Freightliner cascadia Driver Guide

CASCADIA

Part Number STI 478

Driver’s Manual

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 vehicle, refer to the chassis speciﬁcation pages included in all new vehicles and to the vehicle speciﬁcation decal, located inside the vehicle.

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

IMPORTANT: Descriptions and speciﬁcations in this manual were in effect at the time of printing. Freightliner Trucks reserves the right to discontinue models and to change speciﬁcations or design at any time without notice and without incurring obligation. Descriptions and speciﬁcations 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 discard materials, you should ﬁrst attempt to reclaim and recycle them. To preserve our environment, follow 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 related to vehicle dynamics and safety systems for approximately 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 operating

•

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 routinely 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 maintained 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 coverage of the vehicle under the manufacturer’s warranty. Many maintenance procedures ensure that the vehicle 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 regulations. Components including, but not limited to, tires, cab/sleeper side extenders, chassis fairings, bumper, hood, vehicle speed limiters, and idle reduction timers are speciﬁcally designed and manufactured to exacting standards for regulatory fuel efficiency and greenhouse gas emissions compliance. It is important that these components are always replaced with components that meet or exceed the performance 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-FTLHELP. Call night or day, weekdays or weekends, for dealer referral, vehicle information, breakdown coordination, or Fleetpack assistance. Our people are knowledgeable, professional, and committed to following through to help you keep your truck moving.

Reporting Safety Defects

If you believe that your vehicle has a defect which could cause a crash or could cause injury or death, you should immediately inform the National Highway Traffic Safety Administration (NHTSA) in addition to notifying Daimler Trucks North America LLC.

If the NHTSA receives similar complaints, it may open an investigation, and if it ﬁnds that a safety defect exists in a group of vehicles, it may order a recall and remedy campaign. However, NHTSA cannot become involved in individual problems between you, your dealer, or Daimler Trucks North America LLC.

To contact NHTSA, you may call the Vehicle Safety Hotline toll-free at 1-888-327-4236 (TTY: 1-800-424-9153); go to www.safercar.gov;or write

to: Administrator, NHTSA, 1200 New Jersey Avenue, SE, Washington, DC 20590. You can also obtain other information about motor vehicle safety from www.safercar.gov.

Canadian

customers who wish to report a safetyrelated defect to Transport Canada, Defect Investigations and Recalls, may telephone the toll-free

hotline 1-800-333-0510, or contact Transport Canada by mail at: Transport Canada, ASFAD, Place de Ville Tower C, 330 Sparks Street, Ottawa, Ontario, Canada K1A 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 permission 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

1 V

ehicle Identiﬁcation ...................................................... 1.1

2 V

ehicle Access .......................................................... 2.1

3 Electrical

System ........................................................ 3.1

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

5 Driver

Controls .......................................................... 5.1

6 Driver

Assistance Features ................................................ 6.1

7 Seats

and Restraints ..................................................... 7.1

8 Climate

Control .......................................................... 8.1

9 Cab

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 T

railer 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 examples 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 installations shown on the chassis speciﬁcation sheet. One copy of the component information label is attached 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 Vehicle Safety Standard (FMVSS) certiﬁcation requirements, not all of the labels shown will apply to your vehicle.

Tractors with or without ﬁfth wheels purchased in the U.S. are 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 manufacturer. 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.

rucks 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 domiciled 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 important 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 manufacturer’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 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 side extenders, and fuel tank fairings; vehicle speed limiters; and idle shutdown timers.

A Vehicle Emission Control Information Label is located 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 engines to be equipped with a non-programmable engine 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, insert 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.

o 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 support back-of-cab access, and grabbing or stepping 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. Carelessness 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

f720639

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:

Open the driver side door, and place anything that you are carrying in the cab.

Using both hands, grasp the grab handle that is on the B-pillar, or use your left hand on the integral door lower grab handle. See Fig. 2.3. Reach up

as far as is comfortable.

Place your right foot on the bottom step, and pull yourself up. Move your left hand to the integral door upper grab handle.

Place your left foot on the top step.

Grasp the steering wheel with your left hand, and step up.

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.

Grasp the steering wheel with both hands, place your left foot on the top step, then stand on the threshold facing into the cab.

Using your right hand, grasp the grab handle, located on the B-pillar.

Move your right foot to the bottom step.

Move your left hand to the integral door lower grab handle.

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:

Open the passenger-side door, and place anything that you are carrying in the cab.

Using your left hand, grasp the grab handle that’s on the rear of the door opening. See

Fig. 2.4.

Using your right hand, grasp the integral door lower grab handle.

Place your right foot on the bottom step, and step up to the upper step with your left foot.

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

Move your right hand to the upper grab handle on the windshield post.

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

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.

Place your left foot on the bottom step.

Move your left hand to the lower grab handle located at the rear edge of the door opening. See Fig. 2.4.

Move your right hand to the integral door lower grab handle.

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 desired, 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 convenient 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 opening. To close the door, pull on the strap attached to the inside of the door, or push it closed from the outside, 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 carriers 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)

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, backof-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.

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. Carelessness could cause a person to trip and fall, with possible injury.

Entering Back-of-Cab

When climbing onto the deck plate, do the following:

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

Place one foot on the bottom step and pull yourself up.

Place your other foot on the top step.

Move your lower hand to a higher position on the grab handle.

Step onto the deck plate.

Climbing Down from Back-of-Cab

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

Grasp the sidewall grab handle with both hands.

Step one foot at a time onto the top step.

Move your upper hand to a lower position on the grab handle.

Move one foot to the bottom step.

Move your upper hand to a lower position on the grab handle.

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 overtravel. In the operating position, the hood is secured by a hold-down latch on each side of the hood.

To Tilt the Hood

Apply the parking brakes.

Release both hood hold-down latches by pulling the ends outward.

CAUTION

Do not let the hood free-fall to the full-open position. To do so could cause damage to the hood or hood straps.

Using the bumper step and grab handle, slowly tilt the hood until the straps support it. See

Fig. 2.8.

To Return the Hood

Grasp the grab handle, and lift the hood a justover-center position.

As the hood goes over center, the hood damper controls the rate of descent to the operating position.

Make sure the hood is ﬂush with the cowl, then secure the hood by engaging both hood holddown 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 distribution 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, aftertreatment device, transmission, and other powertrain-related circuits. It is mounted in the engine 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 chassismounted trailer receptacles. The SAM chassis supplies 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 protection devices that will trip when a circuit is overloaded.

Refer to Chapter 25 for fuse and relay locations.

SAM Chassis

The SAM Chassis is located in the engine compartment 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 temperature 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 handling 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 permanently 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.

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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 connection 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 connection between the battery and the most of the vehicle 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 EP

A10 and newer switch.

If the CLDS is turned to the off position while the vehicle 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 exterior lighting to remain on in the event of a SAM Cab or SAM Chassis failure. The emergency power supply will cause certain exterior lamps to ﬂash (depending on if it is the SAM Cab or SAM Chassis that failed), indicating that the vehicle is disabled.

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1. MEGA Fuse Junction Block

2. Main Ground Junction Block

Fig. 3.2, EPA07 MEGA Fuse Junction Block

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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 become unresponsive but the engine will remain running until it is turned off.

When the ignition is in the ON position, the emergency 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 disconnect 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) feature protects the batteries from excessive discharge by disconnecting certain circuits from battery power supply. This allows the batteries to maintain acceptable charge to restart the vehicle.

When battery voltage drops below a predetermined value, loads designated as comfort loads (priority

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

PLVD allows the driver to continue using critical loads, while noncritical loads are temporarily unavailable. Calculations for disconnecting loads are based on battery voltage, ignition switch status, and engine rpm. Also, a time delay is implemented for the shutdown 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 comfort,

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

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1. Circuit Breaker Removal Tool

2. Self-Resetting Circuit Breaker

Fig. 3.5, Self-Resetting Circuit Breaker Removal

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Fig. 3.6, Cab Load Disconnect Switch, EPA07

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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 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 Optimized 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 ........................................................... 4.1

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

Instrumentation Control Units

The instrumentation control unit (ICU) provides the driver with engine and vehicle information. It is comprised of standard and optional gauges, an audible warning, a driver message center, and a lightbar containing warning and indicator lamps (also known as telltales). Warning and indicator lamps illuminate in red (danger), amber (caution), green (status advisory), 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 additional 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 selfcheck. See Fig. 4.4. Observing the ignition sequence is a good way to ensure the ICU is functioning properly.

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

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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 vehicle 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 parking 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.

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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.

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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 (danger), amber (caution), green (status advisory), or blue (high-beam headlights active).

IMPORTANT: Depending upon local jurisdictional 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

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