Freightliner Conventional Service 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 service and maintenance manuals. Custom-built Freightliners 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.

down coordination, or Fleetpack assistance. Our people are knowledgeable, professional, and committed to following through to help you keep your truck moving.

Reporting Safety Defects

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

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

To contact NHTSA, you may call the Vehicle Safety Hotline toll-free at 1-888-327-4236 (TTY: 1-800-424-9153); go to www.safercar.gov; or write to: Administrator, NHTSA, 1200 New Jersey Avenue, SE, Washington, DC 20590. You can also obtain other information about motor vehicle safety from www.safercar.gov.

Canadian customers who wish to report a safetyrelated defect to Transport Canada, Defect Investigations and Recalls, may telephone the toll-free hotline 1-800-333-0510, or contact Transport Canada by mail at: Transport Canada, ASFAD, Place de Ville Tower C, 330 Sparks Street, Ottawa, Ontario, Canada K1A 0N5.

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.).

Customer Assistance Center

Having trouble ﬁnding service? Call the Customer Assistance Center at 1–800–385–4357 or 1–800– FTL–HELP. Call night or day, weekdays or weekends, for dealer referral, vehicle information, break-

For additional road safety information, please visit the Road Safety website at: www.tc.gc.ca/roadsafety/menu.htm.

STI-203-1 (1/10P)

A24-00509-000

Printed in U.S.A.

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.

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

Index .................................................................. I.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 Labels ........................................................ 1.2

Vehicle Identiﬁcation

Vehicle Speciﬁcation Decal

The vehicle speciﬁcation decal (Fig. 1.1) 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 glove box; another copy is inside the rear cover of the

mation for North America

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

Owner’s Warranty Infor-

booklet.

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

Shown

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. The lowest component capacity is the value used 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

02/02/95

f600061b

1. Tire and Rim Labels 2. Certiﬁcation Label

Fig. 1.3, Location of Labels

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.

10/10/2006

Fig. 1.5, Canadian National Safety Mark

f080024

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.

Tire and Rim Labels

Tire and rim labels (attached to the left rear door post) certify suitable tire and rim combinations that can be installed on the vehicle, for the given gross axle weight rating. See Fig. 1.6. 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.

Refer to Fig. 1.6 for U.S. and Canadian tire and rim labels.

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

GAWR TIRES RIMS PSI COLD

24−00273−040

f080054

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. The lowest component capacity is the value used for the system.

Fig. 1.6, Tire and Rim Label

EPA Emission Control Labels

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

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

Instruments and Controls

Identiﬁcation

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

Controls ......................................................................... 2.1

Warning and Indicator Lights ....................................................... 2.13

Collision Warning System (CWS), Eaton VORAD EVT–300, Optional ...................... 2.20

Instruments ..................................................................... 2.25

Exterior Switches ................................................................ 2.31

Instruments and Controls Identiﬁcation

Instrument and Control Panel

Figure 2.1, Figure 2.2, and Figure 2.3 represent a

portion of a typical Freightliner dash equipped with all of the standard and many of the optional instruments and accessories. Most standard and optional instrument gauges and switches can be mounted in this dash.

NOTE: On SilverAero models, switches for cruise control and manual control for the engine fan are standard. If these features are not requested, dummy switches with blank labels are installed.

A warning and indicator light module, located above the speedometer and tachometer, houses all of the standard and optional warning and indicator lights. Some of the controls discussed in this chapter are not dash-mounted.

7 8

14 15

Controls

Ignition Switch and Key

The ignition switch (Fig. 2.4) can be turned to three positions: "Off," "Accessory," and "On." In addition, the same 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, fog lights, dome lights, clearance lights, turn signals, hazard warning lights, utility and baggage lights, spotlights, electric wipers, horn, CB radio, power mirrors, cigarette lighter, clock, refrigerator, fuel heater, electric oil pan heater, and electric or diesel-ﬁred engine-coolant preheaters can be operated in the off position (regardless of whether the key is inserted or not).

In the "Accessory" position, the key is turned counterclockwise. The auxiliary (bunk) fan, windshield fan(s), radio or stereo system, mirror heat, ether start

02/02/95

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

1. Water Temperature Gauge

2. Engine Oil Pressure Gauge

3. Pyrometer

4. Tachometer

5. Warning and Indicator Light Module (VIGIL and Kysor shown)

6. Parking Brake Indicator Light

7. Antilock Braking System (ABS) Tractor Warning Light

8. ABS Wheel Spin Indicator Light

9. ABS Trailer Warning Light (dash light for DDEC Optimized Idle

10. Speedometer/Odometer

11. Application Air Pressure Gauge

12. Dual System Air Pressure Gauge

13. Voltmeter

14. Fuel Gauge

2.1

, if so equipped)

Fig. 2.1, Instrument and Control Panel Layout (upper dash) Pre-EPA07

15. Fuel Tach

16. Engine Brake Switches

17. Trailer Air Supply Valve

18. Parking Brake Control Valve

19. Fifth Wheel Air Slider Control Valve Switch

20. Interaxle Differential Lockout Control Valve Switch

21. Transmission Oil Temperature Gauge

22. Forward Differential Oil Temperature Gauge

23. Rear Differential Oil Temperature Gauge

24. Engine Oil Temperature Gauge

25. Turbocharger Boost Pressure Gauge

26. Fuel Pressure Gauge

27. Automatic Engine Idler/Timer

28. Intake-Air Restriction Gauge

29. Digital Clock

30. Radio (optional)

f600831

Instruments and Controls Identiﬁcation

8 9

17 18

03/14/2007

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

1. Water Temperature Gauge

2. Engine Oil Pressure Gauge

3. Pyrometer

4. Tachometer

5. Warning and Indicator Light Module (VIGIL and Kysor shown)

6. Engine Malfunction Indicator Light (MIL)

7. DPF Regen Warning Light

8. High Temperature Exhaust Warning Light (HEST)

9. Parking Brake Indicator Light

10. Antilock Braking System (ABS) Tractor Warning Light

11. ABS Trailer Warning Light (dash light for DDEC Optimized Idle

, if so equipped)

12 Air Suspension Warning Light

13. Speedometer/Odometer

14. Application Air Pressure Gauge

15. Dual System Air Pressure Gauge

17. Fuel Gauge

18. Fuel Tach

19. Engine Brake Switches

20. Trailer Air Supply Valve

21. Parking Brake Control Valve

22. Fifth Wheel Air Slider Control Valve Switch

23. Interaxle Differential Lockout Control Valve Switch

24. Transmission Oil Temperature Gauge

25. Forward Differential Oil Temperature Gauge

26. Rear Differential Oil Temperature Gauge

27. Engine Oil Temperature Gauge

28. Turbocharger Boost Pressure Gauge

29. Fuel Pressure Gauge

30. Automatic Engine Idler/Timer

31. Intake-Air Restriction Gauge

32. Digital Clock

33. Radio (optional)

16. Voltmeter

Fig. 2.2, Instrument and Control Panel Layout (upper dash) EPA07

910

f600831a

02/02/95

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

1. Ignition Switch

2. Engine Start Button

3. Engine Shutdown Override Button

4. Mirror Heat Switch

5. Right Side Power Mirror

6. Fog Light Switch

7. Utility Light Switch

8. Panel Light Control Knob

9. Headlight/Parking Light Switch

10. Marker Light/Taillight Interrupt Switch

11. Windshield Wiper/Washer Control Knob

12. Intermittent (delay) Wiper Control Knob

13. Auxiliary Heater Fan Switch

14. Heater/Air Conditioner Fan Switch

15. Airﬂow Lever Slide Control

16. Temperature Lever Slide Control

Fig. 2.3, Instrument and Control Panel Layout (lower dash)

f600832

2.2

Instruments and Controls Identiﬁcation

Manual Override Push Button, Optional Engine Shutdown System

1234

01/18/95

1. Ignition Switch

2. Engine Start Button

3. Manual Override Push Button

4. Mirror Heat Switch

5. Right-Side Power Mirror Switch

Fig. 2.4, Ignition/Start/Override/Mirror Switches

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. All electrical systems are operable. Low air- and oilpressure warning lights and buzzer operate until the engine is started and pressure is built up. The engine can be started and operated only when the ignition switch is on.

For vehicles built to operate in Canada, switching on the ignition and releasing the parking brakes automatically activates the headlight low beams (later model vehicles) or high beams (earlier model vehicles) at half voltage as daytime running lights. The daytime running lights will operate until the parking brakes are applied; then they will switch off. Turning on the regular headlights will override the daytime running lights. The vehicle cannot be driven unless either the headlights or daytime running lights are activated.

Engine Start Button

CAUTION

Do not push the engine start button with the engine running. To do so could result in starter damage.

With the ignition switch on, push the engine start button (Fig. 2.4) to engage the electric or air starter. See the applicable engine operating instructions in

Chapter 7 for complete starting instructions.

On vehicles equipped with a Neutral start switch, the transmission must be in Neutral before the engine can be started.

f600068a

If the vehicle is equipped with an engine shutdown system with a manual override push button (Fig. 2.4), simultaneously depress the engine start button and the manual override push button. Once the engine has started, release the engine start button, but continue to depress the override push button until the warning bell stops.

Mirror Heat Switch, Optional

One or both outside door mirrors can be heated to keep them defrosted. Whenever the mirror heat switch (Fig. 2.4) is on, an indicator light illuminates on the warning and indicator light module.

Power Mirrors

Both outside mirrors can be equipped with an electrical remote control. Move the toggle switch (Fig. 2.4) to adjust the mirror.

Detroit Diesel Electronic Engine Control (DDEC) Operator Control

The DDEC system is centered around a computer that is programmed to automatically control engine timing and fuel injection, providing maximum engine performance and fuel economy.

Some DDEC II shutdown option. This option will shut down the engine if potentially damaging conditions are detected. An override button (on DDEC II engines, this button is labelled "Override") is provided for emergency situations. It is mounted to the right of the ignition switch, and provides the driver with an extra 30 seconds of engine operating time.

Standard DDEC III gine if sensors indicate an emergency engine condition such as low coolant level, high coolant temperature, or high oil temperature. If such a condition occurs, the yellow "Check Engine" light in the lightbar will glow. If the problem gets bad enough to cause possible engine damage, the DDEC III will gradually cut engine power down to 70 percent of original power. At that point, the red "Shutdown Engine" light will turn on, and 30 seconds later, DDEC III will shut down the engine.

systems have an automatic engine

systems will shut down the en-

2.3

Instruments and Controls Identiﬁcation

If DDEC III detects low oil pressure, both the "Check Engine" and "Shutdown Engine" lights will go on, and the engine will shut down in 30 seconds.

NOTE: If the vehicle is in a hazardous place when the "Shutdown Engine" light goes on, the driver must immediately press the "Override/ Chk" button or the engine will shut down in 30 seconds. Pressing the button will give the driver an additional 30 seconds to move the vehicle. If this is still not enough time, the driver must press the button again for another 30-second delay before engine shutdown.

Once the engine has shut down, cycle the ignition key off and then on, and press the "Override/Chk" button to restart the engine.

The cruise control and PTO governor options are controlled in one of two ways:

By two switches on the instrument control panel

(Fig. 2.5). The "On/Off" switch turns on the cruise control option, and the spring-loaded "Set/Resume" switch selects the cruise speed or resumes cruise control after slowing down. For PTO operation, the "On/Off" switch turns on the PTO, and the "Set/ Resume" switch either selects or resumes the engine operating speed.

By three optional buttons on the transmission shift knob

(Fig. 2.6). The "Pause" button allows the driver to temporarily interrupt cruise control. The "Resume" button allows the driver to resume the cruise speed after slowing down. The "Set" button allows the driver to select the cruise speed. For PTO operation, the "Pause" button temporarily interrupts PTO operation, the "Resume" button resumes PTO operation at the previously selected engine speed, and the "Set" button is used to select the engine operating speed. See Chapter 7 for complete instructions.

If the vehicle is equipped with Optimized Idle®, the cruise control "On/Off" switch is also used to control this option. Optimized Idle can be used to keep the engine oil warm, recharge the battery, and maintain sleeper temperature when the vehicle is parked for long periods. See Chapter 7 for more information and complete operating instructions.

03/30/94

A. If equipped with Jacobs engine brake controls, the

cruise switches may be installed here. The location may vary depending on other vehicle options.

Fig. 2.5, Cruise Control Switches, Standard Location

05/23/95

Fig. 2.6, Transmission Shift Knob Buttons

f600705

f260316

Caterpillar C-10, C-12, and C-15 Electronic Engine Operator Control

The Caterpillar C-10, C-12, and C-15 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 data link used for programming the electronic control module and troubleshooting the system.

2.4

Instruments and Controls Identiﬁcation

All Caterpillar electronic engines have an engine check light in the lightbar 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 level 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 potentially damaging conditions are detected. See the engine manufacturer’s service literature for troubleshooting procedures.

The cruise control and PTO governor options are controlled in one of two ways:

By two switches on the instrument control panel

By three optional buttons on the transmission shift knob

BrakeSaver Control, Optional

The BrakeSaver (optional on Caterpillar C-15 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 pressure oil to the point of maximum braking in the BrakeSaver is about 1.8 seconds.

Cummins PACE and CELECT

™

Electronic Engines, Operator Control

Cummins PACE, CELECT, and CELECT IV are electronic fuel control systems installed on model L10 and, for PACE only, Big Cam IV engines. These elec-

tronic engines are controlled by a microprocessorbased 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 a yellow engine check light and a red engine stop light in the lightbar located above the speedometer and tachometer. With the ignition switch on, both 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.

If the yellow engine check light comes on while driving, some features will not work, but the vehicle can still be driven. If the red engine stop light comes on while driving, and if the engine will not accelerate, pull off of the road and shut down the engine. In either situation, have the problem repaired as soon as possible.

With the CELECT IV system—if the system is programmed to shut down—the engine shuts down 30 seconds after the red engine stop light comes on. The ignition switch will restart the engine after shutdown, but if the potentially damaging problem still exists, the engine will operate at the reduced speed or torque level allowed just prior to shutdown. To check whether a vehicle is equipped with CELECT or with CELECT IV, see the vehicle service manual.

The cruise control and PTO governor options are controlled in one of two ways:

By two switches on the instrument control panel

By three optional buttons on the transmission shift knob

2.5

Instruments and Controls Identiﬁcation

button is used to select the engine operating speed. See Chapter 7 for complete instructions.

Ether Start Push Button, Optional

For cold weather starting, the vehicle may be equipped with one of several manual-control, ether start systems. To start the engine in cold weather, push the ether button (Fig. 2.7), then start the engine. See the engine operating instructions in Chap-

ter 7 for additional information.

01/18/95

1. Ether Start Push Button

2. Battery Boost Push Button

Fig. 2.7, Ether Start and Battery Boost Controls,

Optional

f600648a

Low Voltage Disconnect, Optional

The optional Sure Power Low Voltage Disconnect (LVD) system monitors battery power when accessories are being used when the engine is shut down. 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 predetermined cab and sleeper circuits, and illuminate an LED indicator on the LVD module, located inside the baggage compartment. 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 should have a sticker on the dash indicating the presence of the system. Another sticker is located inside of the baggage compartment, along with the LVD module.

Battery Boost Push Button and Optional Battery Isolator System

A battery isolator system has two or three regular batteries to turn the starter motor, and one or two gel cell batteries to provide power for cab and sleeper accessories when the engine is off. The system uses an isolator relay, which is normally open. The relay isolates the engine-starting batteries while the engine is not running, so that the engine can still be started even if the gel cell battery has been used to the point of complete discharge.

When all four batteries have a charge, the engine can be started in the normal manner, by turning the ignition key to the "Start" position and pressing the starter push button.

To start the engine when the gel cell battery is drained, press and hold the BATT BOOST push button (Fig. 2.6) while pressing the starter push button. This will temporarily close the isolator relay, and connect the engine-starting batteries to the ignition switch for engine starting.

The isolator relay is closed only while the engine is running or the BATT BOOST push button is depressed. With the engine running, all four batteries are connected in parallel, allowing the alternator to charge them all, in addition to supplying power for all vehicle loads.

When the engine is not running, the gel cell provides all of the vehicle’s electrical needs except for turning the starter motor. The gel cell is longer-lived and cheaper to use than a standard wet cell, but it can take a charge only within an extremely narrow range—13.8 to 14.1 volts.

At 14 volts, a gel cell has a very high charge acceptance rate. Because a truck charging system operates at approximately 14 volts, under normal conditions a gel cell will never need to be recharged with an external charger.

CAUTION

Do not attempt to charge a gel cell with a standard battery charger. All standard battery chargers supply at least 16 volts to the battery. This will damage the gel cell.

IMPORTANT: To recharge a gel cell, see an authorized Freightliner dealer or the instructions in

2.6

Instruments and Controls Identiﬁcation

Group 54 of the

Manual

Heavy-Duty Trucks Service

However, the single gel cell, like any other single battery, has limited current-supply capability, and will drain down faster than a standard multiple-battery installation that has no battery isolator system. Avoid ultra-deep discharging. Repeated ultra-deep discharging of a gel cell will reduce its life signiﬁcantly.

To protect against ultra-deep discharging, a low voltage warning alarm and indicator light activate when the battery voltage falls to 12.0 volts or less. To silence the alarm, turn off all cab electrical loads or start the engine.

Fuel-Tach™Switch, Optional

The FloScan Fuel-Tach is an electronic monitoring system that records fuel consumption and displays average miles per gallon. The Fuel-Tach gauge provides you with immediate feedback, showing a percentage difference between the current fuel consumption rate and the total trip miles per gallon average.

The system is controlled by a toggle switch. See

Fig. 2.8.

for example, "F37." Fault codes are also stored in a history ﬁle for later viewing. For engine fault code instructions, see "Fuel Tach Gauge" in this chapter.

The "Reset" toggle switch cancels the information in memory used for calculating average miles per gallon and erases the fault code history ﬁle. To reset, press and hold the reset switch. The average MPG reading slowly blinks on and off for about 10 seconds, indicating that you are in the reset mode. After erasing the memory, the display blinks "Er" until you release the reset switch. If you release the reset switch before the display changes to "Er," the engine fault code history will be displayed and the memory will not be erased. After being reset, the display will show "0" MPG until you drive at least 150 feet (46 m).

Fog Light Switch, Optional

The fog light switch (Fig. 2.9) operates the fog lights, mounted on the bottom edge of the front bumper or recessed into the front bumper.

01/18/95

Fig. 2.8, Fuel-Tach Switch, Optional

f600070b

With nonelectronically controlled engines the "On" position allows you to receive average miles per gallon information for speciﬁc periods of time. In this position, the Fuel-Tach system stays on and stores the average miles per gallon information in memory, even if the engine is shut down.

In the IGN position, the Fuel-Tach system is on only when the ignition switch is on. Shutting down the engine cancels the information in memory.

With electronically controlled engines the digital display normally shows trip average miles per gallon. If the engine datalink sends an electronic fault code, the Fuel-Tach interrupts the miles per gallon display for 60 seconds, showing an "F" plus the fault code,

01/18/95

1. Fog Light Switch

2. Utility Light Switch

3. Panel Lamp Control Knob

4. Headlight/Parking Light Switch

5. Marker Light/Taillight Interrupt Switch

Fig. 2.9, Light Controls

f600071a

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

For vehicles built to operate in Canada, the taillights and clearance lights must be on before the fog lights can be turned on. Unless the headlight switch is all the way up (headlights, taillights, clearance lights, marker lights, and panel lights on) or down (taillights, clearance lights, marker lights, and panel lights on), the fog light switch will not turn on the fog lights.

2.7

Instruments and Controls Identiﬁcation

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 bunk. They are operated by the utility light switch (Fig. 2.8) which, when turned on, also illuminates a red indicator light on the dash.

Panel Lamp Control Knob

The circuit to the panel lamps is activated by the headlight switch. When the headlights are on, the panel lamp knob (Fig. 2.8) controls the intensity of the instrument panel lamps. Turn the knob counterclockwise to brighten them and clockwise to dim them. Turning the knob counterclockwise to the peg will also turn off the panel lamps.

Headlight Switch and Daytime Running Lights

A three-position headlight switch (Fig. 2.8) 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, and 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 green light in the warning and indicator light module goes on. The ignition switch must be on for the high beams to operate.

Interrupt Switch

A spring-loaded interrupt switch (Fig. 2.8) 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.

Windshield Wiper/Washer Controls

Air Wipers

To operate the air wipers, turn the "Wash-Wipe" knob (Fig. 2.10) clockwise. To increase wiper speed, continue to turn the knob clockwise. Turning the knob counterclockwise decreases wiper speed. To turn the windshield wipers off, turn the knob counterclockwise to its full stop. When the wiper blades are parked, release the knob.

01/18/95

1. Windshield Wiper/Washer Control Knob

2. Intermittent (delay) Wiper Control Knob

Fig. 2.10, Windshield Wiper/Washer Controls

The "Delay" switch controls intermittent operation with air wipers. Rotating the knob clockwise increases the time interval between wiper strokes. Turn the knob clockwise until the desired interval is reached. The longest delay is approximately 10 seconds between strokes.

The delay knob operates the delay feature only; it will not turn the wipers on.

IMPORTANT: After using the intermittent windshield wipers, turn off the wiper control

and

(Fig. 2.9)

the intermittent (delay) control. If the wiper control is off, but the intermittent control remains on, that control will continue to cycle whenever the ignition is in the on or accessory position. Continued, constant cycling will shorten the life of the intermittent wiper control.

Electric Wipers

To operate the electric wipers, turn the knob clockwise to the ﬁrst position for low speed. Turn the knob to the second position for high-speed operation.

f600433

2.8

Instruments and Controls Identiﬁcation

In electric wiper systems, the delay feature is integrated with the wiper switch between the stop and low-speed positions. Turn the knob between the stop and low speed until the desired interval is reached. The longest delay is approximately 10 seconds between strokes.

CAUTION

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

Windshield Washer Control

To operate the windshield washers, turn the windshield wipers to the desired speed. Push the "WashWipe" knob in to actuate the washers. Hold the knob in for a constant stream of washer ﬂuid. Push the knob in and release it for intermittent streams of ﬂuid.

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.

Heater/Air-Conditioner Controls (Standard) and Auxiliary Heater Switch (Optional)

Jacobs Engine Brake Switches, Optional

Jake Brake controls consist of two dash-mounted toggle switches (Fig. 2.12) which control the degree of engine braking. In conjunction with these switches, an engine-mounted microswitch (controlled by the throttle pedal) and an under-deck-mounted microswitch (controlled by the clutch pedal) actuate the engine brake.

10/26/98

1. Engine Brake Switch

2. Interaxle Differential Lockout Control Valve Switch

3. Fifth Wheel Air Slider Control Valve Switch

4. Parking Brake Control Valve Knob

5. Trailer Air Supply Valve Knob

f600507b

Heater/air-conditioner controls (Fig. 2.11) consist of two lever slide controls, a four-speed fan control switch, and a switch for the optional auxiliary heater fan. See Chapter 4 for detailed operating instructions of the heater/air-conditioner and the auxiliary heater.

01/18/95

Fig. 2.11, Heater/Air-Conditioner Controls

2.9

f600497

Fig. 2.12, Brake Switches and Control Valves

See Chapter 7, under the heading "Engine Braking System, Optional," for additional information.

Interaxle Differential Lockout Control Valve Switch

Differential lockout, standard on all dual-drive vehicles, is driver-actuated by means of a "Lock/ Unlock" control valve switch (Fig. 2.12) mounted on the control panel. 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 prevents it from being accidentally activated.

Instruments and Controls Identiﬁcation

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

WARNING

Do not activate the ﬁfth wheel air slider control valve when the vehicle is in motion. Doing so could result in damage to the ﬁfth wheel member, kingpin, cab, or trailer, and ultimately, to the drivetrain. A guard is positioned around the switch to prevent it from being accidentally activated.

The ﬁfth wheel air slider valve permits repositioning of the sliding ﬁfth wheel from inside of the cab. Moving the air slider control valve switch (Fig. 2.12)to the lock position deactivates the control valve and locks the ﬁfth wheel to the baseplate. 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 tractortrailer 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 slider is unlocked.

Parking Brake Control Valve and Trailer Air Supply Valve

The yellow diamond-shaped knob (Fig. 2.12) operates the parking brake valve. Pull the knob out to apply both the tractor and the trailer spring parking brakes. Push the knob in to release the tractor spring parking brakes. Before the spring parking brakes can be released, the air pressure in either air brake system must be at least 65 psi (447 kPa).

The red octagonal-shaped knob (Fig. 2.12) operates the trailer air supply valve. After the vehicle and its air hoses are connected to a trailer, and the pressure in the air system is at least 65 psi (447 kPa), push the trailer air supply valve knob in (it 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, pull the trailer air supply valve knob out.

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

Controlled Traction Differential Control Valve Switch

On vehicles equipped with an Eaton single-drive rear axle, a controlled traction differential feature is standard. A control valve switch (Fig. 2.13) engages and disengages the controlled traction feature. A guard is positioned around the switch to prevent it from being accidentally activated.

See Chapter 9 for complete operating instructions.

10/04/93

Fig. 2.13, Controlled Traction Differential Control Valve

Switch

f600307

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. A control valve switch (Fig. 2.14) exhausts and ﬁlls the air suspension. To exhaust air from the suspension, move the switch to LOWER. A guard is positioned around the switch to prevent it from being accidentally activated.

CAUTION

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

2.10

Instruments and Controls Identiﬁcation

with the engine idling. The automatic timer will shut the engine off at the end of the selected time.

01/18/95

Fig. 2.14, Air Suspension Dump Valve Switch, Optional

f600545a

AirLiner Plus Suspension, Optional

The AirLiner Plus suspension is used on vehicles with pusher or tag axles to improve traction performance. The system maintains an accurate leveling of frame height whether the vehicle is in motion or parked. The Meritor WABCO Controlled Air Suspension) system uses a height sensor mounted between the frame and the drive axle housing as well as other sensors to provide frame height information to a control unit mounted inside of the cab. The electronic control unit quickly lowers or raises the frame height, as necessary. Altering the height of the frame while the vehicle is parked can be performed using a hand-held remote control unit.

ECAS (Electronically

01/18/95

1. Automatic Engine Idler/Timer

2. Kysor Digital Clock

Fig. 2.15, Engine Idler/Timer and Clock

f600508a

Cigarette Lighter

Push the lighter in (Fig. 2.16) to heat the element. The lighter will stay in and will automatically pop out when the element is hot.

WARNING

Stand away from the rear of the vehicle when raising or lowering the height of the frame. The ECAS system operates quickly, and contact could result in personal injury.

For the optional automatic function to work, the vehicle must be equipped with a rear axle air suspension and ABS. Automatic Traction Control is recommended for optimal vehicle traction control.

Automatic Engine Idler/Timer, Optional

A Henke automatic engine idler/timer (Fig. 2.15) 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

2.11

01/18/95

1. Cigarette Lighter

2. Air Window Control Valve Switch

3. Antenna Connection

4. CB Radio Connections

Fig. 2.16, Window Control Switch

f600146a

Air Window Control Valve Switch, Optional Right-Hand Air Window

WARNING

Before raising the window, be sure that hands, ﬁngers, and other body parts or objects are away from the window frame. Otherwise, serious physical injury could result.

Instruments and Controls Identiﬁcation

A toggle switch (Fig. 2.16) controls the air window. Push the switch up to raise the window, or push it down to lower the window.

CB Radio Connections

An antenna connection and positive (+) and negative (–) power connections are provided for a CB radio. See Fig. 2.16.

Turn Signal Lever

The turn signal lever (Fig. 2.17) is mounted on the steering column. Pushing the lever counterclockwise turns on the left-turn signal lights; pushing 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, return the lever to the neutral position, except when equipped with an optional self-canceling switch.

01/18/95

1. Turn Signal Lever

2. Hazard Warning Light Tab

3. Headlight Dimmer Push Button

4. Trailer Brake Hand Control Lever

Fig. 2.17, Turn Signal Lever

f460194a

Hazard Warning Light Tab

The hazard warning light tab (Fig. 2.17) is located below the lever on the turn signal switch. Activate the hazard warning lights by pulling the tab out. When the hazard warning light 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.

Headlight Dimmer

The headlight dimmer (Fig. 2.17) may be a push button at the end of the turn signal lever, or a lift-handle type built into the turn signal lever.

To operate the push button type dimmer, press the button once to change from low beam to high beam headlights; press it again to cancel the high beam lights.

To operate the lift-handle type dimmer, pull the turn signal lever up 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 green 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 fog lights.

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

Trailer Brake Hand Control Valve Lever

This lever is used for applying the trailer brakes without applying the truck or tractor brakes and is mounted on the steering column. See Fig. 2.17. See

Chapter 6 under the heading "Brake System," for

operating instructions.

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 on the header or sun visor above the driver’s windshield.

See Chapter 8 for complete transmission operating instructions.

Suspension Seat Adjustment Controls

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

IMPORTANT: Due to the maximum adjustability of mid- and high-back 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

2.12

Instruments and Controls Identiﬁcation

responsibility of the driver to adjust the seat to prevent damage to the seat and the cab interior.

Dome Light Switches

For vehicles with a single dome light mounted on the roof inside of the cab, the light is operated by a three-position switch mounted in the dome light. The switch provides both a low- and a high-intensity setting; in the middle position, the dome light is off.

For vehicles with a single dome light and two reading lights mounted on the roof inside of the cab, each light is operated by its own on/off switch, mounted in the dome light.

Tilt Steering Wheel

The tilt steering wheel (Fig. 2.18) has a tilt range of 15 degrees, and a telescoping range of 2-5/8 inches (67 mm). A control lever is located just below the turn signal switch on the steering column.

f460309a03/09/94

1. Control Lever

2. Tilt Wheel Assembly

Fig. 2.18, Tilt Steering Wheel

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

To adjust the height of the steering wheel, pull upward on the control lever. While holding the control

lever in this position, move the steering wheel upward or downward to the desired position. Release the control lever to lock the steering wheel in place.

WARNING

Make sure that the control lever is in the locked (neutral) position before driving the vehicle. Never try to adjust the height of the steering wheel or tilt the steering column while driving the vehicle. Doing so could cause loss of vehicle control, personal injury, and property damage.

Warning and Indicator Lights

All of the standard and optional warning and indicator lights are housed in a lens and bezel assembly, located above the speedometer and tachometer.

For pre-EPA07 vehicles, up to six rectangular indicator lights may be installed on the center dash panel between the tachometer and speedometer. See

Fig. 2.19. The pre-EPA07 standard installation in-

cludes one parking brake indicator light and two antilock braking system (ABS) lights, the tractor warning light and the wheel spin indicator light. One other ABS light, the trailer warning light, is optional. The other two lights represent a variety of optional functions that may not be installed on all models.

For EPA07 vehicles, up to ten rectangular indicator lights may be installed on the center dash panel between the tachometer and speedometer. See

Fig. 2.20. The EPA07 standard installation includes

three indicator lights for the after treatment device; an engine malfunction indicator light (MIL), a diesel particulte ﬁlter (DPF) regen light, and a high exhaust system temperature (HEST) light. Details of the aftertreatment lights can be found in Chapter 7, under the heading The other standard lights are the parking brake indicator light, and two antilock braking system (ABS) lights. The other lights are for optional functions that may not be installed on all models.

EPA07 Aftertreatment System (ATS)

Parking Brake Indicator Light

The red parking brake indicator light (Fig. 2.19) comes on whenever the parking brakes are activated and the ignition is on.

Additional optional lights may be installed in the center dash.

2.13

Instruments and Controls Identiﬁcation

10/26/98

A. Parking Brake Indicator Light B. Tractor ABS Warning Light C. Wheel Spin Indicator Light D. Trailer ABS Warning Light

1. Left-Turn Signal Light

2. Oil Pressure Warning Light

3. Low-Water Warning Light

4. Water Temperature Warning Light

5. High-Beam Indicator Light

6. Low Air Pressure Warning Light

7. Right-Turn Signal Light

8. Tachometer

9. Speedometer

Fig. 2.19, Dash Assembly for VIGIL and Kysor Warning

Systems Pre-EPA07

A B C D

f600769b

03/14/2007

A. MIL Engine Warning Light B. DPF Regen Warning Light C. Hi-Temperature Exhaust Warning Light D. Parking Brake Indicator Light E. Tractor ABS Warning Light F. Trailer ABS Warning Light G. Air Suspension Warning Light

1. Left-Turn Signal Light

2. Oil Pressure Warning Light

3. Low-Water Warning Light

4. Water Temperature Warning Light

5. High-Beam Indicator Light

6. Low Air Pressure Warning Light

7. Right-Turn Signal Light

8. Tachometer

9. Speedometer

C D E F G

f600769c

Meritor WABCO®Antilock Braking System (ABS)

The Meritor WABCO®Antilock Braking System (ABS) may have up to three of the following amber lights (the ﬁrst two are standard: a tractor warning light (TRAC ABS), a wheel spin indicator light (WHL SPIN), and an optional trailer warning light (TRLR ABS). Vehicles built before July, 1994, also have a DEEP SNOW/MUD indicator light.

With the tractor ABS system, the tractor warning light (TRAC ABS) comes on after the engine is started (Fig. 2.19). Once the vehicle moves faster than about 4 mph (6 km/h), the warning light goes out only if all of the tractor’s ABS components are working.

With the tractor and trailer ABS system, the vehicle also has a trailer warning light labelled TRLR ABS (Fig. 2.19).

After the engine is started, the TRLR ABS light comes on if the trailer is equipped with a compatible

Fig. 2.20, Dash Assembly for VIGIL and Kysor Warning

Systems EPA07

ABS system. Once the vehicle moves faster than about 4 mph (6 km/h), the TRLR ABS warning light goes out only if all of the trailer’s ABS components are working. For more detailed information about TRLR ABS light operation, see Chapter 6.

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.

The wheel spin indicator light (WHL SPIN) comes on ﬂashing if one of the drive wheels spins during acceleration (Fig. 2.19). The ﬂashing light goes out when the wheel stops spinning. A label (Fig. 2.21)onthe dash explains what actions should be taken when the WHL SPIN indicator light starts to ﬂash.

If equipped with an electronic engine, an automatic traction control (ATC) system may be installed. On

2.14

Instruments and Controls Identiﬁcation

blink code diagnostics are activated. See Group 42 of the

IF REAR WHEEL SPIN OCCURS,

PARTIALLY RELEASE THROTTLE

PEDAL UNTIL WHEEL SPIN

AMBER LIGHT EXTINGUISHES,

THEN ENGAGE AXLE LOCK.

09/22/98

Fig. 2.21, Dash Label

these vehicles, the ATC system automatically controls wheel spin during reduced-traction starts.

An "ATC Function" switch (if equipped), allows the driver to select from two levels of drive axle tractioncontrol assistance:

•

NORMAL—which reduces drive axle wheel spin on icy, wet, or sand covered roads.

•

DEEP SNOW/MUD—which allows a higher threshold of drive axle wheel spin to help burn through a thin layer of ice, or to help throw off accumulated mud or snow.

The Deep Snow/Mud mode is indicated by a ﬂashing WHL SPIN light. To engage this mode, the ATC function switch must be in the Normal position when the vehicle is initially powered up. Once the vehicle is started, the ATC function switch can be set to the Deep Snow/Mud position. The ECU indicates this change by a constant ﬂashing of the WHL SPIN lamp (or by illumination of the Deep Snow/Mud light on vehicles built before July, 1994).

If the ATC function switch is in the Deep Snow/Mud position when the vehicle is powered up, the ECU will not accept this function change and will remain in the Normal mode. Indication of this condition will be the absence of the ﬂashing WHL SPIN light (on vehicles built before July, 1994, the absence of an illuminated Deep Snow/Mud light). To engage the Deep Snow/Mud mode in this situation, change the position of the ATC function switch to the Normal mode. After two seconds, move the switch to the Deep Snow/ Mud position. When this occurs, the indicator light will activate as previously described.

The "ABS Chk" switch (if equipped), activates blink code diagnostics, which are used to read ABS and ATC system fault codes on the WHL SPIN light. This switch is located in the lower dash panel cover, just below the ignition switch, on the left side of the steering wheel. When turned on (in the "up" position),

f600311a

Heavy-Duty Trucks Service Manual

shooting procedures.

IMPORTANT: ABS and ATC blink code diagnostics should only be performed when the vehicle is stopped. If the vehicle is equipped with ATC, turning "on" the ABS CHK switch will reduce engine speed to idle for three seconds and affect ATC function performance. If the vehicle is driven with the ABS CHK switch "on" (in the "up" position), the WHL SPIN light will illuminate continuously. Under this condition, turning the ABS CHK switch "off" (in the "down" position), while the vehicle is still in motion, will only turn off the WHL SPIN light, but will not restore ATC function performance. To fully restore engine and ATC function capability, the vehicle must be brought to a complete stop. Then, move the ABS CHK switch to "off" (in the "down" position).

See the brake system operating instructions in Chap-

ter 6 for more information.

Bendix Antilock Braking System (ABS)

With the Bendix Antilock Braking System (ABS), the tractor warning light (TRAC ABS) comes on after the key is turned on (Fig. 2.19). The warning light goes out only if all of the tractor’s ABS components are working properly.

If the tractor is attached to a trailer with a compatible ABS system, the trailer ABS warning lamp (TRLR ABS) will also come on momentarily after the key is turned on.

Vehicles equipped with a Bendix ABS system may also be equipped with an automatic traction control (ATC) system. The ATC system automatically controls wheel spin during reduced-traction starts.

The wheel spin indicator light (WHL SPIN) comes on if one of the drive wheels spins during acceleration (Fig. 2.19). The light goes out when the wheel stops spinning. The Bendix system will either reduce engine torque or apply gentle brake pressure to force the differential to drive the stationary or slowly spinning wheel. If slippery road conditions continue, engage the axle lock.

for trouble-

2.15

Instruments and Controls Identiﬁcation

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. See Group 42 of the

vice Manual

See the brake system operating instructions in Chap-

ter 6 for more information.

for troubleshooting procedures.

Heavy-Duty Trucks Ser-

VIGIL I Warning System

Standard Indicator Lights

Standard indicator lights (Fig. 2.19) include:

The green right- and left-turn signal lights ﬂash on and off whenever the outside turn signal lights are ﬂashing.

The green high-beam indicator light comes on when the headlights are on high beam.

Standard Warning Lights

Standard red warning lights (Fig. 2.19) are for oil pressure, water temperature, and low air pressure. Whenever conditions cause one or more of these lights to come on, a warning buzzer also alerts the driver:

The water temperature warning light and buzzer activate whenever the engine coolant temperature exceeds a preset point determined by the engine manufacturer. See the engine manual for this temperature.

The oil pressure warning light and buzzer activate whenever the oil pressure falls below the minimum oil pressure recommended by the engine manufacturer.

The low air pressure warning light and buzzer activate whenever air pressure in the primary or secondary air reservoir falls below 64 to 76 psi (441 to 524 kPa).

When the ignition is turned on, oil- and air-pressure warnings activate until the engine starts and minimum pressures are exceeded. If the low-oil warning light remains lit after running the engine for 15 seconds, shut off the engine and determine the cause. See the procedures.

Heavy-Duty Trucks Service Manual

for repair

WARNING

If the warning system does not activate when the ignition is turned on, repair the system to provide warning protection for oil pressure, coolant temperature, and brake system air pressure.

Optional Warning and Indicator Lights

The most common optional warning and indicator lights (Fig. 2.19) consist of any combination of the following:

•

Interaxle differential indicator light, which is standard on all dual-drive vehicles. An indicator light illuminates whenever the interaxle differential is locked out (switch is in the lock position).

•

Automatic sludge ejector (moisture ejection valve) indicator light. An indicator light comes on whenever the ejector is operating.

•

Utility light(s) indicator light. If utility lights are installed in the back of the vehicle, an indicator light comes on when they are in use.

•

Mirror heat indicator light. An indicator light comes on whenever the mirror heat switch is on.

•

Low-water warning light, which is standard when a low-water probe warning system or a four-way engine shutdown system is installed. A warning light comes on whenever the coolant level in the radiator drops below the low-water probe.

•

Fifth wheel slider indicator light. An indicator light comes on whenever the air-operated lockpins on a ﬁfth wheel are retracted from the baseplate (the ﬁfth wheel slider is unlocked).

Optional warning and indicator lights and their locations may vary, because of different optional equipment installed. Other optional accessories and standard equipment that are or can be equipped with warning or indicator lights include: engine heater, parking brakes, tire sanders, spotlights, oil level, oil temperature, cruise-control system, engine fan, and other options.

2.16

Instruments and Controls Identiﬁcation

VIGIL II Warning System, Optional

The VIGIL II system is an electronically controlled warning and engine shutdown system. It controls the turn signal functions and various optional functions. A solid state lightbar (Fig. 2.22) in the instrument panel contains displays for the functions.

12 3456 78

10/26/98

1. Left-Turn Signal Light

2. Oil Pressure Warning Light

3. Low-Water Warning Light

4. Water Temperature Warning Light

5. Engine Shutdown Light

6. High-Beam Indicator Light

7. Low Air Pressure Warning Light

8. Right-Turn Signal Light

Fig. 2.22, VIGIL II and Kysor VIP Warning System,

Optional

Engine Functions

The system monitors engine coolant temperature, coolant level, and oil pressure.

•

If the engine overheats, a warning light comes on and a buzzer sounds. The temperature that triggers the warning light and buzzer varies with engine type and is programmed into the system at the factory. If the temperature continues to rise to critical levels, the engine shutdown light comes on, and the engine will be shut down.

•

If the coolant level drops below a sensor in the cooling system, the low water level light comes on. After 5 seconds, a buzzer sounds, and after 30 seconds, the system will shut down the engine.

•

If the oil pressure drops below a preset level, the low oil pressure light comes on and a warning buzzer sounds. If the oil pressure drops to a preset critical level, the engine shutdown light comes on, and the engine will be shut down.

•

All shutdown features have an automatic override. If the vehicle needs to be moved to a safe location after a shutdown, just crank the en-

f600630b

gine. It will run for about 30 seconds before shutting down again.

Turn Signal Functions

The system operates the turn signal relay and the indicators.

Other Functions

The system also controls several functions such as the headlight high beam indicator, low air pressure warning light, and control of indicators for six optional features. The optional features can be any combination of the following:

•

transmission temperature

•

axle temperature

•

engine heater

•

alternator no charge

•

ﬁfth wheel lock

•

parking brake

•

sand

•

antilock

•

mirror heater

•

utility lights

•

axle lock

•

sludge ejector

or any six that are specially ordered.

Additional Features

When the ignition is turned on, all of the LEDs in the lightbar will light and the low air and low oil pressure alarms will sound. The lights and alarms will activate for two one-second periods, separated by a half second pause. This is a self-test to indicate whether or not the lightbar is working. After the test, the LEDs not in use will turn off. The low air and oil pressure warnings will not sound again until the starter is cranked. Once the starter is cranked, the alarms will sound until system air and oil reach minimum operating pressures. If the lightbar does not operate as described here, test it. For instructions, see Group 54

Heavy-Duty Trucks Service Manual

of the

2.17

Instruments and Controls Identiﬁcation

VIGIL III Warning System, Optional

The VIGIL III system is an electronically controlled warning system with maximum vehicle speed control, vehicle overspeed reporting, and optional engine shutdown. It controls the turn signal functions and various optional functions. A solid-state lightbar (Fig. 2.23) in the instrument panel contains displays for the functions.

•

All shutdown features have an automatic override. If the vehicle needs to be moved to a safe location after shutdown, just crank the engine. It will run for about 30 seconds before shutting down again.

Turn Signal Functions

The system operates the turn signal relay and the turn indicators (Fig. 2.23).

The system features a special heavy-duty relay for ﬂashers, capable of driving up to fourteen 32candlepower bulbs.

10/26/98

1. Left-Turn Signal Light

2. Oil Pressure Warning Light

3. Starter Lockout Warning Light

4. Low-Water Warning Light

5. Water Temperature Warning Light

6. Engine Shutdown Light

7. High-Beam Indicator Light

8. Overspeed Light

9. Low Air Pressure Warning Light

10. Right-Turn Signal Light

Fig. 2.23, VIGIL III Warning System, Optional

f600292b

Engine Functions

The system monitors engine coolant temperature, coolant level, and oil pressure.

•

If the engine overheats, a warning light (Fig. 2.23) comes on and a buzzer sounds. The temperature that triggers the warning light and buzzer varies with engine type and is programmed into the system at the factory. If the temperature continues to rise to critical levels, the engine shutdown light comes on, and the engine will shut down (if equipped with the shutdown feature).

•

If the coolant level drops below a sensor in the cooling system, the low water level light comes on. After 5 seconds, a buzzer sounds, and after 30 seconds the system shuts down the engine (if equipped with the shutdown feature).

•

Other Functions

The system protects the starter by locking out the starter button whenever any of the following conditions exist:

•

Voltage at the key switch is greater than 18 volts or less than 9 volts before the starter button is pressed.

•

The starter button has been pressed within the last two seconds.

•

Engine speed exceeds 350 rpm.

•

The starter has been cranked for a total of 30 seconds within the last minute (the starter button is locked out for two minutes to allow the starter to cool).

NOTE: If the lockout feature activates to let the starter cool, the starter lockout warning light (Fig. 2.23) will be on for the two-minute cooling period. If the lockout feature activates for any other reason, the light will glow only if the starter button is pressed within two seconds of the lockout occurring, and it will be on only as long as the button is pressed.

•

The system features a speed governor for maximum vehicle speed control. The governor can be set anywhere between 45 and 85 mph (70 and 140 km/h), and controls vehicle speed by cutting fuel delivery pressure when the predetermined speed is reached. If this system is malfunctioning, the lightbar overspeed light (Fig. 2.23) will ﬂash on for ten seconds each time that the engine is started.

2.18

Instruments and Controls Identiﬁcation

•

While driving, the overspeed light will ﬂash on if the driver exceeds a second predetermined speed set by the customer.

The system also controls several functions such as headlight high beam indicator (Fig. 2.23), low air pressure warning light and alarm, and control for four optional features. The optional features can be any combination of the following or any four that are specially ordered:

•

transmission temperature

•

axle temperature

•

engine heater

•

alternator no charge

•

ﬁfth wheel lock

•

parking brake

•

sand

•

antilock

•

mirror heater

•

utility lights

•

axle lock

•

sludge ejector

Additional Features

When the ignition is turned on, all the LEDs in the lightbar will light and the low air and low oil pressure alarms will sound. The lights and alarms will activate for two one-second periods, separated by a halfsecond pause. This is a self-test to indicate whether or not the lightbar is working. After the test, the LEDs not in use will turn off. The low air and oil pressure warnings will not sound again until the starter is cranked. Once the starter is cranked, the alarms will sound until system air and oil pressures reach minimum levels. If the lightbar doesn’t operate as described here, test it. For instructions, see Group 54

Heavy-Duty Trucks Service Manual

of the

Kysor Vehicle Instrumentation and Protection (VIP) System, Optional

The Kysor VIP system is an electronically controlled warning and engine shutdown system. It also controls the turn signal functions and various optional functions. A solid state lightbar (Fig. 2.22) in the instrument panel contains displays for the functions.

Engine Functions

The system monitors engine coolant temperature, coolant level, and oil pressure.

•

If the coolant level drops below a sensor in the cooling system, the low water level light comes on, and a buzzer sounds. After 30 seconds, the system will shut down the engine. The low coolant shutdown feature may be turned on or off by setting a DIP switch in the control module.

•

All shutdown features have an automatic override. If the vehicle needs to be moved to a safe location after a shutdown, just crank the engine. It will run for about 30 seconds before shutting down again.

Turn Signal Functions

The system operates the turn signal relay and the indicators.

Other Functions

The system also controls several functions such as the headlight high beam indicator, low air pressure warning light and intermittent buzzer, dimming of the turn signal indicators when the headlights are turned on, and control of indicators for six optional features (Fig. 2.22). The optional features can be any combination of the following:

•

transmission temperature

•

axle temperature

•

engine heater

•

alternator no charge

2.19

Instruments and Controls Identiﬁcation

•

ﬁfth wheel lock

•

parking brake

•

sand

•

antilock

•

mirror heater

•

utility lights

•

axle lock

•

sludge ejector or any six that are specially ordered. Three of the six optional indicators can trigger the

warning buzzer. The buzzer feature can be activated at the factory or in the ﬁeld by setting DIP switches on the control module. The low air pressure buzzer is an intermittent signal; all other warning buzzers give a constant signal. When the air pressure is low, the buzzer will sound intermittently, regardless of what optional features are selected, how the DIP switches are set, or what other warnings might be on.

Additional Features

When the ignition switch is turned on and the starter is engaged, all of the LEDs in the lightbar will light up as a check that they are working. When the starter is released, those LEDs not in use will turn off.

If the ignition switch is turned on and the engine is not cranked, there will be no warning buzzer for any of the warning features. The warning buzzer is triggered by the start circuit if the engine is cranked, releasing the start switch turns on the buzzer. After releasing the starter, the oil pressure buzzer sounds during the time engine oil pressure is rising.

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 of 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 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.

Optional side sensor(s) mounted on the side of the vehicle also transmit and receive radar signals for a distance of 2 to 10 feet (0.5 to 3 meters) alongside your vehicle. The side sensor(s) provide a 15 degree vertical by 15 degree horizontal beam pattern. The side sensor(s) 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.

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

Driver Display Unit (DDU)

NOTE: All system controls are located on the DDU. See Fig. 2.24. Indicators to inform the driver about the system’s operation are located on both the DDU and the optional side sensor display.

2.20

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. 2.24, Driver Display Unit, EVT-300

The DDU controls system power, range for vehicle warnings, speaker volume, and all other system functions. At the lower front edge of the DDU, a slot is provided to insert the optional 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 insert the identiﬁcation card.

A light sensor automatically adjusts alert and indicator light brightness depending on cab 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.

1011 9

7. Photo Light Sensor

8. Driver’s Identiﬁcation Card Slot

9. Red Alert Light

10. Orange Alert Light

11. YellowAlert Light

12. Distance/Danger Alert Lights

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 5 seconds and then release it to activate the failure display mode.

NOTE: The system may be conﬁgured to have no on/off capability and the volume may be conﬁgured to allow only some volume control.

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 (if enabled) to change the ﬁrst alert detection range from 3 to 2 seconds. This will also change the second alert detection range from 2 to 1.75 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.

f610258

2.21

Instruments and Controls Identiﬁcation

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 5 seconds to display fault codes. The fault codes will be blinked out as a pattern of ﬂashes on this indicator light. See

Table 2.1 for fault codes.

Fault Codes (blink 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 SmartCruise 31 J1587 32 J1939 33 VBUS 34 DDU Communications 35 Antenna Assembly Communications 41 No Fault or End of Fault Codes

Table 2.1, Fault Codes or Blink Codes

The green SC indicator light will ﬂash 8 times if the range knob is pressed to store accident reconstruction information. It will also ﬂash 8 times after the system is activated, after the power-on LED test is ﬁnished, and if accident reconstruction data was previously stored.

The photo light sensor senses lighting conditions in the cab 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 yellow and orange alert lights illuminate when your vehicle is within a 3-second following interval behind another vehicle in the same lane. If you are within a 2-second following interval, and closing on the vehicle ahead, a warning tone will also sound.

11.

The yellow, orange, and red alert lights illuminate when you are 1 second (and less than 1 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 less than 3.4 mph (5.5 km/h) in the same lane is detected within 220 feet (67 meters) and within 3 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 system is disabled in turns with a radius of less than 750 feet (230 meters) and when the brakes are applied.

13.

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

NOTE: All warnings apply only to objects within the maximum detection range and in your lane. Proximity alert tones and vehicle-closing 1/2second and 2-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 3-second and 2-second alert levels may be adjusted with the range control knob. A single low-frequency tone sounds when a system failure is detected. A

2.22

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