Freightliner Columbia User Manual
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.
Foreword
© 2001–2011 Daimler Trucks North America LLC. All rights reserved. Daimler Trucks North America LLC is a Daimler
company.
No part of this publication, in whole or part, may be translated, reproduced, stored in a retrieval system, or transmitted
in any form by any means, electronic, mechanical, photocopying, recording, or otherwise, without the prior written 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.
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
1
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
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
2
1
11/21/96
3
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.
1
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
2
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
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
2
1
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.
3
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
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
W
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
2
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
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
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.
Flashes on and off whenever the outside turn signal lights
are flashing.
2.2
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.
NO
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)
Instruments and Controls Identification
40
PSI
0
100
OIL
200
150
F
100
250
WATER
12
200
F
100
300
OIL
3
90
F
10
30
150
PYRO
12
8
16
VOLTS
4
40
PSI
0
80
TURBO
56
10060
PSI
P
7
8
0 160
AIR
11 12
15
25
5
MPH
45
55
35
70
65
90
50
110
30
10
75
130
85
km/h
13
1/2
EF
FUEL
190
270
F
110
350
TRANS
15
RPM
X 100
20
25
30
10
10
5
0
9
15
14
16
PSI
0 160
200
F
100
AXLE
200
F
100
AXLE
10060
S
AIR
300
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)
4
56
3
2
1
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
78
910
20
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
11
19
Warning
12 13
14
15
16
1718
f610707
2.4
Instruments and Controls Identification
4
5
3
2
1
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)
67
17
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
89
16
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
10
11
12
13
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
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
Push
Push
Hold
Go to the Diagnostic
Hold
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
Instruments and Controls Identification
If Service Cycle screens not enabled
Push
Or
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
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
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
Instruments and Controls Identification
65
75
85
1/2
5
E
F
FUEL
6
50
100
PSI
150
0
AIR
50
100
PSI
8
150
0
AIR
f610205b06/02/99
™
System is
7
50
3
PSI
0
100
OIL
200
150
2
F°
100
250
WATER
225
1
F°
100
350
TRANS
4
20
25
15
10
5
0
RPM
X100
30
10
45
55
35
70
90
50
25
15
5
110
30
130
10
km/h
9
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
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
3
4
12
18
24
22
2
1
10
11
16
17
23
11. Engine Protection Warning
(optional)
5
25
6
13 14
19
78
15
21
20
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
9
f610231a
(optional)
4
3
10
9
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
2
1
OPT OPT OPT OPT OPT OPT OPT OPT OPT
8
14
15
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
16
56
11
17
ABS
BRAKE
12
7
ABS
13
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
Instruments and Controls Identification
HEADLIGHTS ON
888888.8
MI
ODOMETER
SCREEN
IF NO FAULTS
WERE DETECTED
123456.7
MI
12.3 VOLTS
PARK BRAKE
RELEASED − MOVING
123456.7
MI
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
Instruments and Controls Identification
123456.7
MI
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
n
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
EC
EC
*Lo
**MI **HOURS
**no
Push
Push
Push
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
Instruments and Controls Identification
1
4
7
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
3
2
5
6
9
8
Fig. 2.13, Dash Message Center, ICU2L
10
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
14
15
18
17
19
16
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
Instruments and Controls Identification
10/03/97
123456
ODOMETER
SCREEN
PARK BRAKE
RELEASED − MOVING
HEADLIGHTS ON
MI
IF NO FAULTS
WERE DETECTED
123456
123456
MI
MI
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
2
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
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)
1
3
*
At Rated RPM:
psi (kPa)
2
4
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.
5
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)
6
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
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.
1
2
3
4
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)
5
6
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
Instruments and Controls Identification
(121°C) for Eaton®Fuller®transmissions. See
Fig. 2.17.
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.
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.
O
,inTable 2.4, the air cleaner needs to be
2
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
O
2
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.
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
2
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
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.
1.
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.
2.
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.
3.
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
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
or
(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.
1
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
2
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.
1.
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
or
—Push the SET button on the transmis-
sion shift knob.
2.18
Instruments and Controls Identification
2.
To disengage the cruise control:
2.1
Depress the brake pedal or clutch pedal.
2.2
or
—Press the lower half of the SPD CNTL
rocker switch on the instrument control
panel.
2.3
or
—Push the PAUSE button on the transmission shift knob.
3.
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
or
—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.
4.
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
or
—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
or
—Push the SET button on the transmis-
sion shift knob.
2.
To disengage the PTO:
2.1
Depress the brake pedal or clutch pedal.
2.2
or
—Press the lower half of the SPD CNTL
rocker switch on the instrument control
panel.
2.3
or
—Press the PAUSE button on the shift
knob.
3.
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
or
—Press the RESUME button on the
transmission shift knob.
4.
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
or
—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).
1.
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
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.
1
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
TM
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
Instruments and Controls Identification
3 4
2
1
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
1.
Activate Optimized Idle (engine mode) as fol-
10
5
MODE
°F
°C
9
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.
2.
Activate the thermostat mode (if so equipped) as
follows:
6
7
8
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).
3.
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.
4.
To deactivate the thermostat mode and return to
just the engine mode, press the
and hold it for 3 seconds.
Mode
UP
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
Instruments and Controls Identification
5.
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
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