from 8th to 7th gear.

3. Shift downward through each of the high range

gears, alternating the procedures in steps 1 and

2, above, until reaching 5th direct.

4. While in 5th direct and ready for the downshift to

4th (13-speed transmissions) or 4th overdrive

(18-speed transmissions), push the range prese-

lection lever down. Then, double-clutch through

neutral and move the shift lever to the 4th gear

position. On 18-speed transmissions, move the

splitter control button to the overdrive (forward)

position beforeengaging the clutch. Do not move

the control button while the shift lever is in neu-

tral.

5. Continue downshifting from 4th to 1st as follows:

For 13-speed transmissions:

Downshift through the low range gears as condi-

tions require.

For 18-speed transmissions:

Manual Transmissions and Hydraulic Clutch

14.3

Continue downshifting from 4th overdrive to 4th

direct, then 4th direct to 3rd overdrive, 3rd over-

drive to 3rd direct, etc. Single-clutch when split

shifting (direct to overdrive, overdrive to direct).

Double-clutch when making lever shifts (4th to

3rd, 3rd to 2nd, etc.).

IMPORTANT: Never use the clutch brake when

downshifting, or as a brake to slow the vehicle.

Eaton Fuller 10-Speed Range-

Shift Transmissions

Refer to the Eaton website for additional information,

www.roadranger.com.

General Information, Eaton Fuller

Range-Shift

To operate a range-shift transmission, move the shift

lever through all the low gear positions and then acti-

vate a range switch to provide an additional set of

ratios in the high range. Using the same shift lever

positions as in low range, move the shift lever

through each position as before. On some models,

the initial low gear is often used only in low range.

IMPORTANT: Not all lever positions are used in each

range and the shift patterns vary between transmis-

sions. Be sure to read the shift pattern decal on the

dash for the operating instructions for the speciﬁc

transmission installed in your vehicle.

10-Speed FR/FRO and RT/RTO/RTX

Models

Eaton Fuller 10-speed transmissions have 10 selec-

tive, evenly spaced forward ratios. Each transmission

has a 5-speed front section and a 2-speed rear

range section. The 10 forward speeds are obtained

by twice using a 5-speed shift pattern: the ﬁrst time

in low range, the second time in high range. See

Fig. 14.3 for the shift patterns.

NOTE: The 4th/9th and the 5th/10th shift posi-

tions in the RT (direct ratio) and RTX (overdrive

ratio) transmissions are directly opposite in the

RTO (overdrive ratio) transmissions

Operation, Eaton Fuller Range-Shift

1. When operating off-highway, or under adverse

conditions, always use low gear (if so equipped)

when starting to move the vehicle.

When operating on-highway, with no load, or

under ideal conditions, use 1st gear when start-

ing to move the vehicle (except when equipped

with a 9-speed RTO transmission, then always

start in low gear).

For all conditions, use the highest gear that is

still low enough to start the vehicle moving with

engine idling, and without slipping the clutch ex-

cessively.

2. Use the clutch brake to stop gear rotation when

shifting into low (or 1st) or reverse when the ve-

hicle is stationary. The clutch brake is actuated

by depressing the clutch pedal all the way to the

ﬂoor.

For normal upshifts and downshifts, only a partial

disengagement of the clutch is necessary to

break engine torque.

3. Do not make range shifts with the vehicle moving

in reverse gear.

4. Never attempt to move the range preselection

lever with the gear shift lever in neutral while the

vehicle is moving. Preselection with the range

preselection lever must be made prior to moving

the shift lever out of gear into neutral.

5. Do not shift from high range to low range at high

vehicle speeds.

f261053

12/15/1999

A. High Range B. Low Range

Fig. 14.3, Eaton Fuller 10-Speed Transmission Shift

Patterns

Manual Transmissions and Hydraulic Clutch

14.4

6. Double-clutch between all upshifts and down-

shifts.

7. After your shifting ability improves, you may want

to skip some of the ratios. This may be done

only when operating conditions permit, depend-

ing on the load, grade, and road speed.

Upshifting

1. Position the gear shift lever in neutral. Start the

engine, and bring the air system pressure up to

100 to 120 psi (689 to 827 kPa).

2. Position the range preselection lever down, into

low range.

3. Press the clutch pedal to the ﬂoor; shift into low

or 1st gear (Table 14.1), then engage the clutch,

with the engine at or near idle speed, to start the

vehicle moving. Accelerate to 80 percent of en-

gine governed speed.

Eaton Fuller Shift Progressions

TRANS.

MODEL

LOW RANGE HIGH

RANGE

Off-Highway On-Highway

10-Speed

Direct or

Overdrive

(RT or

RTX)

f260329

810

f260330

Table 14.1, Eaton Fuller Range-Shift Shift

Progressions

4. Shift progressively upward from low or 1st gear,

to the top gear in low range (Table 14.1),

double-clutching between shifts, and accelerating

to 80 percent of engine governed speed.

5. While in the top gear of the low range shift pat-

tern, and ready for the next upshift, ﬂip the range

preselection lever up into high range. Double-

clutch through neutral, and shift into the bottom

gear in high range (Table 14.1). As the shift lever

passes through neutral, the transmission will au-

tomatically shift from low range to high range.

6. With the transmission in high range, shift pro-

gressively upward through each of the high

range gears (Table 14.1), double-clutching be-

tween shifts.

Downshifting

1. With the transmission in high range, shift pro-

gressively downward to the bottom gear in high

range, double-clutching between shifts.

2. When in the bottom gear of the high range shift

pattern, and ready for the next downshift, push

the range preselection lever down into low range.

Double-clutch through neutral, and shift into the

top gear of the low range shift pattern. As the

shift lever passes through neutral, the transmis-

sion will automatically shift from high range to

low range.

3. With the transmission in low range, downshift

through the low range gears as conditions re-

quire.

IMPORTANT: Never use the clutch brake when

downshifting, or as a brake to slow the vehicle.

Clutch

General Information

The hydraulic clutch control system consists of a

pedal unit and a slave cylinder, connected by a hy-

draulic hose and fastened with quick-disconnect

clamps. The components of the system have been

specially designed to use DOT 4 brake ﬂuid. The

pedal unit includes a hydraulic subassembly, com-

posed of the master cylinder and reservoir, which

can be removed from the pedal unit for service pur-

poses. When the clutch pedal is depressed, the ﬂuid

in the master cylinder is forced through a hydraulic

line to the slave cylinder. The ﬂuid pressure moves

the slave cylinder piston, pushing the plunger rod

and clutch release lever, which disengages the

clutch. The hydraulic system is self-adjusting.

Clutches are designed to absorb and dissipate more

heat than encountered in typical operation. The tem-

peratures developed in typical operation will not

break down the clutch friction surfaces. However, if a

clutch is slipped excessively, or asked to do the job

of a ﬂuid coupling, high temperatures develop quickly

and destroy the clutch. Temperatures generated be-

tween the ﬂywheel, driven discs, and pressure plates

can be high enough to cause the metal to ﬂow and

the friction facing material to char and burn.

Heat and wear are practically nonexistent when a

clutch is fully engaged. But during the moment of

engagement, when the clutch is picking up the load,

Manual Transmissions and Hydraulic Clutch

14.5

it generates considerable heat. An improperly ad-

justed or slipping clutch will rapidly generate suffi-

cient heat to destroy itself.

To ensure long service life of the clutch; start in the

right gear, be alert to clutch malfunctions, and know

when to adjust the clutch.

Clutch Operation

Clutch Break-In

With a new or newly installed clutch, the clutch may

slip for a short time while the friction surfaces break-

in. However, allowing the clutch to slip for more than

two seconds can severely damage the clutch disc,

pressure plate, and the ﬂywheel.

During initial operation of a new vehicle or a vehicle

with a new clutch, check for clutch slippage during

acceleration. If the clutch slips, decelerate until the

clutch does not slip. Allow the clutch to cool 15 to 30

seconds, and then gradually accelerate again. If the

clutch continues to slip, repeat the procedure. If nec-

essary, repeat the procedure up to ﬁve times. If the

clutch slips after ﬁve attempts, stop the vehicle. Allow

the clutch to cool for at least one hour. Notify your

Freightliner dealer of the problem.

CAUTION

Do not allow sustained slippage of the clutch;

this could severely damage the clutch disc, pres-

sure plate, or ﬂywheel. Damage caused by clutch

slippage due to improper break-in is not warrant-

able.

Moving the Vehicle in the Proper Gear

An empty truck can be started in a higher transmis-

sion gear than can a partially or fully loaded truck. A

good rule of thumb for the driver to follow is to select

the gear combination that allows the vehicle to start

moving with an idling engine, or, if necessary, just

enough throttle to prevent stalling the engine. After

the clutch is fully engaged, the engine can be accel-

erated to the correct rpm for the upshift into the next

higher gear.

Gear Shifting Techniques

Shift into the next higher gear when the vehicle

speed allows the transmission input shaft speed to

match the ﬂywheel speed when engaging the clutch.

This technique results in the smallest speed differ-

ence between the clutch disc and the ﬂywheel and

causes the least heat and wear on the clutch assem-

bly. When downshifting, the input shaft speed must

be increased by slightly revving the engine to match

the ﬂywheel speed for smooth clutch engagement.

For transmission operating instructions, refer to the

transmission headings in this manual.

Vehicle Loading

Clutches are designed for speciﬁc vehicle applica-

tions and loads. These weight limitations should not

be exceeded.

CAUTION

Exceeding vehicle load limits can not only result

in damage to the clutch, but can also damage the

entire powertrain.

Using the Clutch

The clutch pedal must be used only to start the ve-

hicle moving or while shifting. To start the vehicle

moving, depress the clutch pedal all the way to the

ﬂoor plate (see "Using the Clutch Brake") and shift

from neutral to a low gear. Slowly raise your foot until

the clutch starts to engage. In this position the clutch

is starting to connect the transmission input shaft to

the ﬂywheel and is causing the most heat and wear.

Slightly increase the engine speed and smoothly

allow the clutch pedal to return to its at rest position.

Do not allow the clutch to remain in the partially en-

gaged position any longer than necessary to obtain a

smooth start.

To shift gears while the vehicle is moving, push the

clutch pedal most of the way (but not all of the way)

to the ﬂoor plate. Shift the transmission into neutral

and fully release the clutch pedal. If upshifting, wait

long enough for the engine speed to decrease to the

road speed. If downshifting, increase the engine

speed to match the road speed. Again, push down

the clutch pedal part way and then move the shift

lever to the next gear position. Fully release the

clutch pedal after completing the shift.

Slightly depressing the clutch pedal while driving is

damaging to the clutch, because partial clutch en-

gagement causes slippage and heat. Resting your

foot on the clutch pedal will also put a constant thrust

load on the release bearing, thinning the bearing lu-

bricant and increasing the wear on the bearing.

Manual Transmissions and Hydraulic Clutch

14.6

Using the Clutch Brake

The clutch brake is applied by depressing the clutch

pedal past the fully released clutch position, almost

to the ﬂoor plate. The last part of the clutch pedal

travel will compress the clutch brake plates together,

stopping the transmission input shaft. The purpose of

the clutch brake is to stop the transmission gears

from rotating in order to quickly engage a transmis-

sion gear after idling in neutral.

CAUTION

Never apply the clutch brake when the vehicle is

moving. If the clutch brake is applied when the

vehicle is moving, the clutch brake will try to

stop or decelerate the vehicle, causing rapid

wear of the clutch brake friction discs. Consider-

able heat will be generated, causing damage to

the release bearings and the transmission front

bearings.

Holding the Vehicle on an Incline

Always use the vehicle service brakes to prevent the

vehicle from rolling backwards while stopped on a

hill. Slipping the clutch on a hill to maintain the ve-

hicle position will quickly damage the clutch assem-

bly.

Coasting

Coasting with the clutch pedal depressed and the

transmission in a low gear can cause high driven

disc speed. The clutch speed can be much higher

under these conditions than when the engine is driv-

ing the clutch. This condition creates a hazardous

situation due to the lack of vehicle control and due to

the high clutch disc speed. Engaging the clutch

under these conditions can cause component dam-

age because of the shock loads to the clutch and

drivetrain.

WARNING

Always shift into the gear that is correct for the

traveling speed of the vehicle and engage the

clutch. Coasting with the clutch disengaged can

prevent engagement of the correct transmission

gear which can cause loss of vehicle control,

possibly resulting in personal injury or property

damage.

High clutch disc speeds while coasting can also

cause the clutch facing to be thrown off the disc.

Flying debris from the clutch can cause injury to

persons in the cab.

Clutch Maintenance

Clutch Adjustment

Eaton Fuller Solo clutches are adjustment-free. As

the clutch wears, its wear-adjusting technology moni-

tors clutch components and makes any necessary

adjustments. The wear adjusting technology comes

from two sliding cams, which rotate to maintain the

proper adjustment. Atop the upper cam, a wear indi-

cating tab mirrors the cam’s movement, letting you

know when it’s time to replace the clutch.

CAUTION

Operating the vehicle with incorrect free pedal

could result in clutch damage.

Hydraulic Clutch Fluid Reservoir

Checking

Make sure that the clutch ﬂuid reservoir is full. See

Fig. 14.4. The reservoir is full when the ﬂuid level is

up to the "max" mark. The ﬂuid level must always be

above the "min" mark. Use only heavy-duty brake

ﬂuid, DOT 4, in the clutch hydraulic system.

06/05/2007 f250664

Fig. 14.4, Clutch Fluid Reservoir

Manual Transmissions and Hydraulic Clutch

14.7

Automated Transmissions

Detroit™Automated Transmissions .................................................. 15.1

Freightliner SmartShift Shift Control ................................................. 15.5

Eaton Fuller UltraShift ............................................................ 15.6

Eaton Fuller AutoShift Automated Transmissions ...................................... 15.11

Eaton Fuller UltraShift PLUS ...................................................... 15.14

Detroit™Automated

Transmissions

Detroit transmissions have twelve forward gears and

up to four reverse gears that can be shifted automati-

cally or manually. Shifting and clutch actuation are

computer controlled, and there is no clutch pedal

needed to operate the vehicle. Automatic shifts are

selected for fuel economy or engine power. Manual

shifts can be requested with the shift control and the

transmission ECU grants them when conditions per-

mit. In all cases, shifts depend on the following fac-

tors: engine speed, accelerator pedal position, ser-

vice brake usage, engine brake operation, vehicle

load status, and road conditions.

NOTE: To avoid potential engine stall risk or un-

expected shifting, use the interaxle differential

lock when the vehicle is operated in slippery

conditions. See Chapter 16 for information

about the interaxle differential lock.

Detroit™Multifunction Control

Vehicles with Detroit transmissions use the control

shown in Fig. 15.1. This control can be used to re-

quest manual shifts, change driving mode, and set

engine brake levels. See Table 15.1 for an overview

of control functionality.

D/N/R Switch

Use the "D/N/R Switch" to request drive (D), neutral

(N), or reverse (R).

Mode Switch

The driving mode can be changed using the Mode

switch on the shift control (see Fig. 15.1). To activate

the manual drive mode, press and hold the switch

brieﬂy. Press the switch quickly to activate the auto-

matic drive mode or change between Automatic

Economy and Automatic Performance modes.

Upshifting and Downshifting

Gear shifts can be requested manually; push the

lever away to request a downshift, or pull the lever

toward you to request an upshift. See Table 15.1 for

more information about upshift and downshift

requests.

( + )

( − )

05/30/2012 f270163a

See Table 15.1 for a description of control functionality.

A. Front View

B. Shift Requests

C. Four positions for engine brake settings

1. Engine Brake Symbol

2. D/N/R Switch

3. Mode Switch

4. Gear Shift Symbol

Fig. 15.1, Detroit Multifunction Control

Automated Transmissions

15.1

Functionality, Detroit Multifunction Control

Function/Switch Action/Position Request

D/N/R

D Forward gears

N Neutral

R Reverse gears

Mode Depress switch and release it quickly Activate the automatic drive mode, or switch between

Automatic Economy and Automatic Performance.

Depress switch and hold it brieﬂy Activate the manual drive mode.

Upshifting and

Downshifting

Pull the lever toward you momentarily Upshift, single gear

Pull the lever toward you in quick repetitions Upshift, multiple gears

Push the lever away momentarily Downshift, single gear

Push the lever away in quick repetitions Downshift, multiple gears

Engine Brake*

Lever at position 0 (top) Engine brake off

Lever at position 1 Low intensity

Lever at position 2 Medium intensity

Lever at position 3 (bottom) High intensity

*For functions with cruise control active, see Chapter 5.

Table 15.1, Functionality, Detroit Multifunction Control

Engine Brake

The engine brake is controlled by the lever position

(as shown in Fig. 15.1, Ref. C). At the top position,

the engine brake is off, and at the three lower posi-

tions, the engine brake is on and the intensity (low,

medium, high) increases with each step down. For

more information about using the engine brake, see

Chapter 13.

NOTE: Using the engine brake with cruise con-

trol can be used to activate Descent Control

Mode or Deceleration Mode. For more informa-

tion, see "Cruise Control" in Chapter 5.

Power Up and Shift into Gear

1. With the parking brake set and Neutral (N) se-

lected on the shift control, turn the ignition switch

to the ON position.

2. Start the engine.

3. Apply the service brake.

4. Select the desired starting gear.

5. Release the parking brake.

6. Release the service brake and apply the accel-

erator.

Gear Display Window

The gear display window shows the current transmis-

sion gear and driving mode. See Fig. 15.2.

Driving Modes

There are three driving modes: Manual, Automatic

Economy, and Automatic Performance.

In Automatic Economy mode, gear shifts are de-

signed for saving fuel. In Automatic Performance

mode, gear shifts are designed for higher perfor-

mance and are made at higher engine speeds. In

manual mode, gear shifts are requested manually.

See Chapter 5 for more information about upshifting

and downshifting using the control.

A econ

07/09/2012 f611187

70 °F

1. Driving Mode

2. Current Gear

Fig. 15.2, Gear Display Window

Automated Transmissions

15.2

NOTE: In Automatic Performance mode, the

transmission will automatically change to Auto-

matic Economy mode if it hasn’t received a re-

quest for more power in several minutes, unless

current road conditions require higher engine

performance.

Selected Gear

If the selected gear is different than the current gear

for longer than a half second, the current gear dis-

play will ﬂash and the selected gear value will be

shown. Once the current gear and selected gear

match, the selected gear display disappears and the

current gear display stops ﬂashing. See Fig. 15.3.

Suggested Shift

In Manual mode only, a suggested shift is displayed

to indicate the most economical gear available. The

suggested shift is the number of up or down arrows

from the current gear with a maximum of three up or

down arrows. See Fig. 15.4.

eCoast

The eCoast feature can improve driving economy.

When conditions permit, the transmission control au-

tomatically shifts the transmission to neutral to coast

at speeds of approximately 22 mph (35 km/h) and

above. An "E" shows in the gear display window

when eCoast is in effect. See Fig. 15.5.

The eCoast function is not active when any of the

following occur:

•the accelerator pedal is pressed.

•vehicle acceleration rate is exceeded.

•the service brake pedal is pressed.

•the engine brake is in use.

•cruise control brakes or accelerates.

•vehicle speed exceeds the cruise control set

speed by more than approximately 4 mph (6

km/h).

•the speed limiter is active and the maximum

speed set is exceeded.

•diesel particulate ﬁlter (DPF) regeneration oc-

curs.

The eCoast function cannot be deactivated when the

Automatic Economy mode is active.

NOTE: To disable eCoast, see an authorized

Freightliner service facility.

Creep Mode

Creep mode allows the vehicle to be maneuvered at

very slow speeds. To activate Creep mode for the

ﬁrst time within the current driving cycle, press the

accelerator pedal to launch the vehicle, thereby fully

07/09/2012 f611188

A econ

70 °F

1. Selected Gear

2. Current Gear

Fig. 15.3, Selected Gear Display

Manual

07/09/2012 f611189

70 °F

1. Suggested Shift Arrows

2. Current Gear

Fig. 15.4, Suggested Shift

07/09/2012 f611190

A econ

70 °F

NOTE: Upshift and downshift arrows are not shown

when "E" is shown in the gear display window.

Fig. 15.5, eCoast Display

Automated Transmissions

15.3

engaging the clutch. Following this and for the dura-

tion of the current driving cycle, Creep mode is ac-

tive.

Once the vehicle is stopped via the service brakes,

the vehicle will begin to creep again, without the ac-

celerator pedal actuation, as soon as the service

brakes are released.

To begin using Creep mode (once active) from a

parked position, shift from neutral to either drive or

reverse, release the service brakes, and brieﬂy de-

press the accelerator pedal. The vehicle’s urge to

move can then be felt.

If creep is active and no acceleration is achieved

within ﬁve seconds, then Creep mode will abort. A

display message notiﬁes the operator when Creep

mode is about to be aborted.

IMPORTANT: When slowing down from higher

speeds in drive or reverse, remember that

Creep mode will be in effect at lower speeds.

Use the service brakes to stop the vehicle.

Clutch Abuse Protection

A vehicle equipped with a Detroit transmission does

not have a clutch pedal, but still has a clutch that is

operated automatically and can be damaged by abu-

sive driver actions. To protect the clutch, the vehicle

has a clutch abuse protection system that alerts the

driver and restricts functionality when needed. Ex-

tended periods in Creep Mode, slipping the clutch

(using the accelerator pedal to hold the vehicle on a

hill, for example), and high clutch temperatures can

activate the clutch abuse protection system. A display

message notiﬁes the operator when the protections

are needed.

NOTICE

To hold the vehicle stationary on an uphill slope,

use the service brakes, not the accelerator pedal.

Using the accelerator pedal can overheat and

damage the clutch. To start moving, use the ac-

celerator pedal and release the brakes as the ve-

hicle begins to move.

There are three clutch abuse protection levels. At

each, the driver is alerted and functionality is modi-

ﬁed; see Table 15.2.

To avoid clutch overheating, follow these tips:

•To hold the vehicle stationary on an uphill

slope, use the service brakes, not the accel-

erator pedal.

•To start moving on an uphill slope, use the ac-

celerator pedal and release the brakes as the

vehicle begins to move.

•When hooking up to a trailer, ensure the trailer

is high enough to back under, and use ﬁrst

gear reverse.

•Avoid starting in higher gears, and start in ﬁrst

gear when a trailer is attached.

•Ensure trailer brakes have had time to com-

pletely release prior to starting.

•Do not use Creep mode for an extended pe-

riod. Stop or adjust the vehicle speed when

warned to deactivate Creep mode.

Engine Overspeed Alerts

To help protect the engine, the system has display

messages to notify the operator when the engine has

exceeded certain thresholds and needs to be slowed

down before signiﬁcant engine damage occurs.

There are two warnings, one at about 2400 rpm and

another at 2500 rpm, indicated with messages and a

fault code.

Low Transmission Air Warning

Pneumatic controls are used to shift the transmis-

sion. If there is inadequate air pressure, a warning is

displayed and the quality of gear shifts may be de-

graded. Wait for air pressure to build before operat-

ing the vehicle.

IMPORTANT: If the low transmission air warning

indicator appears while the vehicle is in opera-

tion, safely pull the vehicle off the road, and cor-

rect the problem.

Clutch Abuse Alerts and Protections

Alert Level Alert Protections

Highest Start Gear Creep Mode Clutch Function

1 Heavy clutch load message 1 No restriction Normal function

Automated Transmissions

15.4

Clutch Abuse Alerts and Protections

Alert Level Alert Protections

Highest Start Gear Creep Mode Clutch Function

2 Heavy clutch load message 1 Disabled Normal function

3Clutch overload message and

buzzer 1 Disabled

If the accelerator pedal is

depressed, the clutch closes

at ﬁxed rate.

If the accelerator pedal is

released, the clutch opens at

ﬁxed rate.

Table 15.2, Clutch Abuse Alerts and Protections

Freightliner SmartShift Shift

Control

General Information, SmartShift

The SmartShift transmission control is an electronic

transmission control device. It is installed with the

following transmissions:

•Eaton Fuller UltraShift™

•Eaton Fuller UltraShift™PLUS

•Eaton Fuller AutoShift™

It replaces the typical ﬂoor-mounted shift lever or

dash-mounted push button control.

SmartShift accepts driver requests for transmission

functions and transmits them through hard wiring to

the transmission control unit (TCU). SmartShift is a

true shift-by-wire system.

SmartShift offers two main advantages over conven-

tional transmission control devices. Without a ﬂoor-

mounted shift control, usable cab space is increased.

The SmartShift control mounts to the right-hand side

of the steering column and is operated by the ﬁngers

of the driver’s right hand, allowing both hands to re-

main on the steering wheel.

A two-position slide switch (Fig. 15.6) is mounted on

the body of the control lever just before the paddle

widens out. The slide switch allows the driver to

choose automatic (AUTO) or manual (MAN) mode.

In AUTO mode, gears shift automatically, without

driver interaction. Manual gearshifts are accom-

plished by a momentary pull or push on the control in

the plane perpendicular to the steering wheel. Pull

upward (toward you) on the control to upshift and

push downward (away from you) to downshift. The

control is spring-loaded and returns to mid-position

when released after an upshift or downshift.

For Eaton Fuller UltraShift, UltraShift PLUS, and Au-

toShift transmissions (Fig. 15.6), a four-position (R,

N, D, L) selector switch is located at the end of the

lever.

01/24/2003

11 12

f270120

To upshift manually, pull the lever up (towards you). To

downshift manually, push the lever down (away from

you).

1. SmartShift Control Lever

2. Slide Switch (forward driving mode switch)

3. MAN Mode (of slide switch)

4. AUTO Mode (of slide switch)

5. Upshift Direction

6. Reverse Position (of selector switch)

7. Selector Switch

8. Neutral Lock Button

9. Neutral Position (of selector switch)

10. Drive Position (of selector switch)

11. Low Position (of selector switch)

12. Downshift Direction

Fig. 15.6, SmartShift Control (Eaton Fuller UltraShift,

UltraShift PLUS, and AutoShift Transmissions)

Automated Transmissions

15.5

Embedded in the selector switch is a small neutral

lock button to prevent accidental shifts into gear from

neutral. Any time you shift through N, press down on

the neutral lock button to move the switch from neu-

tral (N) to another gear, such as drive (D), low (L), or

reverse (R). When shifting to N, it is not necessary to

press the neutral lock button.

Eaton Fuller UltraShift

General Information, UltraShift DM

Eaton® Fuller® UltraShift™DM is a ten-speed heavy-

duty fully automated transmission. No clutch pedal is

required to operate the vehicle.

UltraShift DM uses a dry clutch system which is of-

fered only on this automated transmission system.

The UltraShift transmission uses the four-position

SmartShift lever on the steering column to select

gears. To know what gear the transmission is in, look

at the round current gear indicator on the right-hand

control panel as shown in Fig. 15.7. All forward shifts

can be made either manually or automatically, at the

driver’s choice.

Operation, UltraShift DM

Power Up

1. With the parking brake set, select neutral (N) by

moving the selector switch to the N position.

2. With the transmission in neutral, turn on the igni-

tion switch. The CHECK TRANS and TRANS

TEMP telltale lights come on and go out again

(bulb check).

3. After the ignition is turned on, the current gear

indicator shows the dot display, arranged in a

square pattern. All dots in the pattern should light

up, without gaps or spaces. See Fig. 15.8.

4. Wait for the current gear indicator to show a solid

N. When the N is solid, rather than ﬂashing, the

UltraShift DM TCU is powered up. Apply the ser-

vice brake and start the engine.

5. Select drive (D) by pressing in the neutral lock

button and moving the selector switch downward

to the position below neutral. Release the park-

ing brake. The gear is displayed on the current

gear indicator.

NOTE: When D is selected, the transmission

controller starts up in second gear. If desired,

the driver can select to start up in ﬁrst. No other

start gear is available.

6. On a level grade, release the service brake and

press down on the throttle pedal to allow the ve-

hicle to move forward. The vehicle will not move

until the pedal is depressed.

12/22/2003 f270079a

To know what gear the transmission is in, look at the

current gear indicator.

1. Current Gear Indicator

2. SmartShift Control

Fig. 15.7, Shift Controls and Indicators, UltraShift

Transmissions

10/13/2003 f610678

Fig. 15.8, Power-Up Dot Display

Automated Transmissions

15.6

WARNING

When starting or stopping on hills and grades,

use extra care to prevent the vehicle from rolling

back. A rollback accident could cause death, seri-

ous personal injury, or property damage.

7. Prevent the vehicle from rolling backwards when

stopped on a hill or grade, or when the vehicle is

starting from a stop on a hill or grade.

7.1 To start from a full stop on a hill or grade,

quickly move your foot from the brake

pedal and press ﬁrmly on the throttle

pedal.

On steep hills, set the parking brake, and

release it only when there is enough en-

gine power to prevent rollback.

7.2 To stop on a hill or grade, press and hold

the brake pedal to keep the vehicle from

moving.

On steep hills, set the parking brake.

When parking, chock the tires, front and/or

rear. Never hold a hill with the throttle

pedal. This will cause the clutch to over-

heat.

Power Down

1. Apply the service brakes.

2. Select neutral (N) by pressing in the neutral lock

button and moving the selector switch to N.

When the N on the current gear indicator is solid,

rather than ﬂashing, the UltraShift DM TCU is

ready to power down.

3. With the transmission in neutral, set the parking

brake.

4. Turn off the ignition key and shut down the en-

gine.

Automatic and Manual Modes

The SmartShift control has a slide switch located on

the body of the control lever just before the paddle

widens out. See Fig. 15.9. The slide switch controls

the forward driving mode, automatic or manual.

To change mode at any time, move the slide switch

in the desired direction. This allows the driver to re-

spond to a wide range of driving conditions, such as

blind corners, tight curves, and steep hills.

IMPORTANT: Whatever the mode, it is always

possible to shift manually by moving the lever

up or down as needed. When the engine speed

is within 75 revolutions per minute (rpm) of the

load-based shift point for an automatic shift, the

UltraShift DM TCU will advance the shift.

In either mode, the gear indicator displays the cur-

rent gear. See Fig. 15.10.

01/21/2004 f270079c

1. Slide Switch (controls forward driving mode)

2. Selector Switch (controls gear selection)

3. Neutral Lock Button (prevents accidental shift into

gear)

Fig. 15.9, Switches, UltraShift Transmissions

10/13/2003 f610680

NOTE: The gear indicator displays the current gear. In

this example, it displays ﬁrst gear.

Fig. 15.10, Current Gear Display

Automated Transmissions

15.7

At the start of a shift, the current gear continues to

display until the transmission has been pulled into

neutral. At this point, as the transmission is synchro-

nizing for the new (target) gear, the gear indicator

ﬂashes the number of the new gear.

When the shift is complete, the new gear displays

solid, without ﬂashing.

Automatic Mode (AUTO)

In automatic drive mode (AUTO), upshifts and down-

shifts are made by the transmission without driver

intervention. Press in the neutral lock button, move

the selector switch to drive (D), and press down on

the throttle pedal. The transmission will shift auto-

matically.

If driving conditions require, it is still possible to re-

quest a manual shift. The transmission will make the

shift if the engine speed is within 75 rpm of the load-

based shift point for that gear.

If the driver presses down on the throttle pedal after

a manual downshift in automatic mode, the transmis-

sion will upshift again if the UltraShift DM TCU re-

quires it.

Manual Mode (MAN)

In manual drive mode (MAN), upshifts and down-

shifts are made by the driver:

•To shift up, pull the lever up (towards you).

•To shift down, push the lever down (away from

you).

The system will hold the current gear until the driver

requests a shift. In downhill situations in particular,

the driver must be alert to vehicle speed by down-

shifting and/or using the service brakes as needed.

A shift request will still be refused if the selected gear

would cause engine overspeed or excessive lugging.

Selecting Gears

Reverse

Reverse (R) is at the upper end of the four-position

selector switch located at the end of the SmartShift

control lever. To select R, press in the neutral lock

button and move the selector switch upward to the

position above neutral.

UltraShift DM has two reverse gears, reverse low

and reverse high. To shift manually between them,

use the shift lever as described for MAN mode.

There is no AUTO mode for reverse.

When reverse low is selected, the letter R displays

on the current gear indicator. When reverse high is

selected, the letter H displays on the current gear

indicator. See Fig. 15.11.

IMPORTANT: Under normal conditions, do not

select reverse with the vehicle moving forward.

The vehicle must be moving at less than two miles

per hour (3 km/h) before selecting reverse. If reverse

is selected when the vehicle is moving faster, an au-

dible alert will sound and continue sounding at three-

second intervals until the control lever is returned to

the D position or the vehicle slows to the proper

speed.

If necessary to rock the vehicle, use the selector

switch to shift back and forth at low speed between

reverse and drive.

Neutral

IMPORTANT: Always start the engine with the

transmission in neutral, the parking brake set,

and the service brakes applied.

Neutral (N) is directly below R on the four-position

selector switch located at the end of the SmartShift

control lever. To select N, press in the neutral lock

button and move the selector switch to the position

below R. When neutral is selected, the letter N dis-

plays on the current gear indicator. See Fig. 15.12.

10/14/2003 f610681

Fig. 15.11, Reverse Gear Display

Automated Transmissions

15.8

WARNING

Do not coast in neutral. Coasting in neutral can

cause an accident, possibly resulting in severe

personal injury or death.

Neutral is always available during operation, what-

ever the vehicle speed. When in neutral, requests to

upshift or downshift are ignored. If the selector switch

is moved from neutral to drive while the vehicle is

moving, the transmission will shift into a gear within

the engine’s operating speed range.

When shifting from neutral, always press on the

brake pedal. If the brake pedal is not pressed, the

transmission will not shift, the current gear display

will ﬂash N, and an audible alert will sound.

NOTE: To reset the transmission, return the se-

lector switch on the SmartShift lever to N and

attempt the shift again, this time with the brake

pedal pressed.

Before shutting down the engine, return the selector

switch to N. When the ignition is turned off, the trans-

mission will reset to neutral in a few minutes regard-

less of the position of the shift lever.

Drive

Drive (D) is directly below N on the four-position se-

lector switch located at the end of the SmartShift

control lever. To select D, press in the neutral lock

button and move the selector switch to the position

below N. When drive is selected, the number of the

currently selected forward gear (1 through 10) dis-

plays on the gear indicator. See Fig. 15.10.

When in drive, requests to upshift or downshift are

enabled. Either manual or automatic mode can be

selected on the slide switch.

Two starting gears are available, ﬁrst and second.

The default starting gear is second, but ﬁrst can be

selected by the driver, if desired. To change the start-

ing gear, press the brake pedal and select D with the

vehicle stopped. The current gear indicator will dis-

play the starting gear. Move the shift lever up or

down until the desired starting gear is displayed.

The UltraShift DM TCU adapts to the working condi-

tions of each vehicle and its driver. After power up or

a load change, it needs to learn the new conditions.

While learning, it may hold a gear too long before

upshifting. Start the upshift manually. It may take

three or four shifts before UltraShift succeeds in

learning the new load-based shift points, but after

that it will handle the shifting automatically.

Low

Low (L) is at the lower end of the four-position selec-

tor switch located at the end of the SmartShift control

lever. To select L, press in the neutral lock button

and move the selector switch to the position below

When in low, the current gear is maintained. Re-

quests to upshift are not enabled.

IMPORTANT: If the engine is approaching over-

speed, the UltraShift DM TCU will override the

current gear setting and upshift to prevent en-

gine damage.

To enhance engine braking, downshifts are per-

formed at higher rpm than normal.

If L is selected from neutral while stopped, the ve-

hicle starts up in ﬁrst gear and stays there until the

engine approaches overspeed.

Upshifting

To request an upshift with the transmission in drive,

pull the control lever up (towards you). If the gear is

available, the transmission upshifts and the new gear

displays on the gear indicator. No skip shifts are

available while upshifting.

No upshifts are available in low, except to prevent

engine overspeed.

10/13/2003 f610679

Fig. 15.12, Neutral Display

Automated Transmissions

15.9

If the transmission does not upshift quickly enough

after power-up or a load change, begin the shift

manually. The UltraShift DM TCU will learn the new

load-based shift conditions after three or four shifts.

If the gear requested is unavailable, a tone will

sound. An unavailable request to upshift is not stored

in memory. The upshift must be requested again.

Downshifting

NOTE: The driver can manually downshift at

any time, even when the slide switch is set to

AUTO mode.

To request a downshift with the transmission in drive

or low, push the control lever down (away from you).

If the gear is available, the transmission downshifts

and the new gear displays on the gear indicator. Skip

shifts are available while downshifting.

For best engine braking, select low while moving. In

low, downshifts are performed at higher rpm than in

drive.

IMPORTANT: If the engine is approaching over-

speed, the UltraShift DM TCU will override the

current gear setting and upshift to prevent en-

gine damage.

If the gear requested is unavailable, a tone will

sound. An unavailable request to downshift is not

stored in memory. The downshift must be requested

again.

When coasting to a stop, the UltraShift DM TCU may

not ﬁnish the downshift until the driver presses down

on the throttle pedal again.

IMPORTANT: A downshift request can never

result in a shift into neutral, even if the vehicle is

in the drive position in the lowest possible gear.

Before starting down a hill, slow down. Downshift to

a speed that you can control without hard pressure

on the service brakes.

Before entering a curve, slow down to a safe speed.

Downshift if necessary. This lets you use some

power through the curve to help the vehicle be more

stable on the turn. It also allows you to regain speed

faster as you come out of the curve.

Ultrashift Diagnostics

Clutch Protection Fault

Excessive clutch slippage creates heat and reduces

the life of the clutch. These are some conditions

which lead to clutch abuse:

•Using the throttle to hold the vehicle on a

grade

•Starting the vehicle in too high a gear

•Overloading the vehicle

•Using high idle with the vehicle in gear

The UltraShift DM TCU is programmed to prevent

clutch abuse. When the clutch overheats, the follow-

ing alerts take place:

•The TRANS TEMP light comes on

•The current gear indicator displays CA

•A warning tone sounds at one-second intervals

The alerts continue until the clutch cools, the throttle

is released, or the clutch is fully engaged.

System Problem

In the event of a problem, do the following steps.

1. Note the driving conditions at the time the prob-

lem occurred.

2. Record the status of the transmission at the time

of the problem (AUTO or MAN mode, gear set-

ting R, N, D, or L, current gear, engine speed,

etc.)

3. Reset the system, using the procedure below.

Reset Procedure

Transmission operation can sometimes be restored

by doing the following reset procedure:

1. Stop the vehicle when it is safe to do so. Set the

parking brake.

2. Place the selector switch in neutral and turn off

the ignition.

3. Check all harness connectors as described in

Chapter 21.

4. Wait at least two minutes with the engine shut

down.

5. Restart the engine.

Automated Transmissions

15.10

If the problem continues, contact an authorized

Freightliner or Eaton service facility.

Locked In Gear

If the transmission becomes locked in gear, a dash

(–) will appear on the current gear indicator when the

vehicle is restarted during the reset procedure.

NOTE: If the transmission becomes locked in

gear while the vehicle is moving, increased

braking effort may be required to stop the ve-

hicle.

If the current gear indicator displays a dash during

power-up with the selector switch in neutral, do the

following steps.

1. Make sure the parking brake is set.

2. Turn off the ignition and wait at least two min-

utes.

3. Apply the service brakes.

4. With the service brakes applied, release the

parking brake.

5. Make sure the selector switch is in neutral and

turn on the ignition key. Do not attempt to start

the engine at this time.

6. If necessary to get the transmission to shift into

neutral, release the pressure on the brake pedal

slightly.

7. Once the UltraShift DM TCU reaches neutral, a

solid N will appear on the current gear indicator

and the vehicle will start. Make sure the service

brakes are applied and the parking brake is set.

If the current gear indicator continues to display a

dash, contact an authorized Freightliner or Eaton ser-

vice facility.

Eaton Fuller AutoShift

Automated Transmissions

Refer to the Eaton website for additional information,

www.roadranger.com.

General Information, AutoShift

10-Speed RT/RTO Models

Eaton Fuller 10-speed AutoShift transmissions have

10 forward speeds and two reverse speeds. The

transmission consists of a 5-speed front section and

a 2-speed rear section. The driver must use the

clutch to start and stop the vehicle.

The driver does not need to break torque or increase

or decrease engine speed to synchronize the shift.

The transmission signals the engine controller when

to break torque and the engine controller automati-

cally increases or decreases engine speed. When

engine speed is correct, the transmission engages

the next gear and signals the engine controller to

resume operation.

WARNING

When starting or stopping on hills and grades,

use extra care to prevent the vehicle from rolling

back. A rollback accident could cause death, seri-

ous personal injury, or property damage.

The AutoShift system consists of the following com-

ponents:

•The SmartShift control paddle on the steering

column. See Fig. 15.6.

•The gear display module (Fig. 15.13) mounted

on the dashboard indicates the current gear

position or transmission status. The display

also ﬂashes the next gear to be engaged while

the transmission is in neutral during a gear

change.

•The shifter mechanism performs shifts at the

front portion of the transmission. It preselects

the shift to neutral and completes the gear

change after driver input.

•The Electronic Control Unit (ECU) includes two

controllers: a transmission ECU and a system

ECU. The transmission ECU controls all trans-

mission shift functions and the system ECU

manages all vehicle interfaces for transmission

shift functions.

•An electronic range valve, controlled by the

transmission ECU, is used to perform range

shifts.

Operation, AutoShift with SmartShift

Automatic and Manual Modes

A two-position slide switch (forward driving mode

switch) is located near the end of the control

(Fig. 15.6). The switch positions are labelled MAN

Automated Transmissions

15.11

(manual shift mode) and AUTO (automatic drive

mode).

NOTE: In automatic drive mode, upshifts and

downshifts require no driver interaction. Move

the selector switch to the drive (D) position, dis-

engage the clutch to engage the gear selected,

engage the clutch and drive the vehicle. In

manual shift mode, upshifts and downshifts re-

quire either a pull upward or push downward on

the control.

Driver Message Center

Gear information is presented to the driver on the

dash display. In automatic drive mode, the number of

the forward gear currently engaged appears continu-

ally on the message display screen when in drive

(D). In manual shift mode, the current gear is dis-

played until a new gear is requested. When neutral

(N) is engaged, "N" will appear on the message dis-

play screen. When reverse (R) is engaged, either

"RL" or "RH" will appear on the message display

screen.

IMPORTANT: The information shown on the

message display screen indicates the state of

the transmission only, not the state of the

SmartShift control.

Neutral Position

Select neutral by sliding the selector switch to the

"N" position.

NOTE: Neutral is always available during opera-

tion. When in neutral, upshift and downshift re-

quests are ignored. If the mode selector switch

is moved from neutral (N) to drive (D) while the

vehicle is moving, the transmission will shift into

a gear causing the engine to go to a high torque

level, under the engine’s rated torque.

WARNING

Do not coast in neutral. Coasting in neutral can

cause an accident, possibly resulting in severe

personal injury or death.

Selecting a Starting Gear

1. In automatic mode, select drive (D) by sliding the

selector switch downward to the next position

below the neutral position.

2. Disengage the clutch to engage the gear se-

lected. Engage the clutch and drive the vehicle.

Changing the Default Starting Gear

To select a starting gear other than the default start-

ing gear, follow the instructions below.

1. Make sure the vehicle is stopped and in drive.

2. In either automatic or manual mode, pull upward

on the control (to increase), or push downward

(to decrease). Each pull upward on the control

increases the starting gear by one gear, but no

higher than fourth gear.

3. The number of the gear selected will ﬂash on the

message display screen until the driver engages

the clutch. This gear will be stored in memory as

the default starting gear until either a different

starting gear is selected by the driver or the en-

gine is shut down.

NOTE: The transmission may also be pro-

grammed so that it is not possible to select a

starting gear other than the preprogrammed de-

fault starting gear.

Upshifting

NOTE: With the transmission in drive (D) in the

automatic mode, upshifts require no driver inter-

action.

10/13/2003 f610680

NOTE: The gear indicator displays the current gear. In

this example it displays ﬁrst gear.

Fig. 15.13, Gear Display Module

Automated Transmissions

15.12

1. With the transmission in drive in the manual

mode, request an upshift by pulling upward on

the control. If the requested gear is available, the

transmission will upshift.

NOTE: A single, momentary pull upward on the

control selects the next higher gear when it is

available. Two consecutive, momentary upward

pulls will cause a skip shift when the next two

higher gears are available and conditions are

right.

2. To skip shift, move the control two times in less

than 1/2 second. The number of the gear en-

gaged will appear on the message display

screen.

NOTE: The Eaton Fuller AutoShift 18-speed

transmission is able to perform triple upshifts

when the next three higher gears are available

and conditions are right. To triple-shift this trans-

mission, move the control three times in less

than 1/2 second.

If a requested gear is not available, an audible

warning will sound and the gear display module

will indicate that the gear is not available. An

unavailable requested upshift is not stored in

memory. The upshift must be requested again.

Downshifting

NOTE: With the transmission in drive (D) in the

automatic mode, downshifts require no driver

interaction.

1. With the transmission in drive in the manual

mode, request a downshift by pushing downward

on the control. If the requested gear is available,

the transmission will downshift.

NOTE: A single, momentary push downward on

the control selects the next lower gear when it is

available. Two consecutive, momentary down-

ward pushes will cause a skip shift, when the

next two lower gears are available and condi-

tions are right.

2. To skip shift, move the control two times in less

than 1/2 second. The number of the gear en-

gaged will appear on the message display

screen.

NOTE: The Eaton Fuller AutoShift 18-speed

transmission is able to perform triple downshifts

when the next three lower gears are available

and conditions are right. To triple shift this trans-

mission, move the control three times in less

than 1/2 second.

If a requested gear is not available, an audible

warning will sound and the gear display module

will indicate that the requested gear is not avail-

able. Unlike upshifting, an unavailable requested

downshift is stored in memory and the shift will

be made when the gear is available. The time

limit for this memory is a programmable param-

eter.

Start-Up

1. With the parking brake applied, press the clutch

all the way down to the ﬂoor.

2. Start the engine.

3. Check to make sure the transmission is in neu-

tral.

4. With the transmission in neutral, release the

clutch.

NOTE: This allows the speed sensor on the

input shaft to get a reading.

5. Press down on the clutch again and release the

parking brake.

6. Select the desired starting gear.

7. Release the clutch.

Reverse

1. To engage reverse (R), slide the selector switch

upward to the next position above the neutral

position and disengage the clutch.

NOTE: AutoShift 10- and 18-speed transmis-

sions have a dual-range reverse. Reverse low

(RL) is the default reverse gear.

2. Select reverse high (RH) by pulling upward on

the control.

NOTE: Reverse may be engaged below a pro-

grammable forward speed in order to rock the

vehicle. If reverse is selected above the pro-

grammed forward speed, an audible warning will

Automated Transmissions

15.13

sound and a message indicating that the gear is

not available will appear on the message dis-

play screen.

Low Gear Operation

Use low (L) when descending steep hills and using

compression braking. Engine speed will be increased

by 200 rpm and shift points will be offset by 200 rpm.

The efficiency of the exhaust brake will be maxi-

mized.

Using the Clutch

Use the clutch to start and stop the vehicle.

Eaton Fuller UltraShift PLUS

Eaton Fuller UltraShift PLUS automated transmis-

sions use shift selection software and electric clutch

actuation; a clutch pedal is not needed to operate the

vehicle. These transmissions use the four-position

SmartShift control (see Fig. 15.6) on the steering

column to select mode, direction, neutral, low, and to

make manual shifts. To know what gear the transmis-

sion is in, see the current gear indicator on the dash.

Forward shifts can be made either manually or

automatically.

Power Up

NOTE: Engine cranking is delayed until the

transmission power-up is complete and the gear

display shows a solid "N".

1. With the parking brake set, turn the ignition

switch to the ON position.

2. Start the engine.

3. Apply the service brake.

NOTE: If the service brake is not applied while

selecting a starting gear, the initial start gear will

not be found and the driver will need to select

Neutral and press the service brake while se-

lecting the desired mode.

4. Select the desired mode and starting gear. (Inap-

propriate start gear selections are ignored to

avoid damaging the transmission.)

5. Release the parking brake.

6. Release the service brake and apply the accel-

erator.

Power Down

1. Select Neutral on the shift control.

NOTE: If the gear display does not show a solid

"N", neutral has not yet been obtained. Neutral

should always be reached before powering

down an UltraShift PLUS, except in cases of

emergency.

2. Set the parking brake.

3. Turn off the ignition, and shut down the engine.

Reverse (R)

NOTE: If attempting to select a non-Neutral

mode without applying the service brakes, the

transmission will not shift into gear. To shift into

gear, select Neutral, apply the service brakes,

and select the desired mode again. Also, the

vehicle will not engage reverse above 2 mph (3

km/h).

Reverse (R) is at the upper end of the four-position

selector switch located at the end of the SmartShift

control. To select R, press in the neutral lock button

and move the selector switch to the position above

neutral. The default Reverse gear is engaged.

NOTICE

Avoid launching the vehicle in high range.

Launching the vehicle in high range increases

the likelihood of clutch abuse and could be detri-

mental to clutch life.

Automatic Mode (AUTO)

In automatic drive mode (AUTO), upshifts and down-

shifts are made by the UltraShift PLUS without driver

intervention. Press in the neutral lock button, move

the selector switch to Drive (D), and press down on

the throttle pedal. The transmission will shift auto-

matically.

NOTE: If attempting to select a non-Neutral

mode without applying the service brakes, the

transmission will not shift into gear. To shift into

gear, select Neutral, apply the service brakes,

and select the desired mode again.

In Drive, the start gear is automatically selected. The

selected start gear can vary depending on several

Automated Transmissions

15.14

vehicle inputs such as load, grade, and axle/

transmission ratio. The start gear can be changed

using the SmartShift control, provided the selected

gear would allow the vehicle to launch without dam-

aging the transmission. If the start gear is changed

using the SmartShift control, it will be the default until

the vehicle is powered down or the selection is

changed again manually.

IMPORTANT: Prior to ascending a steep grade,

either reduce the default start gear by one

(using the SmartShift control) or apply full

throttle for the duration of the grade so the ve-

hicle maintains the proper engine and vehicle

speed during the entire grade.

In Drive, the transmission automatically performs up-

shifts and downshifts. However, when the transmis-

sion is near the shift point, the shift can be forced

using the upshift or downshift function of the Smart-

Shift control.

NOTE: The transmission may deny a shift while

ascending or descending a grade if the load of

the vehicle and grade of the terrain in combina-

tion with the drivetrain ratio and engine torque

fall outside of the acceptable range to perform a

shift. If the shift is denied, a tone will sound.

Manual Mode (MAN)

In manual mode (MAN), the driver selects upshifts

and downshifts instead of letting the UltraShift PLUS

select them automatically. Manual shifting may be

helpful when traversing a work site, railroad tracks,

or steep grades, for example. To drive forward, press

in the neutral lock button, move the selector switch to

Drive (D), and press down on the throttle pedal. To

shift up, pull the lever up (towards you); to shift

down, push the lever down (away from you). The

system holds the current gear unless a shift is re-

quested or if the system initiates a manual mode

override.

NOTE: The transmission may deny a shift while

ascending or descending a grade if the load of

the vehicle and grade of the terrain in combina-

tion with the drivetrain ratio and engine torque

fall outside of the acceptable range to perform a

shift. If the shift is denied, a tone will sound.

NOTE: If attempting to select a non-Neutral

mode without applying the service brakes, the

transmission will not shift into gear. To shift into

gear, select Neutral, apply the service brakes,

and select the desired mode again.

Manual Mode Override

The system is equipped with a manual mode over-

ride function. If the vehicle is being "back driven" (for

example, descending a grade and vehicle speed ex-

ceeds engine speed) and the engine speed is exces-

sively high, the system will upshift automatically.

Also, if the start gear is changed and it causes the

engine to lug at takeoff, the system will override the

current position and select the best available gear.

Low (L)

Low (L) is at the lower end of the four-position selec-

tor switch located at the end of the SmartShift con-

trol. Use Low when wanting to maximize engine

braking and minimize the use of the brake pedal—for

example, when driving down long grades or when

coming to a stop. To select Low, press in the neutral

lock button and move the selector switch to the L

position. The lowest available start gear will be se-

lected (the starting gear cannot be changed in Low).

If Low is selected while moving, the transmission will

not upshift (unless the system initiates a Low over-

ride). The system will downshift at the earliest oppor-

tunity to provide maximum engine braking.

NOTE: If attempting to select a non-Neutral

mode without applying the service brakes, the

transmission will not shift into gear. To shift into

gear, select Neutral, apply the service brakes,

and select the desired mode again.

Low Override

The system is equipped with a Low override function.

If the vehicle is being "back driven" (for example, de-

scending a grade and vehicle speed exceeds engine

speed) and the engine speed is excessively high, the

system will upshift automatically. Also, if the start

gear is changed and it causes the engine to lug at

takeoff, the system will override the current position

and upshift.

Clutch Abuse Protection

Although a vehicle equipped with an UltraShift PLUS

uses an automated clutch, the clutch can still over-

heat and slip with improper use. The clutch abuse

Automated Transmissions

15.15

protection feature helps protect the clutch if the auto-

mated clutch starts to overheat. When the clutch

abuse protection feature initiates and sounds a warn-

ing tone, full clutch actuation must be completed

quickly. If it is not completed quickly enough, the sys-

tem will either open the clutch (if the throttle pedal is

not being pressed) or close the clutch (if the throttle

pedal is being pressed). If the abuse continues, the

system will open the clutch and take away throttle

control brieﬂy to allow the clutch to cool down.

To protect the clutch:

•Select the lowest possible start gear for the

application.

•Use Creep Mode when appropriate.

•Use the service brakes and the Hill Start Aid

when launching on a grade.

•Minimize the time it takes to engage the clutch

from rest.

•Do not use the throttle to hold the vehicle on a

grade; use the service brakes.

•Do not use the throttle to stop roll back on an

incline after Hill Start Aid disengages; use the

service brakes, and then relaunch.

•Do not continually start and stop, especially

when loaded; use a lower gear or Creep Mode.

Creep Mode

The Creep Mode function allows the vehicle to main-

tain a constant speed at engine idle without the

driver holding the throttle pedal position. This mode

is useful for very low-speed maneuvering and appli-

cations where steady vehicle speed is required. The

vehicle speed is determined by the selected gear

ratio operating at governed low engine idle speed.

Any available gear may be selected, though the

transmission will downshift or exit Creep Mode to

prevent stalling if the engine lugs due to load condi-

tions.

By default, Creep Mode can be activated while in

Manual Mode or Low. Eaton’s ServiceRanger diag-

nostic software can be used to enable Creep Mode

in Automatic Mode and/or Reverse.

Engaging Creep Mode

To engage Creep Mode:

1. Select Low or Manual Mode and the desired

gear (while stopped or moving).

2. Apply the throttle pedal to accelerate the vehicle

until the clutch is closed (engaged).

3. Release the throttle pedal. The vehicle will con-

tinue moving at governed low engine idle speed.

Exiting Creep Mode

To exit Creep Mode, apply the throttle pedal to accel-

erate temporarily, or select a higher gear in Manual

Mode. (Creep Mode can be resumed in the selected

gear by releasing the throttle pedal.)

NOTE: The transmission will exit Creep Mode if

the engine lugs 150 rpm below the governed

low engine idle speed. In this case, a lower gear

should be selected if available.

Hill Start Aid

UltraShift PLUS transmissions are equipped with a

Hill Start Aid (HSA) feature to prevent the vehicle

from rolling while on grades steeper than 3% and

allow for a controlled launch. A grade sensor is used

to determine when to engage the feature.

HSA is "on" by default. It can be turned off by press-

ing and releasing the override switch on the dash

(see Chapter 5). HSA will turn back on after the ﬁrst

successful launch.

When the vehicle is stopped on a grade greater than

3% and in a forward mode or reverse, depress the

service brakes then release them. The vehicle will

begin to move after 3 seconds, and the clutch will

perform partial engagements to slow the vehicle mo-

tion. Either step on the brake or apply the throttle to

continue negotiating the grade.

Engine Overspeed Protection

The system will upshift if necessary to prevent en-

gine overspeed in Drive, Manual, and Low.

Shuttle Shifting

Shuttle shifting from reverse to any forward mode is

only allowed if the vehicle speed is approximately

zero.

Automated Transmissions

15.16

Auto Start Gear Selection and

Override

The UltraShift PLUS system uses various inputs to

automatically select the best start gear in Drive and

Manual. This selection can be changed using the

SmartShift control; however, if the selection re-

quested could cause damage or engine lugging, the

request will be denied and a tone will sound.

Skip Shifting

When appropriate, the UltraShift PLUS system may

skip shift in Drive. When prevailing conditions like

load and grade allow, skip shifts can be performed in

Manual mode using the SmartShift control.

Auto Neutral

The UltraShift PLUS system will automatically shift to

neutral if the vehicle is left in Drive and the parking

brake is set. "AN" will show on the gear display. To

re-engage the transmission, select Neutral and then

either Drive or Reverse on the shift control (it will re-

engage regardless of whether the parking brake is

released).

Automatic Traction Control

The UltraShift PLUS system requires the Automatic

Traction Control (ATC) option to be enabled when

driving in soft soil/sand to prevent wheel slippage

and shifting issues. The ATC system has two modes:

"normal" (for sand and loose road surface) and a

mud/snow setting.

ATC Normal Mode

In normal mode, the system will engage the brakes

on the wheel or side that the wheel slip is occurring

to help the vehicle gain traction. The point at which

the traction control will actuate the braking system

increases with throttle: low throttle allows the system

to brake the wheels earlier; heavy/full throttle raises

the point of the acceptable wheel slip.

Adhere to the following points when driving in ATC

normal mode:

•If using Automatic mode in soft soil and/or

sand, maintain the engine speed between

1000 and 1300 rpm to prevent unnecessary

upshifting.

•If using Manual mode in soft soil and/or sand,

do not attempt an upshift and try to maintain

the current gear.

•If the vehicle comes to a stop in the sand it

may be necessary to back up prior to attempt-

ing forward movement.

ATC Mud/Snow Mode

To select the mud/snow mode, depress the ATC

switch (see Chapter 5). This mode raises the wheel

slip speed that is allowed before the traction control

activates. The point at which the traction control will

actuate the braking system increases with throttle:

low throttle allows the system to brake the wheels

earlier; heavy/full throttle raises the point of the ac-

ceptable wheel slip.

Load-Based Shifting

The UltraShift PLUS system is adaptive and will

change the shift points based on grade, engine RPM,

throttle position, and vehicle load. After changing

loads or powering up, the system needs to relearn

these inputs for the ﬁrst few shifts to make the

proper adjustments.

Coasting

When coasting to a stop on level terrain, the Ultra-

Shift PLUS system may not downshift into the lower

gears. It will select a gear after the throttle is applied.

Automated Transmissions

15.17

Drive Axles

Differential Locks ................................................................ 16.1

Two-Speed Drive Axles ........................................................... 16.2

Differential Locks

Tandem Drive Axles with Interaxle

Differential Lock

An interaxle differential lock is standard on vehicles

equipped with tandem drive axles. It is driver-

actuated by means of a LOCK/UNLOCK control

valve switch located on the dash in the cab (see

Chapter 5 for more information about the switch).

Engagement can be at any speed, provided the

wheels are not slipping or spinning. A red indicator

illuminates when the interaxle differential lock is en-

gaged.

In the UNLOCK position, there is differential action

between the two axles. The differential compensates

for different wheel speeds and variations in tire size.

Keep the interaxle differential unlocked for normal

driving on roads where traction is good.

In the LOCK position, the interaxle differential is

locked out and the driveshaft becomes a solid con-

nection between the two axles. Power entering the

forward axle is also transmitted straight through to

the rear axle, so both axles turn together at the same

speed. The LOCK position should be used when the

vehicle encounters poor traction conditions; however,

it also increases drivetrain and tire wear and should

be used only when improved traction is required.

Interaxle Differential Lockout Operation

NOTICE

Do not actuate the interaxle differential control

valve while the tires are slipping. Do not operate

the vehicle continuously with the interaxle differ-

ential locked during extended good road condi-

tions. Using the IAD lock when wheels have good

traction can harm the axle, wear the tires exces-

sively, and increases fuel consumption. Release

the IAD lock as soon as road conditions permit it.

To lock the interaxle differential and achieve maxi-

mum pulling power when approaching slippery or

poor road conditions, move the lockout control valve

to LOCK while maintaining vehicle speed, before en-

countering the poor road conditions. Let up momen-

tarily on the accelerator to engage the differential

lock. Proceed over poor road conditions with caution.

Do not wait until traction is lost and the tires are

spinning before locking the interaxle differential.

To unlock the interaxle differential, move the lockout

control valve to UNLOCK while maintaining vehicle

speed, after leaving the poor road conditions. Let up

momentarily on the accelerator to allow the shift,

then resume driving at normal speed.

Driver-Controlled Differential Lock

(DCDL)

Some vehicles are equipped with a driver-controlled

differential lock (DCDL) that is operated by a dash

switch in the cab (see Chapter 5 for more informa-

tion about the switch). The differential lock provides

maximum traction for slippery conditions by forcing

the wheels on a drive axle to rotate together. The

differential lock should be engaged when the vehicle

is stopped or moving at a low, constant speed and

the wheels are not spinning, slipping, or losing trac-

tion. Do not exceed 25 mph (40 km/h) when the dif-

ferential lock is engaged.

On tandem axles there are three possible DCDL op-

tions:

•Forward-rear carrier only

•Rear-rear carrier only

•Both rear carriers.

An indicator light comes on when the DCDL is en-

gaged. An optional buzzer can also be used to indi-

cate DCDL engagement.

The DCDL provides maximum traction under slippery

conditions. When the DCDL is engaged, the clutch

collar completely locks the differential case, gearing,

and axle shafts together, maximizing traction of both

wheels and protecting against spinout. Under normal

traction conditions, do not engage the DCDL; operate

the axle with differential action between both wheels.

WARNING

Be especially careful when driving under slippery

conditions with the differential locked. Though

forward traction is improved, the vehicle can still

slip sideways, causing possible loss of vehicle

control, personal injury, and property damage.

Drive Axles

16.1

Main Differential Lock Operation

NOTICE

The differential lock should be engaged when the

vehicle is stopped or moving at a low, constant

speed and the wheels are not spinning, slipping,

or losing traction. Engagement at high speed or

power can damage the axle(s).

Do not permit rear wheels to spin freely for more

than ten seconds when traction is lost. Shift into

LOCK to prevent damage to interaxle and main

differentials.

To lock the main differential and obtain maximum

traction under slippery conditions, move the control

switch to the lock position.

NOTE: On some vehicles, the differential lock

system is connected through the low speed

range of the transmission. If this system is used,

the transmission must be in the low speed

range for the differential to fully lock.

If the vehicle is moving, maintain a constant vehicle

speed while engaging the differential lock. Brieﬂy let

up on the accelerator to relieve torque on the gear-

ing, allowing the differential to fully lock. The indica-

tor light should come on and the buzzer should

sound on vehicles so equipped. When the differential

is fully locked, the turning radius will increase be-

cause the vehicle understeers. See Fig. 16.1. Drive

cautiously and do not exceed 25 mph (40 km/h).

To unlock the main differential, move the control

switch to the unlock position. Brieﬂy let up on the

accelerator to relieve torque on the gearing, allowing

the differential to fully unlock.

NOTE: If the differential lock system is con-

nected through the low speed range of the

transmission, shifting out of low speed range will

also unlock the differential.

When the differential lock disengages, the indicator

light will go off and the buzzer will stop.

Single Drive Axles with Traction

Equalizer

Some single drive axles are equipped with a traction

equalizer that is a load-sensing, self-actuating fea-

ture. A traction equalizer provides normal differential

action where traction is good. When one wheel be-

gins to spin faster than the other, clutch plates in the

differential housing automatically engage, delivering

power to both wheels. There is no operator control

with this feature.

A traction equalizer occasionally tends to slip in a

jerking motion, producing irregular intervals of sharp

noises. This generally occurs when the vehicle is op-

erating at low speeds on fairly sharp turns. This con-

dition is corrected by adding a friction modiﬁer to the

axle lubricant. This additive tends to reduce the static

coefficient of friction to a value equal to, or lower

than, the sliding coefficient.

See Group 35 of the Cascadia™Maintenance

Manual for additional information on friction modiﬁers

and when to add them to axle lubricants.

CAUTION

Tire sizes on both rear wheels should be the

same on axles equipped with a traction equalizer.

If not, excessive wear may occur in the traction

equalizer.

Two-Speed Drive Axles

Axle Shift

CAUTION

To prevent transmission and axle damage, make

sure the automatic transmission is in high range

02/09/96 f350079a

A. Turning Radius When Differential is Locked

(engaged)—Understeer Condition

B. Turning Radius When Differential is Unlocked

(disengaged)

Fig. 16.1, Turning Radius

Drive Axles

16.2

when performing an axle shift with the vehicle

moving.

Axle shift is a function installed on vehicles with two-

speed axles to allow the use of the low speed range

when greater traction and maximum pulling power is

needed at low engine speed (rpm).

Under normal operating conditions, the vehicle is op-

erated using the high-speed gear ratios of the axle.

Under extreme weather or off-road conditions, at low

speed and rpm and/or to pull heavy loads, the ve-

hicle must be operated using the low-speed, or re-

duction, gear ratios of the axle.

Axle Shift Switch

The axle shift switch is a two-position rocker switch

(Fig. 16.2) installed on vehicles with two-speed

axles.

To shift the axle from low speed to high speed, press

the top of the switch. To turn the axle shift off (switch

from high speed back to low speed), press the bot-

tom of the switch. When the axle has shifted speed,

the LED turns off.

When the panel lights are on, the AXLE SHIFT leg-

end is backlit in green.

IMPORTANT: If the LED in the switch begins to

blink during normal operation, when the switch

has not been activated, this indicates an error

condition. Bring the vehicle to an authorized

Freightliner service facility as soon as possible.

When the axle shift switch is pressed, three re-

sponses are possible: a normal response, a slow re-

sponse, and an abnormal response.

Normal Response: The LED in the switch blinks until

the axle shifts speed. At this point, the LED comes

on steady and stays illuminated. In normal operation,

the axle may shift so quickly that the blinking of the

switch is barely noticeable.

If operation of the switch is not possible for any rea-

son (interaxle lock is on, ignition is turned off, etc.),

the LED will stop blinking and turn off.

Slow Response: If operation of the switch is slowed

for any reason (by cold weather, low air pressure,

etc.), the switch will continue to blink until the axle

shifts. As in the normal response, the LED comes on

steady and stays illuminated.

Abnormal Response: If the LED blinks for more than

30 seconds, the axle shift function/mechanism may

not be operating correctly. Bring the vehicle to an

authorized Freightliner service facility for testing.

Axle Switch Interlock

NOTE: On vehicles with tandem drive axles,

there is an interlock that prevents an axle from

shifting speed whenever the interaxle lock is on.

If the axle shift switch is pressed when the interaxle

lock is on, the axle shift will not be completed. The

LED does the following:

•If the LED is off, the LED comes on brieﬂy and

turns off again.

•If the LED is on, it stays on.

To complete the axle shift, turn off the interaxle lock

and press the axle shift switch again. If still needed,

the interaxle lock can then be reactivated.

AXLE

SHIFT

f61095106/12/2007

Fig. 16.2, Axle Shift Switch

Drive Axles

16.3

Steering System

Power Steering System General Information .......................................... 17.1

Power Steering Systems .......................................................... 17.1

Power Steering System

General Information

When there is no load on the vehicle, and the front

tires are pointed straight ahead, the steering wheel

spokes should be centered, ±10 degrees, as shown

in Fig. 17.1. See Group 46 of the Cascadia™Work-

shop Manual for steering adjustment procedures.

CAUTION

Never steam clean or high-pressure wash the

steering gear. Internal damage to gear seals, and

ultimately the steering gear, can result.

WARNING

Driving the vehicle without the power-assist fea-

ture of the steering system requires much greater

effort, especially in sharp turns or at low speeds,

which could result in an accident and possible

injury.

Drivers should carefully use the power available with

a power steering system. If the front tires become

lodged in a deep chuckhole or rut, drive the vehicle

out, instead of using the steering system to lift the

tires from the hole. Also, avoid turning the tires when

they are against a curb, as this places a heavy load

on steering components and could damage them.

Power Steering Systems

Steering Gear System

The steering gear system includes the power steer-

ing gear, hydraulic hoses, power steering pump, res-

ervoir, and other components. Some models are also

equipped with a separate hydraulic power cylinder on

the right side of the front axle, or a right-hand slave

gear (such as the TRW RCH-45). The power steering

pump, driven by the engine, provides the power as-

sist for the steering system. If the engine is not run-

ning, there is no power assist. If the power-assist

feature does not work due to hydraulic ﬂuid loss,

steering pump damage, or some other cause, bring

the vehicle to a safe stop. Do not drive the vehicle

until the cause of the problem has been corrected.

Rack and Pinion Steering System

The rack and pinion steering gear is mounted to the

front axle with two brackets, and connected by tie-

rod ends to the axle steering arms. When the steer-

ing wheel is turned, the intermediate steering shaft

turns the input shaft, rotating the torsion bar and the

valve. When the valve turns, power steering ﬂuid is

redirected and provides power assist to turn the pin-

ion gear meshed with the rack teeth, moving the rack

left or right. The rack, with a tie-rod at each end,

then moves the steering arms on the axle, and pivots

the wheels.

This design provides drivers with more responsive

steering, with increased performance and “road feel.”

It virtually eliminates steering issues when the driver

hits a bump (bumpsteer), and signiﬁcantly reduces

roll steer when a vehicle goes into a curve. Wander-

ing is signiﬁcantly reduced as well, so the vehicle

tends to drive straight on the highway. It has a lower

steering ratio, which means drivers don’t have to turn

the steering wheel as much to get the wheels to turn

a given distance. Overall, rack and pinion steering

greatly improves steering response, and reduces

driver effort and fatigue.

06/13/2007 f462080

10°

1. 9 o’Clock 2. 3 o’Clock

Fig. 17.1, Proper Steering Wheel Position (with tires

pointed straight ahead)

Steering System

17.1

Fifth Wheels

Fifth Wheels, General Information ................................................... 18.1

Fifth Wheel Coupling ............................................................. 18.1

Fifth Wheel Uncoupling ........................................................... 18.4

Fifth Wheel Slide ................................................................ 18.7

Fifth Wheels, General

Information

WARNING

Do not use any ﬁfth wheel that fails to operate

properly. Doing so may cause loss of vehicle

control, possibly resulting in severe personal in-

jury or death.

Air-Suspension Dump Valve

The air-suspension dump valve may be used to ad-

just the tractor height to aid with coupling to or un-

coupling from a trailer. See Fig. 18.1. When the

switch is set to LOWER, the air-suspension dump

valve deﬂates the air springs to lower the rear of the

vehicle. In the AUTO position, the automatic ride-

control valves operate for normal driving.

WARNING

Never exhaust air from the suspension while

driving. The suspension will not absorb road

shocks, possibly damaging components, and ve-

hicle handling may be compromised. This could

result in loss of vehicle control, possibly result-

ing in severe personal injury or death.

NOTICE

Do not operate the vehicle over uneven ground

such as ramps, speed bumps, curbs, etc. with

the air springs deﬂated. Doing this may lead to

air bag separation from the piston, preventing the

suspension air springs from inﬂating.

Fifth Wheel Lubrication

WARNING

Keep the ﬁfth wheel plate lubricated to prevent

binding between the tractor and trailer. A binding

ﬁfth wheel could cause erratic steering and loss

of vehicle control, possibly resulting in personal

injury or death.

The standard ﬁfth wheel plate must be kept well lu-

bricated with chassis grease to prevent friction and

binding between the tractor ﬁfth wheel plate and the

trailer.

For a low-lube ﬁfth wheel plate, inspect the condition

of the low-lube pads. There should be no damaged

or missing pieces. Slight puckering at the outside

edges is normal.

For lubrication instructions, see Group 31 of the

Cascadia® Maintenance Manual.

Fifth Wheel Coupling

Fifth wheel coupling is activated with the lock control

handle located on either the right side or left side of

the ﬁfth wheel. Coupling has successfully occurred

when the kingpin has been forced into the jaws and

the lock control handle has moved to the locked

position.

NOTICE

Some ﬁfth wheels may be mounted on sliding

rails. Before attempting to couple a trailer to a

sliding ﬁfth wheel, the slide feature must be

locked to prevent the top plate from sliding rap-

idly forward or rearward, causing damage to the

ﬁfth wheel or kingpin.

Fontaine and Holland Fifth Wheels

Coupling

1. Chock the front and rear of the trailer tires to

prevent the trailer from moving.

2. Ensure the ﬁfth wheel jaw is fully open and the

operating rod is in the unlocked position. See

Fig. 18.2 or Fig. 18.3.

3. Make sure the ﬁfth wheel top plate is tilted so the

ramps are as low as possible.

10/25/2010 f611101

DO NOT LOWER

WHEN VEHICLE

IS IN MOTION

LOWER AUTO

SUSP

AIR

Fig. 18.1, Air-Suspension Dump Valve

Fifth Wheels

18.1

4. Position the tractor so that the center of the ﬁfth

wheel is in line with the trailer kingpin. The king-

pin should be in a position to enter the throat of

the locking mechanism.

NOTICE

Attempting to couple at the wrong height may

cause improper coupling, which could result in

damage to the ﬁfth wheel or kingpin.

5. Adjust the trailer height if required.

For a standard ﬁfth wheel plate, the trailer

should contact the ﬁfth wheel approximately 4 to

8 inches (10 to 20 cm) behind the ﬁfth wheel

pivot. See Fig. 18.4.

For a low-lube ﬁfth wheel plate, the ﬁfth wheel

must slide freely under the trailer, and the trailer

should contact the ﬁfth wheel at the pivot. See

Fig. 18.5.

6. With the ﬁfth wheel lock opening aligned with the

trailer kingpin, back the tractor slowly toward the

trailer. After sliding under the trailer, STOP to

prevent from hitting the kingpin too hard, then

resume backing slowly until the ﬁfth wheel locks.

On a standard ﬁfth wheel, the ﬁfth wheel must lift

the trailer.

On a low-lube ﬁfth wheel, do not lift the trailer as

this may damage the ﬁfth wheel plate.

10/26/2010 f310110a

NOTE: Make sure the safety latch is down when the

control handle is locked.

A. Unlocked B. Locked

1. Safety Latch 2. Lock Control Handle

Fig. 18.2, Fontaine Locking Mechanism

11/02/2010 f310447

1. Safety Latch

2. Operating Rod (locked)

3. Operating Rod (unlocked)

Fig. 18.3, Holland Simplex SE Locking Mechanism

10/28/2010 f311124

A. Fifth wheel must lift

trailer

B. Adjust trailer height

C. Ramps tilted down

D. 4 to 8 inches

Fig. 18.4, Trailer Connection Point, Standard Fifth

Wheel

Fifth Wheels

18.2

7. Apply the tractor parking brakes.

WARNING

A visual inspection is required by law. Some im-

proper couplings can pass a pull test. Sound is

not reliable. Get out of the cab and look. Incor-

rect coupling could cause the trailer to discon-

nect, possibly resulting in serious personal injury

or death.

8. Perform a coupling inspection, checking that

there is no gap between the bottom of the trailer

and the ﬁfth wheel, and that the kingpin is se-

curely locked. See Fig. 18.6

When lockup has occurred, the ﬁfth wheel con-

trol handle moves to the locked position. Make

sure that the safety latch is down over the lock

control handle to hold the control handle in the

locked position. (The safety latch will only rotate

down if the operating rod is fully retracted in the

locked position.) See Fig. 18.2 for Fontaine ﬁfth

wheels. See Fig. 18.3 for Holland ﬁfth wheels.

9. Release the tractor parking brakes. Test for king-

pin lockup slowly inching the tractor forward, pull-

ing on the trailer against the chocks.

10. After lockup is completed, connect the tractor-to-

trailer air system lines and the electrical cable to

the trailer. Take care to prevent dirt or foreign

material from entering the air system lines.

NOTICE

Always make sure the connection hanger keeps

the trailer air hoses and electrical cables posi-

tioned so that they do not rub on anything. Rub-

bing may wear through hoses or cables, resulting

in air leaks, or exposed or broken wires, poten-

tially affecting trailer brake or electrical systems.

11. Charge the air brake system with air, checking

that the air connections do not leak.

WARNING

Incorrect ﬁfth wheel lock adjustment could cause

the trailer to disconnect, possibly resulting in se-

rious personal injury or death.

12. With the trailer wheels chocked and the brakes

set, check for clearance between the kingpin and

the ﬁfth wheel jaws by moving the tractor forward

and backward against the locked kingpin. If slack

is present, uncouple the trailer and have the ﬁfth

wheel inspected and adjusted by a certiﬁed

technician.

Jost Fifth Wheel Coupling

1. Tilt the ramp down.

2. Open the kingpin locks. See Fig. 18.7.

3. Back the vehicle close to the trailer, centering the

kingpin on the ﬁfth wheel.

4. Chock the trailer wheels.

5. Connect the air lines and electrical cable.

6. Ensure that the red trailer air supply valve (trailer

brake) is pulled out, and that the trailer parking

09/10/2010 f311125

A. Adjust trailer height B. Ramps tilted down

Fig. 18.5, Trailer Connection Point, Low-Lube Fifth

Wheel

09/10/2010 f311126

A. No gap between trailer

and ﬁfth wheel

B. Kingpin inside lock

Fig. 18.6, Coupling Inspection

Fifth Wheels

18.3

brakes are set. See Chapter 5 in this manual for

operation of the dash-mounted brake controls.

NOTICE

Attempting to couple at the wrong height may

cause improper coupling, which could result in

damage to the ﬁfth wheel or kingpin.

7. Adjust the trailer height (if required).

For a standard ﬁfth wheel plate, the trailer

should contact the ﬁfth wheel approximately 4 to

8 inches (10 to 20 cm) behind the pivot. See

Fig. 18.4.

For a low-lube ﬁfth wheel plate, the ﬁfth wheel

must slide freely under the trailer, and the trailer

should contact the ﬁfth wheel at the pivot. See

Fig. 18.5.

8. Back the tractor under the trailer.

On a standard ﬁfth wheel, the ﬁfth wheel must lift

the trailer.

On a low-lube ﬁfth wheel, do not lift the trailer as

this may damage the ﬁfth wheel plate.

9. After sliding under the trailer, STOP to prevent

from hitting the kingpin too hard, then resume

backing slowly until the ﬁfth wheel locks.

WARNING

A visual inspection is required by law. Some im-

proper couplings can pass a pull test. Sound is

not reliable. Get out of the cab and look. Incor-

rect coupling could cause the trailer to discon-

nect, possibly resulting in serious personal injury

or death.

10. Apply the tractor parking brake, then perform a

physical check for positive kingpin lockup, and

that there is no gap between the trailer and the

ﬁfth wheel. See Fig. 18.6.

11. Ensure that the release handle is in the locked

position adjacent to the casting. See Fig. 18.8.

12. Release the tractor parking brakes and test for

kingpin lockup by slowly moving the tractor for-

ward, pulling on the trailer against the chocks.

Fifth Wheel Uncoupling

Manual Uncoupling

1. Apply the tractor and trailer parking brakes.

2. Chock the trailer rear wheels.

3. Lower the trailer landing gear until the weight is

removed from the ﬁfth wheel.

4. Disconnect the tractor-to-trailer air system lines

and electrical cable. Plug the air lines to prevent

dirt or foreign material from entering the lines.

5. Verify that both the yellow parking-brake and red

trailer-air-supply knobs are out, the tractor and

trailer parking brakes are set, and that the trailer

is prepared for uncoupling.

6. Release the kingpin locking mechanism following

the instructions for each manufacturer below.

6.1 Fontaine: Lift the safety latch and pull the

lock control handle to the unlocked posi-

tion. See Fig. 18.2.

6.2 Holland: In the locked position the safety

indicator swings freely over the operating

rod. See Fig. 18.9, View A.

To unlock the mechanism, manually rotate

the safety indicator toward the rear of the

ﬁfth wheel. See Fig. 18.9, View B.

Pull the operating rod out. When the

upper operating rod shoulder is outside

the slot, raise the handle and place the

shoulder of the upper rod against the plate

casting, above the slot. See Fig. 18.9,

View C.

09/10/2010 f311128

A. Lock held open by catch mechanism

Fig. 18.7, Jost Release Handle Unlocked

Fifth Wheels

18.4

The ﬁfth wheel is now in the lockset posi-

tion and is ready for uncoupling. As the

tractor pulls away from the trailer the king-

pin forces the jaw to rotate, contacting the

lock. Continued rotation of the jaw forces

the lock to move outward, and drops the

upper rod back into the slot. See Fig. 18.9

View D. The wheel is now ready for

coupling.

6.3 Jost: Pull the retractable handle out, then

secure it in the open position with the

catch. See Fig. 18.7.

7. Release the tractor parking brake then drive out

slowly, allowing the trailer to slide down the ﬁfth

wheel and pick-up ramps.

Air-Actuated Uncoupling

An air-actuated kingpin release valve is optional with

all ﬁfth wheels. See Fig. 18.10.

NOTE: In the event of an air system failure, air-

actuated kingpins can be manually released fol-

lowing the instructions for manual unlocking.

WARNING

Once the kingpin release valve has been pulled

the kingpin lock is released. The vehicle MUST

NOT be driven with the trailer until the trailer has

been uncoupled and coupled again. Failure to do

so may result in separation of the trailer from the

tractor, possibly causing serious personal injury

or death.

Preparing the Trailer for Uncoupling

Before using the air valve to unlock a ﬁfth wheel

kingpin, prepare the trailer as follows.

1. Apply the tractor and trailer parking brakes.

2. Chock the trailer rear wheels.

3. Lower the trailer landing gear until the weight is

removed from the ﬁfth wheel.

4. Disconnect the tractor-to-trailer air lines and elec-

trical cable. Plug the air lines to prevent dirt or

foreign material from entering the lines.

Fontaine and Holland Fifth Wheels Air-

Activated Kingpin Unlock

1. Verify that both the yellow parking-brake and red

trailer-air supply knobs are out, the tractor and

trailer parking brakes are set, and that the trailer

is prepared for uncoupling.

NOTE: On Fontaine and Holland ﬁfth wheels, if

the tractor parking brake is not set, the air-

actuated kingpin-release valve will not activate.

09/10/2010 f311127

OK OK

Fig. 18.8, Jost Release Handle Locked

Fifth Wheels

18.5

2. Pull and hold the kingpin release valve

(Fig. 18.10) until the kingpin lock mechanism

opens and locks in place.

3. Release the pull valve.

4. Release the tractor parking brake.

5. Drive out from under the trailer.

Jost Fifth Wheels Air-Activated Kingpin

Unlock

1. Verify that both the yellow parking-brake and red

trailer-air-supply knobs are out, the tractor and

trailer parking brakes are set, and that the trailer

is prepared for uncoupling.

11/02/2010 f311133

A. Locked Position

B. Unlatched Position (safety indicator rotated towards the

rear of the ﬁfth wheel)

C. Lockset Position (upper rod resting against casting

above slot)

D. Open Position (ready for recoupling)

1. Safety Indicator

2. Operating Rod

3. Upper Rod

4. Plate Casting

Fig. 18.9, Holland Kingpin Locking Mechanism

Fifth Wheels

18.6

NOTE: With Jost ﬁfth wheels, if the trailer park-

ing brake is not set the air-actuated valve will

not activate.

2. Release the tractor parking brake.

3. Pull and hold the kingpin release valve, then

drive forward slowly.

4. After the trailer has slid down the ﬁfth wheel and

pick-up ramps, release the pull valve.

Fifth Wheel Slide

WARNING

Adjust the ﬁfth wheel slide correctly, and do not

overload any tractor axle by incorrectly loading

the trailer. Incorrect slide adjustment or improper

axle loading could cause erratic steering and

loss of vehicle control, possibly resulting in seri-

ous personal injury or death.

On sliding ﬁfth wheel assemblies, the ﬁfth-wheel

plate is attached to rails that allow forward and rear-

ward movement of the ﬁfth wheel to optimally distrib-

ute the load across the axles. Slots are evenly

spaced along the slide rails, and retractable wedges

are positioned through the slots to hold the ﬁfth

wheel in the desired position.

The amount of load distribution on the front steering

axle and rear drive axle(s) will have a direct effect on

the steering control of the vehicle. Determine the

front and rear axle weights by weighing the vehicle

on scales designed for this purpose.

The maximum axle weight ratings are shown on the

Federal Motor Vehicle Safety Standard (FMVSS)

label or Canadian Motor Vehicle Safety Standard

(CMVSS) label attached to the left rear door post of

the tractor. The desired load on the axle is no less

than 80 percent of the maximum axle weight rating,

but in no instances should the axle load exceed the

maximum axle weight rating given on the FMVSS or

CMVSS label.

Manual Slide Operation

The manual slide feature is operated from the ﬁfth

wheel plate with a manual release handle using the

following procedure. See Fig. 18.11.

1. Stop the tractor and trailer in a straight line on

level ground. Pull the red trailer air supply knob

to apply the trailer parking brakes.

2. Apply the tractor parking brake, then release the

sliding mechanism using the appropriate method

for the ﬁfth wheel manufacturer.

2.1 Fontaine: Lift the slide release pull handle

to disengage it from the guide plate. Then,

pull out the handle until it is in the un-

locked position and can be positioned

against the guide plate to hold it out. The

10/26/2010 f611102

Fig. 18.10, Air-Actuated Kingpin Release Valve

07/25/95 f310190

1. Locking Wedge

2. Slide Release Pull Handle

Fig. 18.11, Manual Release Sliding Fifth Wheel

(Fontaine shown)

Fifth Wheels

18.7

handle will stay in the unlocked position

until it is manually disengaged from the

guide plate. See Fig. 18.12.

2.2 Holland: Pull the operating rod out. Make

sure both side plungers have released.

See Fig. 18.13.

3. Lower the trailer landing gear just enough to re-

move the weight from the tractor.

4. Chock the front and rear of the trailer tires to

prevent the trailer from moving.

5. Release the tractor parking brakes, then slowly

move the tractor forward or backward until the

ﬁfth wheel is in the desired location.

NOTICE

When moving the ﬁfth wheel to the desired posi-

tion, be sure the trailer landing gear will not at

any time come in contact with the tractor frame

or other components. Make sure that the front of

the trailer will not come in contact with the rear

of the cab or with other components if they ex-

tend beyond the rear of the cab.

WARNING

Check that the locking wedges have seated in the

slots. Failure to achieve complete lockup may

allow disengagement of the tractor from the

trailer, possibly resulting in serious personal in-

jury or death.

6. Apply the tractor parking brakes, then lock the

sliding member in position using one of the fol-

lowing methods:

6.1 Fontaine: Disengage the slide release

pull handle from the guide plate. The slide

release pull handle is spring-loaded in the

locked position and will seek the locked

position when disengaged from the guide

plate. After the slide release pull handle

returns to the fully locked position, visually

and physically check the locking wedges

to make sure they are fully inserted into

the slots in the slide rails. Make sure the

handle is locked in position against the

guide plate.

6.2 Holland: Raise the operating rod so that it

is free to move inward. Make sure that the

lock pins have seated in the base plate

rail holes and the operating rod moves

into the locked position.

NOTE: The ﬁfth wheel may need to be moved

slightly to enable the locking wedges to enter

the fully locked position.

10/26/2010 f310050

Fig. 18.12, Releasing the Sliding Fifth Wheel, (Fontaine)

10/26/2010 f310445

1. Baseplate

2. Bolted Stop

3. Baseplate Rail

4. Fifth Wheel Mount

5. Slider Saddle Plate

6. Safety Latch

7. Operating Rod

8. Operating Lever

Fig. 18.13, Sliding Fifth Wheel Manual Release,

(Holland Simplex)

Fifth Wheels

18.8

Air Slide Operation

The slide feature may be operated with an air switch

mounted in the dash, that operates an air cylinder

that locks and unlocks the slide. See Fig. 18.14.

1. Set the air-slide switch (Fig. 18.14) to UNLOCK.

Ensure the locking plungers have released. See

Fig. 18.15.

For Jost ﬁfth wheels, the mechanism activates as

shown in Fig. 18.16.

2. Lower the trailer landing gear just enough to re-

move the weight from the tractor.

3. Pull the red trailer-air-supply knob to set the

trailer-parking brakes.

4. Slowly move the tractor forward or backward

until the ﬁfth wheel is in the desired location.

NOTICE

Ensure the trailer landing gear does not come in

contact with the tractor frame or other compo-

nents, and that the front of the trailer will not

come in contact with the rear of the cab or other

components if they extend beyond the rear of the

cab.

5. Apply the tractor parking brakes.

WARNING

Check that the locking wedges have seated in the

slots. Failure to achieve complete lockup may

LOCKUNLOCK

FIFTH

WHL

SLIDE

MUST BE

LOCKED WHEN

VEHICLE IS IN

MOTION

10/22/2009 f611074

1. Fifth Wheel Air-Slide Switch

Fig. 18.14, Air-Slide Switch

07/25/95 f310189

1. Locking Wedge 2. Air Cylinder

Fig. 18.15, Air-Operated Sliding Fifth Wheel (Fontaine

shown)

09/10/2010 f311131

A. Unlocked B. Locked

Fig. 18.16, Jost Sliding Fifth Wheel

Fifth Wheels

18.9

allow disengagement of the tractor from the

trailer, possibly resulting in serious personal in-

jury or death.

6. Set the air-slide switch to LOCK. Visually inspect

the locking wedges or plungers to make sure

that they are fully inserted in the slide rail slots.

Verify that the plungers have engaged by tugging

the tractor forward while the trailer brakes are

locked and the wheels are chocked.

NOTE: The ﬁfth wheel may need to be moved

slightly to enable the locking wedges to fully

lock.

Fifth Wheels

18.10

Trailer Couplings

Air-Suspension Dump Valve ....................................................... 19.1

Holland Trailer Coupling ........................................................... 19.1

Air-Suspension Dump Valve

The air-suspension height switch may be used to aid

in connecting or disconnecting from a trailer. When

the switch is set to LOWER, the air-suspension

dump valve deﬂates the air springs to lower the rear

of the vehicle. In the AUTO position, the automatic

ride-control valves operate for normal driving.

NOTICE

Do not operate the vehicle over uneven ground

such as ramps, speed bumps, curbs, etc. with

the air springs deﬂated. Doing this may lead to

air bag separation from the piston, preventing the

suspension air springs from reinﬂating.

NOTICE

Never exhaust air from the suspension while

driving. When the air is exhausted, the suspen-

sion will not absorb road shocks, and compo-

nents may be damaged.

Holland Trailer Coupling

General Information

The Holland PH-T-60-AL trailer coupling is designed

for use with trailers having a maximum gross weight

of 10,000 lb. See Fig. 19.1. It is a rigid-type pintle

hook, used only on tractor applications, and is fas-

tened to the rear closing crossmember of the vehicle.

It is a non-air-adjusted coupling.

Operation

Trailer Hookup

1. Chock the front and rear tires of the trailer.

2. Remove the cotter pin, then lift the lock and raise

the latch.

3. Back up the vehicle, until the drawbar eye is

over the pintle hook.

4. Lower the trailer, until the drawbar eye rests on

the pintle hook.

5. Close the latch, then insert the cotter pin.

6. Hook up the trailer electrical and air lines.

7. Remove the chocks from the trailer’s tires.

Trailer Release

1. Apply the tractor and trailer parking brakes.

WARNING

Do not use the trailer air supply for parking trail-

ers not equipped with spring parking brakes.

This applies the trailer service brakes only. As air

bleeds from the trailer brake system, brake appli-

cation is lost. This could allow the unattended

vehicle to roll away, possibly resulting in serious

personal injury or death.

2. Chock the front and rear tires of the trailer.

3. Disconnect the trailer air and electrical lines.

Plug the air lines to keep out dirt.

4. Take the weight of the trailer drawbar off the

pintle hook.

5. Open the latch, by ﬁrst removing the cotter pin,

then lift up the lock and raise the latch.

6. Slowly drive the vehicle away from the trailer.

01/20/95 f310314a

1. Lock

2. Cotter Pin

3. Latch

4. Pintle Hook

Fig. 19.1, Holland PH-T-60-AL Trailer Coupling

Trailer Couplings

19.1

Pre- and Post-Trip

Checklists

Periodic Inspections and Maintenance, General Information .............................. 20.1

Checklists ...................................................................... 20.1

Fluids Added .................................................................... 20.2

Periodic Inspections and

Maintenance, General

Information

Regulations in Canada and the U.S. clearly indicate

that it is the driver’s responsibility to perform an in-

spection, and ensure the complete road-worthiness

of a vehicle, before placing it into service. Commer-

cial vehicles may be subject to inspection by autho-

rized inspectors, and an unsafe vehicle can be taken

"out of service" until the driver or owner repairs it.

Use the following checklists to ensure that vehicle

components are in good working condition before

each trip. Careful inspections eliminate stops later to

ﬁx overlooked or forgotten items.

The checklists in this chapter can be copied and kept

as a record that the procedures have been com-

pleted. For details on how to inspect each item on

the checklists, see the corresponding procedure

(step number) in Chapter 21.

Checklists

NOTE: Checklists in this chapter correspond

with the procedures and steps in Chapter 21,

Pre- and Post-Trip Inspections and Mainte-

nance. Your vehicle may not be equipped with

all components listed below.

Daily Pretrip Inspection Checklists

See the following tables for a list of procedures that

should be performed daily, before the ﬁrst trip. Place

a check mark in the complete (Comp.) column to

indicate a procedure has been performed.

Inspector Date

Suspension and Slack Adjusters Comp.

1 Suspension components

2 Slack adjusters

Wheels and Tires Comp.

1 Wheel covers

2 Tire condition

3 Tire inﬂation

4 Rims and wheel components

Wheels and Tires Comp.

5 Wheel bearing oil seals and lubrication levels

6 Mud Flaps

Saddle Tank Areas Comp.

1Drain air reservoirs (without automatic drain

valves)

2 Fuel tank(s) secure

3 Frame rails and crossmembers

4 Visible exhaust components

Engine Compartment Comp.

1 Leakage under engine

2 Air intake system

3 Engine oil level

4 Power steering reservoir level

5 Engine coolant level

6 Visible engine wiring

7 Frame rails

Cab Comp.

1Reset dash-mounted air intake restriction

indicator

2 Air-pressure warning systems

3 Air governor cut-in and cut-out pressures

4 Air pressure build-up time

5 Air system leakage

6 Air pressure reserve

7 Mirrors, windows, windshield

8 Horn, windshield wipers, windshield washers

9 Heater and defroster

10 Interior lights

11 Exterior lights

12 Seat belts and tether belts

13 Fuel level

14 Mirror adjustment

15 Service brakes

16 Backup alarm

Natural Gas Fuel System Comp.

1 Fuel tanks

2 Required decals

3 Vent caps

4Plumbing components, fuel ﬁll ﬁtting, fuel

lines

5Fuel gauge components, fuel level sender

cable, LNG fuel tank pressure

6 Coolant hoses

7 LNG fuel tank pressure

Pre- and Post-Trip Checklists

20.1

Natural Gas Fuel System Comp.

8 LNG vaporizer

9 Low pressure ﬁlter drain

Weekly Post-trip Inspection Checklist

See the following table for procedures that should be

performed weekly, post-trip. Place a check mark in

the complete (Comp.) column to indicate a proce-

dure has been performed.

Inspector Date

Engine Compartment Comp.

1 Windshield washer reservoir level

2 Air intake restriction indicator

3 Water evacuation components

4 Automatic transmission ﬂuid level

5 Water in fuel/water separator

6 Steering components

7 Serpentine drive belts

Monthly Post-trip Inspection

Checklists

See the following tables for procedures that should

be performed monthly, post-trip. Place a check mark

in the complete (Comp.) column to indicate a proce-

dure has been performed.

Inspector Date

Brake Components Comp.

1 Brake system components

2 Brake chambers

3 Air brake lines

4 Flex air hoses

5 Brake linings and brake drums

6 Brake lining thickness

Saddle Tank Areas Comp.

1Drain air reservoirs (with automatic drain

valves)

2 Batteries (location may vary)

3 Aerodynamic components

Engine Compartment Comp.

1 Hood and bumper

2 Hydraulic clutch reservoir

3 Radiator and heater hoses

4 Steering wheel play

Fluids Added

Use the following table to note any ﬂuids that were

added during the inspection and maintenance proce-

dures.

Fluids Added During Inspection

Fluid Amount Added

Wheel Bearing Lubricant

Engine Oil

Power Steering Fluid

Engine Coolant

Windshield Washer Fluid

Automatic Transmission

Fluid

Hydraulic Clutch Fluid (DOT

4 brake ﬂuid)

Pre- and Post-Trip Checklists

20.2

Pre- and Post-Trip

Inspections and

Maintenance

Daily Pretrip Inspection and Maintenance ............................................. 21.1

Weekly Post-Trip Inspections and Maintenance ....................................... 21.10

Monthly Post-Trip Inspections and Maintenance ...................................... 21.13

Daily Pretrip Inspection and

Maintenance

Complete the following inspection and maintenance

procedures to ensure that vehicle components are in

good working condition before each trip. A driver who

is familiar with the vehicle and drives it regularly can

perform the daily inspections, then add the weekly

and monthly post-trip inspections as scheduled.

If the driver does not operate the vehicle on a con-

sistent basis, all daily, weekly, and monthly inspec-

tion and maintenance procedures should be per-

formed before the trip.

IMPORTANT: The pre- and post-trip checklists,

inspections, and maintenance procedures de-

tailed in this chapter are not all-inclusive.

Refer to other component and body manufactur-

ers’ instructions for speciﬁc inspection and

maintenance instructions, as well as local, state,

and federal guidelines.

NOTE: If any system or component does not

pass this inspection, it must be corrected before

operating the vehicle. Whenever equipment re-

quires adjustment, replacement, and/or repair,

see the Cascadia Workshop Manual for proce-

dures and speciﬁcations.erticﬁed

Suspension and Slack Adjuster

Inspection

Walk around the vehicle and visually inspect suspen-

sion and slack adjuster components.

1. Inspect the following suspension components for

signs of structural damage, cracks, or wear.

•springs

•spring hangers

•shocks

•suspension arms

•suspension brackets

•axle seats

•bushings

2. Inspect slack adjusters for signs of damage. See

Fig. 21.1,Fig. 21.2,orFig. 21.3.

f421398

06/17/2003

1. 7/16-inch Adjusting

Nut

2. Grease Fitting

3. Boot

4. Link

5. Brake Chamber Piston

Rod

6. Clevis

7. ½-inch Clevis Pin

8. 1/4-inch Clevis Pin

9. Grease Relief

Opening

10. Slack Adjuster Spline

Fig. 21.1, Gunite Automatic Slack Adjuster

10/11/2005 f421397

1. Clevis

2. Slack Adjuster

3. Clevis Pin

4. Manual Adjusting Nut

5. Control Arm

6. Control-Arm Washers

and Nut

7. Anchor Strap Slot

8. Anchor Strap

9. Brake Chamber

Fig. 21.2, Haldex Automatic Slack Adjuster

Pre- and Post-Trip Inspections and Maintenance

21.1

•Inspect slack adjuster boots, if equipped,

for cuts or tears.

•Inspect anchor straps, if equipped, for

damage.

•Look for worn clevis pins on brake cham-

ber pushrods.

•Look for missing or damaged cotter pins

on the clevis pins.

•Ensure chamber piston rods are in line

with the slack adjusters.

Wheel and Tire Inspection

Walk around the vehicle and visually inspect each

wheel and tire assembly.

IMPORTANT: Wheel covers decrease drag force

as a vehicle moves, thereby improving fuel effi-

ciency. If replacement of a wheel cover is nec-

essary, the replacement cover must meet or ex-

ceed the drag reduction performance of the

originally installed cover in order to maintain

compliance with greenhouse gas and full effi-

ciency regulations (GHG14).

1. If the vehicle was originally equipped with wheel

covers, ensure all wheel covers are present. In-

spect wheel covers for damage or wear. Remove

wheel covers from rear drive wheels, if equipped,

prior to inspecting the tires and wheel compo-

nents.

NOTE: During wheel cover installation, ensure

the V-notch in the liner inner retaining ring is

centered on the valve stem. The inner and outer

retaining rings should be uniformly aligned to

each other and to the wheel rim. The outer re-

taining ring of the liner is equipped with two

canvas ﬂaps. When installing the face cover,

make sure the cover retaining ring is inserted

between the two canvas ﬂaps on the liner outer

retaining ring so that the Velcro strips line up

between the face cover and the liner. Make cer-

tain the detachable view cover is centered on

the face cover, and the Velcro strips are

pressed ﬁrmly in place.

2. Inspect each tire for the following:

•valve stem caps on every tire, screwed on

ﬁnger-tight

•bulges, cracks, cuts, and penetrations

•oil contamination (petroleum derivatives will

soften the rubber and destroy the tire)

•tread depth—if tread is less than 4/32 inch

(3 mm) on any front tire, or less than 2/32

inch (1.5 mm) on any rear tire, replace the

tire

•debris lodged between duel tire sets

IMPORTANT: Low-rolling resistance (LRR) tires

minimize wasted energy as a tire rolls, thereby

decreasing rolling effort and improving fuel effi-

ciency. If tire replacement is necessary, replace-

ment tires must meet or exceed the rolling resis-

tance of the originally installed tires in order to

01/31/2011 f422530

1. Grease Fitting (if

equipped)

2. Slack Adjuster

Housing

3. Brake Chamber

Pushrod

4. Clevis

5. Clevis Pin (large)

6. Clevis Pin (small)

7. Actuator Rod

8. Boot

9. Manual Adjusting Nut

10. Camshaft Splines

Fig. 21.3, Meritor Automatic Slack Adjuster

Pre- and Post-Trip Inspections and Maintenance

21.2

maintain compliance with greenhouse gas and

full efficiency regulations (GHG14).

Contact your tire manufacturer/supplier to deter-

mine the rolling resistance of the originally in-

stalled tires. Visit www.epa.gov/smartway for

additional information and resources.

3. Check tire inﬂation.

For inﬂation pressures and maximum loads, see

the tire manufacturer’s guidelines. Inﬂate the tires

to the applicable pressures if needed.

If a tire has been run ﬂat or under-inﬂated, check

the wheel and tire for damage before adding air.

Keep compressed air reservoirs and lines dry

during tire inﬂation. Use well-maintained inline

moisture traps and service them regularly.

WARNING

Do not operate the vehicle with underinﬂated or

overinﬂated tires. Incorrect inﬂation can stress

the tires and make the tires and rims more sus-

ceptible to damage, possibly leading to rim or

tire failure and loss of vehicle control, resulting

in serious personal injury or death.

NOTICE

A weekly pressure loss of 4 psi (28 kPa) or more

in a tire may indicate damage. The tire should be

inspected and, if necessary, repaired or replaced

by a qualiﬁed tire service facility.

IMPORTANT: The load and cold inﬂation pres-

sure must not exceed the rim or wheel manu-

facturer’s recommendations, even though the

tire may be approved for a higher load inﬂation.

Consult the rim or wheel manufacturer for the

correct tire inﬂation pressure for the vehicle

load.

4. Examine each rim and wheel component.

4.1 Remove all dirt and debris from the as-

sembly. Rust streaks or metal build-up

around stud holes, or out-of-round or worn

stud holes, may be caused by loose wheel

nuts.

WARNING

Have any worn or damaged wheel components

replaced by a qualiﬁed person using the wheel

manufacturer’s instructions and the wheel indus-

try’s standard safety precautions and equipment.

Otherwise a vehicle or workshop accident could

occur, possibly resulting in serious personal in-

jury or death.

4.2 Inspect for broken, cracked, badly worn,

bent, rusty, or sprung rings and rims.

NOTICE

Use the recommended torque values and follow

the proper tightening sequence. Insufficient

wheel nut torque can cause wheel shimmy, re-

sulting in wheel damage, stud breakage, and ex-

treme tire tread wear. Excessive wheel nut torque

can break studs, damage threads, and crack

discs in the stud hole area.

4.3 Make sure all wheel nuts are tightened. If

tightening is necessary, use the tightening

pattern in Fig. 21.4 to initially tighten the

ﬂange nuts to 50 to 100 lbf·ft (68 to 136

N·m). Then tighten the ﬂange nuts to 450

to 500 lbf·ft (610 to 678 N·m).

5. Inspect the outboard side of all wheel hubs and

the hub oil seal area on the inboard side of each

wheel for signs of oil leakage. If any oil is found

f400268

10 8

04/30/2007

Fig. 21.4, Tightening Pattern, 10-Hole Wheels

Pre- and Post-Trip Inspections and Maintenance

21.3

on wheel and tire or brake components, remove

the vehicle from service until the leak has been

ﬁxed.

If needed, ﬁll the hubs to the level indicated on

the hub cap. See Group 35 of the Cascadia

Maintenance Manual for recommended lubri-

cants.

6. Check that mud ﬂaps are undamaged and hang

10 inches (25.4 cm) or less from the ground.

Saddle Tank Areas Inspection

WARNING

When draining the air reservoir, do not look into

the air jets or direct them toward anyone. Dirt or

sludge particles may be in the airstream and

could cause injury.

NOTICE

If the water drained from the air reservoirs is

cloudy or oily, it may indicate a problem with the

compressor. If oil is allowed to contaminate the

air dryer, it will not remove the water from the air

brake system, which could adversely affect brak-

ing.

1. Drain the brake system air reservoirs (reservoirs

without automatic drain valves only).

WARNING

Never operate the engine with the fuel tank shut-

off valves partially closed. This could damage the

fuel pump, causing sudden loss of engine power,

possibly resulting in serious personal injury due

to reduced vehicle control.

2. Ensure fuel tanks are secured to their mounting

brackets and that the mounting brackets are se-

cured to the frame.

If equipped with fuel tank shutoff valves, be sure

the valves are fully open.

3. Inspect visible frame rails for missing bolts, shiny

areas, or rust streaks. Check all visible cross-

members for damage or signs of looseness.

4. Inspect visible components of the exhaust sys-

tem to ensure connections are tight.

Inspect upstream of the aftertreatment device

(ATD), if equipped, for cracking or signs of leaks,

such as soot trails. Inspect downstream of the

ATD for signs of exhaust leaks, such as blister-

ing or warping of nearby components.

Engine Compartment Inspection

1. Check the ground underneath the engine for fuel,

oil, or coolant leaks.

2. Inspect the air intake system for leaks or dam-

age.

NOTICE

Failure to maintain a sealed air intake system

could allow the entry of dirt and contaminants

into the engine. This could adversely affect en-

gine performance and result in engine damage.

2.1 Push the reset button on the air intake

restriction indicator located on the air

cleaner, if equipped.

2.2 Check the air intake duct from the air

cleaner to the engine intake. Make sure

the duct components are secure and air-

tight.

3. Check the engine oil level.

NOTICE

Operating the engine with the oil level below the

minimum ﬁll (or "add") mark or above the maxi-

mum ﬁll (or "full") mark could result in engine

damage.

3.1 Check the oil level with the vehicle parked

on a level surface. See the engine manu-

facturer’s guidelines for engine shutdown

time requirements prior to checking the oil

level.

IMPORTANT: On engines that comply with

EPA07 or newer regulations, use CJ-4 en-

gine oil with less than 1% sulfated ash. Fail-

ure to use CJ-4 oil may void the warranty on

emission aftertreatment components.

3.2 If the oil level is at or below the minimum

ﬁll (or "add") mark on the dipstick, add

enough oil to maintain the level between

Pre- and Post-Trip Inspections and Maintenance

21.4

the minimum and maximum ﬁll marks. See

the engine operation manual for recom-

mended lubricants.

For natural gas vehicles, use only Exxon

Busgard® Geo 15W-40 natural gas engine

oil.

4. Check the power steering reservoir ﬂuid level.

The power steering ﬂuid level should be between

the MIN COLD mark and the middle mark just

above it. See Fig. 21.5. If needed, ﬁll the reser-

voir with automatic transmission ﬂuid that meets

Dexron III or TES-389 speciﬁcations.

NOTICE

Low coolant could result in engine overheating,

which could cause engine damage.

IMPORTANT: The surge tank must be cool to

check the coolant level.

5. Check the engine coolant level in the radiator

surge tank. See Fig. 21.6.

NOTICE

Coolant must be ﬁlled to the COLD MAX line of

the surge tank. Low coolant could result in en-

gine overheating, which could cause engine dam-

age.

5.1 If the coolant is low, ﬁll the surge tank to

the MAX line with a 50/50 mixture of water

and the type of antifreeze currently in-

stalled in your vehicle.

For natural gas vehicles, use only Fleet-

guard ES Compleat™EG Premix 50/50

engine coolant.

5.2 If the surge tank was empty, start the en-

gine after reﬁlling and check the level

again when the engine is at operating

temperature.

6. Inspect visible engine wiring for damage or

looseness. Check for loose wiring, chafed insula-

tion, and damaged or loose hold-down clamps.

7. Inspect visible frame rails for missing bolts, shiny

areas, or rust streaks.

Cab Inspection

1. Push the reset button on the dash-mounted air

intake restriction indicator, if equipped.

2. With the ignition switch in the OFF position,

check the air-pressure warning system.

2.1 If not previously drained, drain the air res-

ervoirs using moderate brake applications

until pressure in both reservoirs is less

than 70 psi (483 kPa).

05/21/2007

f462079

NOTE: Typical reservoir shown; conﬁgurations may

vary.

1. Filler Cap

Fig. 21.5, Power Steering Fluid Reservoir

f500390

02/05/2013

1. Pressure Relief Cap

2. Filler Cap

3. COLD MAX Fill Line

4. COLD MIN Fill Line

5. Coolant Level Sensor

Fig. 21.6, Coolant Surge Tank

Pre- and Post-Trip Inspections and Maintenance

21.5

2.2 Turn the ignition to the ON position. The

ICU will complete a full gauge sweep and

bulb check, and an audible warning will

sound. Ensure the low air pressure lamp

(BRAKE AIR) remains illuminated and an

audible warning continues to sound after

the gauge sweep is complete.

3. Check air governor cut-in and cut-out pressures.

3.1 Start the engine and ensure the BRAKE

AIR lamp goes out and the buzzer si-

lences when pressure reaches approxi-

mately 70 psi (483 kPa) in both air reser-

voirs.

The air governor should cut out at ap-

proximately 120 psi (827 kPa). For ve-

hicles with an optional dryer reservoir

module (DRM), the cut-out pressure is

approximately 130 psi (896 kPa).

3.2 With the engine idling, apply the brake

pedal several times. The air governor

should cut in when pressure in the primary

air reservoir (top air gauge) reaches ap-

proximately 100 psi (689 kPa).

4. Check air pressure build-up time.

4.1 With the air system fully charged, make

one full brake application and note the air

pressure reading on the primary air

gauge.

4.2 Further reduce air pressure using moder-

ate brake applications, then run the en-

gine at governed rpm.

4.3 Note the time that the pressure reaches

the previously noted reading on the pri-

mary air gauge, then note the time that

the air pressure reaches cut-out pressure.

4.4 If it takes longer than 30 seconds to reach

cut-out pressure after the primary air

gauge passes the previously noted pres-

sure (noted after one full brake applica-

tion), eliminate any leaks or replace the air

compressor before operating the vehicle.

5. Check air leakage in the system.

5.1 With the parking brake applied, the trans-

mission out of gear, and the air system

fully charged, release the service brakes

and shut down the engine.

5.2 Wait one minute and note the air pressure

drop in psi (kPa) per minute from the pri-

mary air reservoir.

If the pressure drop exceeds the limits

shown in Table 21.1, eliminate any leaks

before operating the vehicle.

6. Check the air pressure reserve.

With the engine still off, make one full brake ap-

plication and observe the pressure drop on the

primary air gauge. If pressure drops more than

25 psi (172 kPa), eliminate any leaks before op-

erating the vehicle.

Maximum Allowable Air Leakage

Description

Pressure Drop:

psi (kPa) Per Minute

Released Applied

Truck or Tractor Only 2 (14) 3 (21)

Truck or Tractor w/Single Trailer 3 (21) 4 (28)

Truck or Tractor w/Two Trailers 5 (35) 6 (42)

Table 21.1, Maximum Allowable Air Leakage

WARNING

When cleaning windshields and windows, always

stand on the ground or on a secure ladder or

platform. Use a long-handled window cleaner. Do

not use the cab steps, tires, fenders, fuel tanks,

engine, or under-hood components to access the

windshield or windows. Doing so could cause a

fall and result in an injury.

7. Inspect the mirrors, window glass, and wind-

shield for cracks or other damage.

8. Ensure that the horn, windshield wipers, and

windshield washers are operating properly.

These devices must be in good working order for

safe vehicle operation.

9. Ensure the heater and defroster are operating

properly.

10. Check the operation of all interior lights.

10.1 Turn on the headlights and leave them on.

Ensure all equipped gauge bulbs illumi-

nate in the dash message center.

10.2 Ensure all equipped driver control

switches illuminate.

Pre- and Post-Trip Inspections and Maintenance

21.6

10.3 Ensure both turn signal indicator bulbs

illuminate in the dash message center

when the turn signal switch is activated.

11. Check the operation of all exterior lights. See

Fig. 21.7.

11.1 Activate the high-beam headlights and

hazard warning lights.

11.2 Exit the cab and check that all exterior

lights and reﬂectors are clean and intact.

11.3 Check that the brake lights, taillights,

headlights, turn signals, marker lights,

identiﬁcation lights, and clearance lights

are working properly.

12. Inspect the seat belts and tether belts.

02/03/2012 f544971

234

1. High-Beam Headlight

2. Fog Light, or Auxiliary High-Beam Light

3. Low-Beam Headlight

4. Marker Light

5. Turn Signal

6. Side Turn Signal and Marker Light

7. Clearance Light

8. Stop Light, Taillight, and Turn Signal

9. Back-Up Light

10. Identiﬁcation Light

Fig. 21.7, Exterior Lights

Pre- and Post-Trip Inspections and Maintenance

21.7

WARNING

Inspect and maintain seat belts. When any part of

a seat belt system needs replacement, the entire

seat belt must be replaced, both retractor and

buckle side. Any time a vehicle is involved in an

accident, and the seat belt system was in use,

the entire vehicle seat belt system must be re-

placed before operating the vehicle. Do not at-

tempt to modify the seat belt system; doing so

could change the effectiveness of the system.

Failure to replace worn or damaged seat belts, or

making any modiﬁcations to the system, may re-

sult in personal injury or death.

12.1 Check the web for fraying, cuts, extreme

dirt and dust, or for severe fading from

exposure to sunlight, especially near the

buckle latch plate and in the D-loop guide

area.

12.2 Check operation of the buckle, latch, Kom-

fort Latch or Sliding Komfort Latch (if

equipped), web retractor, and upper seat

belt mount on the door pillar. Check all

visible components for wear or damage.

12.3 Check the seat belt and tether belt con-

nection points and tighten any that are

loose.

WARNING

Never ﬁll fuel tanks to more than 95 percent of

their liquid capacity. This could make them more

likely to rupture from impact, possibly causing

ﬁre and resulting in serious personal injury or

death by burning.

Do not mix gasoline or alcohol with diesel fuel.

This mixture could cause an explosion, possibly

resulting in serious personal injury or death. Do

not ﬁll the fuel tanks in the presence of sparks,

open ﬂames, or intense heat. These could ignite

the fuel, possibly causing severe burns.

IMPORTANT: On engines that comply with

EPA07 or newer regulations, use ultralow-sulfur

diesel (ULSD) with 15 ppm sulfur content or

less. Failure to use ULSD fuel may void the

warranty on emission components.

13. Check the fuel level in the fuel tank(s). To keep

condensation to a minimum, fuel tanks should be

ﬁlled at the end of each day.

14. Adjust the rearview and down view mirrors as

necessary.

15. Test the service brakes.

15.1 With the engine running and air system

fully charged, set the parking brake.

15.2 Put the vehicle in the lowest gear and

gently attempt to move it forward. The ve-

hicle should not move.

If the vehicle moves, the parking brakes

are not operating correctly and must be

repaired before the vehicle is operated.

16. Test the backup alarm.

16.1 Release the parking brake and put the

transmission in reverse.

16.2 Move the vehicle slightly backward to en-

sure that the backup alarm is operating

correctly.

Natural Gas Fuel System Inspection

WARNING

As with all pressure vessels, CNG/LNG storage

and fuel delivery systems are inherently danger-

ous and should be treated as such. Beyond the

visual inspections listed below, all maintenance

and repairs to compressed natural gas (CNG) or

liquiﬁed natural gas (LNG) systems should be

performed by trained personnel. Individuals who

are not trained in all aspects concerning CNG/

LNG fuel delivery systems are not permitted to

service, maintain, test, or inspect a system in any

way. Failure to comply with safety regulations

may lead to ﬁre or explosion, resulting in prop-

erty damage, personal injury, or death.

1. Inspect fuel tanks for dents, scratches, gouges,

or other signs of damage. Inspect the fuel lines

and connections for leaks.

Check that the fuel tanks are securely mounted.

Look for signs of abrasion between components.

CNG Fuel System: Ensure that the CNG fuel cyl-

inder storage box is secured to the frame. In-

spect for signs of looseness.

Pre- and Post-Trip Inspections and Maintenance

21.8

(LNG Fuel System: Ensure that the LNG fuel

tank is secured to the mounting brackets and

that the mounting brackets are secured to the

frame. Ensure all rubber isolator straps are se-

cure around the LNG fuel tank.

2. Check for the presence of all required decals

present in the following locations:

•Gas detection system overhead console;

•Above the door handle on both doors;

•Left front bumper;

•End-of-frame crossmember;

•LNG fuel tank ﬁll port (maximum psi), if

equipped.

3. Check for the presence of vent caps on pressure

relief valves and devices. See Fig. 21.8.Ifany

caps are missing, have the fuel system inspected

by a qualiﬁed technician.

CNG Fuel System: Each fuel cylinder should

have two caps (one on each end), which are vis-

ible on the back of the CNG fuel cylinder storage

box. One additional cap is located on the pres-

sure relief valve on the inboard side of the CNG

fuel box, next to the fuel outlet line. If equipped

with saddle tanks, there are also two vent tubes

with caps between the back of the cab and the

back-of-cab fuel tanks.

LNG Fuel System: A red cap should be present

on the secondary relief valve. See Fig. 21.9.

4. Inspect all plumbing components, including the

fuel shutoff valve(s), primary and secondary relief

valves, and the LNG vapor shutoff and excess

ﬂow valves, if equipped, for signs of damage or

leaks. See Fig. 21.9 or Fig. 21.10.

Inspect the fuel ﬁll ﬁtting for signs of damage or

leaks.

Inspect all lines for signs of leaks or damage,

and check all threaded connections.

5. Inspect all fuel gauge components for signs of

leaks or damage. Inspect the fuel level sender

cable and wiring.

6. Inspect all coolant hoses for signs of chaﬁng,

kinks, or leaks. The CNG fuel system utilizes

coolant hoses between the engine and the pres-

sure regulator inside the fuel panel. The LNG

fuel system utilizes coolant hoses between the

engine and the vaporizer.

7. If equipped with an LNG fuel system, check the

fuel tank pressure gauge to ensure that pressure

is within the normal range of 120 to 150 psi (827

to 1034 kPa). If tank pressure exceeds 230 psi

(1586 kPa) and the pressure relief valve does

not open automatically, vent the tank immedi-

ately.

8. Inspect the LNG vaporizer for signs of damage

or leaks. See Fig. 21.9. Inspect the vaporizer

mounting brackets for signs of looseness.

9. On CNG systems, check the low pressure fuel

ﬁlter(s) at the engine for contamination.

9.1 Turn the engine off and remove the key

form the ignition.

9.2 Slowly open the drain petcock and drain

any ﬂuid into an appropriate container.

10. When ﬂuid stops, close the drain petcock.

11. Examine the ﬂuid.

02/05/2014 f470618

Fig. 21.8, CNG Vent Line Caps

Pre- and Post-Trip Inspections and Maintenance

21.9

If more than approximately one ounce of oil or

other contaminants is found, have the system

checked at a qualiﬁed service center.

Weekly Post-Trip Inspections

and Maintenance

Engine Compartment Inspection

WARNING

Washer ﬂuids may be ﬂammable and poisonous.

Do not expose washer ﬂuid to an open ﬂame or

any burning material, such as a cigarette. Always

comply with the washer ﬂuid manufacturer’s rec-

ommended safety precautions.

1. Check the windshield washer reservoir ﬂuid level.

The reservoir is usually located near the right-

hand frame rail. See Fig. 21.11.

02/04/2014 f470617

689

710

1. Pressure Control Regulator

2. Coalescing Filter

3. Fuel Fill Fitting

4. Vapor Shutoff Valve

5. Secondary Relief Valve (red cap)

6. Fill Vent Fitting

7. Primary Relief Valve

8. Tank Pressure Gauge

9. Fuel Shutoff Valve (liquid)

10. Fuel Level Sender Box

11. Cover

12. Fill Check Valve

Fig. 21.9, LNG Tank Plumbing Components

IGH

ESS

LOW

CYLINDERS

INSPECT CYLINDERS

EVERY 36 MONTHS

OR 36000 MILES

WHICHEVER OCCURS FIRST

NATURAL

GAS

VEHICLE

110 PSIG

MANUAL

SHUT OFF

VALVE

OPEN VALVE

SLOWLY

3600 PSIG MAX.

SERVICE PRESSURE

REGULATOR

FILTER

INSPECT PRESSURE

RELIEF DEVICE

EVERY 2000 MILES

DRAIN HOUSING

EVERY 1500 MILES

REPLACE ELEMENT

EVERY 3000 MILES

04/30/2010 f470556

1. High Pressure Gauge

2. Low Pressure Gauge

3. Manual Fuel Shutoff Valve

4. Fuel Fill Port

Fig. 21.10, CNG Fuel Panel

Pre- and Post-Trip Inspections and Maintenance

21.10

2. After resetting the air intake restriction indicator

during the daily pretrip inspection, check the indi-

cator again with the engine off.

2.1 Check an indicator with graduations to see

if air restriction exceeds the value shown

in Table 21.2.

Check a go/no-go indicator without gradu-

ations to see if the colored bar shows

through the clear window.

Air Intake Maximum Restriction Values (inH

Engine Make Pre-EPA07

Engines

EPA07 and

Newer Engines

Cummins 25 25

Detroit 20 22

Mercedes-Benz 22 22

Table 21.2, Air Intake Maximum Restriction Values

2.2 If air restriction exceeds the maximum al-

lowable value, operate the vehicle for one

more day, making sure not to run the en-

gine over rated rpm. Refer to the engine

operation manual for more information on

rated rpm for your engine.

2.3 If air restriction exceeds the maximum

value again, replace the air cleaner. For

instructions, refer to Group 09 of the Cas-

cadia Workshop Manual.

3. Inspect water evacuation components.

3.1 Inspect the vacuator valve(s) installed on

the hood interior and air cleaner. Make

sure the lips of each valve are undam-

aged and pliable, free of debris, and re-

main closed during inspection. See

Fig. 21.12 and Fig. 21.13.

3.2 Inspect the rain tray installed at the base

of the windshield. Ensure that the seal on

the forward edge of the rain tray is in

good condition.

3.3 Inspect the drain hoses installed on the

rain tray. Both hoses should be securely

attached to the rain tray and direct water

down the aft side of the front fenders. See

Fig. 21.14.

4. If the vehicle is equipped with an Allison auto-

matic transmission, check the automatic trans-

mission ﬂuid level.

5. Check for water in the fuel/water separator, if

equipped.

IMPORTANT: When draining ﬂuid from a

fuel/water separator, drain the ﬂuid into an

appropriate container and dispose of it prop-

erly. Many jurisdictions now issue ﬁnes for

draining fuel/water separators onto the

ground.

5.1 Place a suitable container under the fuel/

water separator.

NOTE: A hose may be used to direct water

into the container. Use a hose with a ½-inch

pipe thread on DAVCO models.

5.2 If the engine is equipped with a built-in

water separator, loosen the drain valve,

and allow the water to run out. Close the

drain valve, taking care not to overtighten

it.

5.3 Alliance/Racor Models: Turn the drain plug

counterclockwise to open it. See

Fig. 21.15.

DAVCO Models: Remove the vent cap

and open the drain. See Fig. 21.16.

5.4 Stop draining ﬂuid when fuel begins to

drain out.

05/21/2007 f820442

1. Washer Fluid Filler Cap

Fig. 21.11, Windshield Washer Reservoir

Pre- and Post-Trip Inspections and Maintenance

21.11

Alliance/Racor Models: turn the drain plug

clockwise to close it.

DAVCO Models: close the drain valve.

Install and hand-tighten the vent cap.

6. Inspect the steering components.

6.1 Inspect tie rods, steering arms, and the

drag link for signs of looseness (i.e., shiny

spots or rust tracks). See Fig. 21.17 for a

rack and pinion steering gear; see

Fig. 21.18 for an integral steering gear.

6.2 Check the steering gear mounting bolts

and pitman arm nut, if equipped, for signs

of looseness.

6.3 Check the drag link nuts for missing cotter

pins.

6.4 Inspect the steering intermediate shaft and

end yokes for excessive looseness or

other damage.

NOTICE

Do not drive with a drive belt that is visibly worn

or damaged. If it fails, the lack of coolant ﬂow

could rapidly cause damage to engine compo-

nents.

7. Inspect the serpentine drive belts for signs of

glazing, frayed edges, breaks, cracks, or oil con-

tamination.

345

02/17/2012 f090497

1. Air Cleaner

2. Vacuator Valve

3. Rain Tray Seal

4. Rain Tray

5. Drain Hose

Fig. 21.12, Rain Tray Assembly

03/08/2012 f090498

1. Vacuator Valves

Fig. 21.13, Hood Interior

Pre- and Post-Trip Inspections and Maintenance

21.12

Monthly Post-Trip Inspections

and Maintenance

Brake Component Inspection

Walk around the vehicle and inspect brake system

components for visible damage.

1. Inspect all visible brake system components for

missing fasteners or signs of looseness, such as

rust tracks.

NOTICE

If the external breather tube or breather cap is

missing or incorrectly installed, road dirt and de-

bris can adversely affect the operation of the

brake chamber. Once inside of the chamber, dirt

and debris can cause the internal parts of the

chamber to deteriorate faster.

2. Inspect the exterior surfaces of brake chambers

for damage. Make sure that breather holes are

open and free of debris.

NOTE: Do not route air brake lines on top of

anything likely to be stepped on.

3. Inspect air brake lines for dents, swelling, kinks,

twisting, abrasion, and damage, especially near

moving parts.

4. Inspect ﬂex air lines for deterioration or signs of

abrasion.

02/17/2012 f820466

Ensure drain hoses are securely attached to the rain tray

and drain down the aft side of the front fenders.

Fig. 21.14, Drain Hose

02/03/2010 f470552

1. Washers (qty 2)

2. Nuts (qty 2)

3. Frame Rail

4. Fuel Outlet Port

5. Fuel Inlet Port

6. Priming Pump

7. Mounting Head

8. Mounting Bolts (qty 2)

9. Filter Element

10. Sight Bowl

11. Drain Plug

Fig. 21.15, Alliance Fuel/Water Separator Assembly and

Installation

Pre- and Post-Trip Inspections and Maintenance

21.13

5. Inspect for cracked, worn, or oil-contaminated

brake linings and brake drums (or rotors).

6. Check the thickness of the brake linings. Re-

place brake linings on all brake assemblies on

the axle if any brake linings are worn to less than

approximately 1/4 inch (6.4 mm) at the thinnest

point.

Saddle Tank Areas Inspection

WARNING

When draining the air reservoir, do not look into

the air jets or direct them toward anyone. Dirt or

sludge particles may be in the airstream and

could cause injury.

NOTICE

If the water drained from the air reservoirs is

cloudy or oily, it may indicate a problem with the

compressor. If oil is allowed to contaminate the

air dryer, it will not remove the water from the air

brake system, which could adversely affect brak-

ing.

1. Drain the brake system air reservoirs (reservoirs

with automatic drain valves only).

NOTE: Battery locations vary between vehicles.

2. Inspect the batteries.

WARNING

Battery posts, terminals, and related accessories

contain lead and lead compounds, chemicals

known to the State of California to cause cancer

and reproductive harm. To prevent possible per-

sonal injury, always wash your hands after han-

dling battery parts and related accessories.

2.1 Remove the battery box cover and inspect

all visible battery cables for loose wiring or

damage.

2.2 Check that the battery hold-down is se-

cure.

IMPORTANT: Aerodynamic components de-

crease drag force as a vehicle moves, thereby

improving fuel efficiency. If replacement of an

05/05/2009 f470530

1. Inlet Port/Check Valve

2. Lower Housing

3. Bypass Valve

4. Filter Element

5. Spring

6. Cover O-Ring

7. Clear Cover

8. Vent Cap O-Ring

9. Vent Cap

10. Collar

11. 120VAC Pre-Heater

12. 12VDC Pre-Heater

13. Drain Valve

Fig. 21.16, DAVCO Fuel/Water Separator (Fuel Pro 482

shown)

Pre- and Post-Trip Inspections and Maintenance

21.14

aerodynamic component is necessary, replace-

ment components must meet or exceed the

drag reduction performance of the originally in-

stalled component in order to maintain compli-

ance with greenhouse gas and full efficiency

regulations (GHG14).

3. Inspect the following aerodynamic components, if

equipped, for structural damage, cracks, or wear.

•Chassis fairings

•Roof fairing/deﬂector

•Side skirts

•Cab/sleeper extenders

•Battery access cover

Engine Compartment Inspection and

Adjustments

IMPORTANT: If replacement of the hood or

bumper is necessary, the replacement compo-

nent must meet or exceed the drag reduction

performance of the originally installed item in

order to maintain compliance with greenhouse

gas and full efficiency regulations (GHG14).

1. Inspect the bumper and hood for structural dam-

age, cracks, or wear.

f462167

07/27/2009

1. Steering Tie Rod Arm

2. Castellated Nut

3. Outer Tie Rod

4. Power Steering Fluid Lines

5. Power Steering Fluid Line Fittings

6. Steering Gear Mounting Bolts

7. Steering Gear Mounting Nuts

Fig. 21.17, Rack and Pinion Steering Gear Assembly

Pre- and Post-Trip Inspections and Maintenance

21.15

2. Check the hydraulic clutch reservoir, if equipped.

If necessary, add DOT 4 brake ﬂuid.

3. Inspect the radiator and heater hoses, including

the clamps and support brackets.

3.1 Inspect the radiator and charge air cooler

for damage and accumulated debris.

Straighten bent or damaged ﬁns to permit

airﬂow across all areas of the cores.

NOTE: When traveling through areas of high

insect concentration, it may be necessary to

clean the exterior of the radiator or the

charge air cooler core as often as every 200

miles (320 km).

3.2 Make sure the radiator inlet and outlet

hoses are pliable and are not cracking or

ballooning.

3.3 Make sure the heater hoses are pliable

and are not cracking or ballooning.

3.4 Tighten hose clamps as necessary.

IMPORTANT: Do not overtighten hose

clamps, as hose life can be adversely af-

fected.

3.5 Ensure hose support brackets are se-

curely fastened. Make sure hoses are not

located near sources of wear, abrasion, or

high heat.

IMPORTANT: When replacing hoses, install

service-type knitted or braided yarn-reinforced

neoprene hose. Extended-service-life silicone

hoses may also be used. See the Alliance Parts

Catalog at www.alliancebrandparts.com or

contact your Freightliner Dealer.

4. Check the steering wheel for excessive play.

4.1 Start the engine. With the front tires

straight ahead, turn the steering wheel

until motion is observed at the front

wheels.

4.2 Align a reference mark on the steering

wheel to a rule, then slowly turn the steer-

ing wheel in the opposite direction until

motion is again detected at the wheels.

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

the steering wheel. Excessive lash exists

if steering wheel movement exceeds 2-1/2

inches (64 mm) with a 20-inch (508-mm)

steering wheel, or 2-1/4 inches (57 mm)

with an 18-inch (450-mm) steering wheel.

4.4 If there is excessive lash, check the steer-

ing system for wear or incorrect adjust-

ment before operating the vehicle.

10/11/2001 f461916

1. Steering Gear Mounting Bolts

2. Pitman Arm Pinch Bolt Nut

3. Drag Link Nut

Fig. 21.18, Integral Steering Gear Fasteners

Pre- and Post-Trip Inspections and Maintenance

21.16

Cab Appearance

Cab Washing and Polishing ........................................................ 22.1

Care of Fiberglass Parts .......................................................... 22.1

Care of Chrome Parts ............................................................ 22.1

Care of Exterior Lights ............................................................ 22.1

Dashboard Care ................................................................. 22.2

Vinyl Upholstery Cleaning ......................................................... 22.2

Velour Upholstery Cleaning ........................................................ 22.3

Cab Washing and Polishing

IMPORTANT: Carefully read all instructions be-

fore using or applying any cleaner or product on

the vehicle or components. Failure to follow

manufacturers’ recommendations can result in

damage to the ﬁnish.

WARNING

Do not power wash or steam clean the engine

bay in the area of vehicle electrical components

such as the SAM Cab, SAM Chassis, or powernet

distribution box. Water intrusion can permanently

damage these components, which could result in

ﬁre, personal injury, or property damage.

To protect the ﬁnish of your new vehicle, follow these

guidelines carefully.

•During the ﬁrst 30 days, rinse your vehicle fre-

quently with water. If the vehicle is dirty, use a

mild liquid soap. Do not use detergent.

•During the ﬁrst 30 days, do not use anything

abrasive on your vehicle. Brushes, chemicals,

and cleaners may scratch the ﬁnish.

•During the ﬁrst 120 days, do not wax your

vehicle.

To extend the life of your vehicle’s ﬁnish, follow these

guidelines.

•Avoid washing your vehicle in the hot sun.

•Always use water. After the cab is completely

washed, dry it with a towel or chamois.

•Do not dust painted surfaces with a dry cloth,

as this will scratch the paint.

•Do not remove ice or snow from a painted sur-

face with a scraper of any sort.

•To prevent damage to the ﬁnish, wax it regu-

larly. Before waxing, if the ﬁnish has become

dull, remove oxidized paint using a cleaner

speciﬁcally designed for this purpose. Remove

all road tar and tree sap before waxing.

Freightliner recommends that a quality brand of

cleaner or cleaner-polish and polishing wax be

used.

•Do not let diesel fuel or antifreeze stand on a

painted surface. If either should occur, rinse

the surface off with water.

•To prevent rust, have any nicks or other dam-

age on the ﬁnish touched up as soon as pos-

sible.

•Park your vehicle in a sheltered area whenever

possible.

Care of Fiberglass Parts

Wash unpainted ﬁberglass air fairings and shields

monthly with a mild detergent, such as dishwashing

liquid. Avoid strong alkaline cleansers.

Apply a wax speciﬁcally designed for ﬁberglass.

Care of Chrome Parts

To prevent rust, keep chrome parts clean and pro-

tected at all times. This is especially important during

winter driving and in coastal areas where there is

exposure to salt air.

When cleaning chrome parts, use clean water and a

soft cloth or sponge. A mild detergent may also be

used.

Sponge gently, then rinse. If necessary, use a non-

abrasive chrome cleaner to remove stubborn rust or

other material. Do not use steel wool.

To help protect the chrome after cleaning, apply a

coat of polishing wax to the surface. Never use wax

on parts that are exposed to high heat, such as ex-

haust pipes.

Care of Exterior Lights

Clean the headlight lenses by hand only, using a

ﬂannel cloth with mild, non-caustic soap or detergent,

and water.

CAUTION

Do not use a power buffer, paper towels, chemi-

cal solvents, or abrasive cleaners on the head-

light lens, all of which can remove the UV coating

from the surface, and result in yellowing of the

lens.

Cab Appearance

22.1

Dashboard Care

NOTICE

When cleaning the dashboard, instrument panel,

or gauge lens covers, do not use Armor-All Pro-

tectant®, STP Son-of-a-Gun®, window cleaner, or

other equivalent treatments. These cleaners con-

tain vinyl plasticizers which can cause stress

crazing in the interior plastic panels and can re-

sult in cracking of the panels. Some cleaners can

also have an adverse effect on the clear plastic

of instrument panels and gauge lens covers, re-

sulting in a foggy or cloudy appearance. This

type of damage is not covered by vehicle war-

ranty.

To clean the dashboard, instrument panel, and gauge

lens covers, use a cloth dampened with warm soapy

water. Make certain to wring the cloth out well before

cleaning, as excess water will damage the electrical

components.

Vinyl Upholstery Cleaning

To prevent soiling, frequent vacuuming or light brush-

ing to remove dust and dirt is recommended. Harsh

cleaning agents can cause permanent damage to

vinyl upholstery. To preserve the upholstery and pre-

vent damage, carefully review the following sections

for recommended cleaning procedures. Waxing or

reﬁnishing improves soil resistance and cleanability

for all vinyls. Any hard wax, such as that used on

automobiles, may be used.

Ordinary Dirt

Wash the upholstery with warm water and mild soap,

such as saddle or oil soap. Apply soapy water to a

large area and allow to soak for a few minutes, then

rub briskly with a cloth to remove the dirt. This can

be repeated several times, as necessary.

If dirt is deeply imbedded, use a soft bristle brush

after applying the soap.

If dirt is extremely difficult to remove, wall-washing

preparations normally found around the home can be

used. Powdered cleaners, such as those used for

sinks and tiles, are abrasive and must be used with

caution as they can scratch the vinyl or give it a per-

manent dull appearance.

Chewing Gum

Harden the gum with an ice cube wrapped in a plas-

tic bag, then scrape it off with a dull knife. Any re-

maining traces of gum can be removed with an all-

purpose light oil (peanut butter will also work) and

wiped off.

Tars, Asphalts, and Creosote

Each of these items stains vinyl after prolonged con-

tact. They should be wiped off immediately and the

area carefully cleaned, using a cloth dampened with

naphtha.

Paint, Shoe Heel Marks

Paint should be removed immediately. Do not use

paint remover or liquid-type brush cleaner on vinyl.

An unprinted cloth, dampened with naphtha or tur-

pentine may be used. Use care to prevent contact

with parts of the upholstery that are not vinyl.

Sulﬁde Stains

Sulﬁde compounds, such as those found in eggs and

some canned goods, can stain after prolonged con-

tact with vinyl. These stains can be removed by plac-

ing a clean, unprinted piece of cloth over the spotted

area and pouring a liberal amount of 6 percent hy-

drogen peroxide onto the cloth. Allow the saturated

cloth to remain on the spot for 30 to 60 minutes. For

stubborn spots, allow the hydrogen-peroxide satu-

rated cloth to remain on the area overnight. Use cau-

tion to prevent the solution from seeping into the

seams, or it will weaken the cotton thread.

Nail Polish and Nail Polish Remover

Prolonged contact with these substances causes per-

manent damage to vinyl. Careful blotting immediately

after contact minimizes damage. Do not spread the

liquid during removal.

Shoe Polish

Most shoe polishes contain dyes which penetrate

vinyl and stain it permanently. Shoe polish should be

wiped off as quickly as possible using naphtha or

lighter ﬂuid. If staining occurs, try the procedure used

for sulﬁde stains.

Cab Appearance

22.2

Ball Point Ink

Ball point ink can sometimes be removed if rubbed

immediately with a damp cloth, using water or rub-

bing alcohol. If this does not work, try the procedure

used for sulﬁde stains.

Miscellaneous

If stains do not respond to any of the treatments de-

scribed above, it is sometimes helpful to expose the

vinyl to direct sunlight for up to 30 hours. Mustard,

ball point ink, certain shoe polishes, and dyes often

bleach out in direct sunlight, leaving the vinyl undam-

aged.

Velour Upholstery Cleaning

To prevent soiling, frequent vacuuming or light brush-

ing to remove dust and dirt is recommended. Spot

clean with a mild solvent or an upholstery shampoo,

or the foam from a mild detergent. When using a sol-

vent or a dry-cleaning product, follow the instructions

carefully, and clean only in a well-ventilated area.

Avoid any product that contains carbon tetrachloride

or other toxic materials. With either method, pretest a

small area before proceeding. Use a professional

upholstery cleaning service when extensive cleaning

is needed.

Grease and Oil-Based Stains

Dampen a small absorbent cloth with dry-cleaning

solvent or spot remover. Apply the cloth carefully to

the spot from the outer edge to the center. Pat and

blot the spot with a clean, dry cloth. Repeat several

times, as necessary, turning the cloths so that the

stain does not redeposit on the fabric.

Sugar and Water-Based Stains

Apply water-based detergent or cleaner, working in

circular motions. Pat and blot as dry as possible. Re-

peat, if necessary, before drying thoroughly.

Chewing Gum or Wax

Harden the gum or wax with an ice cube wrapped in

a plastic bag, then scrape it off with a dull knife. Ex-

cess wax can be absorbed by placing a thick white

blotter over the wax and heating with a warm (not

hot) iron. Remove the remainder by using the proce-

dure for grease and oil-based stains.

Mildew

Brush the dry fabric with a soft brush. Sponge with

detergent, and blot. If the fabric is colorfast, dilute a

teaspoon of bleach in one quart (one liter) of cool

water. Apply with a swab, directly on the mildew

stain. Dab repeatedly with clear, cool water, and blot

dry.

Cab Appearance

22.3

Headlight Aiming

Preliminary Checks ............................................................... 23.1

Checking Headlight Aim ........................................................... 23.1

Adjusting Headlight Aim ........................................................... 23.1

Preliminary Checks

Before checking or adjusting the headlight aim, do

the following.

•Check that the hood is closed and latched.

•Remove any large amounts of mud or ice from

the underside of the fenders.

•Check the springs for sagging or broken

leaves.

•Check the suspension for proper functioning of

the leveling mechanism. On cabs with air sus-

pensions, make sure that the height is properly

adjusted.

•Check for damage to the hood and hinge as-

sembly. Repair as necessary.

•With the vehicle unloaded, check that the tires

are inﬂated to the recommended air pressure.

•Clean the headlight lenses. Use a soft cloth

with mild, non-caustic soap or detergent, and

water.

Checking Headlight Aim

1. Park the vehicle on a level surface, 25 ft (7.6 m)

away from, and perpendicular to, a vertical

screen or wall. Shut down the engine and set the

parking brake. Chock the tires.

2. Each headlight has a height adjusting dot. See

Fig. 23.1. Measure the distance from the ground

to the height adjusting dot on each headlight

(Fig. 23.2, Item A). Note those distances.

3. On the screen or wall, mark the locations of each

headlight bulb center using the distances found

in step 2. See Fig. 23.2, Items 2 and 3.

4. Turn on the low-beam headlights.

5. Check the vertical adjustment of the low beams.

The center of each beam projection should fall

on or near the marks made during step 3. See

Fig. 23.3.

6. Use Table 23.1 to determine the maximum verti-

cal distance allowable between the marks on the

wall and the center of each low-beam projection.

If the distance between either projection center

and the mark made on the wall or screen is

greater than the maximum distance given in

Table 23.1, adjust the vertical positioning of that

headlight.

Adjusting Headlight Aim

NOTE: Freightliner vehicles are offered with

various headlight assembly options. Because of

the various options, the location of adjustment

screws on your vehicle’s headlight assembly

may vary from what is shown here.

The adjusting screw is located on the lower outside

corner of the headlight assembly. See Fig. 23.4. Turn

the adjusting screw clockwise to raise the beam and

counterclockwise to lower it, until the beam pattern

meets the acceptable standard.

01/23/2012 f545869

Measure beam height from the ground to the small dot

roughly in the center of the headlight lens.

Fig. 23.1, Headlight Beam Height Adjusting Dot

Headlight Aiming

23.1

f545850a01/10/2012

25 ft (7.6 m)

A. Measure the distance from the ground to the center of each headlight bulb.

B. Mark where the center of each headlight projection should appear.

1. Screen or Wall

2. Center of Right-Hand Headlight Projection

3. Center of Left-Hand Headlight Projection

Fig. 23.2, Headlight Aiming Screen/Wall

01/10/2012 f545851a

1. Low-Beam Angle Upper Limit

2. Ideal Low-Beam Projection

3. Low-Beam Angle Lower Limit

Fig. 23.3, Vertical Low-Beam Headlight Variation Limits

Headlight Aiming

23.2

Vertical Low-Beam Headlight Variation Limits

Distance Between Ground

and Headlight: in (mm)

Desired Variation (Fig. 23.3,

Item 2): in (mm)

Upper Limit (Fig. 23.3, Item

1): in (mm) up

Lower Limit (Fig. 23.3, Item

3): in (mm) down

22–36 (560–900) 0 3.9 (100) 3.9 (100)

36–48 (900–1200) 2 (50) down 2 (50) 6 (150)

48–54 (1200–1400) 2.5 (64) down 1.6 (40) 6.5 (165)

Table 23.1, Vertical Low-Beam Headlight Variation Limits

06/18/2007 f545076

Fig. 23.4, Headlight Adjusting

Headlight Aiming

23.3

In an Emergency

Hazard Warning Lights ............................................................ 24.1

Fire Extinguisher ................................................................. 24.1

Emergency Kit, Optional .......................................................... 24.1

Emergency Filter Replacement, Davco ............................................... 24.1

Emergency Starting With Jumper Cables ............................................. 24.2

Towing ......................................................................... 24.4

Fire in the Cab .................................................................. 24.7

Hazard Warning Lights

The hazard warning light switch is located on the

dash in what is referred to as the master module.

See Fig. 24.1. The hazard lights can be activated

regardless of the ignition switch position.

To activate the hazard lights, push the center of the

switch once. The switch will blink at the same rate

that the hazard lights ﬂash. Push the switch again to

turn them off. All the turn signal lights on the vehicle

and trailer, as well as the turn signal indicators in the

ICU, ﬂash simultaneously when the hazard lights are

activated.

Fire Extinguisher

A ﬁre extinguisher is located either in the cab by the

driver’s door, or in the baggage compartment.

Emergency Kit, Optional

An optional emergency kit is located in the cab. The

kit includes one or more of the following: a ﬁrst aid

kit, a reﬂective vest, a triangular reﬂector, a ﬂare kit,

and (on vehicles with a Davco fuel/water separator) a

spin-on fuel ﬁlter element.

If there is an emergency while driving, cautiously pull

off the road. Turn on the hazard warning lights. Place

the ﬂares and reﬂector along the side of the road to

alert other drivers that an emergency situation exists.

WARNING

Use extreme care when placing ﬂares in emer-

gency situations that involve exposure to ﬂam-

mable substances such as fuel. An explosion or

ﬁre could occur causing serious personal injury.

Emergency Filter

Replacement, Davco

If the ﬁlter cover on the Davco fuel/water separator is

broken, it will not be possible to operate the vehicle.

A standard spin-on ﬁlter will correct this problem.

Refer to the Davco web site (www.davcotec.com)

for additional information.

To replace the ﬁlter on all Davco fuel/water separa-

tors, follow this procedure:

1. Drain the fuel until it is below the level of the col-

lar. See Fig. 24.2 for the model 232/233 fuel/

water separator and Fig. 24.3 for the model 382

fuel/water separator.

2. Remove the vent and seal.

NOTE: The vent and seal are not needed in the

emergency replacement. They should be re-

tained for later installation at the time when the

cover is replaced.

3. Remove the collar using the DAVCO fuel-water

separator wrench. Do not use pliers or channel-

lock pliers.

4. Remove the cover, cover seal, and spring. Re-

tain them for later assembly.

5. Remove the ﬁlter element and dispose of it prop-

erly.

NOTE: Remove the rubber grommet from the

stud.

6. Install the standard engine spin-on ﬁlter (included

in the emergency kit) on the threaded stud.

7. Install the cover, cover seal, and spring, as re-

moved.

8. Install the collar over the cover. Tighten the collar

ﬁnger-tight.

9. Start the engine and run it at increased rpm for

one minute to purge air from the fuel lines.

03/20/2007 1f610855

1. Hazard Warning Switch

2. Panel Lamps Switch

Fig. 24.1, Master Module

In an Emergency

24.1

Emergency Starting With

Jumper Cables

When using jumper cables, follow the instructions

below.

WARNING

Batteries release explosive gas. Do not smoke

when working around batteries. Put out all ﬂames

and remove all sources of sparks or intense heat

in the vicinity of the battery. Do not allow the ve-

hicles to touch each other. Do not lean over the

batteries when making connections, and keep all

other persons away from the batteries. Failure to

follow these precautions could lead to severe

personal injury as a result of an explosion or

acid burns.

CAUTION

Make sure both electrical systems are the same

voltage. Electronic devices on both vehicles can

f470416

11/14/2001

1. Vent

2. Seal

3. Collar

4. Cover

5. Cover Seal

6. Spring

7. Filter Element

8. Threaded Stud

9. Fuel Port

10. Drain

Fig. 24.2, Davco Model 232 and 233 Fuel/Water Separator

In an Emergency

24.2

be damaged when connected to a vehicle with a

different operating voltage.

NOTE: On vehicles equipped with optional un-

derhood jump start posts, connect to these

posts instead of the batteries.

1. Apply the parking brakes and turn off the lights

and all other electrical devices.

2. Remove the battery box cover by pulling on the

end of each hold-down latch until the end clears

the catch, then pivoting the latches out of the

way, and lifting off the cover. See Fig. 24.4.

CAUTION

Always connect the battery, jumper cables, and

charger correctly (positive-to-positive and

negative-to-negative). Connecting a charging de-

vice backwards (positive-to-negative) can se-

verely damage the vehicle electrical content and

cause non-warrantable failures.

3. Connect the positive (+) jumper cable to the

positive battery post on the Cascadia needing

the jump start, then connect the other end of the

positive jumper cable to the positive battery or

f470417

11/14/2001

1. Collar

2. Vent

3. Seal

4. Cover

5. Cover Seal

6. Spring

7. Filter Element

8. Threaded Stud

9. Fuel Port

10. Drain

11. Bottom-Plate Collar

Fig. 24.3, Davco Model 382 Fuel/Water Separator

In an Emergency

24.3

jump start post of the vehicle providing the jump.

See Fig. 24.5.

WARNING

Do the next step exactly as instructed and do not

allow the clamps of one cable to touch the

clamps of the other cable. Otherwise, a spark

could occur near a battery, possibly resulting in

severe personal injury from explosion or acid

burns.

4. Connect one end of the second jumper cable to

the negative terminal of the booster battery, and

connect the other end of the cable to to the

negative battery post of the Cascadia needing

the jump start.

5. Start the engine of the vehicle with the booster

batteries, and let the engine run a few minutes to

charge the batteries of the other vehicle.

6. Attempt to start the engine of the vehicle with the

batteries receiving the charge. Do not operate

the starter longer than 30 seconds, and wait at

least two minutes between starting attempts to

allow the starter to cool.

7. When the engine starts, let it idle a few minutes.

WARNING

Do the next step exactly as instructed and do not

allow the clamps of one cable to touch the

clamps of the other cable. Otherwise, a spark

could occur near a battery, possibly resulting in

severe personal injury from explosion or acid

burns.

8. Disconnect the grounded cable from the frame or

other non-battery location, then disconnect the

other end of the cable.

9. Disconnect the remaining cable from the newly

charged battery (or jump-start post if equipped)

ﬁrst, then disconnect the other end.

10. Install the cover; be sure it is positioned properly

before fastening the latches.

Towing

When it is necessary to tow the vehicle, make sure

the instructions below are closely followed to prevent

damage to the vehicle.

WARNING

Do not tow an unbraked vehicle if the combined

weight of both vehicles is more than the sum of

06/12/2007 f545070

Fig. 24.4, Battery Compartment

−

f545111

07/06/2007

−

A. – Battery Cable to Vehicle

B. + Battery Cable to Vehicle

C. + Jumper Cable (connect ﬁrst and disconnect last)

D. – Jumper Cable (connect last and disconnect ﬁrst)

Fig. 24.5, Jumper Connections

In an Emergency

24.4

the gross axle weight ratings (GAWR) of the tow-

ing vehicle. Otherwise brake capacity will be in-

adequate, which could result in personal injury or

death.

Front Towing Hookup

1. Disconnect the battery ground cables.

NOTICE

Failure to remove the axle shafts when towing

the vehicle with the rear wheels on the ground

will result in damage to the transmission and

other drivetrain components.

2. Remove both drive axle shafts. On dual drive

axles, if the vehicle is to be lifted and towed, re-

move only the rearmost drive axle shafts.

On vehicles equipped with an air fairing, remove

both the forward and rearmost drive axle shafts if

there is insufficient towing clearance.

3. Cover the ends of the hubs with metal plates or

plywood cut to ﬁt the axle opening, and drilled to

ﬁt the axle shaft studs. This prevents lubricant

from leaking out and will keep contaminants from

getting into and damaging the wheel bearings

and axle lubricant.

NOTICE

Failure to protect the frame rails from the chains

could cause damage, leading to eventual frame

failure.

4. On dual drive axles, if the vehicle is to be lifted

and towed, chain the forward rear-axle assembly

to the vehicle frame. Use protection to keep the

chains from damaging the frame.

5. Remove the bumper end caps and chrome bum-

per (if equipped).

6. Attach the towing device. Do not pass a sling (for

example, a rope or chain) from one tow hook to

another to fasten for towing. Known as reeving,

this practice is not permissible in most industrial

applications of towing and hoisting. Reeving can

overload the hooks and result in damage to the

vehicle. See Fig. 24.8.

7. Lift the vehicle and secure the safety chains. If

extra towing clearance is needed, remove the

front wheels.

NOTE: Due to the many variables that exist in

towing, positioning the lifting and towing device

is the sole responsibility of the towing-vehicle

operator.

8. Connect the clearance lights, taillights, and sig-

nal lights. Connect any special towing lights re-

quired by local regulations.

WARNING

Failure to chock the tires or connect the tow

truck’s air brake system before releasing the

spring parking brakes could allow the disabled

vehicle to suddenly roll. This could cause prop-

erty damage or personal injury.

9. Chock the tires on the disabled vehicle and con-

nect the towing vehicle’s air brake system to the

vehicle being towed. Then, release the spring

parking brakes and remove the chocks.

Rear Towing Hookup

NOTICE

Using a rear towing hookup on a vehicle

equipped with a roof fairing could cause damage

to the cab structure.

If reverse towing at speeds above 45 mph (70

kph) is necessary, note the following precau-

tions:

•Remove the rubber ﬂex extenders (for side

extenders equipped with middle brackets)

or the side extender assemblies (without

middle brackets). Failure to do so could

cause damage to the side extenders and/or

loss of the rubber ﬂex extenders.

•Hold down the cab with tension straps

looped over the cab shocks and under the

frame rails. Failure to do so could allow the

wind load to lift the cab unexpectedly, re-

sulting in damage to the air springs and

other components.

1. If the vehicle is equipped with side extenders,

and reverse towing at speeds above 45 mph (70

In an Emergency

24.5

kph) is necessary, prepare the side extenders as

follows:

•If middle brackets are installed on the side

extenders, as shown in Fig. 24.7, remove

the rubber ﬂex extenders.

•If middle brackets are not installed on the

side extenders, remove the side extenders

from the cab.

2. If the vehicle is equipped with cab air suspen-

sion, and reverse towing at speeds above 45

mph (70 kph) is necessary, hold down the cab as

follows:

2.1 Drain the air from the cab air springs.

2.2 Loop a 2-inch (5-cm) ratchet-style tension

strap (rated 2000 lb [900 kg] minimum

work load) over the top of the cab shock

and under the frame rail. See Fig. 24.8.

Tighten the strap for a snug ﬁt. If the cab

is equipped with two or more shocks, re-

strain the aftmost shock on each side of

the vehicle.

3. Place the front tires straight forward and secure

the steering wheel in this position.

4. Disconnect the battery ground cables.

NOTICE

Failure to protect the frame rails from the chains

could cause damage, leading to eventual frame

failure.

5. On dual drive axles, using protection to keep the

chains from damaging the vehicle frame, chain

the forward-rear drive axle to the frame.

6. Attach the towing device.

NOTE: Due to the many variables that exist in

towing, positioning the lifting and towing device

is the sole responsibility of the towing-vehicle

operator.

7. Lift the vehicle and secure the safety chains. If

extra clearance is needed, remove the bumper

extension if equipped.

07/05/2007

f880793

IMPORTANT: Do not reeve when towing.

1. Tow Hook 2. Chain

Fig. 24.6, Reeving

In an Emergency

24.6

8. Connect the clearance lights, taillights, and sig-

nal lights. Also connect any special towing lights

required by local regulations.

Fire in the Cab

The incidence of ﬁre in heavy- and medium-duty

trucks is rare, according to data from the National

Highway Traffic Safety Administration. Federal Motor

Vehicle Safety Standard #302 limits the ﬂammability

of speciﬁed materials used inside the cab, but de-

spite this, most materials will burn. The cab of this

vehicle contains urethane foam, which is of concern

in this respect.

WARNING

Urethane foam is ﬂammable! Do not allow any

ﬂames, sparks, or other heat sources such as

cigarettes or light bulbs to contact urethane

foam. Urethane foam in contact with such heat

sources could cause a serious, rapid ﬁre, which

could result in death, severe burns, or gas poi-

soning, as well as damage to the vehicle.

In Case of a Cab Fire

As quickly as possible, bring the vehicle to a safe

stop, apply the parking brake, turn off the ignition,

and get out of the vehicle.

01/05/2010 f602410

Fig. 24.7, Side Extender Middle Bracket

05/13/2014 f602527

Fig. 24.8, Tension Strap Installed to Hold Down the Cab

In an Emergency

24.7

Natural Gas Vehicles

Natural Gas Vehicles, General Information ............................................ 25.1

Natural Gas Vehicles, Safety Precautions ............................................ 25.1

Natural Gas Fuel Tank Filling Procedures ............................................. 25.3

Natural Gas Detection System ..................................................... 25.5

Natural Gas Engine Starting ....................................................... 25.9

Major Repairs and Replacement of Natural Gas Components ........................... 25.10

Natural Gas Vehicles, General

Information

The vehicle can be equipped with a compressed

natural gas (CNG) fuel system, or a liqueﬁed natural

gas (LNG) fuel system. CNG is made by compress-

ing natural gas to less than 1% of its volume at stan-

dard atmospheric pressure. LNG is created by con-

densing natural gas into a liquid by cooling it to

approximately -259°F (-162°C).

When vaporized at ambient temperatures, natural

gas is less dense than air, and it rises and disperses.

However, LNG is initially heavier than air due to its

cryogenic temperature. When released in large

amounts, it may drop or pool on the ground before

its temperature rises enough to vaporize. Cold at-

mospheric conditions may prevent natural gas from

dispersing quickly when released in large amounts.

Natural gas is nontoxic, but it can cause asphyxiation

if present in very large concentrations.

CNG often contains an odor-producing chemical,

while LNG does not have any odor. Users of natural-

gas-fueled vehicles should never expect to detect

natural gas leaks by scent.

For natural gas to burn, it must ﬁrst vaporize, then

mix with air in the proper proportions (ﬂammable

range is 5 to 15% by volume in air), and then be

ignited.

A typical natural gas fuel system consists of:

•Fuel supply cylinders that store compressed

gas at high pressure (CNG), or a tank that

stores liqueﬁed gas at an extremely low tem-

perature (LNG).

•A vaporizer or heat exchanging device that

changes LNG to gaseous form (LNG fuel sys-

tems only).

•Pressure relief and manual fuel shutoff valves.

•A ﬁlling connection with a check valve that pre-

vents the gas from ﬂowing back out of the fuel

ﬁlling line.

•High-pressure and low-pressure fuel ﬁlters.

•A pressure control regulator that reduces the

high fuel tank or cylinder pressure to the lower

pressure needed for the engine.

•A fuel contents gauge that indicates the fuel

supply in the tank or cylinders.

Figure 25.1 shows the locations of various compo-

nents of a CNG installation.

Natural Gas Vehicles, Safety

Precautions

DANGER

Natural gas is highly ﬂammable. Failure to ob-

serve the following safety precautions could lead

to the ignition of the natural gas, which could

cause serious bodily injury or death.

CNG systems should be maintained and inspected

exclusively by trained personnel with certiﬁcations in

accordance with the applicable codes. As with all

pressure vessels, CNG storage and fuel delivery sys-

tems are inherently dangerous and should be treated

as such. Individuals involved in any aspect of CNG

fuel system maintenance, emergency response, ser-

vicing, or testing must be properly trained and certi-

ﬁed. Individuals who are not trained and certiﬁed in

all aspects concerning CNG fuel delivery systems

are not permitted to service, maintain, test, or inspect

a system in any way.

Follow these safety precautions when operating or

repairing a natural gas vehicle.

•Only certiﬁed LNG personal can fuel LNG

trucks.

•Do not start the engine if a natural gas leak is

detected.

•Transferring fuel is only allowed as long as a

non-static hose is used. if a non-approved

hose is used, static can build up and ignite the

fuel. A correct hose can be obtained through

Agility fuel systems.

•Do not attempt to cut any fuel supply piping

components.

•Avoid open ﬂames or sparks near a natural

gas vehicle.

•Cover eyes and exposed skin when working on

a natural gas fuel system or fueling a natural

gas vehicle.

Natural Gas Vehicles

25.1

01/21/2014 f470613

1. Sleeper Leak Sensor (zone 3)

2. Engine Compartment Leak Sensor (zone 2)

3. Leak Detection Control Panel (zone 1) (overhead

console)

4. Cylinder Shutoff Valve (back-of-cab box)

5. Shutoff Valve, Right Side Cylinder

6. Shutoff Valve and System Components, Left Side

Cylinder

7. Fill Panel

Fig. 25.1, CNG Component Locations

Natural Gas Vehicles

25.2

•Permit no smoking or other ignition sources in,

or within thirty feet of, a natural gas vehicle.

•Have CO

ﬁre extinguishers (ABC minimum)

located in a highly visible and easily accessible

location.

•Use Purple-K powder (PKP) or a similar dry

powder to extinguish an LNG ﬁre. Do not at-

tempt use water around an LNG ﬁre.

•Always purge the fuel lines before performing

maintenance or repairs on a natural gas fuel

system. Refer to the system manufacturer’s

service manual or the vehicle’s workshop

manuals for the proper purging procedure.

•Always use a natural gas detector to test the

system for leaks, whether an odor is present or

not. Routinely inspect the fuel ﬁltering and

regulating mechanisms, and the fuel lines. An

approved natural gas bubble solution can be

used to pinpoint the exact location of leaks. Do

not use soap and water. Soap and water can

cause premature failure of the O-rings in the

system.

•Make sure black caps are always on the PRD

vent lines to reduce water build up in lines.

•Do not store a natural gas vehicle indoors for

any extended period of time. Do not bring a

natural gas vehicle indoors unless the work-

shop is equipped with a methane detection and

ventilation system.

In Case of Emergency

If a vehicle has sustained damage or a leak has

been discovered:

1. Turn the ignition switch off, and set the parking

brake.

2. Exit the vehicle leaving as many doors and win-

dows open as possible. Get at least 30 feet from

the vehicle, and allow it to vent until it is safe to

do the steps below.

3. Remove all ignition sources from the area sur-

rounding the vehicle.

4. If it is safe to do so, close all fuel shutoff valves.

5. Use a natural gas detector, or approved NG

bubble solution, to identify leaks in the fuel sys-

tem.

Natural Gas Fuel Tank Filling

Procedures

CNG Vehicle Fueling

CNG is moved from the fuel station storage tanks to

the vehicle cylinders through a metered dispenser.

During fueling, as pressure inside of the vehicle cyl-

inders increases, so does the temperature. The dis-

penser shuts off when it determines the CNG cylin-

ders are full.

CNG fuel cylinders cannot be ﬁlled to their full capac-

ity of 3600 psi (24 800 kPa) in cooler weather. Since

temperature change causes gas to expand and con-

tract, less pressure in the cylinders on a cold day is

equal to the same amount of gas at a higher pres-

sure on a warm day. The fuel station dispenser has a

temperature-pressure compensating device, which

accounts for ambient temperature during fueling. See

Table 25.1 for approximate full cylinder pressures at

various temperatures.

CNG Temperature/Pressure Compensation Values

Temperature:

°F (°C)

Fill Station Pressure Set Point

3000 psi (20 684

kPa) Set Point

3600 psi (24 821

kPa) Set Point

100 (37.8) 3415 (23 546) 4086 (28 172)

90 (32.2) 3276 (22 587) 3909 (26 952)

80 (26.7) 3138 (21 636) 3754 (25 883)

70 (21.1) 3000 (20 684) 3600 (24 821)

60 (15.6) 2861 (19 726) 3445 (23 752)

50 (10) 2723 (18 774) 3288 (22 670)

40 (4.4) 2584 (17 816) 3131 (21 587)

30 (-1.1) 2446 (16 865) 2973 (20 498)

20 (-6.7) 2307 (15 906) 2814 (19 402)

10 (-12.2) 2169 (14 955) 2655 (18 306)

0 (-17.8) 2031 (14 003) 2495 (17 202)

-10 (-23.3) 1893 (13 052) 2336 (16 106)

-20 (-28.9) 1755 (12 100) 2180 (15 031)

-30 (34.4) 1616 (11 142) 2024 (13 955)

-40 (-40) 1477 (10 184) 1868 (12 879)

Table 25.1, CNG Temperature/Pressure Compensation

Values

Use the following steps to fuel a CNG vehicle.

1. Shut down the engine and apply the parking

brake.

Natural Gas Vehicles

25.3

IMPORTANT: Close all windows and doors dur-

ing the fueling process. Keeping windows and

doors closed allows for easier leak detection

inside the cab after fueling.

NOTE: If the fuel system has only back of cab

tanks, the fuel ﬁll is located behind the fuel ac-

cess panel on the lower part of the cabinet, or

below the tank cabinet in a separate box. If

truck has saddle mount tanks, the fuel panel is

located on the back end of the left side tank.

Vehicles with back-of-cab cabinets and saddle

tanks are have the fuel ﬁll panel on the back

end of the left side tank. See Fig. 25.2 for side

tanks, or Fig. 25.3 for back-of-cab cabinet

mounted fuel panel.

WARNING

Natural gas fuel tanks, lines, and valves are al-

ways pressurized. Always observe safety precau-

tions. Failure to do so could lead to loss of con-

trol over a ﬁlling hose or to ignition of the natural

gas, which could cause serious bodily injury,

death, or severe property damage.

2. Ensure all fuel cylinder shutoff valves are open.

See Fig. 25.2.

3. Ensure the vehicle fuel system main shutoff

valve is open.

4. If equipped, open the CNG fuel panel access

door and remove the dust cap from the vehicle

fuel ﬁll port.

5. Ensure the O-ring is present inside the fuel ﬁll

port. If the O-ring has been dislodged or is miss-

ing, the station dispensing nozzle will not con-

nect securely to the ﬁll port.

6. Turn the selector knob on the service pump to

the VENT position, if equipped.

7. Connect the quick coupling on the dispensing

nozzle securely to the vehicle fuel ﬁll port.

8. Turn the selector knob on the service pump to

the FILL position, if equipped.

IMPORTANT: If at any time the service pump or

vehicle begins to vent CNG uncontrollably, notify

a station attendant or activate the service sta-

tion emergency shut-off switch to cease the ﬂow

of CNG.

01/21/2014 f470615

1. High-Pressure Gauge

2. Fuel Cylinder Information Sticker

3. Manual Shutoff Valve

4. Fuel Fill Port

Fig. 25.2, CNG Fuel Cylinder Fill Panel (side tank

shown)

IGH

ESS

LOW

CYLINDERS

INSPECT CYLINDERS

EVERY 36 MONTHS

OR 36000 MILES

WHICHEVER OCCURS FIRST

NATURAL

GAS

VEHICLE

110 PSIG

MANUAL

SHUT OFF

VALVE

OPEN VALVE

SLOWLY

3600 PSIG MAX.

SERVICE PRESSURE

REGULATOR

FILTER

INSPECT PRESSURE

RELIEF DEVICE

EVERY 2000 MILES

DRAIN HOUSING

EVERY 1500 MILES

REPLACE ELEMENT

EVERY 3000 MILES

04/30/2010 f470556

1. High Pressure Gauge

2. Low Pressure Gauge

3. Manual Fuel Shutoff Valve

4. Fuel Fill Port and Dust Cap

Fig. 25.3, CNG Under Cabinet Fuel Panel (under

cabinet shown)

Natural Gas Vehicles

25.4

9. Switch on the service pump. A slight hissing

noise may be heard as the fuel cylinders ﬁll.

10. Watch the pressure gauge on the service pump.

When the gauge reads approximately 3600 psi

(24 800 kPa), or when the ﬁll pressure stops

climbing, the CNG cylinders are full. The service

pump will shut itself down automatically. See

Table 25.1 for pressure compensation values

based on ambient temperatures.

11. Move the selector knob on the service pump to

the VENT position, if equipped. A short hiss will

be heard as a small amount of natural gas is

vented into the hose.

WARNING

Do not attempt to remove the ﬁll station nozzle

from the tank ﬁll ﬁtting until venting of pressure

is noted. If no venting occurs, ask for assistance

from the station attendant. Removing an un-

vented coupling could result in an uncontrolled

hose, which could lead to property damage or

personal injury.

12. Remove the station dispensing nozzle from the

vehicle ﬁll port.

NOTE: Some ﬁll ports and dust caps contain a

magnetic start interrupt sensor to prevent a

truck from being started and driven away with

the ﬁll hose connected. These caps must be

installed correctly or vehicle will not start.

13. Install the dust cap on the vehicle fuel ﬁll port

and close the fuel panel access door, if

equipped.

LNG Vehicle Fueling

Only certiﬁed LNG fueling personnel are authorized

to fuel an LNG vehicle.

Natural Gas Detection System

A gas detection system is standard in all Daimler

Trucks natural-gas-fueled vehicles. This system has

a sensor in the engine compartment, one in the cab,

and one in the sleeper (if equipped), all situated in

high areas to detect natural gas buildup as a result

of leaks.

The AMGaDS III Plus is a natural gas detection sys-

tem. This device is meant to serve as a supplemen-

tal warning only. It is not intended to replace stan-

dard safety practices that should be conducted

around ﬂammable gases.

IMPORTANT: To function properly, the gas de-

tection system must be powered at all times.

The gas detection system is directly powered by

the batteries, and can only be powered off by

disconnecting the batteries. When servicing a

natural-gas-fueled vehicle, disconnect the bat-

teries only when necessary, and do not leave

the batteries disconnected for extended periods

of time.

The lower ﬂammability limit (LFL) is the smallest

amount of the gas that supports a ﬂame when mixed

with oxygen and ignited. Zero percent (0%) LFL indi-

cates a gas-free atmosphere. One hundred percent

(100%) LFL indicates that gas concentration has

reached its lower ﬂammability limit (5% gas in air by

volume). The red warning light and audible alarm

located in the overhead console activate when a sen-

sor detects gas fumes in concentrations above 50%

LFL, and should allow ample time to utilize safety

procedures. However, individuals with special needs

should review the system with a professional safety

engineer.

Alarm Procedure

Before operating the vehicle, the driver must be fa-

miliar with the procedures as shown on the interior

sticker on the overhead panel (See Fig. 25.4) and

the exterior sticker on the door (See Fig. 25.5).

IMPORTANT: If an audible alarm activates, do

not operate any electrical switch, including

lights. Avoid causing sparks and stay away from

arcing switches and equipment. Do not use a

telephone, including cellular phones or any

types of portable communication or electronic

devices that have a battery.

If the vehicle is in motion when the audible alarm

activates, bring it to a safe stop, shut down the en-

gine, and exit the vehicle. Do not open the hood.

If outside the vehicle when the audible alarm acti-

vates, do not open the cab door or hood.

In the event of an audible alarm, immediately follow

these procedures, as allowed by conditions:

Natural Gas Vehicles

25.5

1. Immediately shut off all engines. Extinguish any

cigarettes, pilot lights, ﬂames, or other sources of

ignition in the area and adjacent areas.

2. Exit the vehicle leaving as many doors and win-

dows open as possible, and move at least 30

feet away from vehicle. If the vehicle is parked,

stay at lease 30 feet away until it is safe to do

the following.

3. Manually close all fuel shutoff valves, including

those on the LNG tank or CNG cylinders.

4. If the vehicle is indoors (as in a service shop),

immediately open shop windows and doors to

provide extra ventilation to the area. Do not start

the engine or any other type of equipment until

the gas leak is corrected and the area cleared of

natural gas.

5. Evacuate the area.

6. After the area is cleared of natural gas and the

alarm is no longer active, have the vehicle in-

spected by a qualiﬁed technician.

IMPORTANT: Do not consider the area clear

until all alarm indicators are off, and the alarm

panel light returns to green.

Sensors

Gas detection sensors are located on the cab over-

head console (zone 1), in the engine compartment

on the frontwall (zone 2), and in the sleeper, if

equipped (zone 3). The sensors are located in high

areas, where rising gas vapors will pass by or accu-

mulate. On some vehicles, there is a sensor located

under the cab ﬂoor (zone 4). Zone 4 is not used on

DTNA vehicles.

If the system detects that one of the sensors has

been disconnected or has malfunctioned, the sensor

fault light for that zone will illuminate. A failed sensor

may trigger and lock on an alarm. If this happens

have a qualiﬁed technician troubleshoot the system

and make appropriate repairs.

The sensors are sensitive to all hydrocarbon vapors.

An alarm may be triggered by the use of chemicals

such as cleaners, paint, polish, lacquer, gasoline,

silicone, silicone spray, or other harsh chemicals.

The sensors will also detect hydrogen fumes from an

overcharged battery. If a sensor sends an alarm, but

no gas fumes are present, check for recent use of

chemicals or a battery charger.

04/28/2009 f080157

Fig. 25.4, Interior Warning Sticker

04/28/2009 f080158

Fig. 25.5, Exterior Warning Sticker

Natural Gas Vehicles

25.6

NOTICE

Silicone-based chemicals and cleaners will per-

manently disable the sensors. When cleaning the

vehicle, cover the sensors with a plastic cover-

ing. Keep the sensors covered until the area has

been cleared of any cleaning fumes.

Harsh chemicals, including some high alcohol

cotenant washer ﬂuids, and extremely high tem-

peratures may damage the sensor.

Puncture of or damage to the seal located inside

the sensor housing will signiﬁcantly shorten the

sensor life.

Frequent exposure to high concentrations of gas

will accelerate sensor deterioration.

Overhead Console

The overhead console consists of an alarm panel on

the right side and the control module on the left side.

The alarm panel has a green light, a red light, a

buzzer, and a sensor. See Fig. 25.6. It is located

within view from outside of the vehicle. The large

green light is continuously illuminated during normal

operating conditions.

Before entering the vehicle, always verify that the

green light is illuminated. If the green light is not illu-

minated, do not enter the vehicle. Complete the

alarm procedure previously outlined.

The alarm panel meets the California Highway Patrol

Title 13-2008 and NFPA 52 2010 requirements. All

drivers and technicians using it should be trained re-

garding the red and green lights, and the audible

warning.

The control module, located on the center of the

overhead console, contains the status lights and con-

trol buttons for the system. The areas that the sen-

sors monitor are deﬁned as Zone 1 (cab), Zone 2

(engine compartment), and Zone 3 (sleeper, if

equipped). The control module has lights assigned to

each zone that will illuminate if a sensor detects a

trace level leak (between 20% and 30% LFL), a sig-

niﬁcant level leak (above 50% LFL), or if a sensor is

disconnected or malfunctioning.

•Trace Level: If either sensor detects gas fumes

at a concentration greater than 20% to 30%

LFL (1% gas in air by volume), the amber light

next to the Trace indicator for that zone will

ﬂash. There is no buzzer alarm for a trace

level detection, and the large green light on the

alarm panel will remain illuminated.

•Signiﬁcant Level: If either sensor detects gas

fumes at a concentration greater than 50% to

60% LFL (2.5% gas in air by volume), the

small red light next to the SIGNIFICANT indi-

cator for that zone will ﬂash. After approxi-

mately 15 seconds, the large green light on the

alarm panel will switch off, the red light will illu-

minate, and the buzzer will sound. All alarm

indicators will remain on as long as fumes are

detected.

•Sensor Fault: If the system detects that either

of the sensors has been disconnected or has

malfunctioned, an amber light next to the Sen-

sor Fault indicator for that zone will illuminate.

The control module also has buttons used to test or

reset the the control module after an alarm. Red

lights next to each button indicate when they are en-

gaged.

•Shutdown Reset: If an alarm has been acti-

vated and the Relay Engaged light is illumi-

nated, the Shutdown Reset button will reset

the internal relay. Press the Shutdown Reset

button only after the gas has cleared, the

buzzer has turned off, and the alarm panel

light has returned to green.

•Push To Silence: If an alarm has been acti-

vated, the Push To Silence button will silence

the buzzer.

See Table 25.2 for the functions of all lights and but-

tons on the overhead console.

Testing

Daimler Trucks North America strongly recommends

that all operators follow California Code of Regula-

tions (CCR) inspection requirements, regardless of

where the vehicle is operated. Per Title 13 CCR §

935 (2), gas detection systems should be tested

three times per calendar year at equal intervals. The

testing procedure should simulate the same operat-

ing environment in which the vehicle is used, with the

same gaseous fuel.

Natural Gas Vehicles

25.7

Control Module Functions

Item Display Function Action Required

Green Power Light

Illuminated System is on. None required.

Unlit Detection system is not

functioning.

Ensure the batteries are

connected and replace any blown

fuses. If the gas detection system

is still not functioning, replace the

system immediately.

SIGNIFICANT Gas

Concentration Lights Red (illuminated) Dangerous gas concentration

detected.

Suspend vehicle operation

immediately and follow alarm

procedures.

Trace Gas Concentration

Lights Amber (ﬂashing) Minor gas concentration detected.

Suspend vehicle operation

immediately and follow alarm

procedures.

Sensor Fault Lights Off Sensor is functioning properly. None required.

On Sensor has malfunctioned. Replace the sensor immediately.

02/06/2014 f470614

13 42

1. Green Light

2. Red Light

3. Sensor

4. Buzzer Alarm

5. Test Button

6. Sensor Fault Indicator Lights

7. Zone Numbers

8. Trace Leak Indicator Lights

9. Signiﬁcant Leak Indicator Lights

10. Silence Engaged Light

11 Silence Button

12. Relay Reset Button

13. Relay Engaged Light

14. Power Indicator Light

Fig. 25.6, AMGaDS III Overhead Console

Natural Gas Vehicles

25.8

Control Module Functions

Item Display Function Action Required

Shutdown Reset Button — Resets the system after an alarm

activation.

Press to reset the system only

after the gas has cleared, the

buzzer has turned off, and the

alarm panel light has returned to

green.

Relay Engaged Light On Relay is engaged and test or

alarm is being cleared. Press the Shutdown Reset button.

Off Normal condition. None required.

Test Button — Tests the overhead console

operation and circuitry.

Press and hold for one minute to

to activate a test of all overhead

console components.

Silence Button — Silences the alarm buzzer. Press to silence the alarm buzzer.

Silence Engaged Light On Indicates the buzzer is active but

silenced.

Suspend vehicle operation

immediately and follow alarm

procedures.

Off Normal condition. None required.

Table 25.2, Control Module Functions

Test results validating the performance of the gas

detection system within the parameters established

by the component manufacturer and NFPA 52 2010

should be maintained as a permanent part of the ve-

hicle service records. Use of alcohol, propane, and

other harsh liquids or gases are not acceptable

methods for testing.

Always test the system and sensors after any com-

ponent has been replaced, or if the vehicle has been

involved in an accident or ﬁre. Ensure that the gas

detection system is wired directly to the battery.

It is recommended that the highest level of safety

validation be utilized if there are multiple validation

requirements in the state or locality where the vehicle

is operated or domiciled.

Overhead Console Test

Press and hold the Push To Test button for one min-

ute. The system will proceed with a self-diagnostic

test that will include illumination of the Trace and Sig-

niﬁcant gas concentration lights, and the sensor fault

lights. Verify the large red light and buzzer activate,

and that all lights illuminate or ﬂash to ensure that all

bulbs are operational.

Sensor Test

The gas detection system sensors must be tested

using qualiﬁed test gas, which can be purchased as

part of a test kit. Testing with alcohol or heavy gases

such as butane or propane does not satisfy CCR §

935 (2) or NFPA 52 regulations.

Expose each sensor to qualiﬁed test gas for at least

30 seconds. The system will proceed through the

alarm procedure consistent with a signiﬁcant leak

and the buzzer will sound after approximately 15

seconds. If a sensor fails to respond after exposure

to the test gas, replace the sensor.

Natural Gas Engine Starting

NOTE: Before starting the engine, read Chap-

ter 4 for detailed information on how to read the

instruments and Chapter 5 for detailed informa-

tion on how to operate the controls. Read the

operating instructions in the engine manufactur-

er’s operation manual before starting the en-

gine.

1. Before engine start-up, complete the engine pre-

trip and post-trip inspections and maintenance

procedures in Chapter 21.

2. Ensure the fuel shutoff valve is open.

3. Set the parking brake.

4. Ensure that the transmission shift control is in

Neutral (N), Park (P), or the Park Brake (PB) po-

sition.

Natural Gas Vehicles

25.9

5. Without starting the engine, turn the ignition

switch to the ON position (Fig. 25.7). The elec-

tronic gauges on the instrumentation control unit

(ICU) will complete a full sweep of their dials, the

warning and indicator lights will illuminate, and

the buzzer will sound for three seconds.

6. Turn the ignition switch to the START position.

Press down on the clutch pedal, if equipped, but

do not press down on the accelerator pedal.

Release the key the moment the engine starts.

7. Bring the engine up to operating speed gradually

as it warms up and develops stable oil pressure.

If the vehicle has not been operated previously in

a 24-hour period, allow the vehicle to idle for ﬁve

minutes.

NOTICE

Do not rev the engine if the oil pressure gauge

indicates no oil pressure. Shut down the engine

within approximately ten seconds to avoid engine

damage.

8. Check the oil pressure gauge for any drop in lu-

bricating oil pressure or mechanical malfunction

in the lubricating oil system.

Major Repairs and

Replacement of Natural Gas

Components

IMPORTANT: All repairs to natural gas system

and components must be performed by certiﬁed

technicians.

If a natural-gas-fueled vehicle is involved in an acci-

dent, remove the fuel tank or cylinders from service

and have them inspected by a qualiﬁed technician.

Replace any leaking or damaged fuel tanks/cylinders

and fuel lines; repair or replace leaking or damaged

ﬁttings. Install parts and components in accordance

with the manufacturer’s instructions.

07/19/2006 f610805

Fig. 25.7, Ignition Switch Positions

Natural Gas Vehicles

25.10

Speciﬁcations

Fuses and Relays ................................................................ 26.1

Replacement Bulbs .............................................................. 26.3

Fluids and Lubricants ............................................................. 26.4

Fuses and Relays

CAUTION

This vehicle may be equipped with a roof-

mounted Citizens’ Band (CB) antenna. Operation

of an ampliﬁed CB radio with output power

greater than FCC limits (4W AM/12W SSB) is ille-

gal, and may expose vehicle occupants to radio

frequency (RF) radiation that exceeds FCC maxi-

mum permissible RF exposure limits. Vehicle oc-

cupants with electronic medical devices should

consult the device manufacturer’s user manual or

a physician for information on RF radiation expo-

sure limit guidelines.

SAM Cab Fuses

Part Name AMP

F1 Power FD Spare1&3 30

F2 Cab/Slpr HVAC Ctrl

Trans Shift Pnl 15

F3 Power FD Spare2&4 30

F4 MSF 15

F5 OBD J1939

OBD DCDI 10

F6 Dash Power Recp 1 15

F7 Dash Power Recp 2 15

F8 Phone/Radio 15

F9 Ampliﬁer Power 20

F10 Cab HVAC Motor 30

F11 Sleeper HVAC Motor 30

F12 Door Controls, L 20

F13 Door Lock

Coll Warn Sys 20

F14 Fleet Mgm Sys

CB 25

F15 Sleeper Power Recp 3 20

F16A Aux Cab Heater Enable 3

F16B Aux Coolant Heater 20

F17 Power Recp 4 20

F18

GPS

Tire Press Monitor

Antitheft Warn

AuxiliaryTelematics

F19 Heated Seat 20

SAM Cab Fuses

Part Name AMP

F20 CGW 2

F21 Area Light 15

F22 ICU

Horn Switch 5

F23

GPS

Driver Info Sys

Fleet Mgmt Sys

Pyrometer, Axle Temp, Eng

Oil Temp Gauges

F24 Diagnostic Conn

ICU 7.5*

F25

Trans Temp Gauge/Shift

Select

Phone

Collision Warn Sys

10†

F26 SRS Airbags 5

F27 Mirror Heat, L 10

F28 Mirror Heat, R 10

F29 SAM Relay Coils 3

F30 Power Recp 6 20

F31 Power Recp 5 20

F32 Power FD Spare 5 & 6 25

F33 Spotlight 20

F34 Baggage Comp Lamp 3

F35 Dome Lamp 15

F36 Aux Circulation Fan

Road Lamps 15

F37

Clock (cab & sleeper)

Driver Info Sys

CD Player

Keyless Entry

F38 Door Controls, R 20

F39 Power Window, R 15

F40 Power Window, L 15

F41 Aux Mirror Heat 10

*F24 value on assemblies -005 and lower is 10 amps.

†F25 value on assemblies -005 and lower is 7.5 amps.

Table 26.1, SAM Cab Fuses

Speciﬁcations

26.1

SAM Cab Relays

Position Function Source

BR21 Power FD Spare1&3

Dash Power Recp 1 BAT

BR22 Power FD Spare2&4

Slpr Power Recp 3 BAT

R3 Heated Seats IGN

BR23

Dash Power Recp2

Fleet Mgmt Sys

Aux Cab Heater

Aux Coolant Heater

BAT

GPS

Driver Info Sys

Fleet Mgmt Sys

Pyrometer, Axle Temp, Eng

Oil Temp Gauges

IGN

Diagnostic Conn

ICU

Trans Temp/Shift Select

Phone

Coll Warn Sys

SRS Airbags

IGN

R9 Ampliﬁer Power ACC

R10 Mirror Heat (L, R, & Aux) ACC

BR24

Power Recp6

Area Lighting

Baggage Comp Lamp

Dome Lamp

BAT

BR25

PowerRecp4&5

Aux Circulation Fan

Reading Lamp

BAT

R15 Power Windows ACC

Table 26.2, SAM Cab Relays

SAM Chassis Fuses

Part Name AMP

F1 Elec Air Process. Unit

(EAPU) 20

F2 Fuel/Water Separator Heat 20

F3 ABS Bat 1 20

F4 ABS Bat 2 10

F5 Trailer Left-Turn Lamp 20

F6 ABS 15

F7 EAPU/WIF

Rear Camera 10

F8 Trailer Right-Turn Lamp 20

F9 Trailer Marker Lamps 30

F10 SAM Relay Coils 5

F11 Trailer ABS 30

F12 Trailer Stop Lamps 30

F13 Trailer Tail Lamps 20

F14 Trailer Power 30

Table 26.3, SAM Chassis Fuses

SAM Chassis Relays

Position Function

R1 Fuel/Water Separator Heat

R2 Trailer Left-Turn Lamp

ABS

EAPU/WIM

Rear Camera

R4 Trailer Right-Turn Lamp

R5 Trailer Marker Lamps

R6 Trailer ABS

R7 Trailer Stop Lamps

R8 Trailer Power

R9 Trailer Tail Lamps

Table 26.4, SAM Chassis Relays

MEGA Fuse Junction Block (MFJB) Fuses, EPA07

Only

Part Name AMP

F1 Powertrain PDM 175

F2 SAM Cab 175

F3 SAM Chassis 125

F4 Chassis-Mounted Trailer

PDM 125

Speciﬁcations

26.2

MEGA Fuse Junction Block (MFJB) Fuses, EPA07

Only

Part Name AMP

F5 Inverter 200

Table 26.5, MEGA Fuse Junction Block (MFJB) Fuses,

EPA07 Only

Powernet Distribution Box (PNDB) Fuses, EPA10 and

Newer

Fuse Function AMP

AAftertreatment Control

Module 30

B Emergency Power 20

C Radio/Clock 5

D Alternator Remote Sense 5

1 Powertrain PDM 175

2 SAM Chassis 125

3 SAM Cab 175

Table 26.6, Powernet Distribution Box (PNDB) Fuses,

EPA10 and Newer

Trailer PDM Fuses and Relays

Position Function AMP

F1 Trailer Power Fuse 30

F2 Taillight Fuse 30

F3 Left-Turn Lamp Fuse 20

F4 Right-Turn Lamp Fuse 20

F5 Marker Lamp Fuse 30

F6 Stop Lamp Fuse 30

R1 Taillight Relay

R2 Right-Turn Relay

R3 Stop Lamp Relay

R4 Trailer Power Relay

R5 Left-Turn Relay

R6 Marker Lamp Relay

Table 26.7, Trailer PDM Fuses and Relays

Replacement Bulbs

Lamp Assembly Replacement Bulb

Headlight Hi/Low Beam, Fog

light, Driving Light

WEE 12362LLBA

(H11)

Turn/Marker Lamp (in headlight

assy) GE 3457

Incandescent Auxiliary Turn (on

fender) GE 2058U

Integral Stop/Tail/Backup Lights GE 1157/GE 1156

Utility Light WEE 199

Cab Dome Lamp, Clear,

Outboard GN12 BUL 050 R5WC

Cab Dome Lamp, Clear, Inboard GN12 BUL 049 R10W

Cab Dome Lamp (Red) GN12 BUL 050 R5WR

Sleeper Reading Lamp GRLSAP270

Sleeper Dome Lamp GRLBUL049R10W

Sleeper Writing Desk Lamp GRLBUL027578

Sleeper Bunk Lamp GRLBUL0142112

Footwell Lamp (Red) GRLBUL042W5W

Table 26.8, Replacement Bulbs

Speciﬁcations

26.3

Fluids and Lubricants

Type Approved Fluid or Lubricant

Engine Oil*Engines compliant with EPA07 or newer regulations: Engine lube oil with a sulfated ash level less

than 1.0 wt %; currently referred to as CJ-4 oil.

Fuel†Engines compliant with EPA07 or newer regulations: Ultralow-sulfur diesel (ULSD) with 15 ppm

sulfur content or less, based on ASTM D2622 test procedure.

Power Steering Fluid ATF must meet TES 389 or Dexron III speciﬁcations

Hydraulic Clutch Fluid DOT 4

Manual Transmission

Lubricant‡§

MobilTrans SHC 50 (RN 2952 E-5), SAE 50W

Synthetic transmission lubricant approved by Eaton, SAE 50W

Antifreeze

Caterpillar Diesel Engine Antifreeze/Coolant. Contains supplement additives. Available as a

premixed solution.

Detroit™Power Cool, premixed solution with supplement additives.

Old World Industries, Fleet Charge™, with supplement additives.

Drive Axle Lubricant

Recommended SAE Viscosity Grade Ambient Temperature Range

75W –40°F to –15°F (–40°C to –26°C)

75W—80 –40°F to 80°F (–40°C to 27°C)

75W—90 –40°F to 100°F (–40°C to 38°C)

75W—140 –40°F and above (–40°C and above)

80W—90 –15°F to 100°F (–26°C to 38°C)

80W—140 10°F and above (–12°C and above)

*See the engine manufacturer’s manual for speciﬁcations.

†See the engine manufacturer’s manual for speciﬁcations.

‡Do not mix types or brands of ﬂuid. Multi-weight and extreme-pressure gear ﬂuids are not recommended.

§Call 1-800-826-4357 for a complete list of Eaton approved lubricants.

Table 26.9, Approved Fluids and Lubricants

Speciﬁcations

26.4

Subject Page

Accessory Heaters ........................ 8.5

Espar Heater ......................... 8.6

Webasto Heater ....................... 8.7

Adjustable Steering Column

Controls ............................. 5.20

Adjusting Headlight Aim ................... 23.1

Air Brake System ........................ 13.1

Automatic Slack Adjusters ................ 13.3

Brake System Components ............... 13.1

Brake System General

Information ......................... 13.1

Brake System Operation ................. 13.1

Air-Suspension Dump Valve ................. 19.1

Back-of-Cab Access ....................... 2.4

Climbing Down from Back-

of-Cab ............................. 2.5

Entering Back-of-Cab .................... 2.5

Cab Amenities ........................... 9.1

Cup Holders .......................... 9.1

Lighting ............................. 9.1

Power Outlets ......................... 9.1

Radio and CB ......................... 9.2

Storage ............................. 9.2

Cab Climate Control Panel .................. 8.1

Fan Switch ........................... 8.1

Mode Control Switch .................... 8.2

Temperature Control Switch ................ 8.1

Cab Door Locks and Handles ................ 2.1

Cab Washing and Polishing ................. 22.1

Cab-to-Sleeper Access ..................... 2.3

Canadian Motor Vehicle Safety

Standard Labels ........................ 1.1

Care of Chrome Parts ..................... 22.1

Care of Exterior Lights .................... 22.1

Care of Fiberglass Parts ................... 22.1

Cascadia 2.0 High-Back Seat ................ 7.2

Armrest Angle ......................... 7.3

Bottom Cushion Extension ................ 7.3

Fore/Aft Isolator ........................ 7.2

Height Adjustment ...................... 7.2

Lumbar Support ....................... 7.2

Recline ............................. 7.2

Seat Fore/Aft Slide ...................... 7.3

Seat Heating/Ventilation .................. 7.2

Subject Page

Seat Tilt ............................. 7.3

Shock Absorber Adjustment ................ 7.2

Cascadia High-Back Seat ................... 7.3

Backrest Tilt .......................... 7.3

Bottom Cushion Extension ................ 7.3

Fore/Aft Isolator ........................ 7.3

Fore/Aft Seat Slide ...................... 7.3

Front Cushion Height .................... 7.3

Heater .............................. 7.4

Height Adjustment ...................... 7.3

Lumbar Support ....................... 7.3

Rear Cushion Height .................... 7.3

Shock Absorber ........................ 7.3

Checking Headlight Aim ................... 23.1

Checklists ............................. 20.1

Daily Pretrip Inspection

Checklists ......................... 20.1

Monthly Post-trip Inspection

Checklists ......................... 20.2

Weekly Post-trip Inspection

Checklist .......................... 20.2

Climate Controls ........................ 5.17

Cab Climate Control .................... 5.17

Sleeper Climate Control ................. 5.18

Clutch ............................... 14.5

Clutch Maintenance .................... 14.7

Clutch Operation ...................... 14.6

General Information .................... 14.5

Component GWR Label .................... 1.1

Component Information Label ................ 1.1

Cruise Control .......................... 5.11

Cruise Control ("CC") Limiter .............. 5.13

Descent Control and

Deceleration Modes,

Detroit™Automated

Transmissions ....................... 5.13

Run Smart Predictive

Cruise™........................... 5.12

Daily Pretrip Inspection and

Maintenance .......................... 21.1

Cab Inspection ....................... 21.5

Engine Compartment

Inspection ......................... 21.4

Natural Gas Fuel System

Inspection ......................... 21.8

Saddle Tank Areas

Inspection ......................... 21.4

Suspension and Slack

Adjuster Inspection ................... 21.1

Wheel and Tire Inspection ................ 21.2

Index

I-1

Subject Page

Dashboard Care ........................ 22.2

Dash-Mounted Brake Controls ............... 5.14

Antilock Braking System ................. 5.15

Parking Brake Control Valve ............... 5.14

Trailer Air Supply Valve .................. 5.14

Trailer Brake Lever ..................... 5.15

Detroit™Automated

Transmissions ......................... 15.1

Clutch Abuse Protection ................. 15.4

Creep Mode ......................... 15.3

Detroit™Multifunction

Control ........................... 15.1

Driving Modes ........................ 15.2

eCoast ............................. 15.3

Engine Overspeed Alerts ................. 15.4

Gear Display Window ................... 15.2

Low Transmission Air

Warning ........................... 15.4

Power Up and Shift into

Gear ............................. 15.2

Selected Gear ........................ 15.3

Suggested Shift ....................... 15.3

Diesel Exhaust Fluid and Tank,

EPA10 and Newer Engines ................ 12.3

DEF Tank ........................... 12.4

DEF Warnings and Engine

Limits ............................ 12.5

Diesel Exhaust Fluid .................... 12.3

Fuel/DEF Gauge ...................... 12.4

Differential Locks ........................ 16.1

Driver-Controlled Differential

Lock (DCDL) ........................ 16.1

Single Drive Axles with

Traction Equalizer .................... 16.2

Tandem Drive Axles with

Interaxle Differential Lock ............... 16.1

Driver Message Center .................... 4.11

ICU3/ICU4 .......................... 4.11

ICU4Me ............................ 4.19

ICU4M ............................. 4.13

Eaton Fuller 10-Speed Range-

Shift Transmissions ..................... 14.4

General Information, Eaton

Fuller Range-Shift .................... 14.4

Operation, Eaton Fuller

Range-Shift ........................ 14.4

Eaton Fuller 13-Speed and 18-

Speed Splitter and Range-

Shift Transmissions ..................... 14.1

Subject Page

General Information, Eaton

Fuller Splitter and Range-

Shift ............................. 14.1

Operation, Eaton Fuller

Splitter and Range-Shift ................ 14.1

Eaton Fuller AutoShift

Automated Transmissions ................ 15.11

General Information,

AutoShift .......................... 15.11

Operation, AutoShift with

SmartShift ......................... 15.11

Eaton Fuller UltraShift PLUS ............... 15.14

Auto Neutral ........................ 15.17

Auto Start Gear Selection

and Override ....................... 15.17

Automatic Mode (AUTO) ................ 15.14

Automatic Traction Control ............... 15.17

Clutch Abuse Protection ................ 15.15

Coasting ........................... 15.17

Creep Mode ........................ 15.16

Engine Overspeed

Protection ......................... 15.16

Hill Start Aid ........................ 15.16

Load-Based Shifting ................... 15.17

Low (L) ............................ 15.15

Manual Mode (MAN) ................... 15.15

Power Down ........................ 15.14

Power Up .......................... 15.14

Reverse (R) ......................... 15.14

Shuttle Shifting ...................... 15.16

Skip Shifting ........................ 15.17

Eaton Fuller UltraShift ..................... 15.6

General Information,

UltraShift DM ....................... 15.6

Operation, UltraShift DM ................. 15.6

Ultrashift Diagnostics .................. 15.10

Electrical Power Distribution .................. 3.1

Cab Load Disconnect Switch ............... 3.3

Circuit Protection Features ................ 3.1

MEGA Fuse Junction Block,

EPA07 ............................. 3.1

Power Distribution Modules ................ 3.1

Powernet Distribution Box,

EPA10 and Newer ..................... 3.1

Emergency Filter Replacement,

Davco .............................. 24.1

Emergency Kit, Optional ................... 24.1

Emergency Power Supply ................... 3.3

SAM Cab Fault ........................ 3.4

SAM Chassis Fault ..................... 3.4

Emergency Starting With

Jumper Cables ........................ 24.2

Emissions Labels ......................... 1.1

Index

I-2

Subject Page

Aftertreatment System

Indicators Label ...................... 1.1

Certiﬁed Clean Idle Label ................. 1.4

EPA Noise Emission Control

Label ............................. 1.3

Vehicle Emission Control

Information Label ..................... 1.4

Engine Brake .......................... 13.5

Engine Brake Operation ................. 13.5

Engine Idle Limiting ...................... 11.2

California Engine Idle

Limiting ........................... 11.2

Idle Shutdown Timer .................... 11.2

Engine Operation ........................ 10.2

Cold-Weather Operation ................. 10.3

Engine Break-In ....................... 10.3

High-Altitude Operation .................. 10.4

Normal Operation ...................... 10.3

Safety and Environmental

Considerations ...................... 10.2

Engine Protection—Warning

and Shutdown ......................... 11.1

Engine Shutdown ........................ 10.4

Engine Starting ......................... 10.1

Cold-Weather Starting ................... 10.2

Starting After Extended

Shutdown .......................... 10.2

Enhanced Stability Control .................. 6.13

EPA-Regulated Emissions

Aftertreatment Systems ................... 12.1

ATS Warning Lamps .................... 12.3

EPA07 Engines ....................... 12.1

EPA10 and Newer Engines ............... 12.1

Maintenance ......................... 12.3

Regeneration ........................ 12.2

Federal Motor Vehicle Safety

Standard Labels ........................ 1.1

Fifth Wheel Coupling ..................... 18.1

Fontaine and Holland Fifth

Wheels Coupling ..................... 18.1

Jost Fifth Wheel Coupling ................ 18.3

Fifth Wheel Slide ........................ 18.7

Air Slide Operation ..................... 18.9

Manual Slide Operation .................. 18.7

Fifth Wheel Uncoupling .................... 18.4

Air-Actuated Uncoupling ................. 18.5

Manual Uncoupling ..................... 18.4

Fifth Wheels, General

Information ........................... 18.1

Air-Suspension Dump Valve ............... 18.1

Subject Page

Fifth Wheel Lubrication .................. 18.1

Fire Extinguisher ........................ 24.1

Fire in the Cab ......................... 24.7

In Case of a Cab Fire ................... 24.7

Fluids Added ........................... 20.2

Fluids and Lubricants ..................... 26.4

Freightliner SmartShift Shift

Control ............................. 15.5

General Information,

SmartShift ......................... 15.5

Fuses and Relays ....................... 26.1

Grab Handles and Access

Steps ............................... 2.1

Entering the Driver Side .................. 2.2

Entering the Passenger Side ............... 2.2

Exiting the Driver Side ................... 2.2

Exiting the Passenger Side ................ 2.2

Greenhouse Gas Emissions

and Fuel Consumption

Standards ........................... 12.1

Hazard Warning Lights .................... 24.1

Holland Trailer Coupling ................... 19.1

General Information .................... 19.1

Operation ........................... 19.1

Hood Opening and Closing .................. 2.5

To Return the Hood ..................... 2.5

To Tilt the Hood ........................ 2.5

Horn Controls ........................... 5.7

Air Horn ............................. 5.7

Electric Horn .......................... 5.7

Ignition Switch and Key .................... 5.1

Instrumentation Control Units ................. 4.1

Audible Alerts ......................... 4.2

Ignition Sequence ...................... 4.1

Instruments ............................ 4.7

Air Intake Restriction Gauge ............... 4.7

Application Air Pressure

Gauge ............................. 4.8

Coolant Temperature Gauge ............... 4.9

Drive Axle Oil Temperature

Gauges ............................ 4.9

Engine Oil Pressure Gauge ................ 4.9

Engine Oil Temperature

Gauge ............................ 4.10

Index

I-3

Subject Page

Fuel Gauge, Pre-EPA10 ................. 4.10

Fuel/Diesel Exhaust Fluid

(DEF) Gauge, EPA10 and

Newer ............................ 4.10

Primary and Secondary Air

Pressure Gauges ..................... 4.10

Speedometer ......................... 4.11

Tachometer .......................... 4.11

Transmission Fluid

Temperature Gauge ................... 4.11

Turbocharger Boost

Pressure Gauge ..................... 4.11

Voltmeter ........................... 4.11

Lane Departure Warning

Controls ............................. 6.10

Lighting Controls ......................... 5.2

Exterior Lighting Controls ................. 5.2

Interior Lighting Controls .................. 5.6

Major Repairs and

Replacement of Natural Gas

Components ......................... 25.10

Meritor WABCO® Antilock

Braking System ........................ 13.3

Automatic Traction Control ................ 13.4

ECAS Automatic Load

Transfer (ECAS only) .................. 13.4

Trailer ABS Compatibility ................. 13.4

Mirrors ................................ 9.1

Monthly Post-Trip Inspections

and Maintenance ...................... 21.13

Brake Component Inspection ............. 21.13

Engine Compartment

Inspection and

Adjustments ....................... 21.15

Saddle Tank Areas

Inspection ......................... 21.14

Natural Gas Detection System ............... 25.5

Alarm Procedure ...................... 25.5

Overhead Console ..................... 25.7

Sensors ............................ 25.6

Testing ............................. 25.7

Natural Gas Engine Starting ................. 25.9

Natural Gas Fuel Tank Filling

Procedures ........................... 25.3

CNG Vehicle Fueling ................... 25.3

Subject Page

LNG Vehicle Fueling .................... 25.5

Natural Gas Vehicles, General

Information ........................... 25.1

Natural Gas Vehicles, Safety

Precautions .......................... 25.1

In Case of Emergency .................. 25.3

OnGuard™Collision Safety

System .............................. 6.7

Adaptive Cruise Control

(ACC) ............................. 6.8

Additional Features .................... 6.10

Collision Mitigation System

(CMS) ............................. 6.9

Collision Warning System

(CWS) ............................. 6.7

Error Screens ......................... 6.9

OnGuard Display Unit .................... 6.7

Optimized Idle® ......................... 11.2

Overhead Instrument Panel ................. 4.24

ParkSmart™HVAC System .................. 8.3

Standard Vehicle

Conﬁguration ........................ 8.3

Vehicles with Detroit Diesel

Optimized Idle ....................... 8.5

Periodic Inspections and

Maintenance, General

Information ........................... 20.1

Power Steering System General

Information ........................... 17.1

Power Steering Systems ................... 17.1

Rack and Pinion Steering

System ........................... 17.1

Steering Gear System ................... 17.1

Power Takeoff (PTO) Governor ............... 11.2

Powertrain Controls ....................... 5.7

Aftertreatment System

Regen Switches ...................... 5.7

Axle Switches ......................... 5.8

Engine Brake Switch .................... 5.8

Engine Fan Switch ...................... 5.9

Hill Start Aid Override Switch ............... 5.9

PTO Switch .......................... 5.9

Transmission Controls ................... 5.9

Preliminary Checks ....................... 23.1

Progressive Low Voltage

Disconnect ............................ 3.4

Index

I-4

Subject Page

Replacement Bulbs ...................... 26.3

Roll Stability System ...................... 6.11

Hard-Braking Advisor ................... 6.13

Roll Stability Advisor .................... 6.12

Roll Stability Control .................... 6.12

Trip/Leg Totals ........................ 6.13

RollTek Rollover Protection

System .............................. 7.9

Identiﬁcation .......................... 7.9

Inspection and Service .................. 7.11

Operation ............................ 7.9

Sears Atlas Seat ......................... 7.4

Armrest Angle ......................... 7.5

Backrest Tilt .......................... 7.4

Bottom Cushion Tilt ..................... 7.5

Fore/Aft Seat Slide ...................... 7.4

Isolator ............................. 7.5

Lumbar Support ....................... 7.4

Seat Extension ........................ 7.5

Suspension Inﬂation/

Deﬂation ........................... 7.5

Seat Belts and Tether Belts .................. 7.5

Seat Belt Inspection ..................... 7.6

Seat Belt Operation ..................... 7.6

Seat Controls .......................... 5.19

Seats, General Information .................. 7.1

Sleeper Amenities ........................ 9.2

Baggage Compartment

Doors ............................. 9.2

Lighting ............................. 9.2

Power Outlets ......................... 9.2

Sleeper Access Door .................... 9.2

Sliding Side Window .................... 9.3

Sleeper Climate Control Panel ................ 8.2

Fan Switch ........................... 8.2

Temperature Control Switch ................ 8.3

Sleeper Door ........................... 2.3

Sleeper Luggage Door ..................... 2.4

Steering Wheel Air Bag ..................... 7.8

Inspection and Service ................... 7.9

Operation ............................ 7.8

Suspension/Trailer Connection

Controls ............................. 5.16

Air Suspension Dump

Control Switch ....................... 5.16

ECAS Remote Control Unit

(ECAS only) ........................ 5.16

Subject Page

Fifth Wheel Slide Control

Switch ............................ 5.17

Trailer Auxiliary Switch .................. 5.17

Towing ............................... 24.4

Front Towing Hookup ................... 24.5

Rear Towing Hookup ................... 24.5

Two-Speed Drive Axles .................... 16.2

Axle Shift ........................... 16.2

Velour Upholstery Cleaning ................. 22.3

Chewing Gum or Wax ................... 22.3

Grease and Oil-Based Stains .............. 22.3

Mildew ............................. 22.3

Sugar and Water-Based

Stains ............................ 22.3

Vinyl Upholstery Cleaning .................. 22.2

Ball Point Ink ......................... 22.3

Chewing Gum ........................ 22.2

Miscellaneous ........................ 22.3

Nail Polish and Nail Polish

Remover .......................... 22.2

Ordinary Dirt ......................... 22.2

Paint, Shoe Heel Marks ................. 22.2

Shoe Polish ......................... 22.2

Sulﬁde Stains ........................ 22.2

Tars, Asphalts, and Creosote .............. 22.2

VORAD VS-400 System .................... 6.1

Collision Warning System ................. 6.4

Driver Interface Unit ..................... 6.1

Failure Display Mode/Fault

Codes ............................. 6.6

Maintenance .......................... 6.6

Side Object Detection .................... 6.5

SmartCruise .......................... 6.5

Special Road Situations .................. 6.6

Warning and Indicator Lights ................. 4.3

Engine Protection System ................. 4.7

Weekly Post-Trip Inspections

and Maintenance ...................... 21.10

Engine Compartment

Inspection ......................... 21.10

Windows .............................. 9.1

Windshield Wiper/Washer

Controls ............................. 5.15

Index

I-5

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