Freightliner Columbia User Manual

Page 1

Foreword

Introduction

This manual provides information needed to operate and understand the vehicle and its components. More detailed information is contained in the

Warranty Information for North America

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.

Owner’s

booklet, and

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.).

dination, 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.

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 coor-

STI-405-2 (10/11)

A24-01034-000

Printed in U.S.A.

Page 2

Foreword

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.com and www.FreightlinerTrucks.com.

Page 3

Contents

Chapter Page

Introduction, Environmental Concerns and Recommendations, Event Data Recorder, Customer Assistance Center, Reporting

Safety Defects ..................................................... Foreword

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

2 Instruments and Controls Identiﬁcation ....................................... 2.1

3 Vehicle Access .......................................................... 3.1

4 Heater and Air Conditioner ................................................. 4.1

5 Seats and Seat Belts ..................................................... 5.1

6 Steering and Brake Systems ............................................... 6.1

7 Engines and Clutches .................................................... 7.1

8 Transmissions ........................................................... 8.1

9 Rear Axles ............................................................. 9.1

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

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

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

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

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

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

Page 4

Vehicle Identiﬁcation

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

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

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

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

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

Page 5

Vehicle Identiﬁcation

Vehicle Speciﬁcation Decal

The vehicle speciﬁcation decal lists the vehicle model, identiﬁcation number, and major component models. It also recaps the major assemblies and installations shown on the chassis speciﬁcation sheet. One copy of the speciﬁcation decal is attached to the inside of the sliding storage/waste drawer; another copy is inside the rear cover of the

Information for North America

of the decal is shown in Fig. 1.1.

COMPONENT INFORMATION

MANUFACTURED BY MODEL

VEHICLE ID NO. DATE OF MFR

ENGINE MODEL TRANS MODEL MAIN FRONT AXLE MODEL REAR AXLE MODEL

IMRON PAINT−CAB CAB COLOR A: WHITE (4775)

PAINT MFR

CAB COLOR B: BROWN (3295)

PAINT NO.

CAB COLOR C: BROWN (29607) CAB COLOR D: DARK BROWN (7444)

11/21/96

Fig. 1.1, Vehicle Speciﬁcation Decal (U.S.-built vehicle

shown)

Owner’s Warranty

booklet. An illustration

USE VEHICLE ID NO. WHEN ORDERING PARTS

WHEELBASE ENGINE NO. TRANS NO. FRT AXLE NO. REAR AXLE NO. REAR AXLE NO. RATIO

FOR COMPLETE PAINT INFORMATION SEE VEHICLE SPECIFICATION SHEET

PART NO. 24−00273−010

f080021

11/21/96

f080053

1. Date of Manufacture: by month and year

2. Gross Vehicle Weight Rating: developed by taking the sum of all the vehicle’s gross axle ratings

3. Gross Axle Weight Ratings: developed by considering each component in an axle system including suspension, axle, wheels, and tires - and using the lowest component capacity as the value for the system

Fig. 1.2, Certiﬁcation Label, U.S.

NOTE: Labels shown in this chapter are examples only. Actual speciﬁcations may vary from vehicle to vehicle.

Federal Motor Vehicle Safety Standard (FMVSS) Labels

NOTE: Due to the variety of FMVSS certiﬁcation requirements, not all of the labels shown will apply to your vehicle.

Tractors with or without ﬁfth wheels purchased in the U.S. are certiﬁed by means of a certiﬁcation label (Fig. 1.2) and the tire and rim labels. These labels are attached to the left rear door post, as shown in

Fig. 1.3.

If purchased for service in the U.S., trucks built without a cargo body have a certiﬁcation label (Fig. 1.4) attached to the left rear door post. See Fig. 1.3.In addition, after completion of the vehicle, a certiﬁcation label similar to that shown in Fig. 1.2 must be attached by the ﬁnal-stage manufacturer. This label will be located on the left rear door post and certiﬁes

11/01/95

f601086

1. Tire and Rim Labels 2. Certiﬁcation Label

Fig. 1.3, Labels Location

09/28/98

f080023

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

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

1.1

Page 6

Vehicle Identiﬁcation

Canadian Motor Vehicle Safety Standard (CMVSS) Labels

In Canada, tractors with ﬁfth wheels are certiﬁed by means of a "Statement of Compliance" label and the Canadian National Safety Mark (Fig. 1.5), which are attached to the left rear door post. In addition, tire and rim labels (Fig. 1.6) are also attached to the left rear door post.

f08002410/10/2006

Fig. 1.5, Canadian National Safety Mark

VEHICLE ID NO. DATE OF MFR GVWR

TIRES AND RIMS LISTED ARE NOT NECESSARILY THOSE INSTALLED ON THE VEHICLE.

10/31/95

FRONT AXLE FIRST INTERMEDIATE AXLE SECOND INTERMEDIATE AXLE THIRD INTERMEDIATE AXLE REAR AXLE

1. Date of Manufacture: by month and year

2. Gross Vehicle Weight Rating: developed by taking the sum of all the vehicle’s gross axle ratings

3. Gross Axle Weight Ratings: developed by considering each component in an axle system — including suspension, axle, wheels, and tires — and using the lowest component capacity as the value for the system

Fig. 1.6, Tire and Rim Label

If purchased for service in Canada, trucks built without a cargo body and tractors built without a ﬁfth wheel are certiﬁed by a "Statement of Compliance" label, similar to Fig. 1.2. This label must be attached by the ﬁnal-stage manufacturer after completion of the vehicle. The label is located on the left rear door post, and certiﬁes that the vehicle conforms to all applicable CMVSS regulations in effect on the date of completion.

GAWR TIRES RIMS PSI COLD

24−00273−040

f080054

Tire and Rim Labels

Tire and rim labels certify 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.

See Fig. 1.6 for U.S. and Canadian tire and rim labels.

EPA Emission Control

Vehicle Noise Emission Control Label

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

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.

10/06/98

VEHICLE NOISE EMISSION CONTROL INFORMATION

DATE OF MANUFACTURE

Fig. 1.7, Vehicle Noise Emission Control Label

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.

EPA07 Exhaust Emissions

To meet January 2007 emissions regulations, vehicles with engines manufactured after January 1, 2007, are equipped with an emission aftertreatment device. There is a warning label on the driver’s sunvisor, explaining important new warning indicators in the driver’s message display, that pertain to the aftertreatment system. See Fig. 1.8.

01/96

24−00273−020

f080026

1.2

Page 7

Vehicle Identiﬁcation

EXHAUST AFTERTREATMENT SYSTEM INFORMATION

INDICATOR LAMP(S)

Indicator Lamp Message(s)

Diesel Particulate Filter Condition

Required Action

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

(Solid)

Level 1 Level 3Level 2 Level 4

Filter Regeneration Recommended

Filter is reaching capacity

. .

Bring vehicle to highway speeds to allow for an Automatic Regeneration or perform a Parked Regeneration.

(Flashing) (Flashing)

Filter Regeneration Necessary

Filter is now reaching maximum capacity

Switch.

To avoid engine derate bring vehicle to highway speeds to allow for an Automatic Regeneration or perform a Parked Regeneration as soon as possible.

CHECK CHECK

Parked Regeneration Required − Engine Derate

Filter has reached maximum capacity

Vehicle must be parked and a Parked Regeneration must be performed − engine will begin derate.

(Flashing)

Parked Regeneration Required − Engine Shut Down

Filter has exceeded maximum capacity

Vehicle must be parked and a Parked Regeneration or Service Regeneration must be performed. Check engine operator’s manual for details −engine will shut down.

STOP

ARNING

HEST (High Exhaust System Temperature)

Flashing

A regeneration is in progress.

Solid

Exhaust Components and exhaust gas are at high temperature. When stationary, keep away from people and flammable materials or vapors.

See Engine Operator’s Manual for complete Regeneration Instructions.

06/29/2009

Fig. 1.8, Sunvisor Warning Label

It is a violation of federal law to alter exhaust plumbing or aftertreatment in any way that would bring the engine out of compliance with certiﬁcation requirements. (Ref: 42 U.S.C. S7522(a) (3).) It is the owner’s responsibility to maintain the vehicle so that it conforms to EPA regulations.

24−01583−000B

f080147

1.3

Page 8

Instruments and Controls

Identiﬁcation

Instrument and Control Panel ....................................................... 2.1

Instrumentation Control Unit 4 (ICU4 and ICU4-2) ....................................... 2.3

Instrumentation Control Unit 3 (ICU3 and ICU3 ’07) ...................................... 2.7

Instrumentation Control Unit 2L (ICU2L) .............................................. 2.11

Instruments ..................................................................... 2.12

Controls ........................................................................ 2.17

Collision Warning System (CWS), Eaton VORAD EVT–300, Optional ...................... 2.33

™

Lane Guidance

Roll Stability Control .............................................................. 2.39

System, Optional .................................................. 2.38

Page 9

Instruments and Controls Identiﬁcation

Instrument and Control Panel

Engine Protection—Warning and Shutdown Process

WARNING

When the red STOP engine or engine protection light 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.

The driver should be familiar with the vehicle warning system, in order to bring the vehicle to a safe stop if the engine malfunctions. If the driver doesn’t understand how the warning system works, an engine shutdown could occur, causing a safety hazard.

If the engine coolant temperature, the coolant level, the engine oil pressure, or the diesel particulate ﬁlter for the exhaust aftertreatment system, (on some engines, the engine oil temperature, or the intake air temperature also,) reach preset levels, the engine will begin a warning and shutdown process. See the engine manufacturer’s engine operation manual for your vehicle, for speciﬁc details. See the "EPA07 Aftertreatment System" information in Chapter 7 in this manual, for a description of the warning and shutdown modes associated with the exhaust aftertreatment system.

There are four customer-programmable levels for electronic engine protection: OFF, WARNING, DERATE, and SHUTDOWN (factory default).

In the engine monitoring OFF mode, the individual sensor indicator lights will illuminate if a problem exists, but no shutdown action will be started, and the event will not be recorded.

The WARNING mode warns the driver, and the engine electronics will log the event for diagnostic purposes. The amber Check Engine lamp will ﬂash, and the buzzer will sound. The amber Check Engine lamp will go out if the problem stops. See Fig. 2.1

CHECK

03/20/2008 f611000

1. Stop Engine Override Switch

2. Amber Check Engine Warning Lamp

3. Red Stop Engine Lamp

The DERATE and SHUTDOWN modes will reduce the power to the engine, then shutdown the engine, to avoid engine damage. The red Stop Engine light, (ENG PROT or SHUT DOWN for older vehicles), will illuminate when the problem is serious enough to reduce the power or speed. The engine power will ramp down, then shut down, if the problem continues.

The driver has about 30 seconds, after the red Stop Engine light illuminates, to move the vehicle safely off the road. If the vehicle cannot be moved to a safe location within that time, the engine can be restarted by turning the ignition switch to the OFF position for at least 5 seconds, then back ON, or by pushing the stop-engine-overide button if the vehicle is equipped with one. This action can be repeated until the vehicle is safely off the road. Do not operate the vehicle until the problem has been corrected.

123

Fig. 2.1, Engine Lamps

STOP

Warning and Indicator Lights

The dash lightbars have warning and indicator lights that may be lettering or icons. Up until December 31, 2006, the warning and indicator lights are a mixture of ISO icons, and lettering. Since January 2007, ISO icons are used for all standard warning and indicator lights on the dash lightbar. See the following table for a full description of the icons used.

2.1

Page 10

CHECK

STOP

Instruments and Controls Identiﬁcation

Warning and Indicator Lights

Check Engine Lamp (amber)

Stop Engine or Engine Protect Lamp (red)

High Exhaust System Temperature (HEST) Lamp (amber)

Diesel Particulate Filter (DPF) Status Lamp (amber)

Malfunction Indicator Lamp (MIL) (amber)

Indicates an undesirable engine condition is detected or recorded. If the condition gets worse, the stop engine or engine protection light will illuminate.

Indicates a serious fault that requires the engine shut down immediately. The engine ECU will reduce the maximum engine torque and speed, and, if the condition does not improve, will shut down the engine within 30 seconds of the light illuminating. The driver must 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, the engine can be restarted after turning the key to the OFF position for a few seconds.

Slow (10-second) ﬂash, indicates a regeneration is in progress, and the driver is not controlling the engine idle speed.

Steadily illuminated indicates a regeneration is in progress, with high exhaust temperatures at the outlet of the tail pipe, if the speed is below 5 mph (8 km/h). It does not signify the need for service; it only alerts the vehicle operator of high exhaust temperatures. See the engine operation manual for details.

Steadily illuminated indicates a regeneration is required. Change to a more challenging duty cycle, such as highway driving, to raise exhaust temperatures for at least 20 minutes, or perform a parked regeneration. See the engine operation manual for details.

Blinking indicates that a parked regeneration is required immediately.An engine derate and shutdown will occur. See the instructions in the manufacturer’s

manual

Indicates an engine emissions-related fault, including, but not limited to the aftertreatment system. See the engine operation manual for details.

for instructions to perform a stationary regeneration.

engine operation

Tractor ABS Lamp (amber)

Trailer ABS Lamp (amber) Indicates a fault is detected with the trailer ABS.

Left-Turn Signal (green)

Right-Turn Signal (green)

Indicates a problem with the ABS is detected. Repair the tractor ABS immediately to ensure full antilock braking capability.

Flashes on and off whenever the outside turn signal lights are ﬂashing.

2.2

Page 11

Instruments and Controls Identiﬁcation

Warning and Indicator Lights

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

BRAKE

Low Air Pressure Warning Lamp (red)

High Coolant Temperature Warning Lamp (red)

Low Engine Oil Pressure Warning Lamp (red)

Parking/Emergency Brake Lamp (BRAKE!) (red)

Fasten Seat Belt Warning Lamp (red)

Intake Heater Warning Lamp (amber)

Water in Fuel Warning Lamp (amber)

Low Battery Voltage Warning Lamp (red)

Activates with a buzzer when air pressure in the primary or secondary air reservoir falls below 64 to 76 psi (440 to 525 kPa).

Activates with a buzzer when the coolant temperature goes above a maximum level speciﬁed by the engine manufacturer (see the engine manual).

Activates with a buzzer when engine oil pressure goes below a minimum level speciﬁed by the engine manufacturer (see the engine manual).

Indicates the parking brake is engaged, or hydraulic brake ﬂuid pressure is low. A buzzer activates when the vehicle is moving over 2 mph (3 km/h) with the parking brake set.

Illuminates for 15 seconds when the ignition key is turned to the ON position.

Indicates the intake air heater is active.

Indicates that the fuel could contain water.

Indicates battery voltage is 11.9 volts or less.

CHARGE

No Charge Warning Lamp (amber) Indicates an alternator charge output failure.

Instrumentation Control Unit 4 (ICU4 and ICU4-2)

The ICU4 and ICU4-2 instrument clusters are individual-gauge clusters, with intelligent lightbars (ILB) and integrated warning and indicator lights. See

Fig. 2.2 for a typical layout of the gauges. The ICU4

is on vehicles with engines that were manufactured up until December 31, 2006, and the ICU4-2 is on vehicles with engines that were manufactured January 1, 2007 or later, that are EPA07 compliant. They can be differentiated by the ISO icons on the ICU4-2. See Fig. 2.3 and Fig. 2.4. Also, on the ICU4, the message display shows voltmeter readings.

2.3

Standard gauges are:

•

speedometer

•

engine coolant temperature

•

engine oil pressure

•

battery voltmeter

•

fuel level

Gauges with a warning light on the gauge are listed below, with an indication of how the warning light is activated:

•

engine coolant temperature (high)

•

engine oil pressure (low)

Page 12

Instruments and Controls Identiﬁcation

PSI

100

OIL

200

150

100

250

WATER

200

100

300

OIL

F 10

150

PYRO

VOLTS

PSI

TURBO

10060

PSI

0 160

AIR

11 12

MPH

110

30 10

130

km/h

1/2

FUEL

190

270

110

350

TRANS

RPM

X 100

PSI

0 160

200

F 100

AXLE

200

F 100

AXLE

10060

AIR

300

04/01/2004 f610706

1. Engine Oil Pressure Gauge

2. Engine Coolant Temperature Gauge

3. Engine Oil Temperature Gauge

4. Battery Voltage Gauge

5. Pyrometer

6. Turbo Boost Air Pressure Gauge

7. Dash Message Center

8. Mode/Reset Switch

9. Tachometer

10. Speedometer

11. Primary Air Pressure Gauge

12. Secondary Air Pressure Gauge

13. Fuel Level Gauge

14. Axle Temperature Gauge

15. Transmission Oil Temperature Gauge

16. Axle Temperature Gauge

Fig. 2.2, ICU4/ICU4-2 Instrument Cluster (ICU4 shown)

2122

06/22/2004

1. Left-Turn Signal

2. Check Engine Indicator

3. Optional Indicator

4. Engine Protection Indicator

5. Intake Heater Indicator

6. Air Filter Indicator

7. Water in Fuel Indicator

8. Message Display Screen

910

9. Mode/Reset Switch

10. Tractor ABS Indicator

11. Message Indicator

17. Low Air System Pressure Warning

18. High-Beam Indicator

19. Parking/Emergency Brake

12. Trailer ABS Indicator

13. Wheel Spin Indicator

14. Check Transmission Indicator

15. Optimized Idle Indicator

20. Fasten Seat Belt Warning

21. No Charge Indicator (alternator)

22. Low Vehicle Battery Voltage

16. Right-Turn Signal

Fig. 2.3, ICU4 Dash Message Center (typical), Pre-2007

Warning

12 13

1718

f610707

2.4

Page 13

Instruments and Controls Identiﬁcation

09/05/2006

1. Left-Turn Signal

2. Check Engine Indicator

3. Optional Indicator

4. Stop Engine Warning

5. High Exhaust System

6. Diesel Particulate Filter Status

•

CHECK STOP

1819

Temperature (HEST) Warning Lamp (DPF)

Fig. 2.4, ICU4-2 Dash Message Center (typical), EPA07 Compliant

fuel level (low) transmission oil temperature (high)

7. Message Display Screen

8. Mode/Reset Switch

9. Tractor ABS Indicator

10. Trailer ABS Indicator

11. Check Transmission Indicator

12. Optimized Idle Indicator

13. Right-Turn Signal

Other available gauges include:

•

tachometer

•

engine oil temperature

•

transmission oil temperature

•

axle temperature; forward-rear, and rear-rear

•

ammeter

•

air pressure; primary, secondary, application, and suspension

•

pyrometer

•

turbo boost

Buzzer and Chime

A buzzer sounds for three seconds during the selftest at start-up, and when the following conditions exist:

•

low air pressure

•

low oil pressure

•

high coolant temperature

14. Low Air System Pressure Warning

15. High-Beam Indicator

16. Parking/Emergency Brake Warning

17. Fasten Seat Belt Warning

18. Malfunction Indicator Light (MIL)

19. Low Vehicle Battery Voltage

•

the parking brake is applied and the vehicle is

1415

f610817

moving at a speed of at least 2 mph (3 km/h)

A chime sounds when the parking brake is off and the door is open, or when the headlights are on and the door is open.

Ignition Sequence

When the ignition key is turned on, the ICU4/ICU4-2 begins a self-test. During this process, all gauges controlled by the cluster sweep to full scale and return, the buzzer sounds for three seconds, the fasten seat belt warning light illuminates for 15 seconds, and the battery voltage, low air pressure, and parking brake warning lights illuminate then turn off. Then the software revision level of the ICU4/ICU4-2 is displayed, followed by active faults, if any, then the odometer display.

Mode/Reset Switch Functions

The mode/reset switch controls the display of the odometer, trip miles and hours, engine miles and hours, service cycle screens, fault code screens, and oil level screens (on some Mercedes-Benz engines; if equipped and enabled).

Push the switch to scroll through mode selections, and hold the switch to reset trip miles or hours while they are displayed. See Fig. 2.5. With the parking

2.5

Page 14

Instruments and Controls Identiﬁcation

With park brake off

06/01/2004

Default Odometer Display Screen

Push

Hold

Push

Hold

Push

With park brake on

If "SERVICE" is displayed Service Cycle screens are enabled and either "MI" or "HOURS" is also displayed.

On some vehicles "OIL LVL" appears in the top row of the display, if equipped and enabled.

Fig. 2.5, ICU4/ICU4-2 Mode/Reset Switch Basic Functions

To Reset Trip Miles

To Reset Trip Hours

Push

Hold

Go to the Diagnostic

Hold

For setup screens.

and Engine Display Screens figure.

Go to the Diagnostic and Engine Display Screens figure.

f040693

brake released, only the odometer, trip miles, and trip hours can be accessed. Park the vehicle and set the parking brake to access additional screen functions. See Fig. 2.6.

Trip Miles, Trip Hours

When the odometer is displayed, push the mode/ reset switch once to display trip distance. Push it again to display trip hours. Both numbers are calculated from the last time the value was reset. Hold the switch when each number is displayed to reset trip miles or hours to zero.

Diagnostic Screens

During vehicle start-up, with the parking brake on, the ICU4 or ICU4-2 display any active fault codes for three seconds each until the parking brake is released. With active fault codes on display, push the mode/reset switch once to display the initial diagnostic screen (DIAG) and the total number of active faults. If service cycle screens are enabled, and ser-

vice distance or time has been exceeded, the text SERVICE will be displayed with the other fault messages. This will inform the vehicle operator that the service interval has been exceeded and vehicle service is required.

Speciﬁc fault code information can be displayed only with the vehicle parked and the parking brake set. If the odometer screen is displayed, push the mode/ reset switch until the DIAG screen is displayed, then hold the switch to enter the fault code screen sequence. Once the initial fault code is displayed, push the switch to cycle through additional diagnostic codes relating to the ﬁrst fault. Hold the switch to display additional faults or return to the DIAG screen. If service cycle screens are enabled, service interval information is displayed before fault code information is displayed.

If the word SERVICE appears on the DIAG message display screen, service cycle screens are enabled. Hold the mode/reset switch at the DIAG screen to

2.6

Page 15

Instruments and Controls Identiﬁcation

If Service Cycle screens not enabled

Push

Hold

Push

Hold

Service Cycle Screens (if enabled): Holding the button displays Service Miles or Service Hours, remaining or exceeded, to service target. If numbers flash, the service target is exceeded and service is overdue. Also, the "SERVICE" screen will be displayed as an active Fault Code when service miles or hours are ex− ceeded.

Then

Hold

Push

Hold

For additional faults, if any, or return to DIAG screen.

To display total engine miles.

Hold

To display tolal engine hours.

Hold

If "SERVICE" is displayed Service Cycle screens are enabled and either "MI" or "HOURS" is also displayed.

04/28/2004 f040695

On some vehicles "OIL LVL" appears in the top row of the display, if equipped and enabled.

To display OIL LVL screens (if equipped and enabled).

Hold

To display specific OIL LVL amount over or under full.

Push

Fig. 2.6, ICU4/ICU4-2 Mode/Reset Switch Diagnostic and Engine Display Screens

display miles or hours remaining until the next scheduled service. If MI appears on the DIAG screen, service miles are enabled; if HOURS appears on the screen, service hours are enabled. Either service miles or hours can be enabled, but not both. If service miles or hours has been exceeded, the number ﬂashes to indicate service is overdue.

Engine Screens

Push the mode/reset switch once following the DIAG screen and the word ENGINE is displayed in the lower right corner of the digital display. Hold the switch to display total engine miles. Hold it again to display total engine hours. If OIL LVL is displayed earlier with ENGINE (only on vehicles with Mercedes-Benz engines; if equipped and enabled) hold the switch again to access oil level screens.

Instrumentation Control Unit 3 (ICU3 and ICU3 ’07)

Figure 2.7 shows the instrument panel for Columbia

vehicles equipped with the ICU3 and ICU3 ’07. The ICU3 is on vehicles with engines that were manufactured up until December 31, 2006, and the ICU3 ’07 is on vehicles with engines that were manufactured January 1, 2007 or later. They can be differentiated by the ISO icons used on the ICU3 ’07.

The ICU3 and ICU3 ’07 electronic dashboards can accept information from the various sensors installed on the vehicle and feed it to electronic gauges. Only air gauges operate mechanically.

There can be up to eight gauges on the driver’s instrument panel (six electronic and two mechanical). The ICU3 or ICU3 ’07 can not drive gauges located on the auxiliary instrument panel.

The dash message center is the heart of the ICU3 and ICU3 ’07. It has a set of warning and indicator

2.7

Page 16

Instruments and Controls Identiﬁcation

1/2

FUEL

100

PSI

150

AIR

100

PSI

150

AIR

f610205b06/02/99

™

System is

PSI

100

OIL

200

150

F°

100

250

WATER

225

F°

100

350

TRANS

RPM X100

110

130

km/h

MPH

1. Transmission Temperature Gauge

2. Water Temperature Gauge

3. Engine Oil Pressure Gauge

4. Dash Message Center

5. Fuel Gauge

6. Primary Air Pressure Gauge

7. Optional Mode/Reset Push Button

8. Secondary Air Pressure Gauge

9. Speedometer

10. Tachometer

Fig. 2.7, ICU3/ICU3 ’07 Gauge Layout (ICU3 shown)

lights, and a driver display screen. The driver display screen is a one-line by seven-character liquid crystal display (LCD) that normally shows odometer readings.

There are four rows of lights in the dash message center. Lights installed in the top row are optional and their positions may vary. The lights in the bottom three rows are installed in ﬁxed positions on all vehicles. Most are standard, but a few are optional. See Fig. 2.8 and Fig. 2.9.

NOTE: The functions of the ABS/ATC warning lights are explained under "Meritor WABCO Antilock Braking System (ABS)", later in this chapter.

NOTE: The amber LANE SRCHNG warning light for the optional Lane Guidance explained later in this chapter.

Buzzer

A buzzer sounds for three seconds during the selftest at start-up, and when the following conditions exist:

•

low air pressure

•

low oil pressure

•

high coolant temperature

•

the parking brake is applied and the vehicle is moving at a speed of at least 2 mph (3 km/h)

ICU3/ICU3 ’07 Ignition Sequence

If the headlights are turned on, the screen displays the odometer and waits for the ignition to be turned on.

When the ignition is turned on, all the electronic gauges complete a full sweep of their dials, the warning and indicator lights light up, and the buzzer sounds for three seconds.

NOTE: The air gauges do not sweep.

The following lights illuminate during the ignition sequence:

•

Fasten Seat Belt Warning

•

Low Battery Voltage Warning

•

High Coolant Temperature Warning

•

Low Engine Oil Pressure Warning

•

Low Air Pressure Warning

•

Parking Brake On Indicator

•

All engine warning lights, including engine protection, check engine, and (Cummins only) stop engine

•

All ABS warning lights, including wheel spin, tractor ABS, and (if installed) trailer ABS

See Fig. 2.10 for the ICU3/ICU3 ’07 ignition sequence.

NOTE: Although the engine and ABS warning lights illuminate during the ignition sequence, they are not controlled by the ICU, but by their own system ECU (electronic control unit).

When the ignition switch has been turned on, the ICU3 performs a self-test, looking for active faults. During the ﬁrst half of the self-test, all segments of the display illuminate as follows: 888888.8. The ICU3 voltmeter display also illuminates, but with the value

18.8. During the second half of the self-test, the software revision level is displayed.

2.8

Page 17

Instruments and Controls Identiﬁcation

11/10/2006

1. Stop Engine Warning

2. Engine Fan On Indicator (optional)

3. Do Not Shift Indicator (optional)

4. ECAS Failure Warning (optional)

5. ECAS Transfer Indicator (optional)

6. Low Washer Fluid Indicator (optional)

7. Wheel Spin Indicator (optional)

8. EBS Warning (optional)

9. Water In Fuel Indicator (optional)

10. Check Engine Indicator

11. Engine Protection Warning (optional)

13 14

26 27

19. Parking Brake On Warning

20. Recirculated Air Indicator

12. No Charge Indicator (optional)

13. Tractor ABS Warning

14. Transmission Temperature Warning (optional)

15. Trailer ABS Warning

16. Low Oil Pressure Warning

17. High Coolant Temperature Warning

21. Air Restriction Indicator (optional)

22. Left-Turn Signal

23. Low Battery Voltage Warning

24. Dash Driver Display Screen

25. High Beams On Indicator

26. Low Air Pressure Warning

27. Right-Turn Signal

18. Fasten Seat Belt Warning

Fig. 2.8, ICU3 Dash Message Center, Pre-2007

f610231a

(optional)

Status Lamp Temperature (HEST) Warning

08/31/2006

1. Optional Indicator

2. Check Engine Indicator

3. Stop Engine Indicator

4. Malfunction Indicator Light (MIL)

5. Tractor ABS Indicator

6. Transmission Temperature Indicator

7. Trailer ABS Indicator

OPT OPT OPT OPT OPT OPT OPT OPT OPT

8. Low Oil Pressure Warning

9. High Coolant Temperature

10. Fasten Seat Belt Warning

11. Parking Brake On Warning

12. Diesel Particulate Filter (DPF)

13. High Exhaust System

Fig. 2.9, ICU3 ’07 Dash Message Center, EPA07 Compliant

If there are no active faults, the ICU3/ICU3 ’07 displays the odometer. However, if the ICU3/ICU3 ’07

ABS

BRAKE

ABS

18 19

f610836

14. Left-Turn Signal

15. Low Battery Voltage Warning

16. Driver Display Screen

17. High Beams On Indicator

18. Low Air Pressure Warning

19. Right-Turn Signal

has received active fault codes from other devices, it displays them one after the other until the parking

2.9

Page 18

Instruments and Controls Identiﬁcation

HEADLIGHTS ON

888888.8

ODOMETER SCREEN

IF NO FAULTS WERE DETECTED

123456.7

12.3 VOLTS

PARK BRAKE

RELEASED − MOVING

123456.7

02/14/2003

Fig. 2.10, ICU3/ICU3 ’07 Ignition Sequence

12.3 VOLTS

brake is released or the ignition switch is turned off. Once the parking brake is released, the ICU3/ICU3 ’07 displays the odometer again.

Mode/Reset Switch

The mode/reset switch (Fig. 2.11) is located on the right side of the instrument cluster. The mode/reset switch is used to scroll through the displays on the message display screen, and to reset the trip distance and trip hours values to zero.

PUSH− MODE

HOLD−

RESET

09/25/99

Fig. 2.11, ICU3/ICU3 ’07 Mode/Reset Switch

f610340

POWER ON

IGNITION ON

ICU INITIALIZES ELECTRONIC GAUGE NEEDLES SWEEP, WARNING/INDICATOR LIGHTS COME ON, BUZZER SOUNDS

IF FAULT DETECTED

ABS 136

FAULT CODE SCREEN

RELEASE PARK BRAKE

f040420a

See Fig. 2.12 for the state diagram for the LCD display cycle.

NOTE: The systems diagnostics test is used by trained personnel to retrieve fault codes and other diagnostic information pertaining to the vehicle.

When the odometer reading is displayed and the parking brake is applied:

•

Press the mode/reset switch once and the trip distance will display.

•

Press the mode/reset switch a second time and the trip hours (engine hours) will display.

•

Press the mode/reset switch a third time and the SELECT screen and the current units, MI or KM, will display.

•

Press the mode/reset switch a fourth time to return to the odometer reading.

To reset trip miles and/or trip hours to zero, press the mode/reset switch for 1 second or longer. To toggle between MI (miles) and KM (kilometers), press the mode/reset switch while in the SELECT screen.

2.10

Page 19

Instruments and Controls Identiﬁcation

123456.7

12.3 VOLTS

Push

123456.7

TRIP MI

12.3 VOLTS

Push

123456.7

TRIP HOURS

12.3 VOLTS

Push

SELECt MI

Push

dIAG

MI HOURS

Push Push

03/26/2004 f040636a

Default Odometer Dispay Screen

Hold

To Reset Trip Miles

Hold

To Reset Trip Hours

To Toggle between Units

Hold

MI<−−−−>KM

Hold

Dispay Diagnostics

n = Number of Active Fault Codes

MI = CYCLE Miles Enabled HOURS = Cycle Hours Enabled

*Lo

**MI **HOURS **no

Push

CLEAr

123456.7 MI

123456.7

EnG oIL

SEtUP

Hold

Clear Defaults

To Dispay Total Engine Miles EC = Engine Control

To Dispay Total Engine Hours

HOURS

EC = Engine Control

Hold

Dispay Oil Level

*Lo = Oil Level Low

HI = Oil Level High Blank = Oil Level OK

− − = No Message

Dispay Service Interval

Hold

Cycle Screens

**MI = CYCLE Miles Active Mode

**HOURS = CYCLE Hours Active Mode

**no = Service CYCLE Inactive

Fig. 2.12, ICU3/ICU3 ’07 Mode Reset LCD Display Cycle

Instrumentation Control Unit 2L (ICU2L)

The ICU2L is a basic electronic dashboard. It can accept information from the various sensors installed on the vehicle and feed it to electronic gauges. Only air gauges operate mechanically.

There can be up to 14 removable gauges on the driver’s instrument panel (11 electronic, one electromechanical, and two mechanical). The ICU2L can not drive gauges located on the auxiliary instrument panel.

The dash message center is the heart of the ICU2L. It has a set of 18 warning and indicator lights, and a message display screen. The message display screen is a one-line by six-character vacuum ﬂuorescent display.

Warning and Indicator Lights

There can be up to 18 warning and indicator lights installed in the ICU2L. See Fig. 2.13.

WARNING

When the red STOP 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.

CAUTION

Because operating the engine when the red engine protection light is illuminated can lead to

2.11

Page 20

Instruments and Controls Identiﬁcation

06/26/98

Typical installation shown. Location and function of optional lights may vary.

1. Left-Turn Indicator

2. Engine Protection Warning and Indicator

3. Check Eng. Indicator

4. Stop Engine Warning

5. High Coolant Temp. Warning (optional)

6. Low Oil Pressure Warning (optional)

7. Optional Indicator 3

8. Optional Indicator 2

9. Optional Indicator 1

10. Message Display Screen

5 6

Fig. 2.13, Dash Message Center, ICU2L

11. High-Beam Indicator

12. Low Air Warning

13. Right-Turn Indicator

14. Trailer ABS Warning

15. Tractor ABS Warning

16. Wheel Spin Warning

17. Park Brake On Indicator

18. Recirc Air Warning (optional)

19. Optional Indicator 4

11 12 13

f601458

severe engine damage, the driver must move the vehicle to a safe location as quickly as possible.

NOTE: The functions of the ABS/ATC warning lights are explained under "Meritor WABCO Antilock Braking System (ABS)", later in this chapter.

NOTE: The amber LANE SRCHNG warning

™

light for the optional Lane Guidance

System is

explained later in this chapter.

Ignition Sequence

If the headlights are turned on, the screen displays the odometer and waits for the ignition to be turned on. See Fig. 2.14.

When the ignition is turned on, all the electronic gauges complete a full sweep of their dials, the warning and indicator lights light up, and the buzzer sounds for three seconds.

NOTE: The air gauges do not sweep.

The following lights illuminate during the ignition sequence:

•

Fasten Seat Belt Warning

•

Low Battery Voltage Warning

•

High Coolant Temperature Warning

•

Low Engine Oil Pressure Warning

•

Low Air Pressure Warning

•

Parking Brake On Indicator

•

All engine warning lights, including engine protection, check engine, and (Cummins only) stop engine

•

All ABS warning lights, including wheel spin, tractor ABS, and (if installed) trailer ABS

NOTE: Although the engine and ABS warning lights illuminate during the ignition sequence, they are not controlled by the ICU but by their own system ECU (electronic control unit).

When the ignition switch has been turned on, the ICU performs a self-test, looking for active faults. During the ﬁrst half of the self-test, all segments of the display illuminate as follows: 888888.8. During the second half of the self-test, the software revision level is displayed.

Instruments

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 appropriate rpm range. For low idle and rated rpm, see the engine identiﬁcation plate. The green band on the tachometer indicates the best fuel economy range. The yellow band indicates lower fuel economy, the orange band indicates much lower fuel economy, and the red band indicates poor fuel economy. See Fig. 2.15.

Speedometer

The speedometer registers speed in both miles per hour (mph) and kilometers per hour (km/h). See

Fig. 2.15.

2.12

Page 21

Instruments and Controls Identiﬁcation

10/03/97

123456

ODOMETER SCREEN

PARK BRAKE

RELEASED − MOVING

HEADLIGHTS ON

IF NO FAULTS

WERE DETECTED

123456

POWER ON

IGNITION ON

ICU PERFORMS SELFTEST:

ELECTRONIC GAUGE NEEDLES SWEEP, WARNING/INDICATOR LIGHTS COME ON, BUZZER SOUNDS

IF FAULT DETECTED

A/C 190

FAULT CODE SCREEN

RELEASE PARK BRAKE

f040395

Fig. 2.14, ICU2L Ignition Sequence

1. Tachometer 2. Speedometer

Fig. 2.15, Instrument Panel, Level II (center)

Engine Oil Pressure Gauge

The oil pressure gauge should read as shown in

Table 2.1. See Fig. 2.16.

CAUTION

A sudden decrease or absence of oil pressure may indicate mechanical 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.

Oil Pressure

f60099309/25/95

Engine Model

Caterpillar C–10 10–20 (69–138) 30–45 (207–310) Caterpillar C–12 10–20 (69–138) 30–45 (207–310) Caterpillar 3406E 15 (100) min. 40 (275) min.

At Idle Speed:

psi (kPa)

At Rated RPM:

psi (kPa)

2.13

Page 22

Instruments and Controls Identiﬁcation

Oil Pressure

Engine Model

Cummins ISX 10 (69) min. 35–45 (241–310) Cummins ISM 10 (69) min. 35–45 (241–310) Cummins N14 10 (69) min. 35–45 (241–310) Detroit Diesel S60 12 (83) min. 50 (345) min. MBE4000 7 (50) 36 (250) min.

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 2.1, Oil Pressure Speciﬁcations

At Idle Speed:

psi (kPa)

At Rated RPM:

psi (kPa)

Maximum Coolant Temperature

Engine Make Temperature: °F (°C)

Caterpillar 215 (101) Cummins 220 (104) Detroit Diesel 215 (101) Mercedes-Benz 221 (105)

Table 2.2, Maximum Coolant Temperature

Engine Oil Temperature Gauge, Optional

During normal operation, the engine oil temperature gauge should read:

•

190 to 220°F (88 to 104°C) for Caterpillar engines;

•

180 to 225°F (82 to 107°C) for Cummins engines;

•

200 to 230°F (93 to 110°C) for Detroit Diesel engines;

•

181 to 203°F (83 to 95°C) for Mercedes-Benz diesel engines.

Under heavy loads, such as when climbing steep grades, temperatures that exceed the normal oil temperature range for a short period are not unusual. See Fig. 2.16.

1. Engine Oil Pressure Gauge

2. Coolant Temperature Gauge

3. Engine Oil Temperature Gauge (optional)

4. Voltmeter

5. Turbocharger Boost Pressure Gauge (optional)

6. Pyrometer (optional)

Fig. 2.16, Instrument Panel Gauges (left side)

f60112602/12/96

Coolant Temperature Gauge

During normal engine operation, the coolant temperature gauge should read 175 to 195°F (79 to 91°C). See Fig. 2.16. If the temperature remains below 160°F (71°C) or exceeds the maximum temperature shown in Table 2.2, inspect the cooling sys- tem to determine the cause. See the

Workshop Manual

for troubleshooting and repair pro-

Columbia

cedures.

CAUTION

A sudden increase in oil temperature 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 engine until the cause has been determined and corrected.

Voltmeter

The voltmeter indicates the vehicle charging system voltage when the engine is running and the battery voltage when the engine is stopped. By monitoring the voltmeter, the driver can be aware of potential charging system problems and have them ﬁxed before the batteries discharge enough to create starting difficulties. See Fig. 2.16.

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

2.14

Page 23

Instruments and Controls Identiﬁcation

the engine is stopped. A completely discharged battery will produce only about 12.0 volts. The voltmeter will indicate lower voltage as the vehicle is being started or when electrical devices in the vehicle are being used.

If the voltmeter shows an undercharged or overcharged condition for an extended period, have the charging system and batteries checked at a repair facility.

NOTE: Some vehicles may be equipped with a digital display voltmeter integrated into the message display screen, instead of a voltmeter gauge.

Turbocharger Boost Pressure Gauge, Optional

A turbocharger boost pressure gauge measures the pressure in the intake manifold, in excess of atmospheric pressure, being created by the turbocharger. See Fig. 2.16.

Pyrometer, Optional

A pyrometer registers the exhaust temperature near the turbocharger. See Fig. 2.16. Normal exhaust temperatures are listed in Table 2.3.

Variations in engine load can cause exhaust temperatures to vary. If the pyrometer reading shows that exhaust temperature exceeds normal, reduce fuel to the engine until the exhaust temperature is reduced. Shift to a lower gear if the engine is overloaded.

Exhaust Temperature

Engine Model

Caterpillar C–10, C–12 935–1290 (500–700) Caterpillar 3406E 900–1100 (480–595) Cummins M11 800–1000 (430–540) Cummins N14 750–950 (400–510) Detroit Diesel S60 700–950 (370–510) MBE4000 750–1022 (400–550)

Table 2.3, Typical Pyrometer Exhaust Temperature

Readings

Exhaust Temperature:

°F (°C)

Primary and Secondary Air Pressure Gauges

Air pressure gauges register the pressure in the primary and secondary air systems. See Fig. 2.17. Normal pressure, with the engine running, is 100 to 120 psi (689 to 827 kPa) in both systems. A low-airpressure warning light and buzzer, connected to both the primary and secondary systems, activate when air pressure in either system drops below a minimum pressure of 64 to 76 psi (441 to 524 kPa). When the engine is started, the warning light and buzzer remain on until air pressure in both systems exceeds minimum pressure.

02/12/96

1. Primary Air Pressure Gauge

2. Secondary Air Pressure Gauge

3. Fuel Gauge

4. Transmission Oil Temperature Gauge (optional)

5. Forward Axle Oil Temperature Gauge (optional)

6. Rear Axle Oil Temperature Gauge (optional)

Fig. 2.17, Instrument Panel Gauges (right side)

f601127

Fuel Gauge

The fuel gauge indicates the level of fuel in the fuel tank(s). See Fig. 2.17. If equipped with a second (optional) fuel gauge, each fuel tank level is indicated on a separate gauge.

Transmission Oil Temperature Gauge, Optional

2.15

During normal operation, the transmission oil temperature gauge reading should not exceed 250°F

Page 24

Instruments and Controls Identiﬁcation

(121°C) for Eaton®Fuller®transmissions. See

Fig. 2.17.

CAUTION

Forward and Rear Axle Oil Temperature Gauges, Optional

During normal operation, forward and rear axle oil temperature gauges should read between:

•

160 and 220°F (71 and 104°C) for Meritor drive axles;

•

180 and 200°F (82 and 93°C) for Dana Spicer drive axles.

Under heavy loads, such as when climbing steep grades, temperatures up to a maximum of 250°F (121°C) are not unusual. See Fig. 2.17.

™

vice inH

replaced.

,inTable 2.4, the air cleaner needs to be

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

Intake-Air Restriction Indicator

An intake-air restriction indicator measures the vacuum on the engine side of the air cleaner at the air cleaner outlet. See Fig. 2.18. If the yellow signal stays locked at or above the values shown in

Table 2.4 after the engine is shut down, the air

cleaner needs to be serviced. The indicator then needs to be reset by pressing the yellow button.

Intake-Air Restriction Vacuum Readings

Engine Make

Cummins 12 25 Detroit Diesel 12 20

Caterpillar 15 25 Mercedes-Benz 10 22

Turbocharged engines must be checked at full load and governed en-

gine speed.

Table 2.4, Intake-Air Restriction Vacuum Readings

Initial inH2O

Service inH

CAUTION

Application Air Pressure Gauge, Optional

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 register air pressure until the foot brake pedal is depressed or the trailer hand brake is applied.

Intake-Air Restriction Gauge, Optional

An intake-air restriction gauge measures the vacuum on the engine side of the air cleaner at the air cleaner outlet. Vacuum is measured in inH of water). When the vacuum reading in normal operation equals the applicable level shown under

O (inches

Ser-

01/18/95

Fig. 2.18, Intake-Air Restriction Indicator

f600148a

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

Ammeter, Optional

An ammeter measures current ﬂowing to and from the battery. When the batteries are being charged, the meter needle moves to the plus side of the gauge; when the batteries are being discharged, the

2.16

Page 25

Instruments and Controls Identiﬁcation

needle moves to the minus side. A consistent negative reading when the engine is running indicates a possible problem with the charging system.

Analog Clock

The analog clock features electronic setting. Do not pull the set knob. The time can be set either forward (turn knob to the right) or backward (turn the knob to the left). A slight turn of the knob either right or left will change the setting of the clock one minute at a time. Holding the knob to either the right or the left will allow accelerated sweeping of the hands for setting the hour.

Digital Clock, Optional

The digital clock has black characters on a constantly backlighted green display, with a brightness that automatically adjusts for day or night. The clock has a 24-hour alarm with a three-minute snooze feature.

To set the time of day:

1.1

Push the run/set (lower) switch to the right (TIME-SET position).

NOTE: When the hour setting is for a time between noon and midnight, the small letters PM will appear in the lower left corner of the display; no PM indicates an a.m. setting.

1.2

Advance the hour setting to the correct number by pushing and releasing the hour button as many times as needed. Or if the button is pressed and held in for longer than two seconds, the numbers will continue to advance until the button is released.

1.3

Advance the minute setting by repeatedly pushing, or pushing and holding the minute button as needed.

1.4

Push the run/set switch to the middle (RUN) position.

To set the alarm time:

2.1

Push the run/set switch to the left (ALARM-SET position).

2.2

Set the alarm time by using the same procedure that you used to set the time of day. Remember to set the hour for a.m. (no letters in the corner of the display) or p.m. as desired.

2.3

Return the run/set switch to the middle (RUN) position. The readout will return to the time-of-day setting.

To operate the alarm:

3.1

With the alarm time set, push the alarm (upper) switch to the left. An alarm symbol, and the letters AL, will appear in the upper left corner of the display when the alarm is on.

3.2

When the displayed time of day coincides with the alarm time, the alarm will sound. If the SNOOZ button is not pushed or the alarm switch is not moved, the alarm will automatically stop sounding after one minute and will not sound again for 24 hours.

3.3

If desired, press the SNOOZ button while the alarm is sounding to shut the alarm off for three minutes. The alarm symbol will ﬂash in the display when the button is pushed and will continue to ﬂash until the alarm switch is moved or the alarm has sounded for one minute. The snooze procedure can be done as many times as desired.

3.4

Move the alarm switch to the right when you wish to shut off or cancel the alarm; the alarm symbol will disappear.

wave

Controls

Ignition Switch and Key

The ignition switch has four positions: ACCESSORY, OFF, ON, and START. The ignition key locks and unlocks the cab doors, baggage door(s), and if equipped, the bunk door(s).

In the OFF position, the key slot is vertical; the key can be inserted and removed only in this position. The low-beam headlights, taillights, brake lights, road lights, dome lights, clearance lights, turn signals, hazard lights, refrigerator, fuel heater, electric oil pan

2.17

Page 26

Instruments and Controls Identiﬁcation

heater, and electric or diesel-ﬁred engine-coolant preheaters can be operated in the off position (regardless of whether the key is inserted).

In the ACCESSORY position, the key is turned counterclockwise. The auxiliary (bunk) fan, windshield fan(s), radio or stereo system, mirror heat, ether start system, air dryer, backup lights, and all of the electrical systems that are operable in the off position are operable in the accessory position.

In the ON position, the key is turned clockwise and all electrical systems are operable. The low air pressure and low oil pressure warning lights (or messages) and buzzer operate until the engine is started and pressure is built up.

05/23/95

f260316

Cruise Control

IMPORTANT: On vehicles with Eaton VORAD Collision Warning System (CWS) with SmartCruise, see the "Collision Warning System" headings in this chapter before operating cruise control.

The cruise control is activated by the SPD CNTL (on/ off) and RSM/ACC–SET/CST switches on the dash

(Fig. 2.19), SET buttons on the transmission shift knob (Fig. 2.20). The minimum speed at which cruise control can be used is 30 mph (48 km/h). The minimum and maximum speed cruise control set limits can be programmed, by authorized personnel, into the engine electronics.

07/29/98

1. RSM/ACC–SET/CST Switch

2. SPD CNTL (On/Off) Switch

Fig. 2.19, Cruise Control Switches, Dash-Mounted

by optional PAUSE, RESUME, and

f541126

Fig. 2.20, Cruise Control, Transmission Shift Knob

Buttons

WARNING

Do not use the cruise control system when driving conditions do not permit maintaining a constant 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 follow this precaution could cause a collision or loss of vehicle control, possibly resulting in personal injury or property damage.

CAUTION

Do not attempt to shift gears without using the clutch pedal when the cruise control is engaged. Failure to follow this precaution will result in a temporarily uncontrolled increase in engine speed; transmission damage and gear stripping could result.

To cruise at a particular speed:

1.1

Press the upper half of the SPD CNTL (on/off) rocker switch on the instrument control panel.

1.2

Hold the throttle down until the speedometer reaches the desired speed.

1.3

Momentarily ﬂip the RSM/ACC–SET/CST paddle switch on the instrument control panel down to SET/CST.

1.4

—Push the SET button on the transmis-

sion shift knob.

2.18

Page 27

Instruments and Controls Identiﬁcation

To disengage the cruise control:

2.1

Depress the brake pedal or clutch pedal.

2.2

—Press the lower half of the SPD CNTL rocker switch on the instrument control panel.

2.3

—Push the PAUSE button on the transmission shift knob.

To resume a preselected cruise speed:

3.1

If the SPD CNTL rocker switch on the instrument control panel is off, turn it on.

3.2

Momentarily ﬂip the RSM/ACC–SET/CST paddle switch on the instrument control panel to RSM/ACC.

3.3

—Push the RESUME button on the transmission shift knob. Cruise will return to the last speed selected.

NOTE: The resume vehicle speed memory is not maintained if the ignition is shut off.

To adjust cruise speed up or down:

4.1

Hold the paddle switch on the instrument control panel at RSM/ACC to accelerate, or at SET/CST to decelerate, until the desired speed is reached.

4.2

—Press the SET button on the transmission shift knob to accelerate, or the RESUME button to decelerate, until the desired speed is reached.

1.3

Momentarily ﬂip the paddle switch on the instrument control panel down to SET/ CST.

1.4

—Push the SET button on the transmis-

sion shift knob.

To disengage the PTO:

2.1

Depress the brake pedal or clutch pedal.

2.2

—Press the lower half of the SPD CNTL rocker switch on the instrument control panel.

2.3

—Press the PAUSE button on the shift knob.

To resume a previously selected engine speed:

3.1

If the SPD CNTL switch on the instrument control panel is turned off, turn it on.

3.2

Momentarily ﬂip the paddle switch on the instrument control panel up to RSM/ACC.

3.3

—Press the RESUME button on the transmission shift knob.

To adjust engine speed up or down:

4.1

Hold the RSM/ACC–SET/CST paddle switch up to accelerate, or down to decelerate, until the desired speed is reached.

4.2

—Press the SET button on the transmission shift knob to accelerate, or the RESUME button to decelerate, until the desired speed is reached.

Power Takeoff (PTO) Governor

Caterpillar electronic engines may be equipped with a PTO governor. This mode is used only when the vehicle is parked. The PTO mode is activated by the SPD CNTL and RSM/ACC–SET/CST switches on the dash (Fig. 2.19) or by optional PAUSE, RESUME, and SET buttons on the transmission shift knob (Fig. 2.20).

To engage the PTO:

1.1

Press the upper half of the SPD CNTL rocker switch on the instrument control panel.

1.2

Hold the throttle down until the tachometer reaches the desired engine speed.

2.19

NOTE: The resume engine speed memory is not maintained if the ignition is shut off.

Detroit Diesel Electronic Engine Control (DDEC IV

IMPORTANT: This vehicle is equipped with an Instrumentation Control Unit (ICU) that provides warning messages and diagnostic fault codes. See "Instrumentation Control Unit", depending on the type of unit installed in your vehicle.

The DDEC IV system uses a computer that is programmed to automatically control engine timing and fuel injection.

DDEC IV systems will shut down the engine if sensors indicate an emergency engine condition such as low coolant level, high coolant temperature, or high

) Operator Control

Page 28

Instruments and Controls Identiﬁcation

oil temperature. If such a condition occurs, the yellow Check Engine light on the dash will illuminate. If the problem gets bad enough to cause possible engine damage, the DDEC IV will gradually cut engine power down to 70 percent of original power. At that point, the red Engine Protection (ENG PROT) light will turn on and thirty seconds later, DDEC IV will shut down the engine (if programmed). If DDEC IV detects low oil pressure, both the Check Engine and Engine Protection lights will come on, and the engine will shut down in thirty seconds (if programmed). See "Engine Protection—Warning and Shutdown Process" at the beginning of this chapter, for more information.

Optimized Idle

The Optimized Idle option on DDEC IV-equipped vehicles is a system that automatically stops and restarts the engine to accomplish the following:

•

Keep the engine oil temperature between 60 to 104°F (16 to 40°C)

•

Keep the battery charged

•

Keep the cab or sleeper at a constant, desired temperature (if equipped with a thermostat)

The beneﬁts of the system include reduced engine idle time, fuel savings, reduction of exhaust emissions and noise, increased starter and engine life, and less chance of dead batteries due to electrical loads.

Optimized Idle operates in two modes. They are the engine mode or the thermostat mode. The engine mode keeps the battery charged and the engine oil temperature within factory set limits. The thermostat mode is the same as the engine mode, but also keeps the cab and sleeper at a constant preset temperature.

The engine mode is always activated when the system is operated. The thermostat mode is activated when the thermostat is turned on.

The thermostat mode controls the set point, which is the desired temperature of the cab and sleeper, and the comfort zone, which is the number of degrees from the set point before the engine needs to heat or cool the cab. There are three comfort zones: 4°F (2°C), 7°F (4°C), or 10°F (6°C).

Vehicles equipped with Optimized Idle have a label and a dash light. The dash light is on the dash mes-

sage center or the Driver Message Center, on the A panel. See Fig. 2.21. See Fig. 2.22 for the dash label detail. If equipped with the thermostat mode, a thermostat is located in the sleeper, above the bunk. See Fig. 2.23.

FASTEN SEATBELTS

0000432 MILES

02/11/97

1. Optimized Idle Light

Fig. 2.21, Optimized Idle Light Location

OPTIMIZED IDLE

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)

11/13/96

Fig. 2.22, Optimized Idle Dash Label

TO AVOID

UNINTENTIONAL

VEHICLE MOVEMENT,

DO NOT MOVE SHIFT

LEVER OR RANGE

SELECTOR WHEN

OPTIMIZED IDLE IS ON

f601264

f080062

The thermostat consists of an LCD readout and four buttons.

The display normally shows the temperature of the sleeper, but changes accordingly as the buttons are pressed.

The button functions are as follows:

•

Up button: increases the set point and comfort zone.

•

Down button: decreases the set point and comfort zone.

•

Cool/heat button: detects either cooling or heating operation.

•

Mode button: scrolls through the various functions. It can also be used to set desired temperature values.

2.20

Page 29

Instruments and Controls Identiﬁcation

3 4

11/08/96

1. Down Button

2. Up 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. 2.23, Optimized Idle Thermostat

Activate Optimized Idle (engine mode) as fol-

MODE

°F

°C

lows:

1.1

Set the parking brake.

1.2

If it is tilted, close and secure the hood.

1.3

Start the engine and let it idle.

1.4

Put the transmission in neutral.

1.5

Turn on the cruise control.

IMPORTANT: The cruise control must be

after

turned on

the engine is idling. If it was previously turned on, turn off the cruise control, then turn it on again.

1.6

The dash light will begin blinking, indicating that Optimized Idle is active. The system is now in the engine mode and after an initial phase, in which the idle speeds up to 1000 or 1500 rpm (depending on the outside temperature), the engine will stop and start automatically to keep the battery charged and the engine oil warm. The dash light stays on and shines steadily at this point.

Activate the thermostat mode (if so equipped) as follows:

6 7

f601250

NOTE: When the system is in the thermostat mode, it is also in the engine mode. It will continue to operate in the engine mode even if the thermostat mode is turned off.

2.1

With the system in the 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. 2.23.

The display will ﬂash the current sleeper temperature and the previous mode (cooling 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, the system will idle and cycle excessively.

2.4

Select Fahrenheit or Celsius by pressing and holding the the °F or °C is displayed.

2.5

Select the temperature set point by pressing either the button, as applicable. Holding the button will cause the display to count up or down rapidly. When the desired set point is displayed, release the button. The set point is stored in memory.

2.6

Select the temperature comfort zone by pressing the and lower temperature limit icon is displayed. Then use the to select one of the three comfort zones of 4°F (2°C), 7°F (4°C), or 10°F (6°C).

To change the display to either Fahrenheit or Celsius, press the or°Cicon is ﬂashing. Press theUPor button to change to the desired value. The main display will appear 5 seconds after the button is released.

To deactivate the thermostat mode and return to just the engine mode, press the and hold it for 3 seconds.

Mode

MODE

button until either

button or the

DOWN

button until the upper

UPorDOWN

button until only the

DOWN

MODE

button

°F

button

2.21

Page 30

Instruments and Controls Identiﬁcation

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 DDEC features. Use the drive away feature as follows:

5.1

If the engine is running:

ing brakes or put the transmission in gear.

If the engine is not running:

gine. Release the parking brakes or put the transmission into gear.

5.2

Let the engine return to base idle. The active light will turn off. Optimized Idle is now disabled and all the DDEC features are available.

Release the park-

Start the en-

02/19/2008 f545236

Fig. 2.24, Motor Control Module (MCM)

Detroit Diesel Electronic Engine Control (DDEC VI

Because the DDEC VI system is electronic, vehicle battery power must be available to operate the computer. The system operates at 12 volts, however, in the event of a power supply malfunction, the system will continue to operate at reduced voltage. When this occurs, the amber warning lamp (Check Engine) will come on. The engine will operate only at reduced rpm. When the battery reaches a point where the Motor Control Module (MCM) hasn’t enough power to function, the engine will shut down.

Besides the engine and its related sensors, the DDEC VI system has two control modules:

•

a Motor Control Module (MCM) located on the engine;

•

a Common Powertrain Controller (CPC) located in the vehicle cab.

The two control units are connected by a proprietary datalink, through which all necessary data and information is exchanged. The CPC broadcasts information on the J1587 and J1939 datalinks, where it is read by the diagnostic tool. The MCM monitors both the engine and datalink. When a malfunction is detected, the system selects an appropriate response; for example the emergency-running mode may be activated.

) Operator Control

The MCM processes the data received from the CPC; for example, the position of the accelerator pedal, engine brake, etc. This data is evaluated together with the data from the sensors on the engine, such as coolant and fuel temperature, and oil and charge pressure. The data is then compared to the characteristic maps stored in the MCM. From this data, the quantity and timing of fuel injection are calculated.

Common Powertrain Controller (CPC)

The CPC is located in the vehicle cab. See

Fig. 2.25. The CPC communicates with the MCM,

over the J1939 datalink. Data for speciﬁc applications is stored in the CPC. These include idle speed, maximum running speed, and speed limitation.

02/19/2008 f545235

Motor Control Module (MCM)

The MCM is located on the left-hand side of the engine. See Fig. 2.24.

Fig. 2.25, Common Powertrain Controller (CPC)

The CPC receives data from the following sources:

2.22

Page 31

Instruments and Controls Identiﬁcation

•

the operator (accelerator pedal position, engine brake switch, etc.);

•

other electronic control units (for example, the antilock brake system);

•

the MCM (oil pressure, coolant temperature, etc.).

California Engine Idle Limiting

In order to meet the California engine idle limiting standard, an engine idle shutdown feature has been built into the DDEC VI engine control strategy. When the California engine idle limiting feature is enabled, the engine will generally shut down after 5 minutes of continuous idling when the transmission is in neutral or park, and the parking brake is set, or after ﬁfteen minutes when the transmission is in neutral or park, and the parking brake is not set.

Pressing the service-brake pedal, clutch pedal, stopengine override switch, and accelerator pedal, or changing the parking brake status, during the ﬁnal 30 seconds before a shutdown would otherwise occur, will prevent the engine from shutting down, and reset the shutdown timer. After an automatic shutdown, the engine may be restarted and operated normally.

If a parked regen of the aftertreatment system is initiated, it will override the ﬁve-minute idle shutdown. The HEST lamp will ﬂash every ten seconds, indicating a regeneration is in progress, and the driver is not controlling the engine idle.

The automatic shutdown feature is generally disabled on engines certiﬁed by the U.S. EPA for use outside California.

Idle Shutdown Timer

This feature is an optional 1-to-100 minute idle shutdown system. Its purpose is to conserve fuel by eliminating excessive idling, and allowing a turbocharger cool-down period. To activate the shutdown, the transmission must be in neutral with the vehicle parking brakes set and the engine in idle or fast-idle mode.

Data Recording Capability

DDEC VI contains the ability to extract detailed data on the engine use and performance, using DDEC Reports software. This data, known as DDEC Data, is stored in the CPC and contains information on engine performance (such as fuel economy, idle time,

time in top gear), and critical incidents (such as detailed diagnostic data records and hard braking events). DDEC Data can be downloaded using DDEC Reports software to produce reports. See the

Detroit Diesel DD15 Engine Operator’s Guide

complete details.

for

Flashing Malfunction Codes

All malfunction codes are four digits. The malfunction code recorded in the computer memory will remain until it is erased by a technician. The ﬂashing malfunction code can also be obtained by the operator. See the

Guide

Detroit Diesel DD15 Engine Operator’s

for complete details.

Engine Brake

The engine brake is enabled by an ON/OFF switch, with a separate intensity switch to select low, medium, or high braking power.

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 experience 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.

If the engine is equipped with both cruise control and an engine brake, the engine brake can operate automatically while in cruise control mode. If the cruise control/engine brake function is turned on in the DDEC VI system programming, the engine brake will come on "low" when the set road speed increases a few miles-per-hour (kilometers-per-hour) above the cruise set speed. The maximum amount of braking (low, medium, high) is selected with the dash switches. When the vehicle returns to the set cruise speed, the engine brake will turn off.

The engine brake will only operate when the accelerator pedal is fully released. Disengaging the clutch will prevent the engine brake from operating.

2.23

Page 32

Instruments and Controls Identiﬁcation

Vehicles equipped with antilock braking systems (ABS) have the ability to turn the engine brake off if a wheel-slip condition is detected. The engine brake will automatically turn itself back on once the wheel slip is no longer detected. The DDEC VI system will deactivate the engine brake system when the engine speed falls below 1000 rpm or when the vehicle slows down to a preset speed, depending on DDEC programming. This prevents stalling the engine.

For safety reasons, do not use cruise control when it is not possible to keep the vehicle at constant speed due to:

•

Winding roads

•

Heavy traffic

•

Slippery pavement

•

Descending grades calling for engine brake assistance

For a detailed explanation of the engine brake operation, see the

Guide

Detroit Diesel DD15 Engine Operator’s

Caterpillar C–10, C–12, and 3406E Electronic Engine Operator Control

The Caterpillar C–10, C–12, and 3406E electronic engines use a computer (electronic control module) to automatically control engine timing and fuel injection. The electronic features of these engines include an electronic governor, fuel-to-air ratio control, programmable engine ratings, injection timing control, fault analysis and recording, and a datalink used for programming the electronic control module and troubleshooting the system.

All Caterpillar electronic engines have an engine check light located above the speedometer and tachometer. This warning light comes on or ﬂashes if the engine oil pressure is low, the coolant temperature is high, the intake manifold air temperature is high, the coolant is low (optional), or whenever there is a problem within the electronic engine system. Some vehicles equipped with Caterpillar electronic engines have an automatic engine shutdown option. This option will shut off fuel to the engine if poten-

tially damaging conditions are detected. See "Engine Protection—Warning and Shutdown Process" at the beginning of this chapter, for more information. See the Caterpillar electronic engine troubleshooting manual for troubleshooting procedures.

BrakeSaver Control, Optional

The BrakeSaver (optional on Caterpillar 3406E engines) is operated by a lever mounted in the cab. The lever controls the amount of oil being directed through the BrakeSaver. The time required to ﬁll the BrakeSaver with oil pressure to the point of maximum braking in the BrakeSaver is approximately 1.8 seconds.

Cummins CELECT™Plus Electronic Engines Operator Control

Cummins CELECT Plus is an electronic fuel control system. These electronic engines are controlled by a microprocessor-based computer. This computer controls speciﬁc engine and vehicle speed modes of operation to maximize vehicle fuel economy and performance.

Vehicles with these engine systems have three indicator lights: a yellow check engine light, a red stop engine light, and an engine protection (engine ﬂuids) light. These indicators are located in the lightbar above the speedometer and tachometer. With the ignition switch on, the indicator lights come on for about two seconds; then, if there is no problem with the engine system, the lights will go out. Whenever there is a problem within the electronic engine system, one of the lights will come on and stay on as long as the problem exists. See "Engine Protection— Warning and Shutdown Process" at the beginning of this chapter, for more information.

Suspension Seat Adjustment Controls

Due to the maximum adjustability of mid- and highback air suspension seats, it is possible to combine the seat back recline adjustment and the seat slide adjustment so that the seat back contacts the backwall. It is the responsibility of the driver to adjust the

2.24

Page 33

Instruments and Controls Identiﬁcation

seat to prevent damage to the seat and the cab interior.

All adjustment controls for a suspension seat are located on the seat base. See Chapter 5 for complete instructions.

Tilt Steering Wheel, Optional

The optional tilt steering wheel control pedal is located to the left of the clutch pedal. See Fig. 2.26.

Parking Brake Control Valve and Trailer Air Supply Valve

The yellow diamond-shaped knob operates the parking brake valve. Pulling the knob applies both the tractor and the trailer spring parking brakes. See

Fig. 2.27. Pushing the knob in releases the tractor

spring parking brakes. Before the spring parking brakes can be released, the air pressure in either air brake system must be at least 65 psi (447 kPa).

03/10/99

1. Trailer Air Supply Valve Knob

2. Parking Brake Control Valve Knob

Fig. 2.27, Brake Valve Knobs

f610291

11/14/95

A. Driver’s Door Opening

1. Adjustment Valve 2. Air Line Connections

Fig. 2.26, Tilt Steering Wheel Control Pedal

After adjusting the seat to the desired ride position, unlock the steering column by pushing and holding the control pedal all the way down. Tilt the steering column to the desired position, then release the control pedal to lock the steering column in place.

f461069

WARNING

Make sure that the steering column is locked before driving the vehicle. Never tilt the column while driving the vehicle. Doing so could cause loss of vehicle control, personal injury, and property damage.

CAUTION

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 red octagonal-shaped knob operates the trailer air supply valve. See Fig. 2.27. 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), the trailer air supply valve knob must be pushed in (and should stay in) to charge the trailer air supply system and release the trailer spring parking brakes. Before disconnecting a trailer or when operating a vehicle without a trailer, the trailer air supply valve knob must be pulled out.

See Chapter 6 under the heading "Brake System" for instructions regarding use of the trailer air supply valve and parking brake valve.

Power Mirrors

Both outside mirrors can be equipped with an electrical remote control. Operate the driver door-mounted switch to adjust the mirror.

2.25

Page 34

Instruments and Controls Identiﬁcation

Mirror Heat Switch, Optional

One or both outside door mirrors can be heated to keep them defrosted. When the mirror heat (MIRR HEAT) switch is on, an amber indicator light illuminates in the switch.

Heater/Air-Conditioner Controls

Heater/air conditioner controls consist of a fourspeed fan switch, an air selection switch, a temperature control switch, and a fresh-air/recirculation switch. See Fig. 2.28. See Chapter 4 for detailed operating instructions of the heater/air conditioner.

10/26/95 f830717

1. Fan Switch

2. Air Selection Switch

3. Temperature Control Switch

4. Fresh-Air/Recirculation Switch

5. Auxiliary (sleeper bunk) Switch

Fig. 2.28, Heater/Air Conditioner Controls

Left and Right Windshield-Fan Switches, Optional Ceiling-Mounted Fans

Ceiling-mounted defogger fans are operated by LOW/OFF/HIGH toggle switches located in the base of the fan.

Turn Signal Lever

The turn signal lever is mounted on the steering column. See Fig. 2.29. Moving the lever counterclockwise turns on the left-turn signal lights; moving it clockwise turns on the right-turn signal lights. When one of the turn signal lights is on, a green indicator light ﬂashes at the far left or far right of the warning and indicator light panel. To cancel the signal, move the lever to the neutral position. Some style levers may have automatic cancelling, and the turn signal lever automatically returns to the neutral position when the steering wheel returns to the straight-ahead position after a turn.

9/26/95 f461056

1. Turn Signal Lever

2. Trailer Brake Hand Control Valve Lever

3. Hazard Warning Light Switch Tab

Fig. 2.29, Steering Column-Mounted Controls

Ether Start, Optional

For cold-weather starting, the vehicle may be equipped with an automatic ether start system. Always see the instructions in the manufacturer’s engine operation manual for information before using ether. Some electronic engines do not allow the use of ether.

Cigarette Lighter

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

CB Radio Connections

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

Trailer Brake Hand Control Valve Lever

The trailer brake hand control valve lever is used for applying the trailer brakes without applying the truck or tractor brakes and is mounted on the steering column. See Fig. 2.29. See Chapter 6 under the heading "Brake System" for operating instructions.

2.26

Page 35

Instruments and Controls Identiﬁcation

Transmission Controls

If so equipped, the transmission range control valve and splitter valve are attached to the gearshift knob. Transmission shift pattern labels are located inside the cab. For control of the automated mechanical transmissions, use the Freightliner SmartShift Transmission Shift Control mounted on the steering column. See Chapter 8 for complete transmission operating instructions.

Freightliner SmartShift™Transmission Shift Control

The SmartShift transmission shift control is an electronic transmission control device. It is applicable to both automated mechanical and automatic transmissions but must be mated to an Eaton

™

Shift or Meritor

Engine Synchro Shift (ESS) transmission. It replaces either the typical ﬂoor-mounted shift lever or dash-mounted push button control. The SmartShift control mounts to the right-hand side of the steering column and is operated by the driver’s right hand. See Fig. 2.30 and Fig. 2.31. SmartShift accepts driver requests for transmission functions and transmits them through hard wiring to the transmission control unit (TCU).

SmartShift offers advantages over conventional transmission control devices; usable cab space is increased and access to the sleeper is improved by removing the shift lever from the ﬂoor. Also, because of the steering column mounting, the transmission control is within ﬁngertip reach of the steering wheel, which enhances safety.

SmartShift is a true shift-by-wire system. Manual gearshifts (all ESS and AutoShift when in manual mode) are accomplished by a momentary pull or push on the control in the plane perpendicular to the steering wheel. See Fig. 2.32. Pull upward (toward you) on the control to upshift and push downward (away from you) to downshift. For the Eaton Fuller AutoShift transmission, a four-position (R, N, D, L) linear mode selector switch is located at the end of the control. See Fig. 2.30. For the Meritor ESS transmission, a three-position (R, N, F) linear mode selector switch is located at the end of the control. See

Fig. 2.31. The control is spring-loaded and returns to

mid-position when released after an upshift or downshift.

™

Fuller®Auto-

11/23/99

1. SmartShift Control

2. Forward Driving Mode Switch (slide switch)

3. MAN Switch Position

4. AUTO Switch Position

5. Upshift Direction (in manual mode, pull upward)

6. Reverse Selector Position

7. Mode Selector Switch

8. Neutral Selector Position

9. Drive Selector Position

10. Low Selector Position

11. Downshift Direction (in manual mode, push downward)

Fig. 2.30, SmartShift Control (for Eaton Fuller AutoShift

11/23/99

1. SmartShift Control

2. Upshift Direction (pull upward)

3. Reverse Selector Position

4. Mode Selector Switch

5. Neutral Selector Position

6. Forward Selector Position

7. Downshift Direction (push downward)

Fig. 2.31, SmartShift Control (for Meritor Engine

Synchro Shift transmissions)

transmission)

Smart

Shift

SHIFT

PULL

PUSH

SHIFT

DOWN

f270082

f270081

Engine Brake Switch, Optional

The engine brake (ENG BRK) switch controls the degree of engine braking. See Chapter 7 under the

2.27

Page 36

Instruments and Controls Identiﬁcation

06/03/99

1. Upshift (in manual mode, pull upward)

2. Steering Wheel

3. Reverse Position

4. Neutral Position

5. Drive Position

6. Downshift (in manual mode, push downward)

7. Steering Column

Fig. 2.32, SmartShift Control Operation (Eaton Fuller

AutoShift control, showing only R, N, D positions)

f270065

heading "Engine Braking Systems" for additional information.

Exhaust Brake Switch, Optional

The optional exhaust brake is controlled by a dashmounted paddle switch to help slow the vehicle when the throttle is released.

Engine Fan Switch, Optional

10/02/2006

Fig. 2.33, Request/Inhibit Regen Switch

f610848

The style and function of switch will vary with the engine make and model. See the engine operation manual for operation details.

Controlled Traction Differential Control Valve Switch

A controlled traction differential feature is included or available as an option on some rear axles. A control valve switch engages and disengages the controlled traction feature to cause the axle shafts to rotate together. See Fig. 2.34. The controlled traction, or differential lock, should only be engaged when the vehicle is moving slowly at low throttle to avoid causing internal axle damage. The differential lock must only be used for adverse road conditions. The use of the lock increases the turning radius and affects the vehicle handling. A guard is positioned around the switch to minimize accidental activation. See Chap-

ter 9 for complete operating instructions.

The engine cooling fan can be turned on by the engine fan (ENG FAN) 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 the fan operation.

Aftertreatment System (ATS) Request/Inhibit Regen Switch

A parked regen of the ATS can be initiated with the request/inhibit regen switch. It may also be used to inhibit the vehicle from performing an automatic regen. See Fig. 2.33.

09/26/95 f350142

Fig. 2.34, Controlled Traction Differential Switch

2.28

Page 37

Instruments and Controls Identiﬁcation

Interaxle Differential Lockout Control Valve Switch

CAUTION

The interaxle lock should only be engaged when the vehicle is moving slowly at low throttle. Engagement at high speed or power can damage the axle(s).

The interaxle lock, standard on all dual-drive vehicles, is driver-actuated by means of a LOCK/ UNLOCK control valve switch mounted on the control panel. See Fig. 2.35. A red indicator light comes on whenever the interaxle differential is locked out (switch is in the lock position; no differential action between the drive axles). A guard around the switch minimizes accidental activation.

9/07/95 f310489

Fig. 2.36, Fifth Wheel Air Slide Switch

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.

CAUTION

09/26/95

Fig. 2.35, Interaxle Differential Lockout Switch

f350141

Fifth Wheel Air Slide Control Valve Switch, Optional Air-Operated Sliding Fifth Wheel

The ﬁfth wheel air slide valve permits repositioning of the sliding ﬁfth wheel from inside the cab. Moving the air slide control valve switch to the lock position deactivates the control valve and locks the ﬁfth wheel to the baseplate. See Fig. 2.36. Moving the switch to the unlock position activates the control valve and unlocks the ﬁfth wheel slide mechanism, allowing changes to the total length of the tractor-trailer and changes to axle loads to comply with varying state or provincial laws. A red indicator light, if so equipped, is illuminated whenever the ﬁfth wheel slide is unlocked. A guard is positioned around the switch to minimize accidental activation.

Air Suspension Dump Valve, Optional

The air suspension dump valve allows the air in the vehicle air suspension to be quickly exhausted, lowering the rear of the vehicle. This makes it easier to connect to or disconnect from a trailer. To exhaust air from the suspension, move the switch to LOWER. When the switch is moved back to the normal position, the suspension will return to the correct ride height. A guard is positioned around the switch to minimize accidental activation. See Fig. 2.37.

09/26/95

Fig. 2.37, Air Suspension Dump Valve

f350143

2.29

Page 38

Instruments and Controls Identiﬁcation

CAUTION

Never exhaust air from the suspension while driving. When the air is exhausted, the suspension will not absorb road shocks and could be damaged.

Windshield Wiper/Washer Controls

The wipers are operated by a double-paddle WIPER/ WASH switch mounted on the auxiliary instrument panel. The top paddle, when pushed in, turns the wipers on (if they are off) or off (if they are on). When it is pushed up, the top paddle switches the wipers to high speed; when it is pushed down, it switches them to low speed.

The bottom paddle, when pushed in, turns the washers on. When pressed for less than 1/2-second, the wipers will perform a single, low speed dry wipe (mist function). When pressed for more than 1/2second, the wash cycle begins and continues for three cycles or until the paddle is released. When the bottom paddle is pushed up, the wipers operate in fast delay. When the bottom paddle is pushed down, the wipers operate in slow delay. With the wipers in delay mode (fast or slow), push the bottom paddle up to shorten the delay period or push the paddle down to lengthen it.

lights, if equipped. The daytime running lights will operate until the parking brakes are applied or the headlights are turned on.

Headlight Dimmer

Pull the turn signal lever toward the steering wheel to change from low-beam to high-beam headlights or from high beam back to low beam.

When the headlights are on high beam, a blue light on the indicator light panel comes on. For vehicles built to operate in the United States, switching from low beams to high beams will switch off the road lights.

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

Hazard Warning Light Switch Tab

The hazard warning light switch tab is located underneath the turn signal lever. See Fig. 2.29. Hazard warning lights are operated by pulling the tab out. When the hazard warning light switch tab is pulled out, all of the turn signal lights and both of the indicator lights on the control panel will ﬂash. To cancel the warning lights, move the turn signal lever up or down.

Marker Lights Interrupt Switch

CAUTION

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

Headlight Switch and Daytime Running Lights

A three-position headlight switch is used to operate the exterior lights. When the switch is up, the headlights and all other vehicle lights are on. All vehicle lighting is off when the switch is in the middle position. When down, the switch activates only the clearance, instrument panel, marker lights, and the taillights. The switch for the headlight high beams is built into the turn signal lever. When the headlights are on high beam, a blue light in the warning and indicator light module goes on. The ignition switch must be on for the high beams to operate.

Switching on the ignition and releasing the parking brakes automatically activates the daytime running

The marker lights interrupt (MRKR INT) switch temporarily deactivates the marker lights and taillights. With the vehicle lights on, raise and release the interrupt switch to brieﬂy turn off the marker lights and taillights. To alert the driver that the switch is functioning, the dash lights will ﬂash with the marker lights when the switch is actuated.

Road Light Switch, Optional

The road light (ROAD LAMP) switch operates the road lights mounted on the bottom edge of the front bumper or recessed in the front bumper.

For vehicles built to operate in the United States, the low beam headlights must be turned on before the road lights can be turned on. The road lights will not illuminate if the high beam headlights are already on, and switching from low beams to high beams will switch off the road lights.

2.30

Page 39

Instruments and Controls Identiﬁcation

For vehicles built to operate in Canada, the marker lights must be on before the road lights can be turned on.

Utility Light Switch, Optional

Utility lights can be swivel-mounted on top of the cab, mounted on the intake/exhaust support, or ﬂushmounted in the back of the cab or sleeper box. They are operated by the utility light (UTLY LAMP) switch which, when turned on, also illuminates a red indicator light in the switch (if equipped).

Panel Lamp Control Switch

The circuit to the panel lamps is activated by the headlight switch. When the headlights are on, the panel lamp switch controls the intensity of the instrument panel lamps. Slide the switch up to brighten them and down to dim them.

07/14/97

Fig. 2.39, Dome Light with Red Map Light

Red Map Light Switches

Red map lights are available on all cabs. See

Fig. 2.38 and Fig. 2.39. They are located next to the

dome lights in the same ﬁxture. Like the dome lights, the map lights can be turned on by pressing in on the light lens.

f541717

Interior Light Controls

The interior lights include dome lights, red map lights, clear reading lights, and courtesy lights.

SleeperCabs have additional lights in the bunk area, including bunk reading lights, under-bunk lights (baggage compartment lights), and ﬂuorescent lights.

Dome Light Switches

Diffuse dome lights are installed on all cabs. See

Fig. 2.38 and Fig. 2.39. The dome lights are located

either on the overhead console, or on the cab roof (if no overhead console is installed). Both dome lights turn on when either the driver’s or passenger’s door is opened. The dome lights can also be turned on by pressing in on the light lens.

Clear Reading Light Switches, Optional— SleeperCabs Only

Clear reading lights are available on SleeperCabs only. See Fig. 2.38. They are located next to the dome lights in the same ﬁxture. Like the dome lights, the reading lights can be turned on by pressing in on the light lens.

Courtesy Light Switch, Optional

Courtesy lights are available on all cabs. They illuminate the footwell area on both sides of the cab. The driver’s courtesy light is attached to the steering column and the passenger’s footwell light is located on the lower right dash panel. To turn on the courtesy lights, press the rocker switch on the dash. When the lights are on, the switch is illuminated by a light inside it. See Fig. 2.40 and Fig. 2.41.

07/11/97

Fig. 2.38, Dome/Tray, Red Map, and Clear Reading

Lights (SleeperCab)

2.31

f541715

07/14/97

f541716

Fig. 2.40, Driver’s Floor Courtesy Light

Page 40

Instruments and Controls Identiﬁcation

06/10/98

Fig. 2.41, Passenger’s Footwell Courtesy Light

f601053

Bunk Reading Light Switches, Optional— SleeperCabs Only

Bunk reading lights are high-intensity reading lights for use when reading in the bunk. They are located on the bunk control panel for each bunk. To turn on the bunk reading lights, press the rocker switch on the bunk control panel that holds the light.

Baggage Compartment Light Switches (SleeperCabs Only)

Baggage compartment lights are on all cabs. One light is located on each side of the cab on the underside of the lower bunk and illuminates the baggage compartment. Both lights turn on when either baggage compartment door is opened. The lights also come on when the lower bunk is raised. See

Fig. 2.42.

Battery Disconnect Switch, Optional

An external battery disconnect switch cuts off all battery power to the vehicle. The switch is used whenever service operations require that the batteries be disconnected. It is also used whenever the vehicle is placed out of service for extended periods to prevent battery discharge. See Fig. 2.43.

Low Voltage Disconnect, Optional

The optional Sure Power Low Voltage Disconnect (LVD) system monitors battery power when accessories are being used while the engine is shut down.

09/29/95 f541139

1. Under-Bunk Light

2. Bunk

Fig. 2.42, Baggage Compartment Light

01/18/95

Fig. 2.43, Battery Disconnect Switch

The system automatically turns off cab and sleeper accessories when voltage drops to 12.3 volts to ensure that there is enough battery power to start the vehicle. An alarm sounds for one minute before accessories are turned off. If no action is taken within that minute, the LVD module will shut off power to

3. Switch

f600150a

2.32

Page 41

Instruments and Controls Identiﬁcation

predetermined cab and sleeper circuits. These circuits will remain off until the LVD measures 13.0 volts applied to the system, which can be done by starting the engine. After the engine is started, the system will reset.

All vehicles equipped with LVD have a sticker on the dash indicating the presence of the system. Another sticker is located inside the right-hand door frame behind the seat, along with the LVD module. The LVD module is located on the engine tunnel, behind the lower right-hand dash panel.

Automatic Engine Idler/Timer, Optional

A Henke automatic engine idler/timer allows the driver to select the idle time required for engine shutdown. The driver can turn off the ignition, remove the ignition key, lock the vehicle, and leave it with the engine idling; the automatic timer will shut the engine off at the end of the selected time.

Meritor™WABCO®Antilock Braking System (ABS)

The Meritor WABCO Antilock Braking System (ABS) has a tractor warning light (TRACTOR ABS) and, if equipped with automatic traction control (ATC), a wheel spin indicator light (WHEEL SPIN). See

Fig. 2.44.

while driving, repair the ABS system immediately to ensure full antilock braking capability.

Vehicles with ABS may also have automatic traction control (ATC). On these vehicles, the ATC system automatically limits wheel spin when power is applied to the drive axles during reduced-traction situations.

If the vehicle has ATC, there will be a momentary contact rocker switch on the dash labeled NORM/ SPIN and ATC.

When the ATC system is in the NORMAL mode, it will apply gentle braking to the spinning wheel, to force power to the wheel(s) with better traction. If both wheels are spinning, the system will signal the electronic engine to reduce power.

Pressing NORM/SPIN will temporarily allow more drive wheel spin to help burn through a thin layer of ice or to help throw off accumulated mud or snow. SPIN mode is indicated by a ﬂashing WHEEL SPIN light. Pressing NORM/SPIN again will cycle the system back to normal operation.

See the brake system operating instructions in Chap-

ter 6 for more information.

Lane Guidance™System Rocker Switch, Optional

The lane departure warning system is controlled by a dash-mounted rocker switch that toggles the system on and off. Additional information is detailed later in this chapter.

FASTEN SEATBELTS

0000432 MILES

04/02/96

1. Tractor ABS Warning 2. Wheel Spin Indicator

Fig. 2.44, ABS Warning and Indicator Lights (standard)

After the ignition switch is turned on, the tractor warning light (TRACTOR ABS) and (if equipped) the wheel spin (WHEEL SPN) indicator light come on for about three seconds. After three seconds, the lights go out only if all of the tractor’s ABS components are working.

f601125

IMPORTANT: If any of the ABS warning lights do not work as described above or come on

2.33

Collision Warning System (CWS), Eaton VORAD EVT– 300, Optional

The Eaton VORAD EVT–300 is a computerized collision warning system (CWS) that uses front-mounted and side-mounted (optional) radar to continuously monitor vehicles ahead and alongside your vehicle.

The system warns of potentially dangerous situations by means of visual and audible alerts. The system performs in fog, rain, snow, dust, smoke, and darkness. To be detected, objects must be within the radar beam’s ﬁeld of view and provide a surface area that can reﬂect back the radar beam.

The front-looking antenna assembly transmits radar signals to and receives them back from vehicles and

Page 42

Instruments and Controls Identiﬁcation

objects ahead. This allows the determination of the distance to, relative speed of, and angle to the target of vehicles and objects ahead. The system uses this information to warn the driver of potentially dangerous situations.

An optional side sensor(s), mounted on the side of the vehicle, also transmits and receives radar signals for a distance of 2 to 10 feet (0.5 to 3 meters) alongside your vehicle. The side sensor can detect unseen vehicles and objects, moving and stationary, adjacent to your vehicle.

WARNING

The Eaton VORAD EVT–300 Collision Warning System (CWS) is intended solely as an aid for an alert and conscientious professional driver. It is not intended to be used or relied on to operate a vehicle. Use the system in conjunction with rearview mirrors and other instrumentation to safely operate the vehicle. Operate this vehicle, equipped with the EVT–300 Collision Warning System, in the same safe manner as if the EVT– 300 Collision Warning System were not present.

The EVT–300 Collision Warning 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 EVT–300 Collision Warning System may provide little or no warning of hazards such as pedestrians, animals, oncoming vehicles, or cross traffic.

On vehicles with SmartCruise, the vehicle will not deactivate cruise control for stationary targets, such as a car stopped in your traveling lane.

Failure to drive safely and use the system properly could result in personal injury and/or death and severe property damage.

EVT–300 Driver Display Unit

tional driver’s identiﬁcation card. Alert and indicator lights advise of multiple warning levels, system power, system failure, and if so conﬁgured, failure of the driver to enter the identiﬁcation card.

A light sensor automatically adjusts alert and indicator light brightness depending on lighting conditions. A small speaker provides audible alert tones to warn of closing on an object ahead and, when equipped with an optional side sensor, of objects alongside when the turn signal is activated in preparation for a lane change. Additional tones indicate speaker volume, system failure, driver’s card status, and data extraction pass or fail.

The green power-on/driver’s card (optional) status indicator light illuminates when the system is activated and the power-on LED test is complete. If the system is conﬁgured to require that the driver’s card be read, and it is not, the ON light blinks continuously.

Push in the volume control and power ON/OFF knob to turn power on or off. Turn the knob left or right to increase or decrease speaker volume. Press and hold the knob for ﬁve seconds and then release it to activate the failure display mode.

NOTE: The system may be conﬁgured to have no on/off capability.

The speaker is located under the top cover of the DDU. It sounds audible tones to alert the driver to potential hazards. Volume may be restricted to a range above a minimum level.

NOTE: This is a conﬁgurable electronic parameter.

Rotate the range knob to adjust the ﬁrst alert detection range to between 3 and 2.25 seconds. Push and hold the knob for 5 seconds to activate the accident reconstruction function and freeze the most recent data in half of the allocated memory.

NOTE: All system controls are located on the Driver Display Unit (DDU). See Fig. 2.45. Indicators to inform the driver about the system’s operation are located on both the DDU and the optional side sensor display.

The DDU controls system power, range for vehicle warnings, and speaker volume. At the lower front edge of the DDU, a slot is provided to insert the op-

NOTE: The system may be conﬁgured to prevent adjustment of the range levels.

The red system failure indicator light illuminates if a system problem is detected. Press and hold the volume control knob for ﬁve seconds to display fault codes. The fault codes will be blinked out as a pattern of ﬂashes on this indicator light. See Table 2.5 for fault codes.

2.34

Page 43

Instruments and Controls Identiﬁcation

ON SC

FAIL

VOLUME ALERTS RANGE

EATON VORAD

TECHNOLOGIES

10/15/98

1. Red System Failure Indicator Light

2. Green Power ON/Driver’s Card Status Indicator Light

3. Volume Control and Power ON/OFF Knob

4. Speaker

5. Range Knob

6. Green SC Indicator Light

Fig. 2.45, Driver Display Unit (EVT-300)

Fault Codes

Fault Code Suspect Failure

11 Central Processing Unit (CPU) 12 CyberCard 13 Driver Display Unit (DDU) 14 Antenna Assembly 15 Right Side Sensor 16 Left Side Sensor 21 Right-Turn Signal 22 Left-Turn Signal 23 Brake 24 Speed 25 Cruise 31 J1587 32 J1939 33 VBUS 34 DDU Communications 35 Antenna Assembly Communications 41 No Fault or End of Fault Codes

Table 2.5, Fault Codes (EVT-300)

The green SC indicator light will ﬂash eight times if the range knob is pressed to store accident

1011 9

7. Ambient Light Sensor

8. Driver’s Identiﬁcation Card Slot

9. Red Alert Light

10. Orange Alert Light

11. YellowAlert Light

12. Distance/Danger Alert Lights

reconstruction information. It will also ﬂash eight times after the system is activated, after the power-on LED test is ﬁnished, and if accident reconstruction data was previously stored.

The ambient light sensor senses lighting conditions and automatically adjusts the intensity of the indicator and alert lights.

If the system’s conﬁguration requires, insert the driver’s identiﬁcation card in the slot at the lower front edge of the DDU. A high-pitched tone will sound when the driver’s identiﬁcation card has been successfully read. One low tone will sound if the driver’s card has been unsuccessfully read. If so conﬁgured, a repeated low tone will sound if the system is on and the requested driver’s card has not been inserted.

The yellow alert light illuminates when an object is detected within the system’s maximum range of 350 feet (107 meters) on a straight road. Range is reduced in curves by the turn radius of the curve. This light also illuminates when the proximity alarm threshold is crossed.

10.

The orange alert light illuminates, along with the yellow alert light, when your vehicle is within a

f610258

2.35

Page 44

Instruments and Controls Identiﬁcation

two- to three-second following interval behind another vehicle in the same lane. If you are within a two-second following interval and closing on the vehicle ahead, a warning tone will also sound.

11.

The red alert light illuminates, along with the yellow and orange alert lights, when you are less than one second behind a vehicle. If the vehicle ahead is opening the interval, no tone will sound. If you are closing the interval, double tones will sound. Within a 1/2-second or less following interval, opening or closing, the tones will repeat twice per second.

12.

If a stationary vehicle or object, or an object moving at least 20 percent slower than your vehicle is detected within 220 feet (67 meters) and within three seconds, all three alert lights will illuminate and the double tones will sound. This warning overrides all others and is not affected by the range control knob setting.

IMPORTANT: The detection range will be reduced during a sharp turn.

13.

If your vehicle is traveling less than 5 mph (8 km/h) and an object is detected less than 15 feet (4.5 meters) in front of your vehicle and the closing rate is less than 2 mph (3 km/h) but more than 1/2 mph (1 km/h), the yellow alert light will illuminate and a low-frequency double tone will sound.

NOTE: All warnings apply only to objects within the maximum detection range and in your lane. Proximity alert tones and vehicle-closing one- to two-second following interval tones are conﬁgured items. All tones are disabled in sharp turns or when the brakes are applied. If the conﬁguration permits, the three-second alert level may be adjusted with the range control knob. A single low-frequency tone sounds when a system failure is detected. A medium-frequency tone sounds when the volume control level is changed. Successful downloading of Vehicle Information Management System (VIMS) data will cause a double tone to sound. Unsuccessful downloading will cause a low-frequency tone to sound.

14.

A failure of the optional side sensor(s) will cause a continuous red light on the side sensor display to appear.

EVT–300 Side Sensor Display

The yellow indicator light illuminates continuously when no vehicle is detected by the side sensor(s). See Fig. 2.46.

01/27/97

1. Red Alert Light (vehicle or object detected)

2. Ambient Light Sensor

3. Yellow Indicator Light (no vehicle or object detected)

Fig. 2.46, Side Sensor Display (EVT-300)

The ambient light sensor senses lighting conditions and automatically adjusts the intensity of indicator and alert lights.

The red alert light illuminates when objects are detected by the side sensor(s). If the right turn signal is activated and the side sensor detects an object, the red alert light will illuminate and the DDU speaker will sound a high-frequency double tone. This tone is sounded only once per activation of the turn signal. The red light will also illuminate and stay on if a failure of the side sensor is detected. If objects are temporarily unable to be detected during heavy rain, both the red and yellow lights will illuminate.

f601259

2.36

Page 45

Instruments and Controls Identiﬁcation

EVT–300 Special Road Situations

WARNING

The Eaton VORAD EVT–300 Collision Warning System (CWS) is intended solely as an aid for an alert and conscientious professional driver. It is not intended to be used or relied on to operate a vehicle. Use the system in conjunction with rearview mirrors and other instrumentation to safely operate the vehicle. This system will not warn of many possible hazards. Do not assume it is "all clear" if no alert lights are illuminated.

Failure to drive safely and use the system properly could result in personal injury and/or death and severe property damage.

Certain special road situations may affect the system’s ability to detect objects. These situations include the effects of curves, dips, and hills that may provide an unexpected 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 reaching 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, before turning into it, 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.

•

Elevated obstacles such as overpasses and overhead signs may be detected when approaching a roadway descending to a lower elevation.

•

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 far-

ther back, behind 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 of the CWS 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.

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 properly could result in personal injury and/or death and severe property damage.

NOTE: 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.

EVT–300 Accident Reconstruction

The optional accident reconstruction capability provides two segments of system data, one of which can be stored in system memory. Push and hold the DDU range knob for about 5 seconds to store the ﬁrst segment. Within 6 seconds, the green SC indicator light will blink rapidly 8 times conﬁrming that the data has been saved. If the range knob is pushed again, a fail tone will sound. After the ﬁrst segment is saved, the second segment runs continuously but only contains the last 10 minutes (approximately) of system data.

NOTE: Once the ﬁrst memory segment is frozen, the other can’t be frozen. Only by disconnecting the main CPU connector can the second memory segment be preserved. You must return the CPU to Eaton VORAD for downloading and interpretation of accident reconstruction data.

2.37

Page 46

Instruments and Controls Identiﬁcation

EVT–300 Maintenance and Diagnostics

Keep the antenna assembly and side sensor(s) free of a buildup of mud, dirt, ice, or other debris that might reduce the system’s range.

The system tests itself continuously and evaluates the results every 15 seconds. If a problem is detected with the front radar system, the red FAIL light on the DDU illuminates continuously as long as the failure is active. The corresponding fault code is stored in the CPU’s memory.

Both active and inactive fault codes can be indicated by the DDU when the system is placed in failure display mode. Inactive faults are those that have occurred and have cleared. Active faults are still present. Fault codes provide the driver the ability to record the system faults during a trip and to notify his/her maintenance department or Eaton VORAD. See "EVT–300 Failure Display Mode/Fault Codes" below. In this mode, speciﬁc fault codes are indicated by the pattern of blinks of the driver display unit red FAIL light.

Each fault code is a two-digit number, as shown in Table 2.5. The red FAIL light blinks the same number of times as the ﬁrst digit, a pause of approximately 3/4 of a second follows, then the light blinks the same number of times as the second digit.

Additional fault codes are blinked out at intervals of approximately eight seconds. After all the fault codes have been displayed, a code 41 will be ﬂashed.

Position the DDU range knob to the left to blink active fault codes and to the right to blink inactive codes.

Fault codes can only be reviewed, tested, and cleared by using a Pro-Link tool.

9000 diagnostic

Lane Guidance™System, Optional

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 40 mph (64 km/h). The system includes a digital camera mounted high near the center of the windshield inside the cab, a central processing unit in the overhead console, and a stereo speaker above and behind each door that emits a sound similar to a rumble strip. See Fig. 2.47. 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.

EVT–300 Failure Display Mode/Fault Codes

Press and hold the DDU volume control and power ON/OFF knob. Continue pressing the knob until the FAIL light begins to blink in approximately ﬁve seconds. If so conﬁgured, the system will turn off if you release the knob before ﬁve seconds. After ﬁve seconds, the DDU FAIL light begins to blink out the failure ﬂash codes. A code 41 will be displayed either if no faults are found or when all fault codes have been displayed.

11/18/1999

1. Clock

2. Windshield

Fig. 2.47, Lane Departure Warning System Camera

3. Digital Camera

f610358

WARNING

The lane departure warning system is intended only as an aid for a conscientious and alert

2.38

Page 47

Instruments and Controls Identiﬁcation

driver. The system may not indicate lane departures under certain conditions. Read carefully the information in this manual to understand the circumstances 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 possible 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 substitute for safe driving procedures.

Failure to drive safely and use the system properly could result in personal injury and/or death and severe property damage.

IMPORTANT: It is still the responsibility of the driver to change driving styles depending on existing traffic and road conditions.

Starting the vehicle activates the system. On startup, the system performs a self-test, then sounds two chirps through the speakers to indicate the system is ready. The rocker switch on the B instrument panel turns the system on and off. Once the vehicle is started and the system is ready, the ON light at the bottom of the switch illuminates. Pushing the top of the rocker switch turns the system off; pushing the switch again turns the system on. The top portion of the switch reads LANE ALERT and is backlit with the dash lights on.

The LANE SRCHNG amber warning light illuminates to indicate 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 come on include:

•

The system is unable to detect lane markings.

•

Vehicle speed is less than 40 mph (64 km/h).

•

Lane width is greater than 13 feet (4 m).

•

A dirty windshield or a similar problem is obscuring the camera.

•

A system problem is detected.

While the system is capable of detecting a number of different types of lane markers, its performance may be compromised or degraded by certain conditions, including the following:

•

Weather conditions such as snow, heavy rain, ice, or standing water.

•

Damaged, worn, or faded lane markings.

•

Broken pavement, dirt, sand, salt, gravel, or skid marks.

•

Poor lighting, such as heavy glare or an inoperable headlight.

•

A cracked, dirty, or streaked windshield.

The lane guidance system is not meant for use in city traffic or in heavy highway traffic. System alerts are automatically disabled when vehicle speed drops below 40 mph (64 km/h). The system may be manually turned off with the instrument panel rocker switch if an unacceptable level of false alerts is reached.

NOTE: If the green light on the LANE ALERT rocker switch remains off despite depressing the switch and the LANE SRCHNG amber warning light remains on, the system is not fully functional and needs service at a dealer or authorized service facility.

Roll Stability Control

Roll Stability Control is an onboard system capable of automatically slowing the vehicle to reduce the risk of rollover. The goal of the system is to reduce rollover accidents by reducing vehicle speed.

The system uses a lateral acceleration sensor that monitors rollover risk. If the sensor detects the vehicle is at risk of rolling over, Roll Stability Control intervenes and attempts to reduce vehicle speed by reducing engine power, applying the engine brake, and/or applying the tractor and trailer brakes.

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.

2.39

Page 48

Instruments and Controls Identiﬁcation

A decal (Fig. 2.48) on the auxiliary dash panel and an amber-colored dash indicator light (Fig. 2.49) indicate that the vehicle is equipped with the Roll Stability Control system. The dash indicator light illuminates whenever the Roll Stability Control system intervenes.

SAFETY INSTRUCTIONS

lamp indicates traction OR roll control event. Follow instructions in driver’s manual.

07/11/2003

Fig. 2.48, Roll Stability Control Dash Decal

24−01204−000

f080125

06/26/2003 f602128

Fig. 2.49, Roll Stability Control Dash Indicator Light

2.40

Page 49

Vehicle Access

Ignition and Lock Key .............................................................. 3.1

Cab Door Locks and Handles ....................................................... 3.1

Grab Handles and Access Steps ..................................................... 3.1

Door Windows ................................................................... 3.3

Sleeper Compartment Vents ........................................................ 3.3

Circuit Breaker/Relay Panel ......................................................... 3.3

Cab-to-Sleeper Access ............................................................. 3.3

Sleeper Bunk Latches ............................................................. 3.3

Sleeper Door ..................................................................... 3.3

Baggage Compartment Doors ...................................................... 3.4

Back-of-Cab Grab Handles, Steps, and Deck Plate ...................................... 3.4

Battery Box Cover ................................................................ 3.5

Hood Tilting ...................................................................... 3.5

Cab Amenities .................................................................... 3.6

Windshield Washer Reservoir ....................................................... 3.7

Page 50

Vehicle Access

Ignition and Lock Key

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

IMPORTANT: Each key is numbered. Record the number so, if needed, a duplicate key can be made.

Cab Door Locks and Handles

To unlock the driver’s door from outside the cab, insert the key in the lockset and turn it one-quarter turn clockwise (Fig. 3.1). Turn the key counterclockwise to the original position to remove it. Pull out on the paddle handle to open the door (Fig. 3.1).

9/07/95 f600906

1. Lockset 2. Paddle Handle

Fig. 3.1, Exterior Door Handle

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 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 opposite the unlocking direction, then close the door if it is open. Or, push down the inside lock button (Fig. 3.2), then close the door.

To lock either door from inside the cab, push down the lock button (Fig. 3.2), then close the door if it is open. Pull the integral grab bar (Fig. 3.2) when closing the door.

To open the door from the inside, pull the door handle toward you (Fig. 3.2). This will unlatch the door whether or not it is locked. To unlock the door without unlatching it, pull the lock button up.

10/27/95 f600910

1. Lock Button

2. Integral Grab Bar

Fig. 3.2, Door Interior

3. Door Handle

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.

3.1

Page 51

Vehicle Access

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 the Driver’s Side (Fig. 3.3)

Exiting the Driver’s Side (Fig. 3.3)

Exit the cab from the driver’s 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, and stand on the threshold, facing into the cab.

Grasp the grab handle at the aft edge of the door opening with your right hand.

Move your right foot to the bottom step.

Move your left hand to the grab handle.

Step to the ground with your left foot ﬁrst.

Entering the Passenger’s Side (Fig. 3.4)

02/12/96

1. Steering Wheel

2. Grab Handle

Fig. 3.3, Driver’s Side Steps and Grab Handle

3. Top Step

4. Bottom Step

f600911

When entering the cab from the driver’s side, use the grab handle and access steps as follows:

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

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

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

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.

03/27/96

1. Upper Grab Handle

2. Lower Grab Handle

Fig. 3.4, Passenger’s Side Steps and Grab Handles

3. Top Step

4. Bottom Step

f601124

When entering the cab from the passenger’s side, use the grab handles and access steps as follows:

Open the passenger’s door, and place anything that you are carrying in the cab.

3.2

Page 52

Vehicle Access

Grasp the grab handle at the aft edge of the door opening with your left hand.

Grasp the handle on the door (Fig. 3.4) with your right hand.

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

With your left hand, grasp the upper grab handle on the windshield post.

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.

Circuit Breaker/Relay Panel

The circuit breaker/relay panel is located in front of the passenger’s seat under the top cover of the instrument panel. To access the compartment, ﬁrst remove the vertical panel located immediately below the right hand adjustable louvers. Gently pry up the lower edge by using your ﬁngertips or a ﬂat-bladed screwdriver in the slots provided. Rotate the exposed fastener one-quarter turn and lift off the cover. Removal of the smaller exposed duct might also be required.

Cab-to-Sleeper Access

Exiting the Passenger’s Side (Fig. 3.4)

Exit the cab from the passenger’s side as follows:

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

Grasp the grab handle on the windshield post with both hands, 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 grab handle at the aft edge of the door opening.

Move your right hand to the grab handle on the door.

Step to the ground with your right foot ﬁrst.

Door Windows

The windows in both doors operate electrically (if so equipped). Use the appropriate switch to raise or lower a door window.

Sleeper Compartment Vents

To open any sleeper compartment vent, push the vent handle outward and forward with your ﬁngertips. To close the vent, turn your hand so that your ﬁngers are pulling on the handle from the front edge, then pull in and back on the handle. Use care to avoid pinching your ﬁngers.

WARNING

Place rigid or heavy objects in storage areas on the ﬂoor or under the bunk. Sudden stops or swerves could cause personal injury if items fall from overhead storage shelves.

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 Bunk Latches

To move the lower or upper sleeper bunk (if equipped), disengage the latch at the front of the lower bunk, or the latches on both sides of the upper bunk. Lock the bunks into operating position, down for the lower bunk and up or down for the upper bunk, by engaging both the primary and secondary latches.

Sleeper Door

The sleeper door (Fig. 3.5, 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 door, push down on the lever handle located inside the sleeper compartment to the right of the door. The door can be opened from the outside by pulling the release cable strap inside the baggage door opening. To close the door, push it closed until it latches.

3.3

Page 53

Vehicle Access

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.

02/12/96 f601031

1. Sleeper Door

2. Baggage Compartment Door

Fig. 3.5, Passenger-Side Sleeper and Baggage

Compartment Doors

Baggage Compartment Doors

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 supports.

Optional grab handles are mounted either on both cab sidewalls, or on the left sidewall only. See

Fig. 3.6. Steps are mounted either on the fuel tank(s)

or on metal brackets. When a deck plate is necessary, 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.

To unlock the baggage compartment door on the passenger’s side, insert the ignition key in the lockset, and turn it one-quarter turn clockwise. See

Fig. 3.5. Turn the key to the original position to re-

move it. Pull up and outward on the baggage door handle to open the door. To close the door, push it closed until it latches. To lock the door, insert the ignition key in the lockset and turn it one-quarter turn counterclockwise.

Use the same procedure to open the baggage compartment door on the driver’s side, but turn the key counterclockwise to unlock the door and clockwise to lock it.

Back-of-Cab Grab Handles, Steps, and Deck Plate

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

09/24/2007 f602335

1. Steps 2. Grab Handle 3. Deck Plate

Fig. 3.6, Back-of-Cab Access

3.4

Page 54

Vehicle Access

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.

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.

Battery Box Cover

To remove the cover from the frame rail-mounted battery box, release the latches that attach the left chassis fairing panel (if equipped) in front of the battery box. Remove the air fairing panel. See Group 60 of the tions. If no air fairing panel is installed, remove the step plate. Pull on the end of each hold-down latch until the end clears the cover-mounted catch. Pivot the latches out of the way, then lift off the cover. When installing the cover, be sure it is positioned properly before fastening the latches.

To remove the cover from the battery box mounted between the frame rails, remove the deck plate and lift the handle on the top of the battery box cover. If equipped, remove the spring pin.

Columbia®Workshop Manual

for instruc-

Hood Tilting

The hood can be tilted to a full-open position. A grab handle at the front of the hood provides a hand-hold for hood tilting. A torsion bar helps you 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 to the lower cab side panels 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. 3.7.

To Return the Hood

Grasp the grab handle, and lift the hood to the 45-degree position.

3.5

Page 55

11/15/1999

Fig. 3.7, Hood Tilting

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.

f880478

Vehicle Access

Dash Storage Bin

The dash storage bin is located under the cup holders on the center panel. The bin has a hinged cover and can be used to store sunglasses.

Map Holder

An elastic-topped pouch is located above each door. These are intended for holding maps and other items.

Glove Box

Some vehicles have two glove boxes and two small overhead bins, all located in the overhead console assembly. See Fig. 3.8. Above the sun visors on both the driver’s and the passenger’s sides are the glove boxes with latched doors or netted openings. In the middle section of the console assembly are two small bins. The driver’s-side bin is often removed and replaced with a CB radio. The grille underneath this portion of the console allows the radio’s speaker to be heard.

IMPORTANT: Make sure that both hold-down latches are fully engaged before operating the vehicle.

Cab Amenities

Waste Bin

To remove the waste bin, slide the waste bin out as far as it will go. Reach in behind the bin and release the bin from the stops on the bin sides. Remove the bin. To install the bin, insert the bin onto the slides, and then slide the bin into place.

Cup Holders

The Columbia vehicle features two cup holders above the ash tray and waste bin on the center panel.

Ash Tray and Cigar Lighter

The driver’s ash tray and cigar lighter assembly is on the center panel. The tray is removable.

10/15/96

1. Driver’s Glove Box

2. Driver’s Overhead Storage Bin

3. Passenger’s Overhead Storage Bin

4. Passenger’s Glove Box

Fig. 3.8, Glove Boxes and Overhead Storage

f601244

Overhead Lights

Above both the driver’s and the passenger’s seats are three oval-shaped lights mounted to the bottom of the overhead console: a red light and two white lights. The red light is mounted nearest to the windshield. Each light is activated by pushing on the lens cover. Also, the center light, a white light, activates when the doors to the vehicle are opened.

3.6

Page 56

Vehicle Access

Footwell Lights

There are optional red lights mounted underneath the dash on the driver’s and the passenger’s sides of the vehicle. These lights are activated by a rocker switch on the lower dash panel next to the climate control switches.

Windshield Washer Reservoir

The windshield washer reservoir is located on the left-hand side of the frontwall between the surge tank and the hood. See Fig. 3.9.

01/15/97

1. Surge Tank

2. Washer Reservoir

Fig. 3.9, Windshield Washer Reservoir

f820190

3. Drain

3.7

Page 57

Heater and Air Conditioner

Constant Discharge Temperature Control .............................................. 4.1

Cab Climate Control Panel .......................................................... 4.1

Sleeper Climate Control Panel ....................................................... 4.3

Parked HVAC .................................................................... 4.4

Air Outlets ....................................................................... 4.5

Page 58

Heater and Air Conditioner

Constant Discharge Temperature Control

The cab heater and air conditioner system is a Constant Discharge Temperature Control (CDTC) system. The CDTC maintains a constant temperature of airﬂow in the cab regardless of outside air temperature, selected fan speed, engine coolant temperature, or engine coolant ﬂow. Once the temperature control switch is turned to the desired temperature, no other adjustments are necessary. The CDTC system is disabled when the temperature control switch is in the maximum cool or maximum warm position.

Cab Climate Control Panel

The climate control panel allows you to control the heating and air conditioning functions of the heater and air conditioner. See Fig. 4.1.

Fan Switch

The fan switch controls the fan speed and forces fresh air or recirculated air through the selected air outlets. The fan switch has eight fan speeds and an off position.

To increase airﬂow, turn the switch clockwise or to a higher number. To decrease the airﬂow, turn the switch counterclockwise or to a lower number. Setting the fan switch to the off position disables the air conditioner and places the air source in the fresh air mode.

NOTE: When the fan switch on the cab climate control panel is off and the sleeper air conditioner is on, the cab fan will operate at low speed even though the cab fan switch is in the off position. This is necessary to protect the evaporator in the cab heater and air conditioner system from freezing.

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 selftest immediately after the engine is started, which causes the delay.

Air Selection Switch

The air selection switch allows you to control the ﬂow of air through the face outlets, the ﬂoor outlets, the defrost (windshield) outlets, or a combination of these outlets to give you nine air selection modes. See Fig. 4.2.

Face Mode: Directs all airﬂow through the face or instrument panel outlets.

Selection between Face Mode and Bi-Level Mode: Directs 75 percent of the airﬂow through

the face outlets and 25 percent through the ﬂoor outlets.

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

BUNK OVRD

06/21/2001

1. Bunk Override Switch

2. Fan Switch

4.1

3. Recirculation Button

4. Air Selection Switch

Fig. 4.1, Cab Climate Control Panel

5. Air Conditioning Button

6. Temperature Control Switch

f610450

Page 59

06/21/2001

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 Floor/Defog Mode

7. Defog Mode

8. Selection Between Defog Mode and Defrost Mode

9. Defrost Mode

f610502

Heater and Air Conditioner

Defrost Mode: Directs all airﬂow through the defrost outlets. The air conditioner automatically turns on in this mode. The recirculation button will not work in this mode.

Temperature Control Switch

The temperature control switch is used to select the desired temperature. On the manual and CDTC cli-

mate control panel, turn the switch clockwise or to the red area for warm air. Turn the switch counterclockwise or to the blue area for cool air.

Air Conditioning

The air conditioner cools and dehumidiﬁes the air inside the cab. Press the air conditioning button to turn the air conditioner on and off. See Fig. 4.3.

Fig. 4.2, Air Selection Switch Modes

Selection between Bi-Level Mode and Floor Mode: Directs 25 percent of the airﬂow through

the face outlets and 75 percent through the ﬂoor outlets.

Floor Mode: Directs all airﬂow through the ﬂoor outlets.

Selection between Floor Mode and Floor/ Defog Mode: Directs 75 percent of the airﬂow

through the ﬂoor outlets and 25 percent through the defrost outlets.

Defog Mode: Directs the airﬂow equally to the ﬂoor outlets and the defrost outlets. The air conditioner automatically turns on in this mode. The recirculation button will not work in this mode.

Selection between Defog Mode and Defrost Mode: Directs 75 percent of the airﬂow through

the defrost outlets and 25 percent through the ﬂoor outlets. The air conditioner automatically turns on in this mode. The recirculation button will not work in this mode.

06/21/2001

1. Amber Indicator

Fig. 4.3, Air Conditioning Button

f610505

When the air conditioner is operating, the amber indicator on the air conditioning button will be on whether the request for air conditioning comes from the cab climate control panel or the sleeper climate control panel. When the instrument panel lights are on, the snowﬂake indicator on the air conditioning button will be on.

The air conditioner will be automatically disabled when:

•

The outside air temperature is low enough to make air conditioning ineffective;

•

The engine is running at low rpm;

•

Speciﬁc conditions exist that result in the heater and air conditioner system going into protection mode.

4.2

Page 60

Heater and Air Conditioner

Recirculation

The 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. 4.4. The recirculation mode can also decrease the time required to cool or heat the cab interior during extreme outside temperature conditions. When the recirculation mode is on, the amber indicator on the recirculation button will be on.

06/21/2001

1. Amber Indicator

Fig. 4.4, Recirculation Button

The recirculation button will not work when the air selection switch is in one of the following modes:

•

defog mode

•

the selection between defog mode and defrost mode

•

defrost mode

f610504

NOTE: To prevent the buildup of fumes or odors and to prevent oxygen depletion inside the cab, the system switches from full recirculation mode to partial recirculation mode after 20 minutes. In extremely dusty or smoky conditions, the partial recirculation mode can be overridden by pressing the recirculation button twice to obtain full recirculation mode. This resets the 20-minute timer.

Bunk Override Switch, Optional

The bunk override (BUNK OVRD) switch allows the driver to remotely control the fan speed and temperature settings in the sleeper. See Fig. 4.1. Press the upper half of the bunk override switch to override the sleeper settings with the cab settings. The amber indicator on the switch is on when the bunk override

mode is on. If the fan speed or temperature setting on the sleeper climate control panel is adjusted when the bunk override mode is on, the bunk override mode will be canceled.

When the heating and air conditioning system is in the bunk override mode, the cab climate control panel can be adjusted without affecting the sleeper settings. To reset the sleeper settings, set the fan speed and temperature settings on the cab climate control panel to the desired sleeper settings and press the upper half of the bunk override switch again. The cab climate control panel can again be adjusted without affecting the sleeper settings.

Press the lower half of the bunk override switch to cancel the override mode. After the override mode is canceled, the sleeper heater and air conditioner system will operate from the sleeper fan speed and temperature settings and the amber indicator will be off.

Sleeper Climate Control Panel

The sleeper heater and air conditioner system features Constant Discharge Temperature Control (CDTC). The sleeper climate control panel is shown in Fig. 4.5. The CDTC maintains a constant temperature of airﬂow in the sleeper regardless of outside air temperature, selected fan speed, engine coolant temperature, or engine coolant ﬂow. Once the temperature control switch is turned to the desired temperature, no other adjustments are necessary.

Fan Switch

The fan switch controls the sleeper heater and air conditioner system fan speed. The sleeper climate control panel has eight fan speeds and an off position. To increase airﬂow, turn the switch clockwise or to a higher number. To decrease the airﬂow, turn the switch counterclockwise or to a lower number.

NOTE: When the cab air conditioner is on, the sleeper fan will operate at low speed even though 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.

Temperature Control Switch

The temperature control switch is used to select the desired temperature in the sleeper. Turn the switch clockwise or to the red area for warm air. Turn the

4.3

Page 61

06/21/2001

1. Fan Switch

2. Temperature Control Switch

Fig. 4.5, Sleeper Climate Control Panel

f610503

switch counterclockwise or to the blue area for cool air.

The air conditioner automatically turns on when necessary to maintain the selected temperature in the sleeper. If the sleeper air conditioner automatically turns on when the cab air conditioner is on, the cab air conditioner fan speed and temperature settings will override the sleeper air conditioner settings.

The CDTC system is disabled when the temperature control switch is in the maximum cool or maximum warm positions.

The bunk override switch allows the driver to remotely control the temperature and fan speed settings in the sleeper. The bunk override mode can be canceled by changing the sleeper fan speed or temperature setting. After the override mode is canceled, the sleeper heater and air conditioner system will operate from the sleeper fan speed and temperature settings and the amber indicator on the switch will be off.

Parked HVAC

The parked HVAC system consists of a compact electrical 3000-BTU air conditioning system, and a diesel-ﬁred heater unit.

Heater and Air Conditioner

Overview

The Bergstrom NITE (No Idle Thermal Environment) parked, or no-idle, air conditioning system is a compact, electrically powered, 3000-BTU system. It is designed to provide a means of air conditioning to the sleeper area without having the engine running. It is completely self-contained, and runs on 12-volt deep-cycle batteries. The system is designed to maintain cool air in the sleeper interior. For optimal operation, the curtain between the cab and the sleeper must be closed when using the A/C system. The parked A/C unit will not cool down a hot sleeper that has been sitting in the sun without the vehicle A/C running. If the interior temperature is higher than desired, start the engine and run the vehicle A/C system until the desired sleeper temperature is achieved. This will help cool the sleeper to a temperature that the parked A/C system can maintain. Once the sleeper temperature is lowered, the system will maintain a comfortable setting.

The A/C unit is located under the lower bunk in the sleeper compartment. The unit gets its intake air from the under-bunk area through a grate in the top panel. An air intake grille is located on the front panel of the lower bunk. The outlet ducting runs from the left side of the unit to an outlet near the bunk occupant’s face on the back wall of the sleeper. It is important to keep the air intake grille, and the area under the bunk, free of objects that might block air ﬂow or put objectionable odors into the cooling air. Air for the condenser is taken in from under the cab and exhausted through another opening in the cab ﬂoor.

The system receives power from four deep-cycle batteries located between the frame rails. These batteries are completely isolated from the starting batteries to keep the starting batteries from being drawn down during operation.

The heater unit is located under the lower bunk in the sleeper compartment next to the A/C unit. The unit gets its intake air through a duct attached to a grille located on the right side of the front panel of the lower bunk. The outlet ducting runs from the back of the unit to a grille on the left side of the front panel of the lower bunk.

Operation

IMPORTANT: Before operating the Parked HVAC system, make sure that the intake and

4.4

Page 62

Heater and Air Conditioner

outlet vents for the A/C and heater units are clear. Blocked vents will hamper the operation of the unit.

The control panel for the parked A/C and heater is located on the back wall of the sleeper near the left side. It has a temperature control dial, and a fourposition mode selector switch. Turn the temperature control dial to the left for cooling, and to the right for heat. See Fig. 4.6. See Table 4.1 for a description of the function of the mode switch.

The system must be turned off whenever it is not in use, or the batteries may not charge properly. After using the system, turn the mode switch to the OFF position, even if the unit is not running.

Parked A/C and Heater Mode Switch Operation

Mode Function

Off Turns the unit off.

Allows the unit to automatically heat or cool the sleeper, depending on the

AUTO

Heat Only

A/C Only

Table 4.1, Parked A/C and Heater Mode Switch

temperature setting and the sleeper temperature. Adjusts the compressor, heater, and fans to keep temperature constant.

Allows only the heat portion of the system to run. Adjusts the heater only to keep the temperature constant.

Allows only the A/C portion of the system to run. Adjusts compressor and fans only to keep the temperature constant.

Operation

08/29/2007 f831760

1. Temperature Control Dial

2. Mode Switch

3. A/C Only

Fig. 4.6, Parked A/C and Heater Control Panel

AUTO

4. Heat Only

5. AUTO

6. Off

Air Outlets

The face outlets on the instrument panel have louvers that can be moved right and left, and up and down. Move the louvers to the desired location or to close the outlet. The defrost (windshield) outlets and the outlets that are directed at the doors are not adjustable.

The sleeper has one or two air outlets on the right side of the cab, depending on the height of the cab. The sleeper air outlet pivots from side to side and has louvers that can be moved up and down or closed.

4.5

Page 63

Seats and Seat Belts

Seats ........................................................................... 5.1

Seat Belts and Tether Belts ......................................................... 5.4

Sleeper Compartment Restraints ..................................................... 5.7

Supplemental Restraint System, Optional .............................................. 5.8

Air Bag, Optional ................................................................. 5.8

SPACE System, Optional ........................................................... 5.9

Page 64

Seats and Seat Belts

Seats

General Information

Unless otherwise noted, all seat adjustments should be made while seated and before the engine is started.

WARNING

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

Seat Adjustment

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. 5.1.

Back Cushion Tilt: This adjustment enables the back cushion to pivot forward or backward.

Lumbar Support: Lumbar support changes the shape of the seat back to give more or less support to the occupant’s lumbar (lower back) area. This adjustment is either mechanical or air controlled, depending on make and model of the seat.

Isolator: This feature (also referred to as backslap isolator or Chugger-Snubber 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.

) reduces the

10/26/2000

1. Back Cushion Tilt

2. Lumbar Support

3. Isolator Feature

4. Height Adjustment

5. Bottom Cushion Angle (fore and aft cushion height)

6. Fore and Aft Seat Adjustment (seat track adjustment)

7. Seat Tilt

8. Upper Back Cushion

Fig. 5.1, Seat Adjustments

f910149a

5.1

Page 65

Height Adjustment: The entire seat moves up or down when adjusting the height. The adjustment is either manually or air controlled, depending on the make of the seat.

Bottom Cushion Angle or Fore and Aft Bottom Cushion Height: This feature enables the occupant to raise or lower the front or back of the bottom cushion. This adjustment is easier to perform when all weight is removed from the seat.

Fore and Aft Seat or Seat Track Adjustment: The entire seat moves forward or backward when this adjustment is made.

Seat Tilt: When this adjustment is made, the seat assembly (back and bottom cushions) tilts forward or backward.

Upper Back Cushion Adjustment: When this adjustment is made, the upper back cushion changes angle to provide upper back support.

Weight Adjustment: On those seats with weight adjustment, the feature is fully automatic. When you sit on the seat, a leveling valve places you in the center of the ride zone. Additional adjustments are possible by using the height adjustment feature.

EzyRider®Seat

For seat adjustment controls on vehicles built before November 28, 2005, see Fig. 5.2. For seat adjustment controls on vehicles built on or after November 28, 2005, see Fig. 5.3.

Back Cushion Tilt

Seats and Seat Belts

03/12/2001

1. Isolator and Fore/Aft Seat Adjustment Lever

2. Bottom Cushion Angle Guide

3. Armrest Adjustment Knob

4. Back Cushion Tilt Position Indicator

5. Back Cushion Tilt Lever

6. Height Adjustment and Lumbar Support Lever

7. Fore/Aft Seat Position Indicator

Fig. 5.2, EzyRider Seat Adjustment Controls (Vehicles

Built Before November 28, 2005)

Fore and Aft Seat Adjustment

Pull the fore and aft seat adjustment lever out to the second stop and slide the seat forward or backward to the desired position.

f910456

To tilt the back cushion, raise the back cushion tilt lever and lean forward or backward. Release the lever to lock the cushion in place.

Lumbar Support

To adjust the amount of support for your lower back, use the lumbar support switch or lever on the side of the seat.

Isolator

To engage the isolator, push in on the isolator lever. To lock out the isolator, pull the isolator lever out to the ﬁrst stop.

Height Adjustment

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

Bottom Cushion Angle

To adjust the bottom cushion angle, pull the bottom cushion up and forward or down and back. The bottom cushion angle is controlled by the guides on each side of the seat.

Seat Position Indicators

Seats installed in vehicles built before November 28, 2005 are equipped with seat position indicators. A back cushion tilt position indicator and a fore/aft seat

5.2

Page 66

Seats and Seat Belts

4 5

01/06/2006

1. Isolator and Fore/Aft Seat Adjustment Lever

2. Armrest Adjustment Knob

3. Bottom Cushion Angle Guide

4. Back Cushion Tilt Lever

5. Lumbar Support Switch

6. Height Adjustment Switch

Fig. 5.3, EzyRider Seat Adjustment Controls (Vehicles

Built on or After November 28, 2005)

f910565

position indicator allow the driver to see where the seat is adjusted within the adjustment ranges.

Armrest Angle (optional armrests)

To adjust the vertical angle of the armrest, turn the adjustment knob on the underside of the armrest.

Freightliner/Bostrom Seat

See Fig. 5.4 for seat adjustment controls.

Back Cushion Tilt

To tilt the back cushion, lean forward slightly to remove pressure from the cushion and hold the back cushion tilt lever rearward. Lean backward slowly to the desired position and release the lever to lock the cushion in place.

10/10/96

1. Back Cushion Tilt Lever

2. Lumbar Support Switch (LSO models)

3. Damper Adjustment Switch

4. Weight and Height Adjustment Switch

5. Bottom Cushion Tilt Knob

6. Fore and Aft Adjustment and Isolator Lever

7. Lumbar Support Knob (non-LSO models)

Fig. 5.4, Freightliner/Bostrom Seat Adjustment Controls

f910131

Weight and Height Adjustment

To raise the seat, press the upper portion of the weight and height adjustment switch. To lower the seat, press the lower portion of the switch.

Isolator

To engage the isolator, put the isolator lever in the center position. Lock out the isolator by moving the lever to the right.

Fore and Aft Seat Adjustment

Hold the fore and aft adjustment lever to the left and slide the seat forward or backward to the desired position.

Bottom Cushion Tilt Adjustment

Rotate the bottom cushion tilt knob to increase or decrease bottom cushion tilt.

5.3

Page 67

Seats and Seat Belts

Lumbar Support

To increase lumbar support on LSO models, press the plus sign on the lumbar support switch. To decrease lumbar support on LSO models, press the minus sign on the switch. To increase lumbar support on non-LSO models, rotate the lumbar support knob forward. To decrease lumbar support on non-LSO models, rotate the knob rearward.

Damper Adjustment

Press the damper adjustment switch to adjust the damper.

National 2000 Series Seat

See Fig. 5.5 for seat adjustment controls.

Height Adjustment

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

Fore and Aft Seat Adjustment

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.

Rear Cushion Adjustment

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.

Isolator

Also called a Chugger Snubber®, the isolator reduces the amount of road shock by isolating the occupant from the motion of the vehicle and allowing the seat to move in a simple pendulum motion. To use the isolator feature, turn the isolator handle to the horizontal position. Turn the isolator handle down when the isolator feature is not desired.

11/14/2000

1. Back Cushion Tilt Knob

2. Lumbar Support Switch

3. Height Adjustment Switch

4. Fore and Aft Seat Adjustment Lever

5. Bottom Cushion Front Height Adjustment Handle

6. Isolator Handle

7. Rear Cushion Adjustment Knob

Fig. 5.5, National 2000 Series Seat Adjustment Controls

f910445

Back Cushion Tilt

To tilt the back cushion, turn the back cushion tilt knob until the desired position is reached.

Lumbar Support

To adjust the lumbar support, use the lumbar support

switch on the side of the seat to give more or less support to your lower back.

Bottom Cushion Front Height

To adjust the height of the front of the bottom cushion, lift the bottom cushion front height adjustment handle, and pull forward or push back to the desired setting.

Seat Belts and Tether Belts

General Information

Seat belt assemblies are designed to secure persons in the vehicle to help reduce the chance of injury or the amount of injury resulting from accidents or sudden stops. For this reason, Daimler Trucks North

all

America LLC urges that the driver and gers, regardless of age or physical condition, use seat belts when riding in the vehicle.

passen-

5.4

Page 68

Seats and Seat Belts

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 Daimler Trucks North America (DTNA) vehicles meet Federal Motor Vehicle Safety Standard 209, "Type 1" and "Type 2" requirements.

When transporting a child, always use a child restraint system or the vehicle seat belts as appropriate. 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 restraint 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 restrain 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 replaced before operating the vehicle. Do not attempt 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 result in personal injury or death.

Inspect the seat belts and tether belts (if so equipped).

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.

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.

Check the seat belt and tether belt connection points and tighten any that are loose.

Seat Belt Operation

Three-Point Seat Belt With Komfort Latch

NOTE: For vehicles not equipped with the Komfort Latch, see the seat belt operation under the heading "Three-Point Seat Belt."

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 accident 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 hazard.

Slowly pull the link end of the three-point seat belt out of the retractor and pull it across your lap (from outboard 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.

Fasten the three-point seat belt by pushing the link into the buckle until it latches (Fig. 5.6). Give the belt a tug at the buckle. If the buckle unlatches, repeat this step. If the problem continues, replace the three-point seat belt.

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. 5.7. If desired, engage the Komfort Latch as follows.

5.5

Page 69

Seats and Seat Belts

01/18/95

Fig. 5.6, Fastening the Three-Point Belt

ABC

08/09/2010 f910634

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. 5.7, Proper Shoulder Strap Fit

f910004a

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 signiﬁcantly reduce the seat belt’s effectiveness in an accident or a sudden stop. While holding the belt slack, press the Komfort Latch lever up, clamping the seat belt webbing (Fig. 5.8 and

Fig. 5.9).

To unbuckle the three-point seat belt, push the button on the buckle as shown in Fig. 5.10.Ifthe Komfort Latch was used, release it by giving the shoulder belt a quick tug. If you lean forward against the shoulder belt, the Komfort Latch will automatically release, and will need to be reset.

01/06/95

A. 1 Inch (2.5 cm) Maximum

Fig. 5.8, Adjusting Shoulder Harness Clearance

11/02/95

Fig. 5.9, Locking Komfort Latch

f910048a

f910144

NOTE: The Komfort Latch does not have to be released in an emergency situation. The Komfort Latch will release by itself under rough road or other abnormal conditions. Make sure the three-point seat belt is completely retracted when it is not in use.

Three-Point Seat Belt

NOTE: For vehicles equipped with the Komfort Latch, see the seat belt operation under the heading "Three-Point Seat Belt With Komfort Latch."

5.6

Page 70

Seats and Seat Belts

01/18/95

Fig. 5.10, Releasing the Three-Point Seat Belt

WARNING

Fasten the seat belts before driving. Fastening a three-point seat belt while driving creates a hazard.

Fasten the three-point seat belt by pushing the latch into the buckle. Listen for an audible click. See Fig. 5.6.

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 threepoint seat belt.

Snug the seat belt to your waist.

Position the shoulder strap diagonally across your chest with the adjustable D-loop bracket (if equipped). The shoulder strap must be centered

f910049a

on your shoulder and chest, away from your face and neck. See Fig. 5.7.

To unbuckle the three-point seat belt, press the release button on the buckle; see Fig. 5.10.

NOTE: Make sure the three-point seat belt is completely retracted when it is not in use.

Sleeper Compartment Restraints

General Information

On vehicles equipped with a sleeper compartment, bunk restraints should be used whenever the sleeper compartment is occupied and the vehicle is moving. Restraints are designed to lessen the chance of injury or the amount of injury resulting from accidents or sudden stops. For this reason, Daimler Trucks North America LLC urges the use of bunk restraints when the sleeper compartment is occupied in a moving vehicle.

WARNING

Do not use the sleeper compartment while the vehicle is in motion unless a bunk restraint is installed and used. Not using the bunk restraint increases the chance of injury, or the degree of injury, from accidents or sudden stops to all occupants of the vehicle.

Bunk Restraint Adjustment

Make sure the belt is attached to the bunk support and sleeper wall.

To lengthen the belt, tip the link end downward and pull the link until it connects with the buckle.

After the belt is connected, shorten it by pulling on the loose end until the belt is snug, but comfortable. Be sure the belts are not twisted. See

Fig. 5.11.

Bunk Restraint Operation

Starting at the foot of the bunk, pull up the link end of the belt far enough to engage the buckle. See Fig. 5.12.

Fasten the belt by pushing the link end into the buckle until they latch. Make sure that the belt is

5.7

Page 71

Seats and Seat Belts

Supplemental Restraint

System, Optional

01/06/95

A. Pull on the loose end to shorten the belt.

1. Buckle

2. Belt Release Button

Fig. 5.11, Bunk Restraint Adjustment

02/14/96

1. Mattress

2. Sleeper Wall

3. Restraint

Fig. 5.12, Bunk Restraint

not twisted. Check the engagement by trying to pull the link out of the buckle. If they come apart, repeat this step. If the problem continues, replace the belt. Repeat steps 1 and 2 for the other two belts located in the middle and upper portion of the bunk to lock the restraint in place.

To release the bunk restraint, push the release button on the buckle at the head of the bunk and pull the link from the buckle.

Repeat this step for the other two buckles to completely release the bunk restraint.

3. Link

4. Belt Anchor

5. Buckle

f910068a

f910150

The supplemental restraint system can consist of an air bag and SPACE system, or an air bag only system. Your vehicle may or may not have a supplemental restraint system.

Air Bag, Optional

The air bag, when used with seat belts, provides additional protection to the driver in severe frontal collisions. The operational readiness of the air bag system is indicated by the supplemental restraint system (SRS) indicator on the dash. The SRS indicator comes on when the engine is started and then goes off. The indicator will remain on if there is a problem with the air bag system. The vehicle should be serviced if the SRS indicator does not come on when the engine is started or if the SRS indicator remains on.

WARNING

Air bags are designed to inﬂate only in severe frontal collisions. The driver and the passenger should always wear seat belts. For maximum protection in a collision or rollover, always be in a normal seated position with your back against the seat back and your head upright. Fasten your seat belt and ensure that it is properly positioned 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 keep you a safe distance from the inﬂating air bag.

Do not place objects on the steering wheel or between you and the steering wheel. Keep your hands on the sides and lower portion of the steering wheel. Any objects may cause harm during an accident.

Failure to follow these instructions may result in death or personal injury.

Air Bag Safety Guidelines

The air bag system contains components that use combustible chemicals. Because these chemicals are combustible, care must be taken when replacing or handling system components.

5.8

Page 72

Seats and Seat Belts

WARNING

Consider undeployed air bags to be dangerous and capable of deploying at any time. Do not attempt to service the air bag system unless trained to do so. Damaged air bag systems should be examined by qualiﬁed personnel before any attempt is made to remove or to deploy the air bag. All intentional deployments and testing of the system should be performed by trained personnel. Unintentional or improper air bag deployment could cause severe bodily injury or death.

Do not attempt to disassemble the air bag inﬂator unit or breach the integrity of the sealed metallic inﬂator case. Doing so could cause severe bodily injury or death.

Do not allow system chemicals to contact other liquids, combustibles, and ﬂammable materials. Doing so could cause chemical burns or personal injury.

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 irritating to the skin and eyes. Always wear rubber gloves and safety glasses when handling a deployed air bag. Immediately wash your hands and exposed skin areas with a mild soap and water. Flush your eyes immediately if exposed to sodium hydroxide.

Review and comply with the following list of warnings. Failure to do so could result in severe injury or death.

•

Keep all liquids, acids, halogens, heavy metals, and heavy salts away from the air bag system.

•

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

•

Do not expose the air bag module to electricity. Never probe a circuit.

•

Do not attempt to adapt, reuse, or install an air bag system in any vehicle other than the speciﬁc vehicle for which it is designed.

•

Do not cut wires or tamper with the connector between the vehicle wiring harness and the air bag module. Cutting or removing the

connector from the system will disable the safety shunt and could cause unintentional deployment.

•

Allow deployed air bag systems to cool after deployment.

•

Wear rubber gloves and safety glasses when handling a deployed air bag.

•

Wash your hands and exposed skin surface areas immediately after handling a deployed system.

•

Store, transport, dispose of, and recycle deployed air bag system components in accordance with all applicable federal, state, and local regulations.

•

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

perchlorate.

•

Keep all heavy objects in the cab secured.

SPACE System, Optional

The Seat Pretensioner Activation for Crash survival Enhancement (SPACE) system, when used with seat belts, provides additional protection to the driver and/or passenger in severe frontal collisions.

The SPACE system provides a signiﬁcant increase in seat stability during a severe, frontal collision. When the SPACE module senses a severe, life-threatening frontal impact, the module triggers two gas-cylinders mounted at the base of the seat. See Fig. 5.13. 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. See Fig. 5.14. The air bag is activated simultaneously. This sequence of actions occurs in about a tenth of a second.

WARNING

The SPACE system will activate during a severe, frontal collision even if the seat belts are not fastened, but the SPACE system only provides protection to the occupant when the seat belts are fastened. Always use the seat belts when operating the vehicle. Failure to do so can result in severe personal injury or death.

5.9

Page 73

Seats and Seat Belts

1 2

09/03/97

1. Pretensioning Cable Tether

2. SPACE Module

3. Suspension Seat

4. Gas Cylinder

5. Sensor Bracket

Fig. 5.13, SPACE System Components

f910172

WARNING

Damaged seat belts or seat belts that were worn in an accident must be replaced and their anchoring points must be checked. Do not attempt to modify the SPACE system. Doing so could change the effectiveness of the system. The SPACE system must be replaced after being activated. Failure to do so may result in personal injury or death.

Infants and children must not be placed in seats equipped with the SPACE system. The SPACE system is designed for adults only. Failure to follow these instructions may result in personal injury or death.

The operational readiness of the SPACE system is indicated by the supplemental restraint system (SRS) indicator on the dash. The SRS indicator comes on when the engine is started and then goes off. The indicator will remain on if there is a problem with the air bag or SPACE system. The vehicle should be serviced if the SRS indicator does not come on when the engine is started or if the SRS indicator remains on.

5 6

07/29/97

A. Seat Tether Without the SPACE System B. Seat Belt Assembly B-Pillar Components

1. Height Adjuster

2. Shoulder Loop

3. Seat Belt

4. Latch

Fig. 5.14, SPACE System Seat Belt Assembly

5. Buckle

6. Buckle Cable

7. SPACE Module

8. Seat Tether

f910235

Safety Guidelines for the SPACE System

The SPACE system contains components that use combustible chemicals. Because these chemicals are combustible, care must be taken when replacing or handling system components.

WARNING

Do not attempt to service the air bag/SPACE system. Damaged or deployed air bag/SPACE systems should be examined only by qualiﬁed personnel before any attempt is made to remove, replace, or handle the air bag/SPACE system components. All intentional deployments and testing of the system should be performed by trained personnel. Unintentional or improper deployment of the air bag/SPACE system could cause severe bodily injury or death.

5.10

Page 74

Seats and Seat Belts

Do not attempt to service or to disassemble the SPACE module. The SPACE module cannot be serviced. Doing so could result in severe bodily injury or death.

Although the air bag/SPACE system components will not likely explode, self-deploy, or produce shrapnel, take care when it is necessary to replace or perform work around the air bag/SPACE system components. Review and comply with the following list of warnings. Failure to do so could result in severe injury or death.

•

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

•

Keep all liquids, acids, halogens, heavy metals, and heavy salts away from the air bag/SPACE system.

•

Do not expose the air bag/SPACE system components to electricity.

•

Do not attempt to adapt, reuse, or install an air bag/SPACE system in any vehicle other than the speciﬁc vehicle for which it is designed.

•

Keep hands and tools away from the scissor points under the seats.

•

Do not cut wires or tamper with the connectors between the vehicle wiring harness and the air bag/SPACE system. Cutting or removing the electrical connectors could cause unintentional deployment.

•

Do not expose the air bag/SPACE system to electricity. Never probe a circuit.

•

Store, transport, dispose, and recycle deployed air bag/SPACE system components in accordance with all applicable federal, state, and local regulations.

•

Replace damaged seat belts or seat belts that were worn in an accident, and check all anchoring points. Only qualiﬁed personnel familiar with air bag/SPACE systems should replace the seat belts used in a vehicle with an air bag/SPACE system.

•

The air bag/SPACE system requires a special seat belt. Care must be taken to be sure the correct seat belt is used.

•

Keep all heavy objects in the cab secured.

5.11

Page 75

Steering and Brake Systems

Steering System .................................................................. 6.1

Brake System .................................................................... 6.1

Page 76

Steering and Brake Systems

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. 6.1. See Group 46 of the

shop Manual

10°

10/15/98

1. 9 o’Clock 2. 3 o’Clock

Fig. 6.1, Proper Steering Wheel Position (with tires

for steering adjustment procedures.

10°

pointed straight ahead)

Columbia®Work-

10°

f461694

the vehicle until the cause of the problem has been corrected.

WARNING

Driving the vehicle without the power-assist feature 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.

Brake System

General Information

A dual air brake system consists of two independent air brake 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 system operates the service brakes on the front axle. Service brake signals from both systems are sent to the trailer.

CAUTION

Never steam clean or high-pressure wash the steering gear. Internal damage to gear seals, and ultimately the steering gear, can result.

Power Steering System

The power steering system consists of an integral steering gear (which includes a manual steering mechanism, a hydraulic control valve, and a hydraulic power cylinder), hydraulic hoses, power steering pump, reservoir, and other components. Some models are also equipped with a separate hydraulic power cylinder on the right side of the front axle. The power steering pump, driven by the engine, provides the power assist for the steering system. If the engine is not running, 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

6.1

WARNING

Do not operate the vehicle with the front brakes backed off or disconnected. Backing off or disconnecting the front brakes will not improve vehicle handling and may lead to loss of vehicle control, resulting in property damage or personal injury.

IMPORTANT: On TRACTORS, loss of air pressure in the primary system causes the rear service brakes to become inoperative; front brakes will continue to be operated by secondary system air pressure. On TRUCKS, loss of air pressure in the primary system causes the rear spring brakes to get modulated, controlled by a secondary air signal. In addition, on TRACTORS and TRUCKS, trailer brakes will be operated by the secondary system.

Page 77

Steering and Brake Systems

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 observing the dual system air pressure gauge and the lowair-pressure warning light and buzzer. The warning light and buzzer shut off when air pressure in both systems reaches 64 to 76 psi (441 to 524 kPa).

The warning light and buzzer come on if air pressure drops below 64 to 76 psi (441 to 524 kPa) in either system. If this happens, check the dual system air pressure gauge to determine which system has low air pressure. 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, causing a longer stopping distance. Bring the vehicle to a safe stop, and have the air system repaired before continuing.

IMPORTANT: In the event of a total loss of service brakes with full system air pressure, use the parking brake control valve (yellow knob) to bring the vehicle to a complete stop in the safest location possible.

On tractor-trailer vehicles, if both the primary and secondary systems become inoperative, the trailer service brakes or spring parking brakes will automatically apply when air pressure drops below 35 to 45 psi (242 to 310 kPa). The tractor spring parking brakes will automatically apply when air pressure drops below 20 to 30 psi (138 to 207 kPa). On straight trucks, spring parking brakes will apply when air pressure drops below 20 to 30 psi (138 to 207 kPa). Do not wait for the brakes to apply automatically. When the warning light and buzzer ﬁrst come on, immediately bring the vehicle to a safe stop. Before continuing operation of the vehicle, correct the cause of the air loss.

Before the vehicle 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 serious 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.

Brake System Operation

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 passengers are wearing seat belts.

During normal brake stops, depress the foot brake control pedal until braking action slows down the vehicle. 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 is used in tractor air brake systems when the vehicle is not equipped with ABS. When operating in bobtail mode, the rear brake chambers (whose axle load has been greatly reduced) receive reduced or proportional air pressure, while the front axle brake chambers receive full (normal) air pressure. This results in a different brake pedal "feel," as the pedal seems to require more travel and/or effort to slow or stop the vehicle. However, the air brake proportioning system actually improves vehicle control when the tractor is in the bobtail mode of operation. When the tractor is towing a trailer, the rear brake chambers will receive full (normal) application air pressure.

NOTE: If equipped with main and auxiliary transmissions, do not shift both transmissions into neutral while the vehicle is rolling. Shifting both transmissions back into gear would be difficult while the vehicle is rolling.

The trailer brake hand control valve (Fig. 6.2) actuates the trailer service brakes independently from the vehicle chassis service brakes. The valve can be partially or fully applied, but in any partially-on position it will be overridden by a full application of the foot brake control pedal. Moving the valve handle clockwise actuates the trailer brakes, while moving it counterclockwise releases the trailer brakes. The valve handle is spring-loaded and returns to it’s original, no-air application position when released.

6.2

Page 78

Steering and Brake Systems

9/26/95 f461056

1. Turn Signal Lever

2. Trailer Brake Hand Control Valve

3. Hazard Warning Light Tab

Fig. 6.2, Steering Column-Mounted Controls (left-hand

drive shown)

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 (Fig. 6.3) in the control panel actuates the trailer air supply valve. 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 red knob must be pushed in. It should stay in, to charge the trailer air supply system and to release the trailer spring parking brakes. It must be pulled out before disconnecting a trailer. It must also be pulled out when operating a vehicle without a trailer. If pressure in both air systems drops to 35 to 45 psi (242 to 310 kPa), the red knob automatically pops out, exhausting the trailer air supply, and applying the trailer service or spring parking brakes.

The yellow diamond-shaped knob (Fig. 6.3)inthe control panel actuates the parking brake valve. Pulling out the knob applies both the tractor and trailer spring parking brakes and automatically causes the trailer air supply valve knob to pop out.

CAUTION

Do not use the spring parking brakes if the service brakes are hot, such as after descending a steep grade. Also, do not use the spring parking brakes during freezing temperatures if the ser-

03/10/99

1. Trailer Air Supply Valve Knob

2. Parking Brake Valve Knob

Fig. 6.3, Brake Valve Knobs

vice brakes are wet. To do so could damage the brakes if hot, or cause them to freeze during cold weather.

If the brakes are wet, drive the vehicle in low gear and lightly apply the brakes to heat and dry them. Allow hot brakes to cool before using the spring parking brakes. Always chock the tires.

If the trailer is not equipped with spring parking brakes, pulling out the yellow knob applies the tractor spring parking brakes and the trailer service brakes. When the tractor and trailer parking brakes (or trailer service brakes) are both applied, the trailer brakes are released by pushing in the red knob, leaving the tractor parking brakes applied. Air pressure in the primary or secondary 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.

On trailers not equipped with spring parking brakes, chock the trailer tires before disconnecting the truck or tractor when parking just the trailer.

When parking a truck or tractor with a trailer (combination vehicle), and the trailer is not equipped with spring parking brakes, apply the truck or tractor spring parking brakes.

f610291

WARNING

If a trailer is not equipped with spring parking brakes, do not park it or a combination vehicle by pulling 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.

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Steering and Brake Systems

CAUTION

Never apply the service and spring parking brakes simultaneously. To do so transmits excessive input force to the brake components, which could damage or cause eventual failure of brake actuating components.

Meritor WABCO®Antilock Braking System (ABS)

The Meritor WABCO Antilock Braking System (ABS) is an electronic wheel speed monitoring and control system that works with the standard air brake system. ABS passively monitors vehicle wheel speed at all times, and gency stops. If equipped with Automatic Traction Control, wheel spin is controlled during reducedtraction situations. In normal braking applications, the standard air brake system is in effect.

controls

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 differentsized tires could result in a reduced braking force, leading to longer stopping distances.

ABS includes signal-generating tone wheels and sensors located in the wheel hubs of each sensed wheel. The sensors transmit vehicle wheel speed information to an electronic control unit (located on the frame rail). The control unit’s main circuit interprets the speed sensor signals and calculates wheel speed, wheel retardation, and a vehicle reference speed. If the calculations indicate wheel lockup, the main circuit signals the appropriate solenoid control valve to reduce braking pressure. During emergency braking, the solenoid control valve alternately reduces, increases, or maintains air pressure supply in the brake chamber to prevent front and rear wheel lockup.

If equipped with Automatic Traction Control, an additional solenoid valve is installed. During reducedtraction situations, the valve increases or reduces air pressure supply in the brake chamber to provide better traction whenever wheel spin occurs.

The electronic control unit also has a safety circuit that constantly monitors the wheel sensors, traction control valve (if equipped), solenoid control valves, and the electrical circuitry.

wheel speed during emer-

After the ignition switch is turned on, the tractor warning light (TRACTOR ABS) and, if equipped with Automatic Traction Control, the wheel spin (WHEEL SPIN) indicator light come on for about three seconds. After three seconds, the warning lights go out only if all of the tractor’s ABS components are working.

Vehicles with electronic engines and ABS may have automatic traction control (ATC). On these vehicles, the ATC system automatically limits wheel spin during reduced-traction situations.

If the vehicle has ATC, there will be a momentary contact rocker switch on the dash labeled NORM/ SPIN and ATC.

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 electronic engine to reduce power.

Pressing NORM/SPIN will temporarily allow more drive wheel spin to help burn through a thin layer of ice, or to help throw off accumulated mud or snow. SPIN mode is indicated by a ﬂashing WHEEL SPIN light. Pressing NORM/SPIN again will cycle the system back to normal operation.

The Meritor WABCO ABS system combines one front-axle control channel with one rear axle to form one control circuit. For example, the sensor and solenoid control valve on the left-front axle form a control circuit with the sensor and solenoid control valve on the right rear axle. If, during vehicle operation, the safety circuit senses a failure in any part of the ABS system (a sensor, solenoid control valve, wiring connection, short circuit, etc.), the tractor warning light (TRACTOR ABS) comes on 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 system is completely inoperative, normal braking ability is maintained. An exception would be if a solenoid control valve (or combination solenoid control valve) is damaged and inoperative. As these components are an integral part of the air brake system, normal braking may be impaired or inoperative.

IMPORTANT: If any of the ABS warning lights do not work as described above, or come on while driving, repair the ABS system immediately to ensure full antilock braking capability.

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Steering and Brake Systems

During emergency or reduced-traction stops, fully depress the brake pedal until the vehicle comes to a safe stop; brake pedal fully depressed, the ABS system will control all wheels to provide steering control and a reduced braking distance.

Although the ABS system improves vehicle control during emergency braking situations, the driver still has the responsibility to change driving styles depending on the existing traffic and road conditions. For example, the ABS system cannot prevent an accident if the driver is speeding or following too closely.

do not pump

the brake pedal. With the

Trailer ABS Lamp Operation

Antilock Braking Systems (ABS) on tractors are designed to communicate with trailer ABS systems, if they are compatible. Compatibility will result in the illumination of the trailer ABS lamp during vehicle start-up and fault detection.

The dash-mounted lamp will operate as follows when a compatible trailer is properly connected to a tractor:

•

When the ignition key is turned to the ON position, the trailer ABS lamp will illuminate momentarily, then turn off.

•

If the lamp comes on momentarily during vehicle operation, then shuts off, a fault was detected and corrected.

•

If the lamp comes on and stays on during vehicle operation, there is a fault with the trailer ABS. Repair the trailer ABS system immediately to ensure full antilock braking capability.

The Trailer ABS lamp will not illuminate unless a compatible trailer is connected to the tractor.

IMPORTANT: If a compatible trailer is connected, and the lamp is not illuminating momentarily when the ignition key is turned to the ON position, it is possible that the lamp is burnt out.

Meritor WABCO Electronic Braking System (EBS)

The Meritor WABCO Electronic Braking System (EBS) is designed to continuously monitor and coordinate all aspects of service braking.

The EBS pairs an electronic control system with a pneumatic application system. Key braking data such

as driver brake demand, wheel speed, and vehicle load is gathered by a network of electronic sensing devices (including load sensors, and signal generating tone wheels and sensors located in the wheel hubs of each sensing axle).

An electronic control unit, the central module, oversees the translation of electronic signals into pneumatic actuation. During a braking application, electronic-pneumatic modulators control the brake pressure of each wheel, as well as at the trailer coupling head. As a result, the same amount of vehicle deceleration will occur for a given brake pedal travel, regardless of vehicle load. During emergency stops (i.e. wheel lockup), the EBS also activates the Antilock Braking System (ABS).

The EBS includes a system check for all modulators, sensors, brake system electric circuits and data lines and is thereby able to detect malfunctions in the braking system. When a fault is detected, the central module will disable the affected part of the EBS. Under this safe status (i.e. fail-safe) mode, the nonaffected parts will continue to function. For example, in the case of a sensor malfunction, the system works without the sensor information but at a reduced performance level.

If a serious malfunction causes a total loss of one or more electronic braking circuits, a pure pneumatic backup system is available.

The following functions can be deactivated in the event of a malfunction:

•

ABS can be deactivated at one individual wheel, at one axle, or for the whole vehicle.

•

ATC control can be deactivated. If it is shut down, then both the ATC brake control and the ATC engine control will be shut down.

•

If electrical control is lost, the affected axle is braked by means of the pneumatic redundancy pressure. The driver must compensate by exerting more force on the brake pedal to stop the vehicle.

This system has built-in diagnostics to ensure that all components are operating properly. Under normal conditions, the system performs a three second selfcheck when the ignition is turned on. The two warning lamps (EBS, ABS) and the information lamp (ATC) should illuminate for three seconds and then go out if all EBS components are working properly. If all three lamps do not switch on or if all three lamps

6.5

Page 81

do not switch off after three seconds, the system should be checked.

NOTE: If there is no bulb check and no displayed fault, most likely the brake pedal is partially depressed, either by the driver or by something holding the pedal down. This safety feature alerts the driver that the brake pedal is not fully in the released position.

Automatic Slack Adjusters

Automatic slack adjusters are required on all vehicles equipped with air brakes manufactured after October 20, 1994. 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 situation.

When the brake pushrod stroke exceeds the legal brake adjustment limit on a vehicle, there is likely a mechanical problem with the foundation brake components 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.

Steering and Brake Systems

WARNING

Manually adjusting an automatic slack adjuster to bring the pushrod stroke within legal limits is likely masking a mechanical problem. Adjustment is not repairing. In fact, continual adjustment of automatic slack adjusters may result in premature wear of the adjuster itself. Further, the improper adjustment of some automatic slack adjusters may cause internal damage to the adjuster, thereby preventing it from properly functioning.

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Engines and Clutches

EPA07 Aftertreatment System (ATS) .................................................. 7.1

DD15 Heavy-Duty Engine .......................................................... 7.3

Engine Starting—CAT, Cummins, DDE S60, M-B ........................................ 7.6

Starting After Extended Shutdown or Oil Change—CAT, Cummins, DDE S60, M-B ............. 7.9

Engine Break-In—CAT, Cummins, DDE S60, M-B ...................................... 7.10

Engine Operation—CAT, Cummins, DDE S60, M-B ..................................... 7.10

Cold-Weather Operation—CAT, Cummins, DDE S60, M-B ............................... 7.13

High-Altitude Operation—CAT, Cummins, DDE S60, M-B ................................ 7.15

Engine Shutdown—CAT, Cummins, DDE S60, M-B ..................................... 7.15

Engine Braking Systems—CAT, Cummins, DDE S60, M-B ............................... 7.16

Exhaust Brake System—CAT, Cummins, DDE S60, M-B ................................. 7.19

Clutches ....................................................................... 7.20

Page 83

Engines and Clutches

EPA07 Aftertreatment System (ATS)

On-road diesel engines built after December 31, 2006, 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.

EPA07-compliant engines require ultralow-sulfur diesel (ULSD) fuel, and they should never be run on fuel with sulfur content higher than 15 ppm. In addition, they require low-ash engine oil. The following guidelines must be followed, or the warranty may be compromised.

•

Use ultralow-sulfur diesel (ULSD) with 15 ppm sulfur content or less, based on ASTM D2622 test procedure.

•

Do not use fuel blended with used engine lube oil.

•

Engine lube oil must have a sulfated ash level less than 1.0 wt %, meeting the API CJ-4 index speciﬁcations.

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

The "exhaust system" in EPA07-compliant vehicles is called the aftertreatment system (ATS). The ATS varies according to engine manufacturer and vehicle conﬁguration, but instead of a muffler, an aftertreatment system has a device that outwardly resembles a muffler, called the aftertreatment device (ATD).

IMPORTANT: See the manufacturer’s engine operation manual for complete details and operation of the aftertreatment system.

Inside the ATD on Mercedes-Benz, Detroit Diesel, and Cummins engines, the exhaust ﬁrst passes over the diesel oxidation catalyst (DOC), then it passes through the DPF, which traps soot particles. If exhaust temperature is high enough, the trapped soot is reduced to ash, in a process called passive regeneration (regen). Passive regeneration occurs as the

vehicle is driven normally under load; the driver is not even aware that it is happening. The harder an EPA07 engine works, the better it disposes of soot, as the exhaust heat alone is enough to burn the soot to ash. Over the course of a workday, however, passive regeneration cannot always keep the ATD ﬁlter clean, so the ﬁlter must undergo active regenera- tion. In active regeneration, extra fuel is injected into the exhaust stream to superheat the soot trapped in the DPF and turn it to ash. Active regeneration happens only when the vehicle is moving above a certain speed, determined by the engine manufacturer. Consult manufacturers’ documentation for details.

Both active and passive regeneration happen automatically, without driver input.

NOTE: Caterpillar engines do not use a DOC; CAT engines burn diesel fuel at the regeneration head to superheat the exhaust and burn the trapped soot to ash. Engine software monitors and controls this process.

Only when operating conditions do not allow for ATD ﬁlter cleaning by at-speed active or passive regeneration, the vehicle may require a parked regenera- tion. The vehicle must be standing still, and the driver must initiate the parked regen. Completing a parked regen takes 20 minutes to an hour, depending on ambient conditions.

DANGER

During parked regeneration, exhaust temperatures are very high, and could cause a ﬁre, heat damage to objects or materials, or personal injury to persons near the exhaust outlet.

Before initiating a parked regeneration, make certain the exhaust outlets are directed away from structures, trees, vegetation, ﬂammable materials, and anything else that may be damaged or injured by prolonged exposure to high heat.

The warning lamps in the driver message center alert the driver of a regen in progress, high exhaust temperatures, the need to perform a parked regen either soon or immediately, and of an engine fault that affects the emissions.

A slow (10-second) ﬂashing of the high exhaust system temperature (HEST) lamp indicates that a parked regeneration is in progress, and the engine’s

7.1

Page 84

Engines and Clutches

high idle speed is being controlled by the engine software, not the driver.

A steadily illuminated high temperature (HEST) lamp alerts the operator of high exhaust temperature during the regeneration process, if vehicle speed is below 5 mph (8 km/h). See Fig. 7.1. The HEST lamp does not signify the need for any kind of vehicle or engine service; it only alerts the vehicle operator of high exhaust temperatures. Make sure the engine exhaust pipe outlet is not directed at any person, or at any surface or material that will melt, burn, or explode.

09/25/2006 f610816a

Fig. 7.1, High Exhaust System Temperature (HEST)

Lamp

Fig. 7.2. A DPF lamp blinking at the same time as a

steadily illuminated yellow Check Engine lamp, indicates that a parked regen must be performed immediately, or an engine derate will occur. If the red Stop Engine lamp illuminates with the blinking DPF lamp and the Check Engine lamp, a parked regen must occur or an engine shutdown will occur. Park the vehicle and perform a parked regen. See Fig. 7.3.

09/25/2006 f610815a

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

CHECK

STOP

WARNING

Active regeneration can occur automatically anytime the vehicle is moving. The exhaust gas temperature could reach 1500°F (800°C), which is hot enough to cause a ﬁre, heat damage to objects or materials, or personal injury to persons near the exhaust outlet. See in this chapter for instructions on preventing automatic regen if necessary.

The exhaust temperature can remain high even after the vehicle has stopped. When stopping the vehicle shortly after an automatic regen, ensure the exhaust outlets are directed away from structures, trees, vegetation, ﬂammable materials, and anything else that may be damaged or injured by exposure to high heat.

A steadily illuminated yellow diesel particulate ﬁlter (DPF) lamp indicates that a regen may be required soon. Bring the vehicle to highway speeds to allow for an active regen, or a parked regen should be scheduled for the earliest convenient time. See

Regen-Inhibit Switch

later

03/20/2008 f611000

1. Stop Engine Override Switch

2. Amber Check Engine Warning Lamp

3. Red Stop Engine Lamp

123

Fig. 7.3, Engine Lamps

A solid yellow malfunction indicator lamp (MIL) indicates an engine fault that affects the emissions. See

Fig. 7.4.

When diesel particulate ﬁlter servicing is needed, it must be performed by an authorized technician, and a record must be maintained for warranty purposes. The record must include:

•

date of cleaning or replacement;

•

vehicle mileage;

•

particulate ﬁlter part number and serial number.

The regen switch (Fig. 7.5), located on the dash, is used to initiate a parked regen of the aftertreatment device.

7.2

Page 85

Engines and Clutches

09/25/2006 f610814a

Fig. 7.4, Malfunction Indicator Lamp (MIL)

10/02/2006

Fig. 7.5, Regen Switch

f610848

NOTE: The regen switch can start a parked regen only when at least one of two conditions exists: either the DPF light is illuminated, or the engine software calls for it. If neither of those conditions exist, the regen switch cannot cause a regeneration to happen.

The regen-inhibit switch provides additional control over the aftertreatment regeneration process. The inhibit switch will stop a regeneration cycle in progress, and prevent the start of a regeneration cycle until the switch is no longer active. See

Fig. 7.6.

DD15 Heavy-Duty Engine

See Chapter 2 of this manual for information on the DDEC VI operator controls. See the

DD15 Engine Operator’s Guide

of engine operation.

Detroit Diesel

for complete details

07/30/2009

Fig. 7.6, Regen-Inhibit Switch

f610944

Engine Protection

An engine protection system monitors all engine sensors and electronic components, and recognizes system malfunctions. If a critical fault is detected, an amber Check Engine warning lamp and a red Stop Engine lamp illuminate. See Fig. 7.3.

The standard parameters that are monitored for engine protection are: low coolant level, high coolant temperature, low oil pressure, and high oil temperature.

Amber Check Engine Warning Lamp

When the amber Check Engine warning lamp comes on for any reason, the vehicle can still be operated, and the driver can proceed to the required destination. See Fig. 7.3. This condition should be reported to an authorized service center as soon as possible.

Red Stop Engine Lamp

When the red Stop Engine lamp comes on, the computer has detected a major malfunction in the engine that requires immediate attention. See Fig. 7.3. It is

the operator’s responsibility to shut down the engine to avoid serious damage.This system fea-

tures a 30-second, stepped-down power-shutdown sequence, or an immediate emergency-running mode, in the event that a major engine malfunction occurs. The conditions that will cause the red Stop Engine lamp to come on are:

•

high coolant temperature

•

loss of coolant

•

high oil temperature

7.3

Page 86

Engines and Clutches

•

low oil pressure

•

auxiliary shutdown

Stop Engine Override Switch

In the event that the vehicle is operating in a critical location when a shutdown is initiated, a Stop Engine Override (SEO) switch can be used to override the shutdown sequence. See Fig. 7.3. This override resets the shutdown timer, restoring power to the level when the red stop engine lamp was illuminated. The switch must be recycled after ﬁve seconds to obtain a subsequent override.

CAUTION

Using the override button so the engine operates for an extended period may result in engine damage. The operator has the responsibility to take action to avoid engine damage.

DDEC VI Driving Tips

Accelerating the Vehicle

The accelerator pedal was designed to communicate "percentage" of accelerator pedal travel to the engine MCM. A throttle characteristic you may need time to get used to, is the DDEC limiting speed governor. This allows the driver to command total engine response between idle and rated speed, such as accelerating at half throttle—an advantage when driving under slippery conditions. To obtain 100 percent fueling at any speed, the accelerator pedal must be depressed to the fully pressed position.

Shifting

Depending on your transmission model, the gear split may vary from 400 to 500 rpm. The electronic governor provides almost no overrun capability; if the transmission is downshifted too early, you will experience a temporary loss of pulling power until the engine speed falls below rated speed. In general, when using a 9-speed transmission, you should always downshift between 1000 and 1100 rpm. This is true even on steep grades with heavy loads. When using an 18-, 15-, or 13-speed transmission, you will need to downshift at an rpm that allows "less than rated" rpm, before throttle application in the next gear down. You may want to limit engine speed to 1900 rpm in all gears.

The DD15 engine provides horsepower through 2100 rpm, but fuel economy is not as efficient above 1800 rpm. If you decide to drive at lower rpm for improved fuel economy, don’t let different engine noises throw you off guard. The DD15 engine sounds quiet at 1400 rpm, almost as if it had quit pulling. If you had a boost gauge to look at while driving, you would notice the turbocharger maintaining steady intake manifold pressure, even as rpm falls. Depending on the air intake arrangement, you may also hear a "chuffing" sound as the engine starts to pull hard at lower rpm. This is normal, and caused by the velocity changes of the air ﬂow within the air intake plumbing. Electronic engines can actually deliver more fuel at lower engine speeds than at rated speed.

The DD15 engine has been designed for a very quiet operation, but the air ﬂow may be noticeable to the tuned attentive ear. The turbocharger operates at higher boost pressure, forcing exhaust to ﬂow through the exhaust gas recirculation plumbing. In some situations the driver may believe they have experienced a charge air cooler system leak. Even while connecting trailer lights and air hoses, the driver may hear a different tone (exhaust and under hood with the engine idling). If equipped with a turbo boost gauge, the driver may occasionally note the intake manifold pressure exceeds 35 psi (241 kPa).

Idling

The common belief that idling a diesel engine causes no engine damage is wrong. 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 heat or cooling, the high idle function of the cruise control switches should be used. An idle speed of 900 rpm should be enough to provide cab heat in above freezing ambient temperatures.

Cold-Weather Operation

Precautions must be taken during cold weather to protect your engine. Special cold-weather handling is required for fuel, engine oil, coolant, and batteries. The engine does not require starting aids down to 50°F (10°C). A grid heater is included for temperatures between 50°F (10°C) and –4°F (–20°C). Temperatures below –4°F (–20°C), will require a grid heater, block heater, and oil pan heater.

7.4

Page 87

Engines and Clutches

CAUTION

NEVER use ether as a starting aid on a DD HD engine. Doing so will result in injector damage.

A winterfront may be used to improve cab heating. At least 25 percent of the grill opening should remain open in sectioned stripes that run perpendicular to the charge air cooler tube ﬂow direction. This assures even cooling across each tube, and reduces header-to-tube stress and possible failure. Winterfronts should only be used when the ambient temperature remains below 10°F (–12°C).

Driving on Flat, Dry Pavement

Use the following guidelines when driving on ﬂat, dry pavement.

•

If driving on ﬂat, dry, open stretches, with a light load, place the progressive braking switch in the LOW position.

•

If you ﬁnd you are still using the service brakes, move the switch to a higher position until you do not need to use the service brakes to slow the vehicle.

•

If you are carrying a heavier load and road traction is good, move the progressive braking switch to the HIGH position.

•

Check your progressive braking switch often for proper position, since road conditions can change quickly. Never skip a step when operating the progressive braking switch. Always go from OFF to LOW, and then to a higher position.

Descending a Long, Steep Grade

An explanation of "control speed" may be helpful in understanding how to use the engine brake system while descending a grade. Control speed is the constant speed at which the forces pushing the vehicle forward on a grade, are equal to the forces holding it back, without using the vehicle service brakes. In other words, this is the speed the vehicle will maintain without using the service brakes or throttle.

CAUTION

use of the vehicle brakes will cause them to heat up, reducing their stopping ability. This condition, referred to as “brake fade”, may result in loss of braking, which could lead to loss of control of the vehicle, resulting in personal injury or property damage.

Use the following guidelines when descending a long, steep grade.

•

Before beginning the descent, determine if your engine brake system is operating properly, by lifting your foot brieﬂy off the accelerator pedal. You should feel the system activate.

•

Ensure the progressive braking switch is in the appropriate power position. Check your progressive braking switch often for proper position, since road conditions can change quickly. Never skip a step when operating the progressive braking switch. Always go from OFF to LOW and then to a higher position when on slippery roads.

•

Do not exceed the safe control speed of your vehicle. Example: You could descend a 6 percent grade, under control at 10 mph (16 km/h) without an engine brake, but at 25 mph (40 km/h) it requires an engine brake. You could not descend that same hill at 50 mph (80 km/h) and still expect to remain under control. Know how much slowing power your engine brake can provide before descending hills, and do not exceed a safe control speed.

Driving on Wet or Slippery Pavement

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

•

when driving without a trailer (bobtailing) or pulling an empty trailer

•

if the tractor drive wheels begin to lock, or there is ﬁshtail motion after the engine brake is activated

Do not over apply the vehicle service brakes when descending a long, steep grade. Excessive

7.5

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Engines and Clutches

NOTE: On single trailers or combinations, a light air application of the trailer brakes may be desirable to help keep the trailer stretched out. Follow the manufacturer’s recommended operating procedure when using the trailer brakes.

On wet or slippery pavement, start with the master switch in the OFF position and use the gear you would normally use under these conditions. If the vehicle is maintaining traction, place the selective braking switch in the LOW position and turn ON the engine brake system. If the drive wheels are maintaining traction and you desire greater slowing power, move the braking switch to the next higher position. However, if the tractor drive-wheels begin to lock, or there is a ﬁshtail motion, turn the engine brake system OFF immediately and do not activate it until road conditions improve.

Check your progressive engine braking switch often for proper position, since road conditions can change quickly. Never skip a step when operating the progressive braking system. Always go from OFF to LOW and then to a higher position. See Chapter 2 for the proper operation of the engine brake.

Engine Starting—CAT, Cummins, DDE S60, M-B

Normal Starting

NOTE: Before starting the engine, read Chap-

ter 2 for detailed information on how to read the

instruments and operate the controls. Read the operating instructions in the engine manufacturer’s operating manual before starting the engine.

IMPORTANT: Ring gear and starter pinion damage caused by improper starting procedures is not warrantable.

CAUTION

When starting a vehicle equipped with a manual transmission and clutch lockout switch, the clutch pedal must be fully depressed during the entire start sequence. Failure to do so can cause the pinion to release and re-engage, which could cause ring gear and starter pinion damage.

If a vehicle does not start on the ﬁrst attempt, make sure that the engine has completely stopped rotating before reapplying the starter switch. Failure to do so can cause the pinion to release and re-engage, which could cause ring gear and starter pinion damage.

Moving a vehicle with the starter and/or using the starter to bump the engine for maintenance procedures is strictly prohibited. Use of these methods to bump the engine over or move the vehicle can cause the pinion to release and re-engage, which could cause ring gear and starter pinion damage.

Prestart

NOTE: These prestart steps apply to all the following engines.

Before engine start-up, perform the engine pretrip inspection and daily maintenance checks in

Chapter 11.

Apply the parking brake.

For manual transmissions, place the transmission in neutral and step on the clutch pedal. Do not push the accelerator pedal.

NOTE: On vehicles equipped with a neutral start switch, the transmission must be in neutral before the engine can be started. For air start systems, check the air supply before starting the engine. There must be 100 psi (689 kPa) of air pressure available.

Starting Precautions

CAUTION

Do not crank the engine for more than 30 seconds at a time. Wait two minutes after each try to allow the starter to cool. Failure to do so could cause starter damage.

NOTE: Some starters are equipped with optional overcrank protection. If overcranking occurs, a thermostat breaks the electrical circuit to the starter motor until the motor has cooled.

7.6

Page 89

Engines and Clutches

CAUTION

Protect the turbocharger during the start-up by not opening the throttle or accelerating the engine above 1000 rpm until normal engine idle oil pressure registers on the gauge.

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.

Caterpillar

NOTE: Before doing these steps, do the steps in "Prestart."

Turn the ignition switch to the on position. See

Fig. 7.7. All the electronic gauges on the ICU

(instrumentation control unit) complete a full sweep of their dials, the warning and indicator lights light up, and the buzzer sounds for 3 seconds.

2.1

If the engine does not start after 30 seconds of cranking, turn the ignition switch off.

NOTE: Some starters are equipped with optional overcrank protection. If overcranking occurs, a thermostat breaks the electrical circuit to the starter motor until the motor has cooled.

2.2

Wait two minutes to allow the starter motor to cool. Turn the ignition switch back to the on position and try again to start the engine.

2.3

As soon as the engine starts, release the ignition switch, allowing the engine to run at a slow idle.

CAUTION

If the oil pressure is less than 5 psi (35 kPa), shut down the engine immediately to prevent serious damage. If the vehicle is equipped with an automatic shutdown system, the engine will shut down after 30 seconds.

Caterpillar C–10/C–12/C–15/C–16 engines may be operated at low load and speed once the engine oil pressure has reached 10 to 20 psi (69 to 138 kPa). Caterpillar 3406E engines may be operated at low load and speed once the engine oil pressure has reached 18 psi (124 kPa).

When the engine has reached the normal operating temperature of 189°F (87°C), the engine may be operated at full load.

OFF

ACC

03/22/2001

Fig. 7.7, Ignition Switch Positions

START

f602079

NOTE: The engine electronics supply the correct amount of fuel for starting the engine. Pedal pressure is unnecessary.

Turn the ignition switch to the start position. Do not press down on the throttle pedal. Release the switch the moment the engine starts.

7.7

Detroit Diesel S60

NOTE: Before doing these steps, do the steps in "Prestart."

Turn the ignition switch to the on position. See

Fig. 7.7. All the electronic gauges on the ICU

(instrumentation control unit) complete a full sweep of their dials, the warning and indicator lights light up, and the buzzer sounds for three seconds.

When all the indicators go out, turn the ignition switch to the start position. Without touching the throttle pedal, start the engine. If the engine won’t start within 15 seconds, release the ignition switch and allow the starter motor to cool.

Page 90

Engines and Clutches

IMPORTANT: If the engine won’t start, check the main engine power fuses. The fuses are located along the main engine electrical harness on the left frame rail, near the batteries. If the fuses are blown, replace the fuses. Be sure to ﬁnd the cause of the blown fuses as soon as possible.

NOTE: Some starters are equipped with optional overcrank protection. If overcranking occurs, a thermostat breaks the electrical circuit to the starter motor until the motor has cooled.

WARNING

Check the oil pressure gauge immediately after starting the engine.

If no pressure registers within 10 to 15 seconds or the ENGINE PROTECT indicator comes on, shut down the engine and check the lubricating oil system.

sweep of their dials, the warning and indicator lights light up, and the buzzer sounds for three seconds.

IMPORTANT: On vehicles equipped with an intake air preheater, the INTAKE HEATER indicator stays on for a minimum of two seconds, regardless of coolant temperature. Wait until the INTAKE HEATER indicator goes out before attempting to start the engine.

Turn the ignition switch to the start position. Without touching the throttle pedal, start the engine.

NOTE: Some starters are equipped with optional overcrank protection. If overcranking occurs, a thermostat breaks the electrical circuit to the starter motor until the motor has cooled.

It is not necessary to idle the engine before engaging or starting the operation, but load should be applied gradually during the warm-up period until the oil temperature reaches 140°F (60°C).

Check the oil pressure gauge for any drop in lubricating oil pressure or mechanical malfunction in the lubricating oil system. Minimum oil pressure at idle is 7 psi (50 kPa).

CAUTION

Protect the turbocharger during the start-up by not opening the throttle or accelerating the engine above 1000 rpm until minimum engine idle oil pressure of 12 psi (83 kPa) registers on the gauge.

Idle the engine for about ﬁve minutes at 1000 rpm before operating the engine under load.

Mercedes-Benz

NOTE: Before doing these steps, do the steps in "Prestart."

CAUTION

Never attempt to start any Mercedes-Benz electronic engine using ether or any other starting ﬂuid. Serious engine damage could result.

Turn the ignition switch to the on position. See

Fig. 7.7. All the electronic gauges on the ICU

(instrumentation control unit) complete a full

CAUTION

Do not rev the engine if the oil pressure gauge indicates no oil pressure. Shut down the engine if no oil pressure appears within approximately ten seconds. Check to determine the cause of the problem. Operating the engine with no oil pressure will damage the engine.

Cold-Weather Starting

Modern electronic engines do not normally require special starting aids. At low temperatures, oil pan heaters or water jacket heaters are sometimes used to assist in starting.

Caterpillar

WARNING

If using a cold-weather-start system, be sure to follow the manufacturer’s instructions regarding

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its use, handling, and storage. Many starting ﬂuids are in capsules or pressure cans, and improper usage can be dangerous.

Do not attempt to use any type of vaporcompound start system near heat or open ﬂame. Engine damage due to an explosion or ﬁre in the intake manifold could result.

Do not breathe the ether fumes; doing so could result in personal injury.

Turn the ignition switch to the on position. See

Fig. 7.7.

If the engine doesn’t start after 30 seconds of cranking, turn the key to the off position and wait two minutes; then repeat the starting procedure.

If the coolant temperature is less than 64°F (18°C), the engine will start up in the cold-start strategy. This reduces the amount of fuel available to the injectors, advances the timing, and controls white smoke emissions. The engine remains in the cold-start strategy until the coolant temperature rises above 64°F (18°C), or until it has been running for 12 minutes.

IMPORTANT: Do not move the vehicle when it is in the cold-start strategy. Power will be noticeably reduced.

After a cold engine start of less than 64°F (18°C), Caterpillar electronic engines automatically idle at 800 rpm (for C–10 and C–12 engines), or 600 rpm (for 3406E, C–15, and C–16 engines). These electronic engine systems will adjust the idle speed to 700 to 750 rpm when the engine is warm enough to drive the vehicle.

Detroit Diesel S60

The engine may require the use of a cold-weather starting aid if the outside temperature falls below 40°F (4°C).

Turn the ignition switch to the on position and start the engine.

If the engine doesn’t start after 30 seconds of cranking, turn the key to the off position and wait two minutes; then repeat the starting procedure.

Run the engine slightly above idle until oil pressure shows on the gauge. If oil pressure doesn’t show on the gauge within 30 seconds of starting, turn the key to the off position and wait one minute; then repeat the starting procedure.

Mercedes-Benz

CAUTION

Never attempt to start any Mercedes-Benz electronic engine using ether or any other starting ﬂuid. Serious engine damage could result.

The intake air preheater is activated by turning the ignition switch to the on position. See Fig. 7.7.Ifthe engine is at normal temperature, the INTAKE HEATER indicator goes out after two seconds.

If the temperature is low enough to require the heater, the INTAKE HEATER indicator stays on while the intake air preheater warms up. After the indicator goes out, start the engine. If the engine doesn’t start after about 30 seconds of cranking, turn the key to the off position and wait two minutes; then repeat the starting procedure.

NOTE: If the engine doesn’t start on the second try, wait at least ﬁve minutes before using the intake air preheater again.

Starting After Extended Shutdown or Oil Change—CAT, Cummins, DDE S60, M-B

An engine in storage for an extended period of time (over winter, for example) may accumulate water in the oil pan. Oil diluted by water cannot provide adequate bearing protection at start-up. For this reason, change the engine oil and ﬁlters after extended storage.

Do the following steps after an oil change or after the engine has been shut down for more than three days:

Make sure the transmission is ﬁlled with the correct type of ﬂuid, as recommended by the transmission manufacturer.

Make sure the fuel tank is full. If air has entered the fuel system, prime the fuel system, using the engine manufacturer’s instructions.

If the engine is equipped with a fuel/water separator, drain off any accumulated water.

Check the drive belts to make sure they are in good condition and properly adjusted. Replace any drive belts that are cracked, worn, or glazed.

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Check the turbocharger for signs of oil or exhaust leaks. Correct any problems before starting the engine.

Check the engine mounting bolts for tightness. Retighten them if necessary.

Make sure the battery cable connections are clean and tight. Check that the batteries are charged.

Start the engine. See "Engine Starting".

Engine Break-In—CAT, Cummins, DDE S60, M-B

Caterpillar

Every Caterpillar engine must pass a full-load operation test on a dynamometer before shipment, eliminating the need for a break-in period. Only an initial operational check is necessary.

Cummins

Cummins engines are run on a dynamometer before being shipped from the factory. They do not require a break-in period.

Detroit Diesel S60

Detroit Diesel S60 engines can be put to work upon delivery without having to follow a formal break-in schedule. The engine has been "run-in" on a factory dynamometer during performance and quality assurance tests prior to shipment.

Mercedes-Benz

Each Mercedes-Benz 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 Chapter 2 of the

erator’s Manual

MBE4000 Engine Op-

Engines and Clutches

Engine Operation—CAT, Cummins, DDE S60, M-B

Safety and Environmental Considerations

WARNING

Do not operate the engine in an area where ﬂammable 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.

Operating vehicles with diesel engines in areas where there are concentrated ﬂammable vapors (such as diesel, gasoline, natural gas, or propane fumes) can create a hazardous situation. These vapors can be drawn into the engine through the air intake, and cause engine overspeed. Be especially cautious of low-lying or closed-in areas, and always check for signs posted where ﬂammable vapors may be present.

All diesel engines for these vehicles have been built to comply with the requirements of the Federal (U.S.) Clean Air Act. Once an engine is placed in service, the responsibility for meeting both state and local regulations is with the owner/operator.

It is extremely important to use the correct fuel for EPA07-compliant engines. The following requirements must be met, otherwise damage can occur to the aftertreatment device, and the warranty may be compromised.

•

Use ultralow-sulfur diesel (ULSD) with 15 ppm sulfur content or less, based on ASTM D2622 test procedure.

•

Do not use fuel blended with used engine lube oil.

•

Engine lube oil must have a sulfated ash level less than 1.0 wt %, meeting the API CJ-4 index speciﬁcations.

Adequate maintenance of the engine and the diesel particulate ﬁlter are the responsibility of the owner/ operator, and are essential to keep the emission levels low. Good operating practices, regular maintenance, and correct adjustments are factors that will help to stay within the regulations.

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Engines and Clutches

General Information

See the manufacturer’s engine operation manual for speciﬁc reccomendations for your engine.

Operate the engine at low load when the engine is ﬁrst started. After normal oil pressure is reached and the temperature gauge needle begins to move, the engine may be operated at full load.

Electronic engines automatically idle at a slightly higher speed for the correct warm up time after a cold engine start. These electronic engine systems will reduce the idle speed to normal rpm when the engine has warmed sufficiently to operate the vehicle.

Select a gear that allows a smooth, easy start without increasing engine speed above low idle or slipping the clutch. Engage the clutch smoothly. Jerky starts waste fuel and put stress on the drivetrain.

It is seldom necessary to accelerate the engine to governed speed in the lower gears to get the vehicle moving, except in a high-power-demand situation such as starting on a grade. To conserve fuel, start off in low gear, and develop only the engine speed needed to get rolling. Then, increase engine speed gradually as upward gear shifting progresses. This technique will get the vehicle up to the desired cruising speed while minimizing noise emission and maximizing fuel economy. A progressive shift pattern is illustrated in Fig. 7.8.

Electronic engines can be programmed to limit engine rpm while the vehicle is operated in the lower and higher gears. This feature assists the driver in following "progressive shifting" techniques.

For highway cruising, and for best fuel economy, run the engine at 80 to 90 percent of rated rpm to maintain highway speed. Proper gear selection should permit cruising in the economy range with no appreciable sacriﬁce in desired highway speed.

It is okay to operate below rated rpm at full throttle if you are satisﬁed with the way the vehicle performs. However, there are times when hilly terrain, high winds, or other conditions make it impractical to operate without reserve power. Such conditions are better met if the vehicle is

010

(16)20(32)

11/02/95

1. Governed RPM

2. Engine RPM

3. Idle RPM

4. Miles (kilometers) per Hour

Fig. 7.8, Progressive Shift Pattern

(48)40(64)50(80)60(97)

operated in a lower gear with reserve power available for changes in terrain, wind, etc.

Driving on Hills

When approaching a hill, open the throttle smoothly to start the upgrade at full power, then shift down as desired, to maintain the optimum vehicle speed.

NOTE: A momentary hesitation in throttle response will occur when a vehicle with a turbocharged engine is started on a grade. disengage the clutch. The rpm will recover, and the vehicle will accelerate up the grade.

On uphill grades, begin downshifting when the engine rpm falls to 1200 rpm. Fuel economy will be best if you let the engine lug back to around this speed before you downshift. Downshift until a gear is reached in which the engine will pull the load. Let the engine lug down if you can make it to the top of a hill without downshifting.

If going up a hill causes a steady decline in engine rpm, downshift as required until the engine can maintain a stable uphill speed. Make full use of each gear before going to a lower gear. By remaining in a gear until arriving at the speed of the next lower gear, the vehicle will top the grade in the best possible time on less fuel and fewer shifts.

The driver can greatly improve driving skill by learning the vehicle’s shift points for all gears. By knowing rather than guessing where the shift points are, it is possible to avoid overspeeding

Do not

f250319

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Engines and Clutches

the engine when downshifting too soon or missing the full use of a gear by downshifting too late. The shift points of any vehicle can be determined by a simple road-test method. Run the vehicle, and determine the maximum road speed possible in every gear at the engine governed full-load speed setting.

The top road speed possible in a gear would be the shift point for that gear. The results should be recorded in the proper order of shifting and displayed inside the cab.

For improved operating efficiency (fuel economy and engine life), operate in the higher gear at reduced rpm, rather than in the next lower gear at the maximum rpm.

Cruise at partial throttle whenever road conditions and speed requirements permit. This driving technique permits operating within the most economical power range of the engine.

The diesel engine is effective as a brake on downhill grades, but care must be used not to overspeed the engine going downhill. The governor has no control over engine speed when the engine is being turned by the loaded vehicle. A simple rule to follow for engine braking is to select the same gear (or one gear lower) that would be needed to go up the grade.

Never turn off the ignition switch while going downhill.

IMPORTANT: Do not let Caterpillar C–10, C–12, C–15, C–16, and 3406E electronic engines exceed 2300 rpm (2100 rpm if equipped with an exhaust brake).

rpm. However, during engine braking only, a higher rpm can be used to increase retarding power, if necessary. When using the engine brake it is recommended to use engine speeds up to 2300 rpm. The engine provides maximum braking effect when running at 2500 rpm, but it must not be allowed to exceed this speed.

Continue to downshift as further reduction in vehicle speed is required. If the vehicle is above the allowable maximum speed of a lower gear, use the service brakes to slow the vehicle to an acceptable speed where the transmission may be downshifted safely. Again, the importance of knowing the shift points is demonstrated.

Idling

CAUTION

Do not idle the engine for excessively long periods. Long periods of idling are not good for an engine because the combustion chamber temperatures drop so low the fuel may not burn completely. This will cause carbon to clog the injector spray holes and piston rings, and may result in stuck valves.

The common belief that idling a diesel engine causes no engine damage is wrong. Idling produces sulfuric acid, which breaks down the oil and eats into bearings, rings, valve stems, and engine surfaces. If you must idle the engine for cab heat or cooling, the high idle function of the cruise control switches should be used. An idle speed of 900 rpm should be enough to provide cab heat in above 32°F (0°C) ambients.

CAUTION

Do not allow the engine to exceed its governed speed, or serious engine damage could result.

To slow the vehicle on downgrades and curves (using the engine), shift to a lower gear, and allow the vehicle to decelerate in that gear. The engine provides maximum braking effect when running at the top end of the operating range, but it must not be allowed to exceed its full-load rated rpm.

IMPORTANT: For Mercedes-Benz engines, the maximum speed in regular operation is 2000

WARNING

Do not leave the vehicle unattended with the engine running. If you leave the vehicle and the engine is running, the vehicle can move suddenly, which could result in personal injury or property damage.

If the engine is programmed with the idle shutdown timer, ninety 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 ninety seconds (CHECK ENGINE lamp ﬂashing) the idle shutdown timer will be disabled until it is reset.

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Engines and Clutches

Cold-Weather Operation—CAT, Cummins, DDE S60, M-B

Satisfactory performance of a diesel engine operating in low ambient temperatures requires modiﬁcation of the engine, surrounding equipment, operating practices, and maintenance procedures. The lower the temperatures, the greater the amount of modiﬁcation required; and yet with the modiﬁcations applied, the engines must still be capable of operation in warmer climates without extensive changes.

The following information is provided to engine owners, operators, and maintenance personnel on how the modiﬁcations can be applied to get satisfactory performance from their diesel engines.

There are three basic objectives:

•

Reasonable starting characteristics followed by practical and dependable warm-up of the engine and equipment.

•

A unit or installation that is as independent as possible from external inﬂuences.

•

Modiﬁcations that maintain satisfactory operating temperatures with a minimum increase in maintenance of the equipment and accessories.

If satisfactory engine temperature is not maintained, higher maintenance cost will result due to increased engine wear. Special provisions to overcome low temperatures are deﬁnitely necessary, whereas a change to a warmer climate normally requires only a minimum of revision. Most of the accessories should be designed in such a way that they can be disconnected so there is little effect on the engine when they are not in use.

IMPORTANT: If a winterfront is used on a vehicle with an electronic engine equipped with a charge air cooler, make sure that there are slit openings distributed across the face of the winterfront to allow airﬂow through the entire charge-air-cooler core. Do not use a winterfront with closed areas that block uniform air ﬂow across any sections of the charge-air-cooler crossﬂow tubes. This will adversely affect the operation and durability of the charge air cooler.

On all engines, the following steps are necessary when operating in cold weather:

Check for cracks in the battery cases, for corrosion of the terminals, and for tightness of the cable clamps at the terminals.

Charge the batteries to full capacity. Replace any battery that is unable to hold full charge or is physically damaged.

Check the alternator output.

Check the condition and tension of the drive belts.

Caterpillar

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.

If the engine does not start, prime the fuel system. When the use of unblended No. 2 diesel fuel in win-

ter cannot be avoided, install a thermostatically controlled fuel heater. Fuel heaters can prevent wax from clogging the fuel ﬁlters and formation of ice crystals from water in the fuel.

IMPORTANT: If a fuel heater is used, make sure it has thermostatic controls to prevent excessive heating of the fuel in warm weather. Excessive heating of fuel can cause a loss of engine power.

For cold weather operation, use the following guidelines:

When starting the engine in temperatures below 32°F (0°C), use engine lubricants of lower viscosity. Refer to the Caterpillar

Maintenance Manual

When the temperature is below freezing, use sufﬁcient antifreeze solution in the cooling system to prevent freezing.

During cold weather, give more attention to the condition of the batteries. Test them frequently to ensure sufficient power for starting. See Group 15 of the

Manual

If so equipped, turn off the battery disconnect switch after the engine is shut down, to prevent battery discharge.

For starting below 0°F (–18°C), an optional coldweather starting assist is recommended. For

Century Class Trucks Workshop

for detailed information.

for speciﬁcations.

Operation and

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Engines and Clutches

temperatures below –10°F (–23°C), consult your Caterpillar dealer for recommendations.

When customer parameters include cold-mode operation and the coolant temperature is below 82°F (28°C), the system puts the engine into cold mode. It adjusts the low idle to 600 rpm for the 3406E, C–15, and C–16 engines, and 800 rpm for the C–10 and C–12 engines. It also advances the timing, to reduce white smoke emissions and improve warm-up time. The system will keep the engine in cold mode until the coolant temperature rises above 82°F (28°C). After cold mode has been completed, operate the vehicle at low load and low rpm until the engine coolant reaches normal operating temperature of 189°F (87°C).

Fuel cloud point is the temperature at which wax crystals become visible, which is generally above the pour point of the fuel. To keep the fuel ﬁlter elements from plugging with wax crystals, the cloud point should be no higher than the lowest ambient temperature at which the engine must start.

Cummins

The two most commonly used terms associated with preparation of equipment for low-temperature operation are "winterization" and "arctic speciﬁcations."

Winterization of the engine and/or components, so that starting and operating are possible in the lowest temperature to be encountered, requires:

•

Proper lubrication with low-temperature lubricating oils.

•

Protection from the low-temperature air. The metal temperature does not change, but the rate of heat dissipation is affected.

•

Fuel of the proper grade for the lowest temperature.

•

Heat to raise the engine block and component temperatures to at least –25°F (–32°C) for starting in lower temperatures.

•

Electrical equipment capable of operating in the lowest expected temperature. All switches, connections, and batteries in the electrical system should be inspected and kept in good condition to prevent losses through poor contacts.

Arctic speciﬁcations refer to the design of material and speciﬁcations of components necessary for satisfactory engine operation in extremely low temperatures to –65°F (–54°C). Contact the nearest Freightliner dealer or Cummins engine dealer, to obtain the special items required.

CAUTION

"Antileak" antifreezes are not recommended for use in Cummins engines. Although these antifreezes are chemically compatible with DCA water treatment, the "antileak" agents may clog the coolant ﬁlters.

IMPORTANT: Fuel heaters used on vehicles with Cummins CELECT Plus engine systems could cause high fuel temperatures that affect engine performance and operation of the electronic engine controls. If a fuel heater is used, make sure it has thermostatic controls. If the fuel heater has a timer, set the timer to activate only for a limited period of time before the engine starts. Make sure the fuel heater is used only for starting the engine.

For more information, see the Cummins

and Maintenance Manual

Operation

DDE S60

Preparations made in advance of winter and maintenance performed during the cold months will help to ensure efficient engine starting and operation.

•

Engine oil thickens as it gets colder, slowing cranking speed. When cold, multi-grade oil offers less resistance to the cranking effort of the engine and permits sufficient rpm to be developed to start the engine. See "How to Select Lubricating Oil" in the Detroit Diesel

Operator’s Guide

tions.

•

When an engine equipped with a DDEC system is started at temperatures below 25°F (–4°C), the idle speed automatically increases to 900 rpm. The injection timing is also advanced to decrease white smoke. As the engine oil warms up, the idle speed gradually decreases. When the oil temperature reaches 122°F (50°C), both the idle speed and the injection timing return to normal.

for speciﬁc recommenda-

Engine

7.14

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Engines and Clutches

•

A winterfront may be used to improve cab heating while idling. At least 25% of the grille opening should remain open in sectioned stripes that run perpendicular to the charge air cooler tube ﬂow direction. This assures even cooling across each tube and reduces headerto-tube stress, and possible failure. Winterfronts should only be used when the ambient temperature remains below 10°F (–12°C).

•

During cold weather, the batteries should be tested more frequently to ensure ample power for starting. All electrical connections should be tight and in good condition to prevent losses through loose or corroded connections.

•

Ethylene-glycol-base antifreeze is recommended. An inhibitor system is included in this type of antifreeze, and the corrosion protection is sufficient as long as the recommended concentration range of 30 to 67 percent (antifreeze to water by volume) is employed.

•

If the engine is to be operated in arctic temperatures, consult the nearest Freightliner dealer or an authorized Detroit Diesel engine dealer for information regarding availability of special cold-weather equipment.

Mercedes-Benz

Special precautions must be taken during cold weather. For service products to use in cold weather, see Chapter 5 of the

Manual

IMPORTANT: At outside temperatures below –4°F (–20°C), a coolant preheater is recommended.

Periodically check the coolant mixing ratio (concentration of antifreeze in the coolant). Add more if necessary. The coolant mixing ratio should never rise above 60 percent antifreeze.

Use low-viscosity lubricating oils for adequate lubrication.

At temperatures below 32°F (0°C), do not use summer-grade (2-D) diesel fuel. To avoid fuel problems due to paraffin separation, use wintergrade (1-D or winterized 2-D) diesel fuel only.

MBE4000 Engine Operator’s

WARNING

The addition of kerosene lowers the ﬂash point of diesel fuel. To prevent ﬁre and risk of injuries due to burning, do not smoke or use open ﬂames around fuel mixed with kerosene. Comply with all appropriate safety regulations.

When winter-grade diesel fuel is not adequate, it is possible to mix kerosene with the diesel fuel. If it is an EPA07 engine, ultralow-sulphur kerosene must be used. Add the kerosene only when reﬁlling the tank, and before adding the diesel fuel.

NOTE: Engine power may drop according to the proportion of kerosene. For this reason, never add more than 50 percent kerosene to the fuel.

High-Altitude Operation—CAT, Cummins, DDE S60, M-B

Engines lose horsepower when operated at high altitude because the air is too thin to burn as much fuel as at sea level. This loss is about three percent for each 1000 feet (300 m) altitude above sea level for a naturally aspirated engine. Most turbocharged engines are rated for higher altitudes than naturally aspirated engines.

An engine will have smoky exhaust at high altitudes unless a lower gear is used. The engine will not demand full fuel from the fuel system unless the engine is altitude-compensated by the use of a turbocharger. Shift gears as needed to avoid excessive exhaust smoke.

There is no restriction with respect to altitude operation for Mercedes-Benz MBE4000 engines. These engines will perform properly between sea level and 13,000 ft (4000 m) above sea level.

Engine Shutdown—CAT, Cummins, DDE S60, M-B

Caterpillar

CAUTION

Stopping the engine immediately after it has been working under load can result in overheating and

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Engines and Clutches

accelerated wear of the engine components. Excessive temperatures in the turbocharger centerhousing will cause oil coking problems. Follow the procedure, outlined below, to allow the engine to cool.

With the vehicle stopped, apply the parking brakes. Reduce the engine speed to low idle.

Place the transmission shift lever in neutral.

NOTE: If the engine has been operating at low loads, run it at low idle for 30 seconds before stopping. If the engine has been operating at highway speed or at high loads, run it at low idle for three minutes to reduce and stabilize internal engine temperatures before stopping.

Turn off the ignition switch and shut down the engine.

After engine shutdown, ﬁll the fuel tank.

Check the crankcase oil level. Maintain the oil level between the add and full marks on the dipstick.

If equipped with an idle shutdown timer, it can be set to shut the engine down after a preset amount of time. Ninety seconds before the preset shutdown time, the CHECK ENGINE light will begin to ﬂash at a rapid rate. If the clutch pedal or service brake indicate a position change during this ﬁnal ninety seconds (diagnostic lamp ﬂashing), the idle shutdown timer will be disabled until reset.

If freezing temperatures are expected, allow the engine jacket water expansion tank to cool, then check the coolant for proper antifreeze protection. The cooling system must be protected against freezing to the lowest expected outside temperature. Add permanent-type antifreeze, if required.

Repair any leaks, perform minor adjustments, tighten loose bolts, etc. Observe the vehicle mileage or the service meter reading, if so equipped. Perform periodic maintenance as instructed in the Maintenance Interval Schedule in the Caterpillar

Operation and Maintenance Manual

Allow the engine to run at idle for four to ﬁve minutes. This allows the engine to cool and the turbocharger to slow down.

CAUTION

After high-speed operation, shutting down the engine without idling may cause damage to the turbocharger, as it will continue to turn without an oil supply to the bearings.

Turn off the ignition switch and shut down the engine.

Mercedes-Benz

With the vehicle stopped, apply the parking brakes and put the transmission in neutral.

Allow the engine to idle for one to 2 minutes before shutting it down.

Shut down the engine by turning off the ignition.

Engine Braking Systems—CAT, Cummins, DDE S60, M-B

Several types of engine braking systems are optionally available. Each of these systems uses the engine to retard the vehicle on downgrades and reduces the heat load on the service brakes. The engine brakes are meant to be auxiliary vehicle braking systems in addition to the regular service brakes.

Jacobs®Engine Brake

A Jacobs engine brake is a hydraulic-electric engine attachment that converts a diesel engine into an air compressor. This is done by changing engine exhaust valve operation. An engine brake is not a substitute for a service braking system, except in emergencies, because it does not provide the precise control available from the service brakes.

The Jake mounted paddle switch with three positions: OFF, LO, and HI.

Brake is controlled by a single, dash-

Detroit Diesel S60

With the vehicle stopped, apply the parking brakes, and place the transmission in neutral.

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Engines and Clutches

Jacobs Engine Brake Operation

WARNING

Do not use the engine brake if road surfaces are slippery. Using the engine brake on wet, icy, or snow-covered roads could result in loss of vehicle control, possibly causing personal injury and property damage.

If the engine brake is engaged when the transmission is in neutral, the braking power of the engine brake can stall the engine and result in loss of vehicle control, possibly causing personal injury and property damage.

To engage the engine brake, the dash switch must be in the LO or HI position and both the clutch and throttle pedals must be fully released. To disengage the engine brake, depress the throttle or clutch pedal, or move the dash switch to OFF. Use the LO position when driving on ﬂat, open stretches of road. If you need to use the service brakes to slow down, switch to a higher position until there is no need for the service brakes.

WARNING

The control speed varies, depending on vehicle weight and the downhill grade.

Below a set engine speed (set at the factory to 700 rpm), the engine control unit (ECU) will not engage the engine brake. The engine brake will not work below the set engine speed.

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.

IMPORTANT: When descending a grade, remember that frequent use of service brakes causes them to become hot, which results in a reduction of their stopping ability. Grade descent speed should be such that the service brakes are used infrequently and that they remain cool, thus retaining their effectiveness.

A driver may descend slower than control speed by selecting a lower gear, one that will not overspeed the engine. The engine brake retarding force will then be sufficient to cause vehicle deceleration. Occasional deactivation of the engine brake may be necessary to maintain the designated road speed under these conditions.

The engine brake must be disengaged when shifting gears. The clutch must be used if the dash switch is in the LO or HI position. If the engine 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.

Since the engine brake is most effective at rated engine speed, gear selection is very important. Gearing down the vehicle within the limits of the rated engine speed makes the engine brake more effective. Recommended engine braking speed is above 1800 rpm and below the rated speed.

IMPORTANT: Maximum retarder performance is obtained when you use the lowest possible gear without exceeding the recommended engine braking speed.

"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.

WARNING

Using the engine brake as a primary braking system when the service brakes are operable is dangerous. This can cause long, unpredictable stopping distances, possibly resulting in personal injury or property damage.

Whenever vehicle braking is required, the engine brake may be used with the service brakes. There is no time limit for operation of the engine brake.

After the engine is warmed up and the vehicle is in motion, move the paddle switch to the desired position, LO or HI. Depending on the engine model, LO will provide 1/3 or 1/2 of the full braking capacity of the engine. HI will provide maximum engine braking.

The engine brake activates when the dash switch is in LO or HI position and the driver’s feet are removed from both the clutch and throttle pedals. If it fails to activate, take the vehicle to an authorized Freightliner dealer for service.

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Engines and Clutches

To obtain maximum retarding, maintain the top governed speed of the engine through appropriate selection of gears when the engine brake is in use.

CAUTION

If the engine brake fails to shut off when either the throttle or clutch pedal is depressed, place the dash switch in the OFF position and do not use the engine brake until the throttle or clutch switch system is repaired. If the engine brake fails to shut off when the dash switch is turned off, the engine should be shut down and the engine brake repaired before continuing operation. Failure to do so could result in damage to the engine.

When either the clutch or throttle pedal is depressed, the engine brake is deactivated.

BrakeSaver

The BrakeSaver (optional on 3406E engines) permits the operator to control the speed reduction of the vehicle on grades, curves, or anytime speed reduction is necessary but long applications of the service brakes are not desired.

During downhill operation, the crankshaft is turned by the rear wheels (through the drivetrain). To reduce the speed of the vehicle, an application of braking force can be made to the crankshaft. The BrakeSaver does this by converting rotation energy into heat, which is removed by the engine cooling system. The BrakeSaver is controlled by the driver, as necessary, by operating a lever on the instrument panel. Braking force increases as the lever is moved toward the ON position. An air pressure gauge provides a relative indication of the braking force. An oil temperature gauge indicates the heat in the BrakeSaver during its operation. If the temperature gauge indicates HOT, the BrakeSaver control lever must be moved to the OFF position. The oil temperature will decrease rapidly with the BrakeSaver off. When the temperature reaches normal, the BrakeSaver can be used.

CAUTION

Do not engage the BrakeSaver and control the wheel speed with the accelerator. The design of the cooling system is for the control of the tem-

perature of the oil at full engine power or full BrakeSaver capacity, but not both at the same time.

Turbo Brake (MBE4000 only)

For high braking output, the Mercedes-Benz MBE4000 engine can be equipped with an optional turbo brake.

The turbo brake can be operated either manually or automatically, through the cruise control function. If the turbo brake is operated manually, there is a fourposition switch on the dashboard:

HIGH.

The turbo brake provides 600 brake horsepower at 2500 engine rpm. In the braking condition, the MBE4000 turbo brake engine operates as a turbocharged compressor, resulting in high braking output. It is recommended to operate the turbo brake up to the 2300 rpm level. This provides approximately 550 brake horsepower which should cover most situations. If additional braking power is required, engine speed can be increased to 2500 rpm maximum, resulting in 600 brake horsepower.

OFF/ LOW/ MED/

CAUTION

Do not allow the engine to exceed 2500 rpm. Serious engine damage could result.

Because the charge air pressure is maintained at a high level during braking, full throttle response is available immediately, if the operator desires it, without any turbo lag.

CAUTION

The turbo brake should only be operated when the engine coolant temperature exceeds 140°F (60°C). It cannot be engaged below this level. Be aware that no engine retarding system is available during engine warm-up.

The MBE4000 turbo brake is combined with Mercedes-Benz constant throttle technology, but an exhaust ﬂap is not used. The turbo brake emits very low levels of noise, making it an environmentally friendly system. It is maintenance-free, highly reliable, and adds virtually no weight to the engine.

7.18

Freightliner Columbia User Manual

Specifications and Main Features

Frequently Asked Questions

User Manual