freightliner S2 Operator's Manual

S2 CHASSIS

STI-479-6

A24-01453-000

Operator’s Manual

Foreword

Introduction

This manual provides information needed to operate
and understand the chassis and its components.
More detailed information is contained in the Owner’s
Warranty Information for North America booklet, and
in the vehicle’s workshop and maintenance manuals.

Freightliner chassis are equipped with various chas­sis and cab components; not all of the information
contained in this manual applies to every vehicle. If
parts on your chassis differ from those shown, they
may have been installed by the vehicle final-stage
manufacturer.

The safety or performance of your vehicle could be
adversely affected by the installation of nonstandard
components. Note the limitations and specifications
provided in the vehicle and chassis manuals, and
consult your selling dealer before making any altera­tions to the vehicle or chassis.

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 Custom Chassis Corporation re­serves the right to discontinue models and to
change specifications or design at any time
without notice and without incurring obligation.
Descriptions and specifications contained in this
publication provide no warranty, expressed or
implied, and are subject to revisions and edi­tions without notice.

Environmental Concerns and
Recommendations

if an air bag is installed, or if the vehicle features a
collision avoidance system, etc.).

This vehicle is equipped with an event data recorder
(EDR). The main purpose of an EDR is to record
data in certain crash or near-crash situations, such
as air bag deployment or hitting a road obstacle, that
will assist in understanding how a vehicle’s systems
performed. The EDR is designed to record data re­lated to vehicle dynamics and safety systems for ap­proximately 60 seconds. This data can help provide
a better understanding of the circumstances in which
crashes and injuries occur. Data recorded includes
the following items:

•

how various systems in the vehicle were oper­ating

•

engine system information

•

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

•

if the driver was depressing the brake pedal

•

how fast the vehicle was traveling

NOTE: Data is not recorded by the EDR under
normal driving conditions. Personal data such
as name, gender, age, and crash location are
not recorded. However, other parties such as
law enforcement could combine the EDR data
with the type of personally identifying data rou­tinely acquired during a crash investigation.

To read data recorded by an EDR, special equipment
is required, and access to the vehicle or the EDR is
needed. In addition to the vehicle manufacturer, other
parties that have the special equipment, such as law
enforcement, can read the information if they have
access to the vehicle or the EDR.

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,

Emissions and Fuel Efficiency
Compliance

This vehicle must be regularly inspected and main­tained as indicated in the S2 Chassis Maintenance

Manual, and in the Pre- and Post-Trip Inspections
and Maintenance chapter in this manual, in order to

continue satisfactory performance and ensure cover­age of the vehicle under the manufacturer’s warranty.
Many maintenance procedures ensure that the ve­hicle and engine continue to comply with applicable
emissions standards. Maintenance procedures, using
components engineered to comply with greenhouse

STI-479-6 (12/15)

A24-01453-000

Printed in U.S.A.

Foreword

gas emissions and fuel efficiency regulations, may be
performed by an authorized Daimler Trucks North
America dealer, an independent outlet, or the vehicle
owner or operator.

The vehicle owner is responsible for determining the
suitability of replacement components to maintain
compliance with federal and local jurisdictional regu­lations. Components including, but not limited to, low­rolling resistance tires are specifically designed and
manufactured to exacting standards for regulatory
fuel efficiency and greenhouse gas emissions compli­ance. It is important that these components are al­ways replaced with components that meet or exceed
the performance of the originally installed compo­nents.

Customer Assistance Center

Having trouble finding service? Call the Customer
Assistance Center at 1–800–385–4357 or 1–800–
FTL–HELP. Call night or day, weekdays or week­ends, for dealer referral, vehicle information, break­down coordination, or Fleetpack assistance. Our
people are knowledgeable, professional, and commit­ted to keeping your vehicle moving.

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 [phone], 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:

roadsafety

.

www.tc.gc.ca/

Reporting Safety Defects

If you believe that your vehicle has a defect that
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 Freightliner Custom Chassis
Corporation.

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 Freightliner Custom
Chassis Corporation.

To contact NHTSA, you may call the Vehicle
Safety Hotline toll-free at 1-888-327-4236 (TTY:
1-800-424-9153); go to
write to: Administrator, NHTSA, 1200 New Jersey
Avenue, SE, Washington, DC 20590. You can also

© 2007–2015 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.comand www.FreightlinerChassis.com.

www.safercar.gov;or

Contents

Chapter Page

Introduction, Environmental Concerns and Recommendations,
Event Data Recorder, Emissions and Fuel Efficiency Compliance,

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

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

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

3 Instruments ............................................................. 3.1

4 Controls ................................................................ 4.1

5 Cab Features ........................................................... 5.1

6 Electrical Systems ....................................................... 6.1

7 Heater, Ventilating, and Air Conditioner (HVAC) ................................ 7.1

8 Engines ................................................................ 8.1

9 Exhaust Aftertreatment Systems ............................................ 9.1

10 Transmission ........................................................... 10.1

11 Drive Axles ............................................................ 11.1

12 Steering System ........................................................ 12.1

13 Hydraulic and Air Brake Systems .......................................... 13.1

14 Pre- and Post-Trip Checklists ............................................. 14.1

15 Pre- and Post-Trip Inspections and Maintenance .............................. 15.1

16 Cleaning and Care ...................................................... 16.1

17 In an Emergency ....................................................... 17.1

18 Headlight Aiming ........................................................ 18.1

19 Propane Fuel System .................................................... 19.1

20 Specifications .......................................................... 20.1

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

1

Vehicle Identification

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

Vehicle Identification Number ....................................................... 1.1

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

Vehicle Identification

Component Information Label

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

The component information label lists the manufac­turer, month and year of manufacture, vehicle identifi­cation number (VIN), gross vehicle weight rating
(GVWR), front and rear gross axle weight ratings
(GAWR), and tire and wheel information. It also indi­cates if the vehicle has been certified as compliant
with Federal Motor Vehicle Safety Standard
(FMVSS). See

Fig. 1.1.

tire and rim label, then the tires and rims determine
the load limitations on each of the axles.

Incomplete chassis intended for service in the U.S.
have an incomplete vehicle certification label at­tached by the final-stage manufacturer. This label will
be attached to the incomplete vehicle document in­cluded with the vehicle, and certifies that the vehicle
conforms to all applicable FMVSS regulations in ef­fect on the date of completion.

Vehicle Identification Number

The chassis vehicle identification number (VIN) is
stamped on a metal plate permanently attached to
the vehicle, and the last six digits (designating the
chassis serial number) are stamped into the metal
frame. See
the body builder. Mounting locations vary, to include
the glove box. See

Fig. 1.2. A VIN label is also mounted by

Fig. 1.3.

4UZA4FVC0TC748531

GAFFNEY, SOUTH CAROLINA, USA

09/11/2002 f080123

Fig. 1.1, Component Information Label

The tire and rim portion of the component information
label certifies suitable tire and rim combinations that
can be installed on the vehicle for the given gross
axle weight rating. Tires and rims installed on the
vehicle at the time of manufacture may have a higher
load capacity than that certified by the tire and rim
label. If the tires and rims currently on the vehicle
have a lower load capacity than that shown on the

04/18/2005

Fig. 1.2, Vehicle Identification Number, Typical

f080061a

NOTE: Always include the chassis serial num­ber (last six digits of the VIN) when communi­cating to Daimler Trucks North America.

Emissions Labels

Aftertreatment System Indicators
Label

Engines and vehicles manufactured after December
31, 2006 and domiciled in the U.S. or Canada are
required to meet all EPA regulations effective as of
the vehicle build date, and are equipped with an
emission aftertreatment system (ATS). Vehicles do­miciled outside of the U.S. and Canada may not
have aftertreatment equipment, depending upon local
statutory emissions guidelines. See

A reference label included with the driver’s documen­tation package contains important warning indicators

Table 1.1.

1.1

Vehicle Identification

in the instrument cluster that pertain to the ATS. See

Fig. 1.4.

12/04/2001

Fig. 1.3, Vehicle Identification Number Label, Typical

It is a violation of U.S. federal law to alter exhaust
plumbing, ATS, or other components in any way that

f080122

02/20/2009

EXHAUST AFTERTREATMENT SYSTEM INFORMATION

INDICATOR
LAMP(S)

(Solid)

(Flashing) (Flashing)

CHECK

Level 1 Level 3Level 2 Level 4

Indicator Lamp
Message(s)

Diesel Particulate
Filter Condition

Required Action

Filter Regeneration
Recommended.

Filter is reaching
capacity

.

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

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

Filter
Regeneration
Necessary

Filter is now
reaching maximum

Switch.

capacity

.

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

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.

.

Service Regeneration Required.
Engine Derate To Idle Only.

Filter has exceeded maximum
capacity.

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

Fig. 1.4, ATS Indicators

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.

f080156

1.2

Vehicle Identification

would bring the engine/vehicle out of compliance with
certification requirements [Ref: 42 U.S.C. S7522(a)
(3)]. It is the owner’s responsibility to maintain the
vehicle so that it conforms to EPA regulations.

A Vehicle Emission Control Information Label indi­cates compliance with GHG14 regulations. See

Fig. 1.5. It is the owner’s responsibility to maintain

the vehicle so that it conforms to EPA and NHTSA
regulations.

Vehicle Emission Control Information
Label

Model year 2013 and later vehicles meet additional
requirements as specified by federal greenhouse gas
and fuel efficiency regulations (GHG14). Model year
2017 and later vehicles meet similar requirements as
specified by GHG17 requirements. These vehicles
are equipped with components that increase fuel effi­ciency and reduce GHG emissions. Components
may include, but are not limited to, low-rolling resis­tance tires.

Applicable Emissions System Based on Build Date and EPA Regulations

Build Date Regulation: Emissions Components

January 1, 2007–December 31,
2009

January 1, 2010–December 31,
2012

From March 5, 2012–December
31, 2015

From January 1, 2016

*

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

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

EPA07 (reduce nitrogen oxides (NOx) emissions to 1.1 g/bhp-hr, and reduce
particulate matter emissions to 0.01 g/bhp-hr): Aftertreatment device (ATD) containing
a diesel particulate filter that traps soot and ash.

EPA10 (reduce NOx emissions to 0.2 g/bhp-hr): EPA07-type ATD, with additional
selective catalyst reduction (SCR) technology that utilizes diesel exhaust fluid (DEF)
to convert NOx to nitrogen and water vapor.

GHG14: Aerodynamic and fuel efficiency components including, but not limited to,
tires, cab/sleeper side extenders, chassis fairings, bumper, hood, vehicle speed
limiters, and idle reduction timers specifically designed to meet regulatory fuel
efficiency and greenhouse gas emissions standards.

GHG17: GHG14 components plus OBD16 instrumentation and sensor upgrades, and
component technology that meets NHTSA and EPA 2017 fuel efficiency and
greenhouse gas emission standards (GHG17) requirements.

03/02/2012 f080183

Fig. 1.5, Vehicle Emission Control Information Label

*

1.3

2

Vehicle Access

Battery Access ................................................................... 2.1

Hood Opening and Closing ......................................................... 2.1

Vehicle Access

Battery Access

Battery Compartment

The battery compartment is located behind the
driver’s area, attached to the frame rail. To open the
battery access door, insert and turn the key, then pull
the access door open. Pull the pull-pin spring latches
out to slide the battery tray forward. See

4

2

1

12/05/2003

1. Battery Access Door

2. Pull-Pin Spring Latch

3

3. Battery Tray

4. Battery

Fig. 2.1.

2

f544365

or the vehicle may not start, and permanent bat­tery damage could occur.

01/18/95

Fig. 2.2, Battery Disconnect Switch

f600150a

Hood Opening and Closing

A torsion spring helps to raise and lower the hood.
Hood restraint cables prevent the hood from over­travel. An optional hood damper limits the closing
speed. In the operating position, the hood is secured
to the half-fenders by a hold-down latch on each
side.

Fig. 2.1, Battery Access

With the battery access door open, it is easy to get
access to the battery terminals for cleaning, charg­ing, or emergency jump starting.

To return the battery to the compartment, slide the
battery tray in until the pin spring latch is in the
locked position. Lock the battery access door with
the key.

Battery Disconnect Switch, Optional

A battery disconnect switch, if so equipped, cuts off
all battery power to the vehicle. It is also used when­ever the vehicle is placed out of service for extended
periods to prevent battery discharge. The battery dis­connect switch is located on the side of the battery
box. See

Fig. 2.2.

NOTICE

The batteries must be disconnected if the vehicle
is not in use for a period exceeding two weeks,

Tilting the Hood

1.

Apply the parking brakes.

2.

Release both hood hold-down latches by pulling
the ends outward. See Fig. 2.3.

3

2

1

10/24/2001

1. Fender

2. Latch Hook

Fig. 2.3, Hood Hold-Down Latch

3. Latch Handle

4. Half-Fender

4

f880555

2.1

NOTICE

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

3.

Standing in front of the hood, tilt the rear of the
hood upward until it reaches the over-center po­sition (45-degrees from vertical). Then slowly
bring it to a stop.

Closing the Hood

1.

Push the hood over center.

2.

As the hood goes over center, the damper (if
equipped)automatically slows its rate of descent.
If needed, you can also slow the rate of descent
with your hand.

3.

Make sure the hood is flush with the cowl, then
secure the hood by engaging both hood hold­down latches.

Vehicle Access

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

2.2

3

Instruments

Instrumentation Control Unit ........................................................ 3.1

Warning and Indicator Lights ........................................................ 3.5

Speedometer and Tachometer ....................................................... 3.9

Standard Instruments .............................................................. 3.9

Optional Instruments ............................................................. 3.11

Instruments

Instrumentation Control Unit

Figure 3.1 and Fig. 3.2 show a typical set of instru-

ments for vehicles equipped with the S2 Chassis
ICU3 instrument cluster.

NOTE: This instrument cluster is shown with the
U.S. speedometer, which shows miles per hour
(mph) more prominently than kilometers per
hour (km/h).

124 5

The S2 Chassis instrument clusters have the capabil­ity to drive independent stand-alone gauges such as
those installed on the auxiliary dash panel.

shows a typical dash.

3.3

Figure

Dash Message Center

The dash message center is the heart of the instru­ment cluster. It has two parts, a set of 27 warning
and indicator lights similar to those found on a con-

3

6

7

13

07/08/2011

1. Engine Oil Pressure Gauge

2. Dash Message Center

3. Headlight High-Beam Indicator

4. Dash Driver Display Screen

5. Fuel Level Gauge

12

6. Diesel Exhaust Fluid (DEF) Gauge

7. Primary Air Pressure Gauge

8. Mode/Reset Switch

9. Secondary Air Pressure Gauge

Fig. 3.1, Gauge Layout (typical, U.S.), EPA10 and Newer Engines

The ICU3 instrument cluster can accept information
from the datalink and from various sensors installed
on the vehicle, and deliver that information to elec­tronic gauges.

There can be up to eight gauges on the driver’s in­strument panel (six electronic and two mechanical).
Only the air gauges operate mechanically.

11

10

10. Speedometer

11. Tachometer

12. Transmission Temperature Gauge

13. Coolant Temperature Gauge

ventional lightbar, and a dash driver display screen.
The driver display screen is a one-line by seven­character liquid crystal display (LCD) that normally
shows odometer readings. Below this display is a
smaller one-line by three-character LCD that shows
voltmeter readings.

The dash message center houses all of the standard
and optional warning and indicator lights. Warning

8

9

f611047

3.1

Instruments

124 5

12

10/26/2006

PSI

150

F°

0

100

F°

100

50

100

OIL

200

250

WATER

225

350

TRANS

CHECK

11

1. Engine Oil Pressure Gauge

2. Dash Message Center

3. Headlight High-Beam Indicator

4. Dash Driver Display Screen

10

5

3

STOP

20

25

15

30

25

15

RPM

0

X100

10

5. Fuel Level Gauge

6. Primary Air Pressure Gauge

7. Mode/Reset Switch

8. Secondary Air Pressure Gauge

OPT

OPTOPTOPTOPTOPTOPTOPTOPT

ABS

BRAKE

ABS

45

70

90

55

65

110

35

50

30

75

10

5

km/h

MPH

130

85

9

1/2

E

F

FUEL

50

100

PSI

150

0

AIR

50

100

PSI

150

0

AIR

PUSH−
MODE

HOLD−
RESET

f610837b

6

7

8

9. Speedometer (U.S. version)

10. Tachometer (optional)

11. Coolant Temperature Gauge

Fig. 3.2, Gauge Layout (typical, U.S.), EPA07-Compliant

messages and diagnostic fault codes will appear in
the driver display screen. For more information on
this system, see the heading "Ignition Sequence" in
this chapter.

Ignition Sequence

The dash message center goes through a prescribed
ignition sequence each time the ignition switch is
turned on. See

When the ignition is turned on, all the electronic
gauges complete a full sweep of their dials, the
warning and indicator lights illuminate, and the
buzzer sounds for 3 seconds.

NOTE: The air gauges do not sweep.

The following lights illuminate during the ignition se­quence:

•

Fasten Seat Belt Warning

Fig. 3.4 for the ignition sequence.

•

Low Battery Voltage Warning

•

High Coolant Temperature Warning

•

Low Engine Oil Pressure Warning

•

Low Air Pressure Warning

•

Parking Brake On Indicator

•

All engine indicator/warning lights, including
Check Engine and Stop Engine

•

All ABS indicator/warning lights, including
Wheel Spin, and Tractor ABS (if installed)

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

3.2

Instruments

1

9

2

3

4

5

4

4

8

6

07/31/2006

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

1. Left-Hand Window Outlet

2. Instrumentation Control Unit
(ICU3)

3. Left-Hand Dash Outlet

When the ignition switch is 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:

•

First line (odometer): 888888.8

•

Second line (units): TRIP MI KM HOURS

•

Third line (voltmeter): 38.8 VOLTS

•

Fourth line: SERVICE ENGINE

4. Windshield Defrost Outlets

5. Right-Hand Dash Outlet

6. Right-Hand Window Outlet

Fig. 3.3, Dash Panel Layout (typical)

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

If there are no active faults, the driver display screen
displays the odometer.

If however, the instrument cluster has received active
fault codes from other devices, it displays them one
after the other until the parking brake is released, or
the ignition switch is turned off. Once the parking
brake is released, the dash message center displays
the odometer again.

7

f831703

7. HVAC Cover

8. Climate Control Panel

9. Auxiliary Dash Panel

3.3

Instruments

HEADLIGHTS ON

888888.8

TRIP MI KM HOURS

38.8 VOLTS SERVICE

ODOMETER
SCREEN

IF NO FAULTS
WERE DETECTED

ENGINE

123456.7

MI

12.3 VOLTS

PARK BRAKE

RELEASED − MOVING

123456.7

MI

10/24/2001

NOTE: If active faults are present, take the ve­hicle as soon as possible to an authorized
Freightliner service facility.

If the fault is mission-critical, that is, if it is a serious
problem that requires immediate attention, the stop
engine system will activate. In most cases, the check
engine light will also illuminate.

Some examples of mission-critical faults include:

•

high coolant temperature

•

low air pressure

•

low coolant level

•

low engine oil pressure

NOTE: The check engine light does not illumi­nate for a low air pressure fault.

The legend SERVICE ENGINE can appear on the
driver display screen as an active fault code. If this
legend appears, it means the trip miles (or hours)
have gone beyond the next required service interval,
as set by the vehicle operator.

IMPORTANT: If the legend SERVICE ENGINE
does appear on the driver display screen while

12.3 VOLTS

Fig. 3.4, Ignition Sequence

POWER ON

IGNITION ON

ICU PERFORMS SELF−TEST:
ELECTRONIC GAUGE NEEDLES
SWEEP, WARNING/INDICATOR
LIGHTS COME ON, BUZZER SOUNDS

IF FAULT DETECTED

ABS 136

FAULT CODE
SCREEN

RELEASE PARK BRAKE

f040420b

operating the vehicle, bring the vehicle to an
authorized Freightliner service facility when
convenient.

Odometer

The odometer is set to display in either miles or kilo­meters, depending on the primary scale of the
speedometer. The legend, either MI or KM, illumi­nates between the odometer and the volts display
when the engine is running or the headlights are
turned on.

The odometer is a seven-digit display with a decimal
point, until the vehicle has traveled 999,999.9 miles
or kilometers (km). At one million miles (km), the
odometer resets itself to 1,000,000, without the deci­mal point, and can continue up to 9,999,999. The
odometer only displays significant figures (no leading
zeros).

Mode/Reset Switch

The mode/reset switch, shown in Fig. 3.5, is located
on the right side of the instrument cluster. The mode/
reset switch is used to scroll through the displays on

3.4

Instruments

the message display screen, and to reset the trip dis­tance and trip hours values to zero.

PUSH−
MODE

HOLD−
RESET

09/25/99

Fig. 3.5, Mode/Reset Switch

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) or KM (kilometers), press the
mode/reset switch while in the SELECT screen.

f610340

Warning and Indicator Lights

There can be up to 27 warning and indicator lights
(telltales) installed in the dash message center. See

Fig. 3.6 and Fig. 3.7. There are four rows of lights.

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.

NOTE: In the second, third, and fourth rows, if
an optional telltale light is not installed, that po­sition is left blank.

The instrument cluster has an emergency buzzer that
sounds when mission-critical conditions occur.

2

1

STOP

CHECK

8

14

07/08/2011

1. Optional Indicator

2. Check Engine Indicator

3. Stop Engine Warning

4. Malfunction Indicator Lamp (MIL)

5. ABS Indicator

6. Transmission Overheat Indicator

7. Trailer ABS Indicator (not used)

8. Low Oil Pressure Warning

9. High Coolant Temperature Warning

10. Fasten Seat Belt Warning

11. Parking Brake On Indicator

12. Diesel Particulate Filter (DPF) Lamp

13. High Exhaust System Temperature (HEST) Lamp

14. Left-Turn Signal Arrow

15. Low Battery Voltage Warning

16. Water In Fuel Indicator

17. Dash Driver Display Screen

18. Headlight High-Beam Indicator

19. Cruise Control Indicator

20. Low Air Pressure Warning

21. Right-Turn Signal Arrow

Fig. 3.6, ICU3 Warning and Indicator Lights, EPA10 and

15

4

3

9

10

17

16

Newer Engines

11

18

56

OPTOPTOPTOPTOPTOPTOPTOPT

ABS

12

20 21

19

7

OPT

ABS

13

f611066

Check Engine Indicator

The amber check engine indicator light (CHECK EN­GINE legend) illuminates when certain faults are de­tected. If a critical engine condition exists (for ex­ample, low oil pressure or high coolant temperature),
the check engine light will illuminate to alert the
driver to correct the condition as soon as possible. If
the condition gets worse, the stop engine light will il­luminate.

NOTE: If the check engine light illuminates dur­ing vehicle operation, take the vehicle directly to
an authorized Freightliner service facility.

3.5

Instruments

2

1

STOP

CHECK

8

14

09/28/2006

1. Optional Indicator

2. Check Engine Indicator

3. Stop Engine Warning

4. Malfunction Indicator Lamp

5. ABS Indicator

6. Transmission Overheat Indicator

7. Trailer ABS Indicator (not used)

8. Low Oil Pressure Warning

9. High Coolant Temperature Warning

10. Fasten Seat Belt Warning

11. Parking Brake On Indicator

12. Diesel Particulate Filter (DPF) Lamp

13. High Exhaust System Temperature (HEST) Lamp

14. Left-Turn Signal Arrow

15. Low Battery Voltage Warning

16. Dash Driver Display Screen

17. Headlight High-Beam Indicator

18. Low Air Pressure Warning

19. Right-Turn Signal Arrow

15

Fig. 3.7, Warning and Indicator Lights, EPA07-

4

3

9

10

16

Compliant

11

17

56

OPTOPTOPTOPTOPTOPTOPTOPT

ABS

BRAKE

12

18 19

7

13

f610838

OPT

ABS

vehicle speed. The vehicle may be driven to a safe
location.

The engine ECU will derate the engine. The driver
must safely bring the vehicle to a stop on the side of
the road.

NOTICE

Because operating the engine when the red stop
engine light is illuminated can lead to severe en­gine damage, the driver must move the vehicle to
a safe location as quickly as possible.

To restart the engine turn the ignition switch to OFF,
leave it there a few seconds, and turn the switch to
START.

IMPORTANT: Do not attempt to restart the en­gine while the vehicle is moving. Bring the ve­hicle to a safe stop and restart the engine with
the vehicle stopped.

Malfunction Indicator Lamp (MIL)

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

ABS Indicator

The amber ABS indicator light illuminates when there
is a malfunction in the vehicle antilock brake system
(ABS).

Stop Engine Warning

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.

The red stop engine warning light (STOP ENGINE
legend) illuminates to indicate that the protection sys­tem available for the engine has been activated. On
some engines, the engine ECU will derate the en­gine, allowing it to run, but at lower rpm and slower

NOTE: For more information about this light and
the ABS system, see

Chapter 13.

Transmission Overheat Indicator

The amber transmission overheat indicator light
(TRANS TEMP legend) illuminates when the tem­perature of the transmission fluid goes above the
preset level set by the transmission manufacturer.

For more information, see the transmission manufac­turer’s manual provided with the vehicle.

Low Oil Pressure Warning

The red low oil pressure warning light (oil can icon)
and emergency buzzer activate whenever the engine
oil pressure goes below the preset minimum speci­fied by the engine manufacturer. See

Table 3.1.

3.6

Instruments

Oil Pressure Specifications

Engine Model

Mercedes-Benz
MBE900

Cummins ISB 10 psi (69 kPa) 30 psi (207 kPa)

*

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.

†

When above minimum pressure, the dash gauge will display the values
listed in this table. If below minimum oil pressure, the dash gauge will
read 0 psi.

†

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

EPA07 MBE900 engines are equipped with an oil pressure switch.

Table 3.1, Oil Pressure Specifications

Pressure at

Idle RPM

50 psi (345

kPa)

*

Pressure at
Rated RPM

50 psi (345 kPa)

High Coolant Temperature Warning

The red high coolant temperature warning light (ther­mometer icon) and emergency buzzer activate when­ever the coolant temperature goes above a preset
maximum specified by the engine manufacturer. See

Table 3.2.

Maximum Coolant Temperature

Engine Model °F (°C)

Mercedes-Benz MBE900 221 (105)
Cummins ISB 225 (107)

Table 3.2, Maximum Coolant Temperature

Fasten Seat Belts Warning

The red fasten seat belts warning light (seat belt
icon) illuminates for 15 seconds after the ignition
switch is turned on.

Diesel Particulate Filter (DPF) Lamp

Solid illumination 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 stationary regenera­tion. See the engine operation manual for details.

Blinking indicates that a stationary regeneration is
required immediately. An engine derate and shut­down will occur. See the instructions in the engine
manufacturer’s operator’s manual to perform a sta­tionary regeneration.

High Exhaust System Temperature
(HEST) Lamp

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

A solid illumination indicates potentially hazardous
exhaust temperatures at the outlet of the tail pipe if
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.

Left-Turn Signal Arrow

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

Both turn signal arrows flash when the hazard warn­ing flasher is turned on.

Low Battery Voltage Warning

Brake System Warning/Parking Brake
On Indicator

The red brake system warning/parking brake on indi­cator light (BRAKE legend) activates whenever the
parking brake is engaged.

If the vehicle is moving at a speed of 2 mph (3 km/h)
or more, the emergency buzzer will sound until the
parking brake is released.

NOTE: The BRAKE legend is required in the
U.S. In Canada, the icon is required.

3.7

The red low battery charge warning light (battery
icon) illuminates when the battery voltage drops
below 12 volts.

Water In Fuel Indicator

The amber water in fuel indicator illuminates when
the system detects water in the fuel tank.

NOTICE

Water in the fuel/water separator will appear as
beads. With the engine off, drain the separator
only enough to remove the water; about two tea­spoons at a time. Do not drain the separator

Instruments

completely or it will be necessary to prime the
fuel system before the vehicle can be started
again.

WARNING

Diesel fuel is flammable and can ignite if exposed
to an open flame, intense heat, or other ignition
source. Do not drain fuel near, or expose fuel
vapor to open flame or intense heat. Exposure to
open flame or intense heat could start a fire, pos­sibly resulting in personal injury or property
damage. When working on a fuel system, have a
fire extinguisher within easy reach.

Drain any water collected in the fuel/water separator.

Headlight High-Beam Indicator

The blue high-beam indicator light (sideways beam
icon) illuminates when the headlight high beams are
on.

Cruise Control Indicator

A green indicator illuminates when the cruise control
is activated.

Low Air Pressure Warning

The red low air pressure warning light (pressure
circle icon) and emergency buzzer activate when the
engine is turned on if air pressure in the primary or
secondary air reservoir is below 65 to 75 psi (448 to
517 kPa), and remain on until air pressure rises
above that level in both reservoirs.

The warning light and buzzer also activate during
operation whenever air pressure in the primary or
secondary air reservoir falls below 65 to 75 psi (448
to 517 kPa).

Right-Turn Signal Arrow

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

Both turn signal arrows flash when the hazard warn­ing flasher is turned on.

Emergency Buzzer

The emergency buzzer sounds during the ignition
sequence and whenever one of the following condi­tions exists:

•

The engine oil pressure falls below the preset
level shown in

•

The coolant temperature rises above the pre­set level shown in

•

The air pressure falls below the preset level,
which is 65 psi (448 kPa).

•

The parking brake remains set with the vehicle
moving at a speed greater than 2 miles per
hour.

Table 3.1.

Table 3.2.

Optional Indicator Lights

The optional indicator lights that are available in­clude: intake heater on indicator, low brake fluid
warning, low coolant warning, low fuel warning, auto­matic transmission range inhibit warning, differential
lock warning, and wheel spin indicator.

Air Filter Indicator

The optional amber air filter indicator light (AIR FIL­TER legend) illuminates when the air cleaner filter
element is clogged, restricting the intake air flow. See

Table 3.3.

If the air filter indicator light is steadily illuminated for
any period of time, check the air intake restriction
gauge. If needed, replace the air filter, and reset the
air intake restriction gauge.

Air Intake Maximum Restriction Values (inH2O)

Engine

Cummins 25 25
Mercedes-Benz 22 22

Table 3.3, Air Intake Maximum Restriction Values

Pre-EPA07

Engines

(inH

O)

2

IMPORTANT: Never attempt to clean the air fil­ter.

Alternator No Charge Indicator

EPA07 and

Newer Engines

The optional amber alternator no charge indicator
light (NO CHARGE legend) illuminates when the al­ternator is not charging properly.

3.8

Instruments

Check Transmission Indicator (diesel
engine only)

NOTE: Although it appears in the row of op­tional indicator lights, the check transmission
indicator is a standard indicator light.

The check transmission indicator light, shown in

Fig. 3.8, notifies the driver of three things. The indi-

cator light has a solid illumination and any of the fol­lowing items could be the cause for activating the
light:

•

oil life monitor (determines when the oil needs
to be changed)

•

filter life monitor (determines when the filter[s]
need to be changed)

•

transmission health monitor (determines when
clutch maintenance is required)

25

5

45

35

30

10

55

70

90

50

km/h

MPH

65

110

75

130

85

f610527

20

15

10

5

0

10/09/2001

1. Tachometer 2. Speedometer

Fig. 3.9, Speedometer and Tachometer

25

30

15

RPM

X100

1 2

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. See

Fig. 3.9.

02/28/2011

Fig. 3.8, Check Transmission Indicator

f611115

When the check transmission indicator illuminates,
refer to the Allison Operator’s Manual or contact cus­tomer support at Allison Transmission to determine
the specific cause activating the indicator light.

Speedometer and Tachometer

Speedometer

Three kinds of speedometer faces are available. The
U.S. version of the speedometer registers speed in
both miles per hour (mph) and kilometers per hour
(km/h), with mph in larger numbers. See

The NAFTA version (not shown) of the speedometer
face reverses this arrangement, with km/h in larger
numbers. The metric only version (not shown) shows
km/h exclusively.

Fig. 3.9.

Standard Instruments

Engine Oil Pressure Gauge

NOTICE

A sudden decrease or absence of oil pressure
may indicate mechanical failure. Bring the vehicle
to a safe stop and investigate the cause to pre­vent further damage. Do not operate the engine
until the cause has been determined and cor­rected.

The engine oil pressure gauge is mission-critical.

Fig. 3.10. If the engine oil pressure falls below

See
the preset levels shown in
engine light will illuminate, and, if the condition does
not improve, the stop engine light will also illuminate
and the buzzer will sound. At this point, the engine
will derate or shut down, depending on the type of
engine protection system installed.

Coolant Temperature Gauge

A sudden increase in coolant temperature may
indicate engine or cooling system failure. Bring
the vehicle to a safe stop and investigate the

Table 3.1, first the check

NOTICE

3.9

50

PSI

0

100

OIL

10/09/2001

Fig. 3.10, Engine Oil Pressure Gauge

cause to prevent further damage. Do not operate
the engine until the cause has been determined
and corrected.

During normal engine operation, the coolant tem­perature gauge should read 175 to 195°F (79 to
91°C). See

Fig. 3.11. If the temperature remains

below 160°F (71°C), or exceeds the maximum tem­perature shown in

Table 3.2, inspect the cooling sys-

tem to determine the cause. See Group 20 of the S2
Chassis Workshop Manual.

f610528

Instruments

Fuel/Diesel Exhaust Fluid (DEF)
Gauge

For engines that are EPA10-compliant or newer, the
fuel and DEF levels are measured in a dual purpose
fuel/DEF gauge. See

The diesel fuel level is indicated at the top of the
gauge, with a low-level warning lamp that illuminates
when the diesel fuel level registers 1/8th of capacity.
One fuel gauge is standard. If equipped with a sec­ond (optional) fuel gauge, each fuel tank level is indi­cated on a separate gauge.

The DEF level is indicated in the lower portion of the
gauge. There is a low DEF level warning lamp that
illuminates when the DEF level reaches 10% of ca­pacity. See

Chapter 9 for details of the DEF gauge

functions.

4

Fig. 3.12.

1/2

ULTRA LOW SULFUR

DIESEL FUEL ONLY

1

FE

150

F°

100

10/09/2001

Fig. 3.11, Coolant Temperature Gauge

200

250

WATER

f610565

The coolant temperature gauge is mission-critical. If
the coolant temperature rises above the preset levels
shown in

Table 3.2, first the check engine light will

illuminate, and, if the condition does not improve, the
stop engine light will also illuminate and the buzzer
will sound. At this point, the engine will derate or shut
down, depending on the type of engine protection
system installed.

DEF

EF

3

08/21/2009

1. Diesel Fuel Level Indicator

2. DEF Level Indicator

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

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

Fig. 3.12, Fuel/DEF Gauge, EPA10

2

f611045

Figure 3.13 shows a fuel gauge installed on EPA07

vehicles.

Primary and Secondary Air Pressure
Gauges

WARNING

If air pressure falls below minimum pressure, the
braking ability of the vehicle will be limited. Slow

3.10

Instruments

1/2

E

10/09/2001

Fig. 3.13, Fuel Level Gauge

the vehicle down and bring it to a gradual stop.
Do not attempt to move the vehicle until air pres­sure has risen above the minimum level. Moving
a vehicle without adequate braking power could
cause an accident resulting in property damage,
personal injury, or death.

Air pressure gauges register the pressure in the pri­mary and secondary air systems. Normal pressure
with the engine running is 100 to 120 psi (690 to 827
kPa) in both systems. See

Air pressure gauges are required on all vehicles with
air brakes. A low-air-pressure 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 65 to 75 psi
(448 to 517 kPa).

When the engine is started, the warning light and
buzzer remain on until air pressure in both systems
exceeds minimum pressure.

F

FUEL

f610566

Fig. 3.14.

Voltmeter

1

2

10/22/2009

1. Primary Air Pressure Gauge

2. Secondary Air Pressure Gauge

Fig. 3.14, Air Pressure Gauges

volts is considered a low battery, and a completely
discharged battery will produce only about 11.0 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.

f610567

The voltmeter is a digital readout located on the bot­tom line of the driver display screen whenever the
ignition switch is turned on.

It 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.

The voltmeter will normally show approximately 13.7
to 14.1 volts when the engine is running. The voltage
of a fully charged battery is 12.7 to 12.8 volts when
the engine is stopped. Battery voltage under 12.0

3.11

Optional Instruments

Optional instruments are not found on every vehicle.
They are stand-alones, not driven by the instrument
cluster, and are usually located on the auxiliary dash
panel. They are listed here in alphabetical order, to
make the information easier to find.

Air Intake Restriction Gauge

The air intake restriction gauge indicates the vacuum
on the engine side of the air cleaner. On standard
installations, it is mounted on the air intake duct in
the engine compartment. See

Fig. 3.15. As an option

for easier viewing, the intake-air restriction indicator
can be mounted on the dash, usually on the right­hand control panel.

Instruments

10/10/2001

Fig. 3.15, Air Intake Restriction Indicator

f610568

Air intake restriction vacuum is measured in inches
of water (inH

O). For vehicles equipped with a gradu-

2

ated indicator or a restriction gauge on the dash,
check the gauge with the engine off. If the yellow
signal stays locked in the red zone once the engine
is shut down, or is at or above 25 inH

O, the air

2

cleaner element needs to be replaced.

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

Ammeter

An optional ammeter measures current flowing to
and from the battery. See
ies are being charged, the meter needle moves to
the plus side of the gauge; when the batteries are
being discharged, the needle moves to the minus
side. A consistent negative reading when the engine
is running indicates a possible problem with the
charging system.

Fig. 3.16. When the batter-

10/10/2001

Fig. 3.16, Ammeter

f610573

Axle Oil Temperature Gauge, Rear

NOTICE

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 vehicle until the cause has
been determined and corrected.

During normal operation, the optional rear axle oil
temperature gauge should read between 160 and
220°F (71 and 104°C) for Detroit
axles. See

Fig. 3.17.

™

and Meritor™drive

10/10/2001

f610571

Fig. 3.17, Axle Oil Temperature Gauge

3.12

Instruments

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

Digital Clock

The optional 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. See

10/11/2001

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 display indicates an AM 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 2 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:

Fig. 3.18.

f610576

Fig. 3.18, Digital Clock

2.1

Push the Run/Set switch to the left
(ALARM-SET position).

2.2

Set the alarm time by using the same pro­cedure used to set the time of day; re­member to set the hour for AM (no letters
in the corner of the display), or PM 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 "wave"
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 1 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 3 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.

Engine Oil Temperature Gauge

NOTICE

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.

During normal operation, the optional engine oil tem­perature gauge should read in the following tempera­ture range:

3.13

•

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

•

177 to 203°F (81 to 95°C) for Mercedes-Benz
MBE900 engines

NOTE: Under heavy loads, such as when climb­ing steep grades, temperatures that exceed the
normal oil temperature range for a short period
are not unusual. If the temperature returns to
normal when the load decreases, there is no
problem. See

Fig. 3.19.

Instruments

NOTICE

A sudden increase in transmission fluid 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 vehicle until
the cause has been determined and corrected.

NOTE: Under heavy loads, such as when climb­ing steep grades, temperatures may climb
above those given here for limited periods.

Turbocharger Boost Pressure Gauge

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

Fig. 3.21.

See

10/10/2001

Fig. 3.19, Engine Oil Temperature Gauge

f610569

Transmission Fluid Temperature
Gauge

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

200

F

125

Fig. 3.20.

275

350

TRANS

f610600

(121°C) at the sump. See

10/30/2001

Fig. 3.20, Transmission Fluid Temperature Gauge

10/10/2001

f610574

Fig. 3.21, Turbo Boost Pressure Gauge

3.14

4

Controls

Ignition Switch and Key ............................................................ 4.1

Lighting Controls .................................................................. 4.1

Multifunction Turn Signal Switch ..................................................... 4.2

Aftertreatment System (ATS) Regen Switch ............................................ 4.4

Horn Control ..................................................................... 4.4

Powertrain Controls ............................................................... 4.5

Braking Controls .................................................................. 4.8

Controls

Ignition Switch and Key

The ignition switch has four positions: ACCESSORY,
OFF, ON, and START. See

09/12/2001

Fig. 4.1, Ignition Switch Positions

In the OFF position, the key slot is vertical; the key
can be inserted and removed only in this position.
The following can be operated in the OFF position
(regardless of whether the key is inserted): low beam
headlights, taillights, brake lights, road lights, clear­ance lights, turn signals, hazard warning lights, horn,
CB radio, clock, and electric oil pan heater.

In the ACCESSORY position, the key is turned coun­terclockwise. The radio (if so equipped), mirror heat,
air dryer, backup lights, and all of the components
that are operable in the OFF position are operable in
the ACCESSORY position.

All electrical systems are operable in the ON posi­tion. The warning lights and the buzzer for low air
pressure and low oil pressure operate until minimum
pressures are built up.

Turn the key fully clockwise to the START position to
start the engine. When the engine starts, release the
key.

Lighting Controls

The lighting controls operate through switches lo­cated on the dash. Two types of dash switches are
used:

•

Paddle switches have a single paddle located
in the center of the switch. The paddle can be
raised or lowered to perform a function.

Fig. 4.1.

f610509

•

Rocker switches can be pressed up or down to
perform a function. Certain rocker switches are
guarded to prevent them from being switched
on or off accidentally.

When the panel lights are on, most switch legends
are backlit with a colored light, usually green. This
allows the driver to find the switch more easily in the
dark. When the switch is on, the switch icon is nor­mally backlit with a colored light, usually amber.
Some switch icons are dead-fronted (not visible until
the switch is turned on). When turned on, some
switches are illuminated from within by a red or
amber light-emitting diode (LED).

Headlight/Parking Light Switch

The headlight/parking light switch is a paddle switch
located on the left-hand control panel above the
cruise/RPM control switches. See
paddle is lowered, the parking lights illuminate (the
front turn signals, the marker and identification lights,
and the taillights). When the paddle is raised, the
low-beam headlights illuminate, along with all the
parking lights. To turn off all lights, return the paddle
to the center position.

10/15/2001

Raise the paddle to illuminate the low-beam headlights.

Lower the paddle to illuminate the parking lights.

Fig. 4.2, Headlight/Parking Light Switch

NOTE: The front turn signal is the amber lens in
each headlight unit. The low-beam headlight is
the top clear lens in each headlight unit.

When the headlights or parking lights are on, the
panel lights also illuminate. An amber light in the
switch backlights either the top icon (for headlights
and parking lights) or the bottom icon (for parking
lights only).

Fig. 4.2. When the

f610580

4.1

Daytime Running Lights

Switching on the ignition and releasing the parking
brakes automatically activates the daytime running
lights, if so equipped. The daytime running lights will
operate until the parking brakes are applied or the
headlights are turned on.

NOTE: Daytime running lights are standard on
all Canadian vehicles.

The daytime running lights illuminate at about two­thirds of normal power.

Panel Light Increase/Decrease Switch

When the panel lights are on, they can be either
brightened or dimmed by using the INCR/DECR
rocker switch just below the headlight switch. See

Fig. 4.3. To brighten the panel lights, press the upper

part of the switch (at the "INCR+" legend). To dim the
panel lights, press the lower part of the switch (at the
"DECR–" legend).

When the panel lights are on, both legends are back­lit in green.

Controls

05/09/2002

Raise the paddle to flash the marker lights.

Fig. 4.4, Marker Light Interrupt Switch

Multifunction Turn Signal
Switch

The multifunction turn signal switch is attached to the
left-hand side of the steering column. This switch has
the following functions:

•

turn signals

•

windshield wipers and washers

•

high-beam headlights

•

hazard warning lights

See Fig. 4.5 for the multifunction switch and its com­ponent parts.

f610581

10/29/2001

Fig. 4.3, Panel Light Increase/Decrease Switch

f610598

Marker Light Interrupt Switch

The optional marker light interrupt (MRKR INT)
paddle switch temporarily deactivates the marker
lights and taillights. See

With the vehicle lights on, raise and hold the paddle
switch to briefly turn off the marker lights and tail­lights. When the paddle is released the marker lights
will return to normal operation. With the vehicle lights
off, raise the paddle switch to momentarily turn the
marker lights on.

Fig. 4.4.

Turn Signal Lever

The turn signal lever is mounted on the steering col­umn. See Fig. 4.6. Moving the lever down activates
the left turn signal lights; moving it up activates the
right turn signal lights.

When a turn signal is activated, a green indicator
arrow flashes at the far left or far right of the instru­ment panel.

The lever automatically returns to the neutral position
(self-cancels the switch) when the steering wheel
returns to the straight ahead position after a turn. To
cancel the signal manually, move the lever to the
neutral position.

4.2

Controls

4

1

2

3

11/16/2001

Press down on the upper part of the rocker switch to
activate the warning lights.

1. Washer Button

2. Wiper Control Dial

3. Turn Signal Lever

4. Hazard Warning Light Rocker Switch (red)

5. Multifunction Switch Module

Fig. 4.5, Multifunction Turn Signal Switch

5

f820386

marked on the dial by lines of increasing length, and
two steady speed settings, LO and HI.

Rotating the control dial forward (in a counterclock­wise direction) turns the wipers on. If they are al­ready on, rotating the handle further forward in­creases the speed of the wipers through the various
delay settings, and to the LO and HI settings.

Rotating the control dial in the opposite direction
(clockwise) causes the wipers to slow down. Rotating
the control dial clockwise as far as it will go (to the
OFF setting) turns the wipers off.

The washers are operated by a yellow button at the
very end of the turn signal lever. To operate the
washers, press the button in and hold it.

Headlight High Beams

Push the turn signal lever forward, towards the wind­shield, to turn on the high-beam headlights. Pull the
turn signal lever back to its original position to turn
them off. See

Fig. 4.8.

10/17/2001

Move the lever down to activate the left turn signals.

Move the lever up to activate the right turn signals.

Fig. 4.6, Turn Signal Controls

f820384

Windshield Wiper/Washer Controls

NOTICE

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

The wipers are operated by a rotary switch in the
wiper control dial, which is on the end of the turn sig­nal lever. See

Fig. 4.7. There are five delay settings,

2

1

10/29/2001

Rotate the control dial forward to turn the wipers on, or
speed them up.

Rotate the control dial backward to slow the wipers down,
or turn them off.

1. Washer Button

2. OFF Position

3. Delay Positions

4. Wipers On, Low Speed

5. Wipers On, High Speed

Fig. 4.7, Wiper/Washer Controls

3

4

5

f820383

When the high beam headlights are on, a blue light
illuminates on the instrument panel between the ta­chometer and speedometer. For vehicles built to op­erate in the United States, switching on the high
beams will switch off the road lights.

4.3

1

2

10/17/2001

Move the lever forward to turn on the high beams. Move
the lever back to its original position to turn them off.

Move the lever back toward the steering wheel to flash
the high beams momentarily.

1. Turn Signal Lever 2. Boot

f820385

Controls

Aftertreatment System (ATS)
Regen Switch

NOTE: Some alternative fueled vehicles are not
equipped with a regeneration (regen) switch.

A regen switch, located on the dash, allows the
driver to control three states. See Fig. 4.9. These
include:

•

request regeneration

•

default (automatic regeneration)

•

inhibit regeneration

Fig. 4.8, Headlight High Beams

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

With the headlight low beams on, pull the lever back­ward, towards the steering wheel, to flash the high
beams momentarily.

The headlight low beams remain on continuously
during high beam operation. If the low beam head­lights are turned off using the headlight switch, the
high beams turn off also.

Hazard Warning Lights

The hazard warning light flasher is a red rocker
switch located on the top of the multifunction switch
module. See
activated, all of the turn signal lights (front, side, and
rear) and the two green indicator arrows on the in­strument panel will blink on and off.

To activate the hazard warning lights, press down on
the upper part of the rocker switch (towards the
dash). To deactivate the hazard warning lights, press
down on the lower part of the rocker switch (towards
the steering wheel).

Fig. 4.5. When the warning lights are

06/19/2012

Fig. 4.9, Regen Switch

See the engine operation manual for details on op­eration of the regen switch.

f611199

Horn Control

NOTE: It is possible to have both the electric
and the air horn installed on one vehicle.

A single electric horn is standard. Dual electric horns
are available as an option.

Electric Horn

The button for the horn is located in the center of the
steering wheel. To sound the horn, press down on
the button. See

Air Horn

Single and dual air horns are available as options.

The air horn is controlled by a wire lanyard hanging
down just inboard on the driver’s door. See
Pull downward on the lanyard to sound the air horn.

Fig. 4.10.

Fig. 4.11.

4.4

Controls

1

10/17/2001

To sound the horn, press down on the horn button.

1. Horn Button

Fig. 4.10, Electric Horn Control

f461918

NOTICE

If equipped with a manual transmission, 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.

NOTE: Maximum cruise control speed varies
according to vehicle specifications, but cannot
be higher than 75 mph (121 km/h).

1

10/17/2001

To sound the air horn, pull down on the lanyard (arrow).

Fig. 4.11, Air Horn Control

f610592

Powertrain Controls

Cruise Control Switch

WARNING

Do not use the cruise control system when driv­ing conditions do not permit maintaining a con­stant speed, such as 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.

2

09/13/2001

To turn the cruise control on, press the upper half of the
On/Off (rocker) switch. To turn cruise control off, press
the lower half of the On/Off (rocker) switch.

1. Cruise Control On/Off (rocker) Switch

2. Cruise Control Set/Resume (paddle) Switch

Fig. 4.12, Cruise Control Switches, Dash-Mounted

f610510

On standard models, cruise control is activated by
two dash switches. See

Fig. 4.12. On some models,

the cruise control can be activated by a button on the
transmission shift knob.

•

The On/Off Switch—this two-position rocker
switch bears the legend SPD CNTL on the
lower half of the switch. When the cruise con­trol is on, an amber light illuminates in the top
part of the switch.

4.5

Controls

•

The Set/Resume Switch—this three-position
paddle switch bears the legend RES/ACC
above the paddle and SET/CST below the
paddle.

1.

To cruise at a particular speed, do these steps:

1.1

Press the upper half of the On/Off rocker
switch on the instrument panel.

1.2

Hold the accelerator pedal down until the
speedometer reaches the desired speed.

1.3

Momentarily lower the Set/Resume switch
paddle.

2.

To disengage the cruise control, do these steps:

2.1

Depress the brake pedal (on automatic or
manual transmission) or

Depress the clutch pedal (on manual
transmission only)

2.2

Press the lower half of the On/Off rocker
switch on the instrument panel.

3.

To resume a preselected cruise speed, do these
steps:

3.1

If the On/Off rocker switch on the instru­ment panel is off, turn it on.

3.2

Momentarily raise the paddle of the Set/
Resume switch to RES/ACC. Cruise will
return to the last speed selected.

NOTE: If the ignition is shut off, the speed
memory will be lost.

4.

To adjust cruise speed up, raise the paddle of
the Set/Resume switch to RES/ACC and hold it
there until the vehicle accelerates to the new
speed, as desired.

5.

To adjust the cruise speed down, lower the
paddle of the Set/Resume switch to SET/CST
and hold it there until the vehicle decelerates to
the new speed, as desired.

NOTE: For more information about cruise con­trol operation, see the engine manufacturer’s
service manual.

Fast Idle System

If the vehicle is equipped with this option, it is avail­able for use only with cruise control. There are three
preset speeds available: 800, 900, or 1000 rpm.

The fast idle system can be used to increase engine
idle speed whenever the following conditions are
met.

•

The brake pedal is not pressed.

•

The vehicle must not be moving and the
throttle must not be pressed.

Fast Idle Operation

1.

To enable the fast idle system, press and release
the cruise control On/Off rocker switch.

2.

For the preset fast idle, press and release the
cruise control set switch. This will set the preset
fast idle speed.

IMPORTANT: The fast idle system does not
have any type of light activation in the instru­ment panel. The only light that will be illumi­nated is the cruise indicator.

Any of the following actions will turn off the fast idle
system:

•

Applying the brake.

•

Moving the transmission shifter out of Park (P)
or Neutral (N); this will engage the transmis­sion.

•

Pressing and releasing the cruise control On/
Off rocker switch when it is on.

Exhaust Brake Switch

An exhaust brake is an optional auxiliary braking sys­tem that assists, but does not replace the service
brake system. The exhaust brake is controlled by a
dash-mounted rocker switch to help slow the vehicle
when the accelerator is released.

To turn the exhaust brake on, press the upper part of
the rocker switch. The exhaust brake turns off auto­matically. See

Fig. 4.13.

Transmission Controls

If so equipped, the transmission range control valve
and splitter valve are attached to the gearshift knob.
Transmission shift pattern labels are located inside
the cab. See
operating instructions.

Vehicles equipped with a standard Allison On­Highway Series automatic transmission, have a
T-handle shift selector. See

Chapter 10 for complete transmission

Fig. 4.14.

4.6

Controls

11/28/2001

Fig. 4.13, Exhaust Brake Switch

When the transmission is in D (drive), the vehicle will
operate in 4th and 5th gear as needed. To shift down
into a lower gear, pull the lower half of the T-handle
selector up. Select the gear needed and release the
lower half of the T-handle selector.

On vehicles with an Allison MD Series automatic
transmission or an Eaton Autoshift automated trans­mission, a push-button shift selector, shown in

Fig. 4.15, provides four, five, or six forward ranges

and one reverse range. See
information about the push-button shift selector.

Chapter 10 for more

f610589

Axle Switches

All axle switches contain a red LED that illuminates
the switch from within when the switch is turned on
(the upper part of the rocker is pressed). The legend
under the LED, if any, is not visible until the switch is
turned on.

IMPORTANT: A guard is positioned around all
axle switches to prevent unintentional activation.

NOTE: For more information on axle switch
function, see

Chapter 11.

Differential Lock Switch, Optional

NOTICE

Differential lock should only be engaged when
the vehicle is stopped or moving slowly at low
throttle. This will prevent internal axle damage.

The differential lock switch is a two-position guarded
rocker switch. It causes the wheels on each axle
governed by the switch to rotate together. It is also
known as side-to-side wheel lock. See

Fig. 4.16.

09/21/2012 f270165

Fig. 4.14, T-Handle Shifter

To lock the wheels together, press the upper half of
the rocker switch momentarily. To turn off differential
lock, press the upper half of the rocker switch again.

When the panel lights are on, the double-axle icon is
backlit in green.

IMPORTANT: The differential lock switch is
guarded to prevent unintentional switch activa­tion. If the LED in the switch begins to blink dur­ing normal operation, when the switch has not
been activated, this indicates an error condition.

4.7

Controls

Braking Controls

Parking Brake Control Valve

1

2

3

4

The yellow diamond-shaped knob on the auxiliary
dash panel operates the parking brake control valve
(park brake switch). See

Fig. 4.17. Pull the knob to

apply the parking brakes; push the knob in to release
the parking brakes. Before the parking brakes can be
released, the air pressure in either air brake system
must be at least 65 psi (448 kPa).

1

07/27/2006

f610804

1. Digital Display

2. Mode Identification Label

3. Mode Indicator LED

4. Mode Button

Fig. 4.15, Push-Button Shift Selector

10/26/2001

f610596

Fig. 4.16, Differential Lock Switch

Take the vehicle to an authorized Freightliner
dealer as soon as possible.

Manual Dump Valve

On vehicles equipped with a manual dump valve,
there are two ways to deflate the rear suspension.
With the key in the OFF position, toggle the dump
valve into the "lower" position. If the key is in the ON
position, the parking brake must be set (ON) before
the dump valve is toggled into the "lower" position.

NOTE: If the key is turned to the ON position
and the parking brake is not engaged, the over­ride will cause reinflation of the air ride system.

f43036012/10/2003

1. Parking Brake Control Valve

Fig. 4.17, Parking Brake Control Valve

Chapter 13 under the heading "Dual Air Brake

See
System" for further information about the parking
brake control valve.

Meritor™WABCO® Antilock Braking
System (ABS)

The Meritor WABCO ABS has an amber indicator
light (ABS legend) and, if equipped with automatic
traction control (ATC), an amber wheel spin indicator
light (WHEEL SPIN legend). See

See the brake system operating instructions in

ter 13

for more information about ABS.

WAIT TO

LOW

START

WATER

OPT 1 OPT 8 OPT 9

STOP

CHECK

06/19/2012 f611198

1. Wheel Spin Indicator 2. Tractor ABS Indicator

Fig. 4.18, ABS Indicator Lights

DEF

QUALITY

WHEEL

SPIN

Fig. 4.18.

CHECK

RANGE

TRANS

INHIBIT

ABS

BRAKE

BRAKE

AIR

12

Chap-

ABS

4.8

5

Cab Features

Windows ........................................................................ 5.1

Mirrors .......................................................................... 5.1

Seats ........................................................................... 5.2

Seat Belts and Tether Belts ......................................................... 5.6

Cab Amenities ................................................................... 5.9

Cab Features

Windows

Standard windows operate mechanically using a
hand crank.

Power windows are optional, and can be installed on
one side or both sides. One power window switch
(window icon) will be installed on the dash for each
window. See
power windows, press up to raise the window; press
down to lower the window. Releasing the switch
causes the window to stop.

10/09/2001

Press up to raise the window; press down to lower the
window. Releasing the switch causes the window to stop.

Standard vent (wing) windows do not open. Operat­ing vent windows are optional. To open the operating
vent window, turn the latch on the window and push
the window open. See

Fig. 5.1. If your vehicle is equipped with

f610522

Fig. 5.1, Power Window Switch

Fig. 5.2.

Mirrors

The standard outside mirrors are mounted on the
door frame. There is a primary rear view mirror and a
convex mirror.

Mirror Heat Switch, Optional

One or both outside door mirrors can be heated to
keep them clear of fog, frost, and ice.

To heat the mirrors, press the upper part of the mir­ror heat switch (MIRR HEAT) on the dash. See

Fig. 5.3. When the mirror heat switch is on, an

amber indicator light illuminates inside the switch.

MIRR
HEAT

10/09/2001

To heat the mirrors, press up; press down to turn off the
heat.

Fig. 5.3, Mirror Heat Switch

The mirror heat switch is a smart switch (fully multi­plexed).

f610524

1

2

10/05/2001

1. Latch 2. Vent Window

Fig. 5.2, Operating Vent Window (optional)

5.1

f670096

Power Mirrors, Optional

The main outside mirrors, if heated, can be equipped
with an electrical remote control located on the
driver’s door. See

To select the mirrors on the left-hand side, press the
left side of the mirror select switch. To select the mir­rors on the right-hand side, press the right side of the
mirror select switch.

The keypad has four arrow keys, pointing up, down,
left, and right. To adjust the mirror position, press the
keypad in the direction you want the mirror to move.

Fig. 5.4.

Down View Mirror, Optional

A down view mirror can be installed on the top of the
passenger door frame to allow the driver a view of

Cab Features

the area adjacent to the right side of the cab. See

Fig. 5.5.

2

1

10/05/2001

To adjust the mirror position, press the keypad on the
door in the direction you want the mirror to move.

1. Mirror Select Switch 2. Keypad

Fig. 5.4, Power Mirror Switch Pad

f610523

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

Due to the high degree of adjustability found in high­back air suspension seats, it is possible to set the
seat back recline adjustment and the seat slide ad­justment in such a combination that the seat back
will come into contact with the rear wall of the cab. It
is the responsibility of the driver to adjust the seat to
prevent damage to the seat and the cab interior.

The following is a description of adjustments that are
available on one or more seats. Not all seats have all
of the adjustments listed below.

1.

Seat Slide (fore-and-aft): When this adjustment is
made, the entire seat moves forward or back­ward on its track. See Fig. 5.6.

B

A

1

10/05/2001

1. Mirror

Fig. 5.5, Down View Mirror (optional)

f720396

Seats

General Information

WARNING

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

10/05/2001

A. Seat Slide (fore-and-aft) Adjustment
B. Isolator Feature

Fig. 5.6, Seat Slide Adjustment and Isolator Feature

2.

Isolator: This feature (also referred to as back­slap isolator or Chugger-Snubber®) reduces the
amount of road shock by isolating the occupant
from the motion of the vehicle, and allowing the
upper seat to move in a simple pendulum mo­tion. Whenever the isolator is not desired, it can
be locked out. See

3.

Lumbar Support: Lumbar support changes the

Fig. 5.6.

shape of the seat back to give more or less sup­port to the occupant’s lumbar (lower back) area.

f910482

5.2

Cab Features

This adjustment is either mechanical or air con­trolled, depending on the make and model of the
seat. See

Fig. 5.7.

A

10/05/2001

A. Lumbar Support B. Headrest Adjustment

Fig. 5.7, Lumbar Support and Headrest Adjustment

4.

Headrest: When this adjustment is made, the
upper part of the backrest (back cushion)
changes angle to provide head and upper back
support as shown in

5.

Backrest Tilt: This adjustment pivots the backrest
forward or backward as shown in

6.

Seat Cushion Tilt: This adjustment raises or low-

Fig. 5.7.

Fig. 5.8.

ers the front and/or back of the seat (bottom)
cushion. This adjustment is easier to perform
when all weight is removed from the seat. See

Fig. 5.8.

7.

Seat Tilt: When this adjustment is made, the seat
assembly, both backrest and seat cushion, tilts
forward or backward as shown in

8.

Ride Height Adjustment: The entire seat moves

Fig. 5.8.

up or down when adjusting the ride height. The
adjustment is either manual or air controlled, de­pending on the make and model of the seat. See

Fig. 5.9.

9.

Damper: When you sit on the seat, a leveling
valve places you in the center of the ride zone.
When the damper is adjusted properly under nor-

B

f910483

A

B

10/05/2001

A. Backrest Tilt B. Seat Cushion Tilt

Fig. 5.8, Cushion Tilt Adjustments

A

10/05/2001

A. Ride Height

Fig. 5.9, Ride Height Adjustment

mal driving conditions, the seat should not top or
bottom against the limits of the vertical travel.

10.

Ride Firmness: A firmer ride gives a better feel
for the road but less protection against uneven­ness in the road surface. A softer ride smooths
out the bumps.

f910484

f910485

5.3

Cab Features

Bostrom Seat

Seat Slide Adjustment

Move the seat slide and isolator lever, shown in

Fig. 5.10, to the left and hold it there to slide the

seat forward or backward to the desired position.

7

6

10/10/96

1. Backrest Tilt Lever

2. Air Lumbar Support Control Valve (optional)

3. Damper Adjustment Switch

4. Height Adjustment Switch

5. Seat Cushion Tilt Knob

6. Seat Slide and Isolator Lever

7. Lumbar Support Knob (standard)

5

4

1

2

3

f910131

Seat Cushion Tilt

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

Backrest Tilt

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

Ride Height and Damper Adjustment

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

Press the damper adjustment switch to adjust the
damper.

National 2000 Series Seat

Seat Slide Adjustment

Move the seat slide lever, shown in Fig. 5.11,tothe
left and hold it there to slide the seat forward or
backward to the desired position. Move the lever
back to its original position to lock the seat in place.

Isolator

To use the isolator feature, turn the isolator handle to
the horizontal position. Turn the isolator handle down
to lock out the isolator.

Fig. 5.10, Bostrom Seat

Isolator

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

Lumbar Support

To increase lumbar support, rotate the lumbar sup­port knob forward. To decrease lumbar support, ro­tate the knob rearward.

On seats equipped with air lumbar support, press the
control valve upward to increase lumbar support.
Press the control valve downward to decrease lum­bar support.

Lumbar Support

To adjust the lumbar support, use the lumbar support
switch on the side of the seat to give more or less
support to your lower back.

Backrest Tilt

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

Seat Cushion Adjustment

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

To adjust the height of the rear of the seat cushion,
remove your weight from the seat and turn the rear
cushion adjustment knob to one of three positions.

5.4

Cab Features

7

6

5

4

11/14/2000

1. Backrest Tilt Knob

2. Lumbar Support Switch

3. Height Adjustment Switch

4. Seat Slide Lever

5. Front Cushion Height Adjustment Handle

6. Isolator Handle

7. Rear Cushion Adjustment Knob

Fig. 5.11, National 2000 Series Seat

3

f910445

Ride Height Adjustment

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

3

2

1

1

2

10/08/2001

1. Seat Slide Lever

2. Seat Cushion Tilt Adjustment

3. Ride Height Knob

4. Lumbar Support Lever

5. Backrest Lever

Fig. 5.12, Sears Low Profile Seat

4

5

f910487

Lumbar Support

Move the three-position lumbar support lever upward
to increase lumbar support (firmer). Move the lever
downward to decrease lumbar support (less firm).

NOTE: This three-position lever (see inset) does
not rotate a full 360 degrees.

For seats with air support, use the aft rocker switch
on the control panel on the left-hand side of the seat.

Fig. 5.14. Press up to make the seat firmer;

See
press down to make the seat less firm.

Sears Seat

Seat Slide Adjustment

Push the seat slide (fore-and-aft adjustment) lever,
shown in Fig. 5.12, all the way to the left and slide
the seat forward or backward, as desired. Release
the lever to lock the seat in the desired position.

Isolator

To engage the isolator (if installed), move the seat
slide and isolator lever shown in
to the right. To lock out the isolator, move the isolator
lever to the center position.

5.5

Fig. 5.13 all the way

Seat Cushion Tilt

To raise the seat cushion, lift upward on the front of
the seat cushion, and then push it rearwards. To
lower the seat cushion, pull forward on the front of
the seat cushion, and then push downwards.

Backrest Adjustment

To adjust the backrest, push downwards on the back­rest lever just below the bottom of the backrest cush­ion. With the lever down, lean forward or backward
to the desired position. Release the lever to lock the
backrest in place.

Ride Height Adjustment

Push the ride height knob inwards to inflate the air
cylinder, raising the height of the seat. Pull the ride

Cab Features

height knob outwards to deflate the air cylinder, low­ering the height of the seat.

For seats with air support, use the forward rocker
switch on the control panel on the left-hand side of

1

the seat. See
press down to lower the seat.

Ride Firmness Adjustment

For a softer ride, remove the snap ring and pin from

2

4

the shock absorber bracket (see inset). Relocate the
pin in the other set of holes in the bracket and se­cure it with the snap ring.

Fig. 5.14. Press up to raise the seat;

8

10/09/2001

NOTE: Armrests are optional.

1. Lumbar Support Lever

2. Backrest Lever

3. Ride Height Knob

4. Shock Absorber Bracket (ride firmness)

5. Pin (ride firmness)

6. Snap Ring (ride firmness)

7. Seat Slide and Isolator Lever

8. Seat Cushion Adjustment

Fig. 5.13, Sears Fleetmaster Seat (with isolator)

10/08/2001

1. Ride Height Switch

2. Air Lumbar Support Switch

Fig. 5.14, Air Controls, Sears Seat

12

3

7

5

f910486

f910488

6

Seat Belts and Tether Belts

General Information

Seat belt assemblies are designed to secure persons
in the vehicle to help reduce the chance of injury or
the amount of injury resulting from accidents or sud­den stops. For this reason, Freightliner Custom
Chassis Corporation (FCCC) urges that the driver
and all passengers, regardless of age or physical
condition, use seat belts when riding in the vehicle.

WARNING

Always use the vehicle’s seat belt system when
operating the vehicle. Failure to do so can result
in severe personal injury or death.

Seat belt assemblies in FCCC vehicles meet Federal
Motor Vehicle Safety Standard 209, "Type 1" and
"Type 2" requirements.

When transporting a child, always use a child re­straint system or the vehicle seat belts as appropri­ate. To determine whether a child restraint system is
required, review and comply with applicable state
and local laws. Any child restraint used must comply
with Federal Motor Vehicle Safety Standard 213,
"Child Restraint Systems." When providing a child
restraint system, always carefully read and follow all
instructions pertaining to installation and usage for
the child. Make certain the child remains in the re­straint system at all times when the vehicle is in mo­tion.

In addition to seat belt assemblies, tether belts are
installed on suspension-type seats. Tether belts help
secure the seat to the floor and are intended to re­strain the seat and seat belt in case of an accident or
sudden stop.

5.6

Cab Features

IMPORTANT: Seat belts have a finite life which
may be much shorter than the life of the vehicle.
Regular inspections and replacement as needed
are the only assurance of adequate seat belt
security over the life of the vehicle.

Seat Belt Inspection

WARNING

Inspect and maintain seat belts and tethers as
instructed below. Seat belts and tethers that were
damaged or stressed in an accident must be re­placed, and their anchoring points must be
checked. When any part of a seat belt system
needs replacement, the entire seat belt must be
replaced, both the retractor and the buckle side.
Do not attempt to modify the seat belt system;
doing so could change the effectiveness of the
system. Failure to replace damaged or stressed
seat belts or any modifications to the system
may result in personal injury or death.

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

1.

Check the web for fraying, cuts, or extreme wear,
especially near the buckle latch plate and in the
D-loop guide area.

2.

Check the web for extreme dirt or dust, and for
severe fading from exposure to sunlight.

3.

Check the buckle and latch for operation and for
wear or damage.

4.

Check the Komfort Latch or the Sliding Komfort
Latch (if equipped) for function and cracks or
other damage.

5.

Check web retractor for function and damage.

6.

Check the mounting bolts for tightness and
tighten any that are loose.

Seat Belt Operation

Three-Point Seat Belt With Komfort Latch
or Sliding Komfort Latch

WARNING

Wear three-point seat belts only as described
below. Three-point seat belts are designed to be

worn by one person at a time. In case of an acci­dent or sudden stop, personal injury or death
could result from misuse.

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

When engaged and used properly, the Komfort Latch
and the Sliding Komfort Latch, shown in
and Fig. 5.16 respectively, introduce a small amount
of slack into the seat belt, resulting in a more com­fortable ride.

A

03/11/2010 f910620

A. Disengaged B. Engaged

Fig. 5.15, Komfort Latch

1.

Slowly pull the latch end of the three-point seat
belt out of the retractor and pull it across your
lap (from outboard to inboard) far enough to en­gage the buckle. If the retractor locks too soon,
allow the belt to retract slightly, then slowly pull it
out again.

2.

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

Fig. 5.17.

See

3.

Tug on the seat belt to make sure it is securely
fastened. If the buckle unlatches, repeat this
step. If the problem continues, replace the three­point seat belt.

B

Fig. 5.15

5.7

Cab Features

11/18/2010 f910621a

Fig. 5.16, Sliding Komfort Latch

position. See

Fig. 5.16. To activate the latch,

lean forward until you hear a click. This will allow
for approximately 1 inch (2.5 cm) of slack be­tween your chest and the shoulder harness.
Once engaged, the latch will allow you to lean
forward about 5 inches (13 cm) without having to
reset the latch. Leaning forward more than 5
inches (13 cm) will disengage the Sliding Kom­fort Latch, requiring it to be reset.

If equipped with a Komfort Latch, pull on the
shoulder strap to lessen the pressure of the strap
on your shoulder and chest. Allow no more than
1 inch (2.5 cm) of slack between your chest and
the shoulder harness. More slack can signifi­cantly reduce the seat belt effectiveness in an
accident or a sudden stop. While holding the belt
slack, press the Komfort Latch lever up, clamp­ing the seat belt webbing. See

Fig. 5.18 and

Fig. 5.19.

A

01/18/95

Fig. 5.17, Fastening the Three-Point Belt

4.

Snug the seat belt to your waist.

5.

Position the shoulder strap diagonally across
your chest with the adjustable D-loop bracket, if
so equipped. If desired, engage the Komfort
Latch or Sliding Komfort Latch as follows.

If equipped with a Sliding Komfort Latch, make
sure that the shoulder strap is snug against your
chest. Without loosening the shoulder strap,
push the Sliding Komfort Latch switch to the ON

f910004a

01/06/95

A. 1 Inch (2.5 cm) Maximum

Fig. 5.18, Adjusting Shoulder Harness Clearance,

6.

Unbuckle the three-point seat belt and release

Komfort Latch

the Komfort Latch or the Sliding Komfort Latch
as follows.

If equipped with a Sliding Komfort Latch, un­buckle the seat belt, then tug on the shoulder
belt to release the Sliding Komfort Latch, or
press the Sliding Komfort latch to the OFF posi­tion, then unbuckle the seat belt.

f910048a

5.8

Cab Features

11/02/95

Fig. 5.19, Locking the Komfort Latch

If equipped with a Komfort Latch, unbuckle the
seat belt, then release the Komfort Latch by giv­ing the shoulder belt a quick tug. If you lean for­ward against the shoulder belt, the Komfort Latch
will automatically release, and will need to be
reset.

f910144

NOTE: Neither the Komfort Latch nor the Sliding
Komfort Latch need to be manually released in
an emergency situation. Each will release by
itself under rough road or other abnormal condi­tions. Make sure the three-point seat belt is
completely retracted when it is not in use.

head console. See
bin is often removed and replaced with a CB radio.

Two map holders with netted openings are located
overhead, one on either side of the overhead con­sole.

Fig. 5.20. The overhead storage

Cab Amenities

Cup Holders

There are two cup holders molded into the lower part
of the auxiliary dash panel, one on either side of the
HVAC control head.

Cab Storage

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

Overhead Storage

Vehicles without an overhead console have two stor­age bins located above the windshield.

On vehicles equipped with an overhead console,
most vehicles have a storage bin located in the over-

5.9

Cab Features

1

10/08/2001

1. Overhead Storage Bin 2. Overhead Console 3. Map Holder Netting

Fig. 5.20, Overhead Storage

2

3

f680027

5.10

6

Electrical Systems

Electrical System General Information ................................................ 6.1

Power Distribution Modules ......................................................... 6.1

Electrical Systems

Electrical System General
Information

The S2 Chassis uses an electrical system where
multiple electrical signals are carried along a simpli­fied set of wires, reducing the size of wiring bundles.
There are significantly fewer wires overall, meaning
less chance of damage, shorts, and other problems.
The information in this chapter is to help familiarize
the driver with the basic electrical system. Servicing
the electrical system requires special skills and
equipment and should be performed only by a quali­fied technician. Take the vehicle to an authorized
Freightliner service facility for repairs.

WARNING

Do not attempt to modify, add, splice, or remove
electrical wiring on this vehicle. Doing so could
damage the electrical system and result in a fire
that could cause serious personal injury or prop­erty damage.

Power Distribution Modules

There are three electrical modules, a main power
distribution module (PDM) located under the hood on
the driver’s side above the fender, a chassis module
located between the frame rails, and a cab module
located to the left of the driver under the switch
panel.

The main PDM distributes battery power to the vehi­cle’s control modules and contains the fuses required
to protect the power feed circuits to the control mod­ules. See
power to the modules, the modules themselves con­trol power flow and circuit protection to the various
components of the vehicle electrical systems. Be­cause of this, traditional PDM devices such as relays
and circuit breakers are no longer necessary on the
main PDM.

Inside the lid of the fuse box there is a sticker that
shows the locations of the fuses and describes the
circuit(s) that each fuse protects. Fuse configuration
will vary depending on the PDM assembly installed.
See
typical set of fuses.

Because the electrical system is multiplexed, no re­lays are needed. The multiplexing module performs
the functions normally provided by relays.

Fig. 6.1. While the main PDM provides

Fig. 6.2. See Table 6.1 for descriptions of a

1

2

09/25/2001

1. Bulkhead Module 2. Main PDM

Fig. 6.1, Location of the Main PDM (under driver side

hood, above fender)

Main PDM Fuse Identification

CAV Description Fuse

F1 Engine VCU (spare) 10A
F2 Blower Motor 30A
F3 Engine ECU 20A
F4 Spare 30A
F5 Ignition Switch 5A
F6 HydroMax RLY (if equipped with

hydraulic brakes)
F7 Bulkhead Module 30A
F8 ICU3 10A
F9 Transmission ECU 10A

F10 Spare —
F11 Spare —
F12 Radio/Diagnostic 20A
F13 Chassis Module 30A
F14 Spare —
F15 Bulkhead Module 30A
F16 ABS ECU 25A
F17 Chassis Module 30A
F18 Bulkhead Module 30A
F19 Chassis Module 30A
F20 Bulkhead Module 30A
F21 Spare —
F22 Bulkhead Module 30A

f543935

30A

6.1

Main PDM Fuse Identification

CAV Description Fuse

F23 Spare —
F24 Hydraulic Pump and RLY (if equipped

with hydraulic brakes)
F25 Spare —
F26 Spare —

Table 6.1, Main PDM Fuse Identification

3 4

25A

Electrical Systems

5

2

1

6

12/19/2003 f544381

1. Battery Power Mega Fuse 1

2. Battery Power Mega Fuse 2

3. Engine Harness (green)

4. Forward Chassis Harness (blue)

Fig. 6.2, Main PDM (top view)

5. Forward Chassis Harness (gray)

6. Frontwall Harness (black)

6.2

7

Heater, Ventilating, and Air

Conditioner (HVAC)

Climate Control Panel ............................................................. 7.1

Heater, Ventilating, and Air Conditioner (HVAC)

Climate Control Panel

The climate control panel controls the HVAC for the
driver. The climate control panel without air condition­ing is shown in
with air conditioning is shown in

Standard controls consist of an eight-speed fan
switch, an air selection switch, and a temperature
control switch. See
conditioning, the panel also contains a telltale light
emitting diode (LED) and an air recirculation button.

NOTE: The vehicle may be equipped with a We­basto heating system. The Webasto heating
system warms the engine prior to starting the
vehicle, and also assists in generating additional
heat for the passengers during operation. For
operating instructions see the Webasto Opera­tor’s Manual.

Fig. 7.1. The climate control panel

Fig. 7.2.

Fig. 7.1. On vehicles with air

1

2

1

3

lets, the defrost (windshield) outlets, or a combination
of these outlets. Nine air selection modes are avail­able on a system without air conditioning. See

Fig. 7.3. A system with air conditioning has 11 air

selection modes, four of which are air conditioning
modes. See

Fig. 7.4.

Air Selection Switch Without Air
Conditioning

1.

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

2.

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

the face outlets and 25 percent through the floor
outlets.

3.

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

23

0

06/17/2003

1. Fan Switch 2. Air Selection Switch 3. Temperature Control Switch

Fig. 7.1, Climate Control Panel Without Air Conditioning

Fan Switch

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

To increase airflow, turn the fan switch clockwise to a
higher number. To decrease the airflow, turn the
switch counterclockwise to a lower number.

Air Selection Switch

The air selection switch allows the driver to control
the flow of air through the face outlets, the floor out-

4

4.

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

the face outlets and 75 percent through the floor
outlets.

5.

Floor Mode: Directs all airflow through the floor
outlets.

6.

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

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

7.

Floor/Defrost Mode: Directs the airflow equally
to the floor outlets and the defrost outlets.

f831452a

7.1

Heater, Ventilating, and Air Conditioner (HVAC)

0

06/18/2003

1. Fan Switch

2. Air Selection Switch

3

2

1

1

2

3

2

1

3

4

54

3. Temperature Control Switch

4. Recirculation Button

Fig. 7.2, Climate Control Panel With Air Conditioning

4

5

6

7

A

8

5. Recirculation Indicator

5

4

3

2

6

7

f831453a

8

9

10

9

06/17/2003

1. Face Mode

2. Selection Between Face Mode and Bi-Level Mode

3. Bi-Level Mode

4. Selection Between Bi-Level Mode and Floor Mode

5. Floor Mode

6. Selection Between Floor Mode and Floor/Defrost
Mode

7. Floor/Defrost Mode

8. Selection Between Floor/Defrost Mode and Defrost
Mode

9. Defrost Mode

Fig. 7.3, Air Selection Switch Without Air Conditioning

8.

Selection between Floor/Defrost Mode and

f831455

Defrost Mode: Directs 75 percent of the airflow
through the defrost outlets and 25 percent
through the floor outlets.

1

06/18/2003

A. Air Conditioning Modes

1. Air Conditioning Face Mode

2. Selection Between Air Conditioning Face Mode and
Air Conditioning Bi-Level Mode

3. Air Conditioning Bi-Level Mode

4. Selection Between Air Conditioning Bi-Level Mode
and Face Mode

5. Face Mode

6. Selection Between Face Mode and Floor Mode

7. Floor Mode

8. Selection between Floor Mode and Floor/Defrost
Mode

9. Floor/Defrost Mode

10. Selection between Floor/Defrost Mode and Defrost
Mode

11. Defrost Mode

Fig. 7.4, Air Selection Switch With Air Conditioning

11

f831462

7.2

Heater, Ventilating, and Air Conditioner (HVAC)

9.

Defrost Mode: Directs all airflow through the
defrost outlets.

Air Selection Switch With Air
Conditioning

1.

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

2.

Selection between the Air Conditioning Face
Mode and the Air Conditioning Bi-Level
Mode: Directs 75 percent of the airflow to the

face outlets and 25 percent to the floor outlets.

3.

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

4.

Selection between the Air Conditioning Bi­Level Mode and the Face Mode: Directs 25

percent of the airflow to the face outlets and 75
percent to the floor outlets.

5.

Face Mode: Directs all airflow through the face
outlets.

6.

Selection between Face Mode and Floor
Mode: Directs the airflow equally through the

face outlets and the floor outlets.

7.

Floor Mode: Directs all airflow through the floor
outlets.

8.

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

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

9.

Floor/Defrost Mode: Directs the airflow equally
to the floor outlets and the defrost outlets. The
recirculation button will not work in this mode.

10.

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

through the defrost outlets and 25 percent
through the floor outlets. The recirculation button
will not work in this mode.

11.

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

Temperature Control Switch

The temperature control switch is used to select the
desired temperature. Turn the switch to the left
(counterclockwise) for cool air, or to the right (clock-

wise) for hot air. There are 21 positions on the tem­perature control switch ranging from full cool air to
full hot air.

Fresh Air Mode

Fresh air, or outside air, is circulated through the
heating and air conditioning system unless the recir­culation mode, if equipped, is turned on.

Recirculation Mode

The recirculation mode is only available on vehicles
with air conditioning.

The recirculation mode limits the amount of outside
air entering the cab. Press the recirculation button to
prevent dusty or smoky air from entering the cab.
The recirculation mode can also be used to decrease
the time required to cool or heat the cab interior dur­ing extreme outside temperature conditions. When
the recirculation mode is on, the recirculation indica­tor will illuminate. See

The recirculation mode is not available when the air
selection switch is in one of the following modes:

•

floor/defrost mode

•

selection between floor/defrost mode and de­frost mode

•

defrost mode

When the recirculation mode is turned on, it will stay
on for 20 minutes, or until the recirculation button is
pressed again, or the air selection switch is turned to
a defrost mode.

Fig. 7.2.

IMPORTANT: The HVAC system enters a partial
recirculation mode for five minutes after being in
full recirculation mode for 20 minutes. This cycle
repeats every 20 minutes.

Defrosting

Before using any of the defrost modes, clear the
screen at the base of the windshield if snow or ice is
present.

Air Conditioning

There are four air conditioning modes on the air se­lection switch. The air conditioning settings on the air
selection switch are blue, in addition to the selection

7.3

Heater, Ventilating, and Air Conditioner (HVAC)

between the air conditioning bi-level mode and the
face mode.

IMPORTANT: Operate the air conditioner at
least five minutes each month, even during cool
weather. This helps prevent drying and cracking
of the refrigerant compressor seals and reduces
the chance of refrigerant leaks in the system.

NOTE: The heating and air conditioning system
has a brushless blower motor with a protection
or shutdown mode to prevent damage due to
overheating and overcurrent conditions. If the
brushless blower motor goes into a protection
mode, the motor will operate at a slower speed.
If the overheating or overcurrent condition con­tinues, the motor will shut down and stop com­pletely.

The motor will resume proper operation after the
motor has cooled or the overcurrent condition
has been resolved. It will be necessary to cycle
the fan switch off, and then on, to reset the
motor. If the problem appears repeatedly, take
the vehicle to an authorized Freightliner dealer
for repairs.

7.4

8

Engines

Engine Starting ................................................................... 8.1

Engine Operation ................................................................. 8.2

Engine Shutdown ................................................................. 8.4

Engines

Engine Starting

For cold-weather starting, refer to the Cummins or
Mercedes-Benz engine manufacturer’s operator’s
manual, as applicable, for detailed instructions.

General Information

NOTE: Before starting the engine, read Chap-

ter 3

and Chapter 4 in this manual for detailed
information on how to read the instruments and
operate the controls.

Before operating the vehicle, perform the engine pre­trip inspection and daily maintenance checks in

Chapter 14 and Chapter 15 of this manual.

NOTICE

When starting a vehicle equipped with a manual
transmission and clutch lockout switch, the
clutch pedal must be fully depressed during the
entire start sequence. Failure to do so can cause
the pinion to release and re-engage, which could
cause ring gear and starter pinion damage.

If a vehicle does not start on the first attempt,
make sure that the engine has completely
stopped rotating before reapplying the starter
switch. Failure to do so can cause the pinion to
release and re-engage, which could cause ring
gear and starter pinion damage.

Moving a vehicle with the starter and/or using the
starter to bump the engine for maintenance pro­cedures is strictly prohibited. Use of these meth­ods to bump the engine over or move the vehicle
can cause the pinion to release and re-engage,
which could cause ring gear and starter pinion
damage.

NOTICE

Never attempt to start any Cummins or
Mercedes-Benz engine using ether or any other
starting fluid. Serious engine damage could re­sult.

1.

Set the parking brake.

2.

Turn the ignition switch to the ON/RUN position.
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.

IMPORTANT: On vehicles equipped with an in­take air preheater, the INTAKE HEATER indica­tor stays on for a minimum of two seconds, re­gardless of coolant temperature. Wait until the
INTAKE HEATER indicator goes out before at­tempting to start the engine.

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

3.

For manual transmissions, place the transmis­sion in neutral and depress the clutch pedal.

For automatic transmissions, make sure that the
transmission shift control is in Neutral (N), or if
so equipped, the Park (P) or Park Brake (PB)
position.

IMPORTANT: Do not depress the throttle pedal
while starting the engine.

4.

Turn the ignition switch to the START position.
After the engine starts, release the key.

NOTICE

Do not crank the engine for more than 30 sec­onds at a time. Wait two minutes after each try to
allow the starter to cool. Failure to do so could
cause starter damage.

NOTE: Some starters are equipped with op­tional overcrank protection. If overcranking oc­curs, a thermostat breaks the electrical circuit to
the starter motor until the motor has cooled.

5.

Bring the engine up to operating speed gradually
as it warms up and develops stable oil pressure.

IMPORTANT: When the engine is started, it
takes a short time to build up a lubricating oil
film between the shafts and bearings, and be­tween the pistons and cylinder walls. The oil
pressure gauge indicates any drop in lubricating
oil pressure within 15 seconds of engine startup.
See the applicable engine manufacturer’s op­erator’s manual for minimum idle oil pressure
specifications.

8.1

Engines

Starting After Extended Shutdown or
Oil Change

NOTE: An engine in storage for an extended
period of time (over winter, for example) may
accumulate water in the oil pan. Oil diluted by
water cannot provide adequate bearing protec­tion at start-up. For this reason, change the en­gine oil and filters after extended storage.

Do the following steps after an oil change or
after the engine has been shut down for more
than three days:

1.

Make sure the transmission is filled with the cor­rect type of fluid, as recommended by the trans­mission manufacturer.

2.

Make sure the fuel tank is full. If air has entered
the fuel system, prime the fuel system, using the
engine manufacturer’s instructions.

3.

If the engine is equipped with a fuel/water sepa­rator, drain off any accumulated water.

4.

Check the drive belts to make sure they are in
good condition and properly adjusted. Replace
any drive belts that are cracked, worn, or glazed.

5.

Check the turbocharger for signs of oil or ex­haust leaks. Correct any problems before starting
the engine.

6.

Check the engine mounting bolts for tightness.
Retighten them if necessary.

7.

Make sure the battery cable connections are
clean and tight. Check that the batteries are
charged.

8.

Start the engine. See the "Engine Starting" head­ing in this chapter.

the air intake, and cause engine overspeed. Be es­pecially cautious of low-lying or closed-in areas, and
always check for signs that flammable vapors may
be present.

DANGER

Do not operate the engine in an area where flam­mable vapors such as gasoline or diesel fumes
are present. Shut down the engine when in an
area where flammable liquids or gases are being
handled. Failure to observe these precautions
could result in serious injury or death.

All diesel engines have been built to comply with the
requirements of the Federal (U.S.) Clean Air Act.
Once an engine is placed in service, the responsibil­ity for meeting both state and local regulations is with
the owner/operator. Good operating practices, regular
maintenance, and correct adjustments are factors
that will help to stay within the regulations.

Adequate maintenance of the engine, which is the
responsibility of the owner/operator, is essential to
keep the emission levels low.

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. See

Chapter 3 for information on the control panel for

these engines.

Follow the directions in the Cummins or Mercedes­Benz engine manufacturer’s operator’s manual and
in this manual for trouble-free, economical vehicle
engine operation.

NOTICE

Engine Operation

IMPORTANT: For cold-weather starting, engine
break-in, and cold-weather operation, refer to
the Cummins or Mercedes-Benz engine manu­facturer’s operator’s manual, as applicable, for
detailed instructions.

Operating vehicles in areas where there are concen­trated flammable vapors (such as diesel, gasoline, or
propane fumes) can create a hazardous situation.
These vapors can be drawn into the engine through

Stop the engine at the first sign of malfunction.
Almost all malfunctions give some warning to the
operator before significant damage occurs. Many
engines are saved because alert operators heed
the warning signs (sudden drop in oil pressure,
unusual noises, etc.) and immediately shut down
the engine.

1.

Cummins and Mercedes-Benz diesel engines are
designed to operate successfully at full throttle
under transient conditions down to rated rpm.
This is consistent with recommended operating
practices.

8.2

Engines

2.

Depending on the vehicle gearing, the posted
speed limit can sometimes allow operation in ei­ther of the top two gears; however, for improved
operating efficiency (fuel economy and engine
life), operate in the top gear at reduced rpm
rather than in the next lower gear at the maxi­mum rpm.

3.

Cruise at partial throttle whenever road condi­tions and speed requirements permit. This driv­ing technique permits operating within the most
economical power range of the engine.

4.

When approaching a hill, open the throttle
smoothly to start the upgrade at full power, then
shift down as desired to maintain the optimum
vehicle speed. The high torque of the engine
may permit topping some grades without shifting.

5.

Engines are designed to operate over a wide
speed range. More frequent shifting than neces­sary does not allow proper utilization of this flex­ibility. The driver who stays in top gear and uses
the wider speed range will achieve the best fuel
economy.

6.

The Cummins and Mercedes-Benz engines are
effective as a brake on downhill grades, but take
care not to overspeed the engine going downhill.
The governor has no control over engine speed
when the engine is being pushed by the loaded
vehicle.

NOTICE

NOTICE

Continuous operation below 140°F (60°C), above
212°F (100°C), or with the oil pressure below 10
psi (69 kPa), can damage the engine.

10.

Do not idle the engine for more than 10 minutes.
Long periods at low idle can damage the engine.

NOTE: Long periods of idling are not good for
an engine because the combustion chamber
temperatures drop so low that the fuel may not
burn completely. This will cause carbon to clog
the injector spray holes and piston rings, and
can result in stuck valves.

11.

If the engine starts to overheat, reduce the
power output of the engine. Do one, or both, of
the following: (1) Release pressure on the accel­erator pedal; (2) Shift to a lower gear. If the tem­perature does not return to normal, shut down
the engine.

High Idle Options

NOTE: To operate the high idle options listed
below, the vehicle must be stopped, the trans­mission shift lever placed in the Neutral (N) or
Park (P) position, and the parking brake set.

IMPORTANT: Do not idle the engine for exces­sively long periods. The extreme heat can cause
the bearings to seize or the oil seals to leak.

Do not allow the engine to exceed its governed
speed, or serious engine damage could result.

7.

Never turn the ignition switch to the OFF position
while going downhill. With the engine still in gear,
fuel pressure will build up against the shutdown
valve and can prevent it from opening when the
ignition switch is turned to the ON/RUN position.

8.

Use a combination of brakes and gears to keep
the vehicle under control at all times, and to
keep the engine speed below the rated governed
rpm.

9.

Check the coolant temperature and oil pressure
gauges frequently.

8.3

High Idle with Cruise Control

1.

Place the shift lever in Neutral (N) or Park (P)
and set the parking brake.

2.

Press the cruise switch located on the dash to
the ON position. Press the RESUME switch to
accelerate the engine revolutions per minute
(rpm) to the minimum set speed. To increase the
engine rpm, press and hold the RESUME switch.
To decrease the engine rpm, press and hold the
SET switch.

NOTE: The rpm can also be increased by de­pressing the throttle pedal until the desired rpm
is met, and then pressing the SET switch.

3.

Disengage the cruise control by depressing the
service brake pedal, or by moving the ON/OFF
switch to the OFF position.

Engines

Voltage-Based Auto High Idle

1.

Place the shift lever in Neutral (N) or Park (P)
and set the parking brake.

2.

The idle rpm will automatically increase when the
voltage drops below 12.2 volts. The rpm will in­crementally increase every five seconds until

13.4 volts is achieved and maintained.

3.

The Voltage-Based Auto High Idle system is dis­engaged by depressing the service brake pedal.

IMPORTANT: The Voltage-Based Auto High Idle
system will not return to normal operation until
one of the following occurs: The parking brake
is depressed and released, the key switch is
turned to the OFF position, or the transmission
gears are changed.

Engine Shutdown

Shut down the engine immediately if:

•

the oil pressure gauge needle swings back and
forth or falls sharply;

•

engine power and rpm fall, even though the
accelerator pedal remains steady;

•

the exhaust pipe gives off heavy smoke;

•

the coolant and/or oil temperature climb abnor­mally;

•

abnormal sounds suddenly occur in the engine
or turbocharger.

gines. The extreme heat can cause bearings to
seize or oil seals to leak.

NOTE: Long periods of idling are not good for
an engine because the combustion chamber
temperatures drop so low that the fuel may not
burn completely. This will cause carbon to clog
the injector spray holes and piston rings, and
can result in stuck valves.

NOTICE

Do not rev the engine before shutting it down.
Revving the engine before shutdown will damage
the turbocharger.

4.

Shut down the engine by turning the ignition
switch to the OFF position.

IMPORTANT: Bearings and seals in the turbo­charger are subjected to the high heat of com­bustion exhaust gases. While the engine is run­ning, this heat is carried away by oil circulation,
but if the engine is stopped suddenly, the turbo­charger temperature may rise as much as 115°F
(46°C).

1.

With the vehicle stopped, place the transmission
in Neutral (N), or if so equipped, the Park (P) or
Park Brake (PB) position.

2.

Set the parking brake.

3.

Idle the engine for three to five minutes before
shutting it down. This allows the lubricating oil
and the coolant to carry heat away from the
combustion chambers, bearings, shafts, etc. This
is especially important with turbocharged en-

8.4

9

Exhaust Aftertreatment

Systems

Aftertreatment System, EPA10 and Newer Engines ...................................... 9.1

Diesel Exhaust Fluid and Tank, EPA10 and Newer Engines ............................... 9.5

EPA07 Aftertreatment System (ATS) .................................................. 9.7

Exhaust Aftertreatment Systems

Aftertreatment System, EPA10
and Newer Engines

Engines manufactured between January 1, 2010 and
December 31, 2012 meet EPA10 requirements. En­gines manufactured from January 1, 2013 meet
NHTSA and EPA 2014 fuel efficiency and green­house gas emission standards (GHG14) require­ments. Engines manufactured from January 1, 2016
meet NHTSA and EPA 2017 fuel efficiency and
greenhouse gas emission standards (GHG17) re­quirements.

Model year 2013 and later vehicles meet additional
requirements as specified by GHG14 requirements.
Model year 2017 and later vehicles meet similar re­quirements as specified by GHG17 requirements.
These vehicles are equipped with components that
increase fuel efficiency and reduce GHG emissions.

IMPORTANT: Depending on local jurisdictional
guidelines, vehicles that are domiciled outside of
the U.S. and Canada may not have emissions
aftertreatment systems (ATS) that are compliant
with EPA regulations.

Principles of Operation

The EPA mandates that all engines built after De­cember 31, 2009 must reduce the level of emissions
exhausted by the engine to the following levels:

•

Nitrogen Oxides (NOx) – 0.2 g/bhp-hr

•

Particulate Matter (PM) – .01 g/bhp-hr

To meet EPA guidelines, engines that are compliant
with EPA10 and newer regulations use an aftertreat­ment system (ATS) with an aftertreatment device
(ATD) and Selective Catalytic Reduction (SCR) tech­nology to reduce NOx downstream of the engine.

NOTICE

Follow these guidelines for engines that comply
with EPA10 or newer regulations, or damage may
occur to the ATD and the warranty may be com­promised.

•

Use ultralow-sulfur diesel with 15 ppm sul-

fur content or less.

•

Do not use fuel blended with used engine

lube oil or kerosene.

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

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

After exhaust gasses leave the engine, they flow into
the ATS. First they flow into a two-part ATD, com­prised of a diesel oxidation catalyst (DOC), and a
diesel particulate filter (DPF). The DPF traps soot
particles, then exhaust heat converts the soot to ash
in the DPF, in a process called regeneration (regen).
The harder an engine works, the better it disposes of
soot. When the engine is running under load and
regen occurs without input, it is called passive regen.
If the engine isn’t running hot enough, the electronic
controls may initiate an active regen, whereby extra
fuel is injected into the exhaust stream before the
diesel particulate filter, to superheat the soot trapped
in the filter and burn it to ash. Both types of regen
occur without driver input.

Active regeneration can occur automatically any­time the vehicle is moving. The exhaust gas tem­perature could reach 1500°F (816°C), which is hot
enough to cause a fire, heat damage to objects
or materials, or personal injury to persons near
the exhaust outlet. See Regen-Inhibit Switch later
in this chapter for instructions on preventing au­tomatic regen if necessary.

The exhaust temperature can remain high even
after the vehicle has stopped. When stopping the
vehicle shortly after an automatic regen, ensure
the exhaust outlets are directed away from struc­tures, trees, vegetation, flammable materials, and
anything else that may be damaged or injured by
exposure to high heat.

•

Engine lube oil must have a sulfated ash
level less than 1.0 wt %; currently referred
to as CJ-4 oil.

•

Use only certified diesel exhaust fluid (DEF)
in the DEF tank.

WARNING

9.1

Exhaust Aftertreatment Systems

Operating at reduced engine load will allow soot to
accumulate in the DPF. When this occurs, the DPF
lamp illuminates, indicating that a regen must be per­formed, and the driver must either bring the vehicle
up to highway speed to increase the load, or park
the vehicle and initiate a parked regen. See Parked
Regen, later in this chapter for instructions.

NOTE: Beginning September 2, 2014 some
chassis are equipped with an option that allows
a regen to occur at 0 or 1 mph (0 or 2 km/h),
instead of the standard 5 mph (8 km/h) thresh­old. Based on the engine programming param­eter, if a regen occurs and vehicle speed is re­duced to either 0 or 1 mph (0 or 2 km/h), the
regen process will not be cancelled.

If the vehicle is programmed for the 0 mph (0
km/h) parameter, vehicle speed can be reduced
to 0 mph (0 km/h) and the regen will continue.
Vehicles with this option are equipped with a
regen inhibit switch to cancel the regen if
needed.

09/25/2006 f610815a

Fig. 9.1, Diesel Particulate Filter (DPF) Status Lamp

If the vehicle is programmed for the 1 mph (2
km/h) parameter, vehicle speed can be reduced
to 1 mph (2 km/h) and the regen will continue. If
vehicle speed is less than 1 mph (2 km/h), the
regen will be cancelled.

After the exhaust stream passes through the ATD, it
flows through another canister housing the SCR de­vice. A controlled quantity of DEF is injected into the
exhaust stream, where heat converts it to ammonia

) gas. This mixture flows through the SCR de-

(NH

3

vice, where the ammonia gas reacts with the NOx in
the exhaust, to produce harmless nitrogen (N
water vapor (H2O), which then exits out of the tail­pipe.

) and

2

ATS Warning Lamps

Warning lamps in the driver’s message center alert
the driver of situations with the ATS.

•

An illuminated DPF lamp indicates a regen is
needed. See

•

A slow, 10-second flashing of the HEST lamp
alerts the driver that a parked regen is in prog­ress, but the exhaust temperatures are still
relatively cool. See
that the high-idle speed is being controlled by
the engine software, not the driver.

Fig. 9.1.

Fig. 9.2. It also indicates

09/25/2006 f610816a

Fig. 9.2, High Exhaust System Temperature (HEST)

•

A steadily illuminated HEST lamp alerts the
operator of high exhaust temperatures when
vehicle speed is below 5 mph (8 km/h) while it
is performing an automatic regen, and during a
parked regen. See

Lamp

Fig. 9.2.

Parked Regen

DANGER

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

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

9.2

Exhaust Aftertreatment Systems

A reference label is included with the driver’s docu­mentation package initially in the glove box, that ex­plains the ATS warnings, and actions required to
avoid further engine protection sequences. See

Fig. 9.3.

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)

(Flashing) (Flashing)

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.

Filter Regeneration
Necessary

Filter is now
reaching maximum

Switch.

capacity

.

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

See Engine Operator’s Manual for complete Regeneration Instructions.

(because the engine software is signaling for a
parked regen).

The regen-inhibit switch (optional when available)
provides additional control over the aftertreatment

W

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.

24−01583−000B

06/29/2009

Fig. 9.3, Exhaust-Aftertreatment Warnings Reference Label

The regen switch, located on the dash, is used to
initiate a parked regen of the aftertreatment device.

Fig. 9.4.

See

06/19/2012

f611199

Fig. 9.4, Regen Switch

NOTE: The regen switch can initiate a parked
regen only when the DPF lamp is illuminated

f080147

regeneration process. A driver may decide to use this
feature if they are hauling cargo that should not be
exposed to possible high exhaust temperatures from
an automatic regen. Depressing the regen-inhibit
switch will prevent a regen from occurring during a
drive cycle. After the vehicle has been shut down
and restarted, regens will occur normally unless the
inhibit switch is pressed again. See

Fig. 9.5.

To initiate a parked regeneration, perform the follow­ing steps.

1.

Park the vehicle away from all combustible and
flammable materials. Chock the tires. Start and
warm the engine until the coolant temperature is
at least 150°F (66°C).

2.

Set the parking brake. If the parking brake was
already set, you must release it, then set it
again.

9.3

Exhaust Aftertreatment Systems

07/30/2009

Fig. 9.5, Regen Inhibit Switch (optional when available)

For manual transmissions, fully depress the
clutch pedal, put the transmission in neutral, then
release the pedal.

If the vehicle has a two-pedal automated trans­mission, shift it into gear, then back to neutral.

IMPORTANT: The driver must remain with the
vehicle during the entire regen cycle.

3.

Press and hold the regen switch for 4 seconds.
The engine will increase rpm and initiate the
regen process.

4.

After the parked regen has run for 20 to 40 min­utes, the regen cycle is completed. The engine
idle speed will drop to normal, and the vehicle
may be driven normally. The HEST lamp may be
illuminated, but will go out when the vehicle
speed exceeds 5 mph (8 km/h), or the system
has cooled to normal operating temperature.

5.

To stop a parked regen at any time during the
process, engage the clutch, brake, or throttle
pedal, or turn off the engine.

Shorting Plug

NOTE: The DPF lamp must be illuminated be­fore the shorting plug will initiate a parked
regen. See

The shorting plug is used to initiate a parked regen
of the ATD. The shorting plug is located under the
dash, next to the steering column. Mounting locations
vary. See

To initiate a parked regeneration, perform the follow­ing steps.

Fig. 9.1.

Fig. 9.6.

f610944

1

2

3

02/11/2009

1. Primary Lock

2. Secondary "Red" Lock

Fig. 9.6, Shorting Plug

1.

Park the vehicle away from all combustible and

3. Plug

f545207

flammable materials. Chock the tires. Start and
warm the engine until the coolant temperature is
at least 150°F (66°C).

2.

Set the parking brake. If the parking brake was
already set, it must be released, then set again.

For manual transmissions, fully depress the
clutch pedal, put the transmission in neutral, then
release the pedal.

If the vehicle has a two-pedal automated trans­mission, shift it into gear, then back to neutral.

IMPORTANT: The driver must remain with the
vehicle during the entire regen cycle.

3.

Disconnect the shorting plug, as follows.

3.1

Slide the secondary red lock away from
the white cover. See Fig. 9.6, Ref. 2.

3.2

Push the primary lock in. See Fig. 9.6,
Ref. 1.

3.3

Pull the plug apart. See Fig. 9.6, Ref. 3.

4.

Wait four seconds.

5.

Connect the shorting plug.

6.

Engine rpm will rise, and initiate the regen pro­cess.

9.4

Exhaust Aftertreatment Systems

7.

The regen cycle will finish after 20 to 60 minutes,
at which time engine idle speed will drop to nor­mal and the vehicle can be driven normally. The
HEST lamp may be illuminated, but will go out
when the vehicle speed exceeds 5 mph (8 km/h),
or the system has cooled to normal operating
temperature. See
shut off.

8.

To stop a parked regen at any time during the
process, engage the clutch, service brake, or
accelerator pedal, or turn off the engine.

Fig. 9.2. The DPF lamp will

DPF Maintenance

Eventually ash will accumulate in the DPF and the
filter will require servicing. DPF servicing must be
performed by an authorized technician, following the
engine manufacturer’s instructions. A record must be
maintained for warranty purposes, that includes:

•

date of cleaning or replacement;

•

vehicle mileage;

•

particulate filter part number and serial number.

Diesel Exhaust Fluid and Tank,
EPA10 and Newer Engines

Diesel Exhaust Fluid

Diesel exhaust fluid (DEF) is used in the ATS to
lower NOx in the exhaust stream. DEF is colorless
and close to odorless (it may have a slightly pungent
odor similar to ammonia). It is nontoxic, nonflam­mable, and biodegradable. It is mildly corrosive to
aluminum, but does not affect the strength or struc­ture of the aluminum.

White crystals may be noticeable around compo­nents that come into contact with DEF. The crystals
are easily removed with water.

DEF consumption varies depending on ambient con­ditions and vehicle application.

Freezing Conditions

DEF freezes to slush at around 12°F (-11°C). It is not
damaged or destroyed if frozen, and is fully usable
when thawed. The DEF in the tank is allowed to
freeze while a vehicle is non-operational. At start-up,
normal operation of the vehicle is not inhibited if the
DEF is frozen; an immersion heater with engine cool-

ant flowing through it warms the DEF once the en­gine is running, allowing the SCR system to operate.

Pre-2013 DEF supply lines are electrically-heated
and are purged when the engine is shut down; com­plete purging of the DEF lines requires approximately
five minutes after the engine is shut down.

DEF supply lines with engine model year 2013 and
newer are designed to survive freezing conditions
while containing DEF, so purging is not required.

DEF Tank

Engines that are compliant with EPA10 and newer
regulations are equipped with a DEF tank located
between the ATS and the fuel tank, or an optional
location forward of the fuel tank. The DEF tank has a
19 mm filler neck inlet that prevents the hose from a
diesel outlet from being inserted, and has a blue cap
for easy identification.

The DEF tank will require filling a minimum of ap­proximately every second diesel refuel depending on
the DEF tank capacity. The S2 Chassis has an 11.5­gallon tank capacity. DEF consumption is approxi­mately 2% of fuel consumption, dependent on ve­hicle operation. For every 50 gallons of diesel fuel
consumed, approximately 1 gallon of DEF will be
consumed.

Fuel/DEF Gauge

The fuel and DEF levels are measured in a dual pur­pose fuel/DEF gauge. See

Fuel level is indicated at the top of the gauge. Below
the fuel level, a low fuel warning lamp illuminates
amber when the fuel level drops below 1/8th of the
capacity.

The lower portion of the gauge has a DEF warning
lamp that illuminates when the DEF tank is near
empty, and a DEF lightbar that indicates the level in
the DEF tank as follows.

•

Four bars illuminated green—Between 75%
and 100% full

•

Three bars illuminated green—Between 50%
and 75% full

•

Two bars illuminated green—Between 25%
and 50% full

•

One bar illuminated green—Between approxi­mately 10% and 25% full

Fig. 9.7.

9.5

Exhaust Aftertreatment Systems

1/2

ULTRA LOW SULFUR

DIESEL FUEL ONLY

FE

DEF

1

11/08/2010 f611037

A. Green bars—DEF level indicators.
B. One bar illuminated amber—DEF very low, refill DEF.

1. Low Fuel Warning Lamp (amber at 1/8 tank of fuel) 2. Low DEF Warning Lamp

EF

2

A C

•

One bar illuminated amber—DEF very low, re­fill DEF

•

One bar flashing red—DEF empty, refill DEF

EF

Fig. 9.7, Fuel/DEF Gauge

1/2

ULTRA LOW SULFUR

DIESEL FUEL ONLY

DEF

B

C. One bar flashing red—DEF empty, refill DEF.

FE

EF

A

1/2

ULTRA LOW SULFUR

DIESEL FUEL ONLY

DEF

FE

DEF Warnings and Engine Limits

IMPORTANT: Ignoring the DEF warning lamps
and not refilling the DEF will result in limited en­gine power with a speed limit of 5 mph (8 km/h)
eventually being applied. See the Cummins Op-
eration and Maintenance Manual for further in­formation.

DEF Level Low—Initial and Critical
Warnings

When the DEF level reads low the following warnings
strongly encourage the driver to refill the DEF tank.

Fig. 9.8.

See

•

The DEF warning lamp illuminates constantly
(initial warning).

•

The DEF warning lamp flashes (critical warn­ing).

•

DEF-level lightbar illuminates solid amber.

B

07/09/2009 f470537

A. DEF Warning Lamp (solid amber)
B. DEF-Level Lightbar (1 bar solid amber)

Fig. 9.8, DEF Level Low Initial and Critical Warnings

•

One bar of the DEF-level lightbar flashes red.

•

The DEF warning lamp flashes.

•

The CHECK engine lamp illuminates.

Engine performance is limited, with progressively
harsher engine power limits applied.

The DEF tank must be filled to cancel the warning
sequence.

DEF Level Empty and Ignored

DEF Empty

When the DEF level reads empty, the following warn­ings are activated. See

Fig. 9.9.

If the empty warning is ignored and the DEF is not
refilled, the red STOP engine lamp illuminates in ad­dition to the DEF warning lamp and the CHECK en­gine warning lamp. See

Fig. 9.10.

9.6

Exhaust Aftertreatment Systems

after the next engine shutdown, or while parked and

A

idling. See

EPA07 Aftertreatment System
(ATS)

Fig. 9.10.

B

11/08/2010 f470539a

NOTE: Engine power is limited.
A. DEF Warning Lamp (flashing amber)

B. DEF-Level Lightbar (1 bar flashing red)

Fig. 9.9, DEF Empty Warning

If the DEF tank is not refilled, a 5 mph (8 km/h)
speed limit will be applied after the next engine shut­down, or while parked and idling.

A

B

11/18/2010 f470540b

NOTE: The STOP engine, CHECK engine, and DEF
lamps illuminate, engine power is limited, speed limit of
5 mph (8 km/h).

A. DEF Warning Lamp (flashing amber)
B. DEF-Level Lightbar (1 bar flashing red)

Fig. 9.10, DEF Empty and Ignored Warning

DEF Quality or SCR Tampering

NOTICE

Once contaminated DEF or tampering has been
detected in the SCR system, the vehicle must be
taken to an authorized service center to check
the SCR system for damage, and to deactivate
the warning lamp and engine limits.

If contaminated DEF or tampering is detected, the
DEF warning lamp flashes, and engine power is lim­ited with progressively harsher limits applied. If the
fault is not corrected, the STOP engine lamp illumi­nates and a 5 mph (8 km/h) speed limit is applied

All on-road diesel engines built after December 31,
2006, (EPA07 engines) must meet strict new guide­lines for reduced exhaust emissions of particulate
matter and nitrogen oxides (NOx). NOx is limited to
just over 1 gram per brake horsepower hour (g/bhp­hr) and particulate matter cannot exceed 0.01 g/bhp­hr.

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

•

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

•

Do not use fuel blended with used engine lube
oil or kerosene.

•

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

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

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

IMPORTANT: See your engine operation manual
for complete details and operation of the after­treatment system.

Inside the ATD, the exhaust first passes over the die­sel oxidation catalyst (DOC), then it passes through

9.7

Exhaust Aftertreatment Systems

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

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

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

DANGER

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

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

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

A slow (10-second) flashing of the high exhaust sys­tem temperature (HEST) lamp indicates that a
parked regen is in progress, and the engine’s high
idle speed is being controlled by the engine software,
not the driver.

A steadily illuminated HEST lamp alerts the operator
of high exhaust temperature during the regeneration
process, if vehicle speed is below 5 mph (8 km/h).
See

Fig. 9.2. The HEST lamp does not indicate the

need for any kind of vehicle or engine service; it only
alerts the vehicle operator of high exhaust tempera­tures. Make sure the engine exhaust pipe outlet is
not directed at any person, or at any surface or ma­terial that will melt, burn, or combust.

WARNING

When the HEST lamp is on, be certain that the
exhaust pipe outlet is not directed at combustible
material or toward anyone. To do so could cause
damage to the vehicle and serious personal in­jury to others.

WARNING

Active regeneration can occur automatically any­time the vehicle is moving. The exhaust gas tem­perature could reach 1500°F (816°C), which is hot
enough to cause a fire, heat damage to objects
or materials, or personal injury to persons near
the exhaust outlet. See Regen-Inhibit Switch later
in this chapter for instructions on preventing au­tomatic regen if necessary.

The exhaust temperature can remain high even
after the vehicle has stopped. When stopping the
vehicle shortly after an automatic regen, ensure
the exhaust outlets are directed away from struc­tures, trees, vegetation, flammable materials, and
anything else that may be damaged or injured by
exposure to high heat.

IMPORTANT: Due to the high exhaust tempera­ture during the regen process, a diffuser is used
to reduce the temperature at the exhaust pipe
outlet. See
it must be replaced to ensure proper operation
of the vehicle and to reduce the possibility of
damage or injury.

A steadily illuminated yellow DPF lamp indicates a
regen is required soon. Bring the vehicle to highway
speeds to allow for an active regen, or a parked
regen should be scheduled for the earliest conve­nient time. See

IMPORTANT: Failure to regen could cause en­gine problems, including derate or loss of

Fig. 9.11. If the diffuser is damaged,

Fig. 9.1.

9.8

Exhaust Aftertreatment Systems

NOTE: The regen switch can start a regen only
when at least one of two conditions exists: ei­ther the DPF lamp is lit, or the engine software
calls for it. If neither of those conditions exist,
the regen switch cannot cause a regen to hap­pen.

The function of the switch will vary by the engine
make and model in the vehicle. See the engine op­eration manual for switch operation details.

09/11/2007 f490294

Fig. 9.11, Exhaust Diffuser

power. As soon as allowed after the DPF lamp
illuminates, maintain highway speeds to allow
automatic regeneration, or park the vehicle in a
safe location and perform a parked regen.

A DPF lamp blinking at the same time as a steadily
illuminated yellow Check Engine lamp indicates that
a parked regen must be performed immediately, or
an engine derate will occur. If the red Stop Engine
lamp illuminates with the blinking DPF lamp and the
yellow Check Engine lamp, a parked regen must
occur or an engine shutdown will occur. Park the ve­hicle and perform a parked regen. See

Fig. 9.4.

Fig. 9.12 and

When diesel particulate filter servicing is needed, it
must be performed by an authorized technician, and
a record must be maintained for warranty purposes.
The record must include:

A steadily illuminated Malfunction Indicator Lamp
(MIL) indicates an engine fault that affects the emis­sions. The MIL lamp applies to the Mercedes-Benz
engine only. See

•

date of cleaning or replacement

•

vehicle mileage

•

particulate filter part number and serial number

Fig. 9.13.

CHECK

07/09/2009 f611036

1. Malfunction Indicator Lamp (MIL)

2. Check-Engine Lamp

3. Stop-Engine Lamp

123

Fig. 9.12, Engine Protection Lamps

STOP

The DPF regen switch, located on the dash, may
have three selectable positions:

•

Request Regeneration

•

Default (can include appropriate normal state
condition—either in an automatic regeneration
or inhibit state)

•

Inhibit regeneration (optional when available)

9.9

09/25/2006 f610814a

Fig. 9.13, Malfunction Indicator Lamp (MIL)

High-Soot-Load Idle Shutdown

Extended idle operation can cause soot to accumu­late in the DPF, which can eventually trigger an ECM
fault, cause the Stop Engine lamp to illuminate, and
require replacement of the DPF. The High-Soot-Load
Idle Shutdown feature (if equipped), determines if the
extended engine idling needs to be shut down before
there is a triggering of the stop engine warning.

The High-Soot-Load Idle Shutdown feature monitors
the soot load during the idle or high-idle operation. If
high-soot-load occurs, the DPF lamp will illuminate,

then the Check Engine lamp will flash for 30 sec­onds, before the engine shuts down.

Exhaust Aftertreatment Systems

9.10

10

Transmission

Driving Precautions .............................................................. 10.1

Allison On-Highway Transmissions .................................................. 10.1

Eaton® Fuller® Straight-Shift Transmissions .......................................... 10.6

Clutches ....................................................................... 10.7

Transmission

Driving Precautions

The vehicle operator should use care when acceler­ating or downshifting on slippery road surfaces. Sud­den acceleration or engine braking, caused by shift­ing to a lower gear range, can result in a loss of
vehicle control. This is very important on snow or ice
covered roads. See
brake operation.

If the vehicle is stuck in sand or mud, do not attempt
to pull the vehicle out under its own power. Request
professional towing assistance.

Do not attempt to rock the vehicle. If rocking the
vehicle is necessary, even at low speeds, it may
cause engine overheating, axle damage, trans­mission damage or failure, or tire damage.

Do not coast the vehicle in neutral. Severe trans­mission damage may result and the vehicle will
not have the benefit of engine braking.

To reduce the risk of personal injury, before
going down a steep or long grade, reduce speed
and downshift the transmission. Do not hold the
brake pedal down too long or too often while
going down a steep or long grade. This could
cause the brakes to overheat, reducing their ef­fectiveness. As a result, the vehicle will not slow
down at the usual rate. Failure to take these
steps could result in loss of vehicle control.

To avoid skidding on slippery roads, do not downshift
into L (low) at speeds above 20 mph (32 km/h).

On slippery surfaces, avoid quick movements of the
steering wheel. Decrease speed and allow for extra
stopping distance required by these conditions. For
non-ABS brakes, apply the brakes by pumping the
pedal steadily and evenly to avoid wheel lock-up and
loss of vehicle control.

Avoid driving through flooded areas unless you are
sure the water is no higher than the bottom of the
wheel rims. Drive through slowly. Allow adequate
stopping distance since wet brakes do not grip well.
After driving through water, gently apply the brakes
several times while the vehicle is moving slowly to
dry the brakes.

Chapter 13 for information on

NOTICE

WARNING

When driving on icy or graveled surfaces, reduce
speed. Avoid sharp turning maneuvers.

Allison On-Highway
Transmissions

The Allison on-highway transmissions are fully auto­matic and include the 2100 Series, 2200 Series,
2350 Series, 2500 Series, and 3000 Series. Refer to

www.allisontransmission.com for additional infor-

mation.

Safety Precautions

2000 Series

WARNING

Do not leave the vehicle unattended with the en­gine running. If you leave the vehicle and the en­gine is running, the vehicle can move suddenly,
which could result in personal injury or property
damage.

On vehicles with Allison 2000 series transmissions,
do the following steps if you have to leave the ve­hicle with the engine running (for example, when
checking the transmission fluid).

Without Auto-Apply Parking Brake

1.

Bring the vehicle to a complete stop using the
service brake.

2.

Ensure that the engine is at low idle rpm.

3.

Put the transmission in neutral.

4.

Apply the parking brake, and make sure it is
properly engaged.

5.

Chock the rear tires and take any other steps
necessary to keep the vehicle from moving.

With Auto-Apply Parking Brake

1.

Bring the vehicle to a complete stop using the
service brake.

2.

Ensure that the engine is at low idle rpm.

3.

Put the transmission in PB (auto-apply parking
brake).

4.

Apply the parking brake (if so equipped), and
make sure it is properly engaged.

10.1

5.

Chock the rear tires and take any other steps
necessary to keep the vehicle from moving.

Range Inhibit Indicator, 2000 Series

A RANGE INHIBIT indicator is a standard feature of
the 2000 series transmissions. The RANGE INHIBIT
indicator comes on to alert the driver that transmis­sion operation is being inhibited and that the range
shifts being requested by the driver may not occur.
When certain operating conditions are detected by
the transmission control module (TCM), the controls
will lock the transmission in the current operating
range.

Shift inhibits occur under the following conditions:

•

Shifts from neutral to reverse or from neutral to
a forward range when the engine is above idle,
greater than 900 rpm.

•

Forward/reverse directional shifts are typically
not permitted if appreciable output shaft speed
is detected.

•

When some types of unusual transmission op­erating conditions are detected by the TCM,
the TCM temporarily limits transmission opera­tion until the vehicle can be driven to a service
location. When this type of situation is de­tected, the TCM will lock the transmission in a
safe gear range.

•

The TCM will prevent shifts from park or neu­tral to another range when auxiliary equipment
is in operation.

•

If a shift from a higher to a lower gear causes
the engine to overspeed.

Operating Instructions, 2000 Series
Transmissions

2000 series transmissions are electronically con­trolled. The shift selector provides four forward
ranges and one reverse range. A T-handle shift con­trol is used by the driver to select the ranges. See

Fig. 10.1.

P (Park)

Use park, if so equipped, when turning the engine on
or off, to check vehicle accessories, or to operate the
engine in idle for longer than 5 minutes. This position
places the transmission in neutral and engages the
park pawl of the transmission.

Transmission

09/21/2012 f270165

Fig. 10.1, T-Handle Shifter (standard)

NOTE: This does not apply the parking brake.

The park pawl is standard on the 2200 series
transmission. The park pawl effectively grounds
the transmission output shaft, thereby prevent­ing rotation of the driveline. Provided the vehicle
is stationary, selecting P (park) on the shift se­lector, if so equipped, places the transmission in
neutral and engages the park pawl.

10.2

Transmission

PB (Auto-Apply Parking Brake, optional
on 2000 Series)

The auto-apply parking brake places the transmis­sion in neutral and applies the parking brake.

R (Reverse)

Reverse is used to back the vehicle. When the selec­tor is in reverse, the reverse warning signal will
sound. Always bring the vehicle to a complete stop
before shifting from a forward range to reverse, or
from reverse to a forward range.

Do not idle in reverse for more than 5 minutes. When
time at idle exceeds 5 minutes, select N (neutral), or
if so equipped, P (park) or PB (auto-apply parking
brake).

NOTE: The shift into reverse may not succeed if
a range inhibitor is active. Check for illumination
of the RANGE INHIBIT indicator.

N (Neutral)

The neutral position places the transmission in neu­tral. When neutral is selected, the vehicle service
brakes, parking brake, or emergency brake must be
applied. Selecting neutral does not apply vehicle
brakes unless an auxiliary system to apply the park­ing brake is installed.

This position is used when starting the engine and
for stationary operation. It is also used to shut down
the vehicle when P (park) or PB (auto-apply parking
brake) are not available on the shifter. In this case,
the parking brake must be applied.

Do not let the vehicle coast in neutral. If the vehicle
is allowed to coast in neutral, the engine brake will
not work and the driver could lose control of the ve­hicle.

D (Drive)

selected. However, during downhill operation, the
transmission may upshift to the next higher range, if
the engine is exceeding its governed speed in the
lower range.

NOTE: The shift into drive may not succeed if a
range inhibitor is active. Check for illumination
of the RANGE INHIBIT indicator.

3 and 2 (Third and Second Ranges)

Use the third or second range for heavy city traffic
and for braking on steeper downgrades.

L (Low Range)

Use low range when pulling through mud or deep
snow, when maneuvering in tight spaces, or when
driving up or down very steep grades. Low range
provides the vehicle with its maximum driving torque
and maximum engine braking effect.

NOTE: To have the transmission select these
ranges automatically, leave the selector lever in
D (drive).

Operating Instructions, 3000 Series

The Allison 3000 series transmission is electronically
controlled and comes with a push-button shift control
that provides five or six forward ranges and one re­verse range. The push-button shift selector has R
(reverse), N (neutral), and D (drive) ranges, up and
down arrows, a mode button, and a digital display.

Fig. 10.2.

See

R (Reverse)

Press the R button to select reverse. The digital dis­play will show R when reverse is selected. Always
bring the vehicle to a complete stop and let the en­gine return to idle before shifting from a forward
range to reverse, or from reverse to a forward range.

In the drive position, the transmission will initially go
into first range when drive is selected. As vehicle
speed increases, the transmission will upshift auto­matically through each available range up to fourth or
fifth range. As the vehicle slows, the transmission will
downshift automatically.

When going downhill, downshift to a lower transmis­sion range to increase engine braking and to help
maintain control. The transmission has a feature to
prevent automatic upshifting above the lower range

10.3

NOTICE

Extended idling in reverse may cause transmis­sion overheating and damage.

Do not idle in reverse for more than 5 minutes. Se­lect neutral when time at idle exceeds 5 minutes.

NOTE: The shift into reverse may not succeed if
a range inhibitor is active. When reverse is se­lected, always be sure that R is not flashing.

Transmission

WARNING

1

2

3

4

07/27/2006

1. Digital Display

2. Mode Identification
Label

Fig. 10.2, Push-Button Shift Selector

3. Mode Indicator LED

4. Mode Button

f610804

N (Neutral)

WARNING

When starting the engine, make sure that the ser­vice brakes are applied. Failure to apply the ser­vice brakes may result in unexpected vehicle
movement, which could cause severe personal
injury or death. Failure to apply the vehicle park­ing brakes when the transmission is in neutral
may allow the vehicle to move unexpectedly, pos­sibly causing property damage or personal injury.

Press the N button to select neutral. The digital dis­play will show N when neutral is selected. It is not
necessary to press neutral before starting the ve­hicle. The electronic control unit (ECU) or TCM auto­matically places the transmission in neutral at start­up.

When neutral is selected, the vehicle service brakes,
parking brake, or emergency brake must be applied.
Selecting neutral does not apply vehicle brakes un­less an auxiliary system to apply the parking brake is
installed.

Do not coast in neutral. Coasting in neutral can
cause an accident, possibly resulting in severe
personal injury or death.

Do not let the vehicle coast in neutral. If the vehicle
is allowed to coast in neutral, the engine brake will
not work and the driver could lose control of the ve­hicle.

Always select neutral before turning off the engine.

D (Drive)

When the D button is pushed, the highest forward
range will appear in the display. The transmission will
normally go into first range when drive is selected
(except for those units programmed to start in sec­ond range). As vehicle speed increases, the trans­mission will upshift automatically through each range.
As the vehicle slows, the transmission will downshift
automatically.

NOTICE

Do not idle in drive for more than 5 minutes. Ex­tended idling in drive may cause transmission
overheating and damage. Always select neutral if
time at idle is longer than 5 minutes.

NOTE: The shift into drive may not succeed if a
range inhibitor is active. When drive is selected
always be sure that D is not flashing.

5, 4, 3, and 2 (Fifth, Fourth, Third, and
Second Ranges)

Occasionally, road conditions, load, or traffic condi­tions will make it desirable to restrict automatic shift­ing to a lower range. Lower ranges provide greater
braking for going down grades. The lower the range,
the greater the braking effect.

Push the up or down arrows on the push-button shift
selector to select individual forward ranges. The digi­tal display will show the selected range. When a
lower range is selected, the transmission may not
downshift until the vehicle speed or engine RPM (en­gine governed speed) is reduced.

10.4

Transmission

WARNING

When going downhill, use a combination of
downshifting, braking, and other retarding de­vices to control vehicle speed and the engine’s
rated governed speed. Failure to do so could re­duce vehicle braking, possibly causing loss of
vehicle control and resulting in personal injury or
property damage.

When going downhill, downshift to a lower transmis­sion range to increase engine braking and to help
maintain control. The transmission has a feature to
prevent automatic upshifting above the lower range
selected. However, during downhill operation, if the
engine governed speed is exceeded in the lower
range, the transmission may upshift to the next
higher range.

1 (First Range)

Use the first range when pulling through mud or
deep snow, when maneuvering in tight spaces, or
when driving up or down steep grades. First range
provides the vehicle with its maximum driving torque
and maximum engine braking effect. Push the down
arrow until the first range appears on the display.

Up and Down Arrows

When a lower range is desired, after D has been
pressed, press the down arrow until the desired
range is shown on the display. Pressing the down
arrow continuously causes the range position to con­tinue to go down until the button is released or the
lowest range is attained.

When the transmission is in drive and the down
arrow has the transmission in a lower range position,
press the up arrow to shift to a higher selector posi­tion. Continuously pressing the up arrow causes the
range position to continue to rise until the button is
released or the highest available position is attained.

Continuously pressing the up or down arrows does
not override the transmission automatic shifting op­eration. If a higher or lower position is selected, the
transmission continues shifting through the ranges
according to the vehicle operating characteristics
until the highest or lowest selection position is
reached.

Mode Button

The MODE button starts a specialized input or output
function that has been previously programmed into
the ECU or TCM. Pressing the MODE button
changes transmission operation for a specific func­tion.

Mode Indicator LED

When the MODE button is pressed, the mode indica­tor LED illuminates. A mode identification label, lo­cated above the MODE button, identifies the function
associated with a mode change.

Digital Display

The dual digital display shows both the selected
range (SELECT) and actual range attained (MONI­TOR). The single digital display shows the selected
range.

Oil Level Sensor

Allison 3000 Series transmissions have an electronic
oil level sensor to read fluid level information. The
fluid level diagnostic will display whether the oil level
is OK, too low, or too high. It will also display a de­fault code and indicate if the preconditions (of receiv­ing the fluid level information) are not met.

IMPORTANT: Maintain the proper fluid level at
all times. If the fluid level is too low, the con­verter and clutch do not receive an adequate
supply of fluid. If the level is too high, the trans­mission may shift erratically or overheat.

To access the oil level display mode, park the vehicle
on a level surface, shift to N (neutral), apply the
parking brake, and idle the engine. Then simultane­ously press both the up and down arrows once. The
oil level will display at the end of a two-minute count­down.

Diagnostic Codes

Diagnostic codes are numerical indications relating to
a malfunction in transmission operation. These codes
are logged in the TCM/ECU memory. The most se­vere or most recent code is listed first. A maximum of
five codes (numbered d1-d5) may be listed in
memory at one time. If the mode indicator LED is
illuminated, the displayed code is active. If it is not
illuminated, the displayed code is not active.

10.5

Transmission

NOTE: During normal operation, an illuminated
mode indicator LED signifies the specialized
mode operation is in use.

To enter diagnostics mode, first park the vehicle and
apply the parking brake. Then simultaneously press
both the up and down arrows twice.

Eaton® Fuller® Straight-Shift
Transmissions

Refer to the Eaton website for additional information,

www.roadranger.com.

General Information, Straight-Shift

Eaton Fuller 5-speed FS models are fully synchro­nized. They have five forward speeds and one re­verse. See

05/21/2008

Eaton Fuller 6-speed FS and FSO models are fully
synchronized. They have six forward speeds and one
reverse. See

05/21/2008

Fig. 10.4, Shift Pattern, 6-Speed FS and FSO Models

These transmissions are designed for use with on­highway, fuel economy engines where a minimum of

Fig. 10.3 for the shift pattern.

R4

2

N

1

Fig. 10.3, Shift Pattern, 5-Speed FS Models

Fig. 10.4 for the shift pattern.

R

1

3

5

35

N

2

4

6

f261049

f261048

shifting is desired and less gear reduction is accept­able.

Operation, Straight-Shift

1.

Always use first gear when starting to move the
vehicle forward.

NOTICE

Do not rest your foot on the clutch pedal while
driving. This causes partial clutch disengagement
which could cause premature clutch wear.

2.

On synchronized models, press the clutch pedal
to the floor when shifting gears. Double-clutching
is unnecessary.

On unsynchronized models, press the clutch
pedal to the floor to contact the clutch brake only
when engaging the first or reverse gears.

NOTE: If the vehicle is moving when shifting,
depress the pedal just far enough to disengage
the clutch. Pressing it to the floor will engage
the clutch brake, if so equipped, causing prema­ture clutch brake wear.

3.

To upshift, do the following steps:

3.1

Accelerate to engine governed speed.

3.2

On synchronized models, depress the
clutch pedal and move the shift lever to
second gear.

On unsynchronized models, depress the
clutch pedal and move the shift lever to
neutral. Release the clutch pedal again.
With the shift lever in neutral, depress the
clutch pedal and move the shift lever to
second gear.

3.3

Release the clutch pedal and note the
drop in engine rpm before accelerating up
to engine governed speed again.

3.4

Continue upshifting using the same se­quence described in the previous step.
Follow the pattern on the shift lever.

4.

To downshift, do the following steps:

4.1

Wait until the engine speed drops to the
rpm noted immediately after the upshift.

10.6

Transmission

4.2

On synchronized models, depress the
clutch pedal and move the shift lever to
the next lower gear.

On unsynchronized models, depress the
clutch pedal and move the shift lever to
neutral. Release the clutch pedal again.
With the shift lever in neutral, depress the
clutch pedal and move the shift lever to
the next lower gear.

4.3

Release the clutch pedal smoothly.

4.4

Use the sequence described above to
shift progressively down through each
successive lower gear, as driving condi­tions require.

Clutches

Clutch Operation

Applying the Clutch Brake

The purpose of the clutch brake is to stop the trans­mission gears from rotating in order to engage the
transmission gears quickly in making an initial start.
To apply the clutch brake, put the transmission in
neutral and press the clutch pedal to the floor.

NOTICE

Never apply the clutch brake while the vehicle is
moving. The clutch pedal should never be
pressed down fully before putting the transmis­sion in neutral. Considerable heat will be gener­ated, which will be detrimental to the friction
discs, release bearings, and transmission front
bearings.

Applying the clutch brake with the transmission still in
gear puts a reverse load on the gear. At the same
time, it will have the effect of trying to stop or decel­erate the vehicle with the clutch brake. Rapid wear of
friction discs will take place, necessitating frequent
replacement.

Vehicle Overload, or Overloading the
Clutch

Clutches are designed for specific vehicle applica­tions and loads. These limitations should not be ex­ceeded.

Riding the Clutch Pedal

Riding the clutch pedal is destructive to the clutch.
Partial clutch engagement permits slippage, and gen­erates excessive heat. Riding the clutch pedal will
also put a constant thrust load on the release bear­ing, which can thin out the lubricant. Release bearing
failures can be attributed to this type of misuse.

Holding the Vehicle on an Incline With a
Slipping Clutch

A slipping clutch accumulates heat faster than it can
be dissipated, resulting in early clutch failures. Never
use the clutch to hold a vehicle on a hill.

Coasting With the Clutch Released
(pedal down) and the Transmission in
Gear

WARNING

Do not allow the vehicle to coast with the clutch
released (pedal down) and the transmission in
gear. If the clutch facing is thrown off the disc,
flying debris could cause injury to persons in the
vehicle.

If the transmission remains in a low gear and the ve­hicle gains speed, as may occur on a downgrade,
the input shaft and clutch driven disc will turn at
speeds that are higher than normal. This occurs be­cause the rear wheels and the driveline become the
input for the transmission, and a higher-than-normal
speed for a given transmission gear translates to a
higher rpm value for the clutch driven disc.

Clutch driven discs are designed to allow for some
amount of excess rotational speed, but the facing
has a limited burst strength. If the clutch driven disc
rpm increases too much, the clutch facing can be
thrown off the disc(s).

Engaging the Clutch While Coasting

NOTICE

Overloading will not only result in damage to the
clutch, but also to the entire powertrain.

10.7

Engaging the clutch while coasting can result in tre­mendous shock loads and possible damage to the
clutch as well as to the entire drivetrain.

Transmission

Report Erratic Clutch Operation Promptly

Reporting erratic clutch operation as soon as pos­sible will give maintenance personnel a chance to
inspect the clutch components.

CAUTION

Operating the vehicle with incorrect clutch pedal
free-travel could result in clutch damage. See
Group 25 of the S2 Chassis Workshop Manual for
free-pedal adjustment procedures and specifica­tions.

On mechanical clutch linkages, free-pedal travel
should be included and commented on daily in the
driver’s report, since clutch free-pedal travel is the
best guide to the condition of the clutch and the re­lease mechanism.

Clutch Wear

The major reason clutches wear out too soon is ex­cessive heat. Clutches are designed to absorb and
dissipate more heat than encountered in typical op­eration. The temperatures developed in typical op­eration will not break down the clutch friction sur­faces. However, if a clutch is slipped excessively or
required to do the job of a fluid coupling, high tem­peratures develop quickly and destroy the clutch.
Temperatures generated between the flywheel,
driven discs, and pressure plates can be high
enough to cause the metal to flow and the friction
facing material to char and burn.

Clutch Adjustments

Some clutches have an internal adjustment. See the
applicable section in Group 25 of the S2 Chassis
Workshop Manual for clutch adjustment procedures
and specifications.

NOTICE

Operating the vehicle with the clutch incorrectly
adjusted could result in clutch or clutch brake
failure.

Clutch Lubrication

The release bearing should be lubricated at frequent
intervals. See Group 25 of the S2 Chassis Mainte-
nance Manual for intervals and procedures.

NOTICE

Failure to lubricate the release bearing as recom­mended could result in release bearing damage
and damage to the clutch.

NOTICE

Do not allow sustained slippage of the clutch;
this could severely damage the clutch disc, pres­sure plate, or flywheel. Damage caused by clutch
slippage due to improper break-in is not warrant­able.

Slipping and excessive heat are practically nonexis­tent when a clutch is fully engaged. But during the
moment of engagement, when the clutch is picking
up the load, it generates considerable heat. An incor­rectly adjusted or slipping clutch will rapidly generate
sufficient heat to destroy itself.

The most important items that a driver should be
aware of to ensure long service life of the clutch in­clude: starting in the right gear, recognizing clutch
malfunctions, and knowing when to adjust a clutch.

10.8

11

Drive Axles

Drive Axles, Detroit™and Meritor™.................................................. 11.1

Drive Axles

Drive Axles, Detroit™and
Meritor

For additional information regarding Meritor axles,
visit the Meritor website at www.arvinmeritor.com.

Drive Axles With Differential Lock

The optional driver-controlled differential lock should
only be used under adverse road conditions where
greater traction is needed. With the differential lock
on, the turning radius is increased and vehicle han­dling is affected. The red differential lock indicator
light illuminates on the dash message center when
the differential lock is engaged.

A differential lock provides maximum traction under
slippery conditions. When the differential lock is en­gaged, the clutch collar completely locks the differen­tial case, gearing, and axle shafts together, maximiz­ing the traction of both wheels and protecting against
spinout. Do not exceed 25 mph (40 km/h) when the
differential lock is engaged.

Under normal traction conditions, do not use the dif­ferential lock feature.

Differential Lock Switch

The differential lock should only be engaged
when the vehicle is stopped or moving slowly at
low throttle. This will prevent internal axle dam­age.

A two-position guarded rocker switch controls the
differential lock. See
together, momentarily press the upper half of the
switch. To unlock the wheels, press the upper half of
the switch again.

IMPORTANT: The differential lock rocker switch
is guarded to prevent unintentional switch acti­vation. If the light emitting diode (LED) in the
switch begins to blink during normal operation,
when the switch has not been activated, an
error condition exists. Bring the vehicle to an
authorized Freightliner service facility as soon
as possible.

™

NOTICE

Fig. 11.1. To lock the wheels

10/26/2001

Fig. 11.1, Differential Lock Switch, Optional

When the differential lock switch is pressed, three
responses are possible: a normal response, a slow
response, and an abnormal response.

Normal Response: The LED in the switch blinks until
the axle has responded to the request to lock the
wheels. At this point, the LED remains illuminated
constantly. In normal operation, the wheels may lock
so quickly that the blinking of the switch is barely
noticeable.

If operation of the switch is not possible for any rea­son (ignition is turned off, vehicle is moving faster
than 25 mph, etc.), the LED will stop blinking and
turn off.

Slow Response: If operation of the switch is slowed
for any reason (vehicle moving too fast, low air pres­sure, etc.), the switch will continue to blink until the
wheels are able to lock. As in the normal response,
the LED remains illuminated when the differential
lock is engaged.

f610596

NOTE: If the vehicle is moving too fast, let up
slightly on the accelerator. As the vehicle slows,
the wheels will lock.

Abnormal Response: If the LED blinks for more than
30 seconds, the lock mechanism may not be fully
engaged/disengaged. Bring the vehicle to an autho­rized Freightliner service facility for testing.

Differential Lock Operation

WARNING

Locking the wheels when the vehicle is traveling
down steep grades or when the wheels are slip­ping could damage the differential and/or lead to
loss of vehicle control, causing personal injury
and property damage.

11.1

Drive Axles

NOTICE

The differential lock should be engaged when the
vehicle is stopped or moving at a low, constant
speed and the wheels are not spinning, slipping,
or losing traction. Engagement at high speed or
power can damage the axle(s).

Do not permit rear wheels to spin freely for more
than ten seconds when traction is lost. Shift into
lock to prevent damage to interaxle and main
differentials.

Lock the wheels only when the vehicle is standing
still or moving at very low speed, less than 5 mph (8
km/h). Never lock the wheels when the vehicle is
traveling down steep grades or when the wheels are
slipping.

NOTE: On some vehicles, the differential lock
system is connected through the low speed
range of the transmission. If this system is used,
the transmission must be in the low speed
range for the wheels to fully lock.

WARNING

A vehicle with locked wheels can still slip side­ways, causing possible loss of vehicle control,
personal injury, and property damage.

Be especially careful when driving under slippery
conditions with the wheels locked. Though forward
traction is improved, the vehicle can still slip side­ways.

If the vehicle is moving, maintain a constant vehicle
speed when the differential lock is turned on. Briefly
let up on the accelerator to relieve torque on the
gearing, allowing the wheels to lock completely.
When the wheels are fully locked, the turning radius
will increase because the vehicle understeers. See

Fig. 11.2. Drive cautiously and do not exceed 25

mph (40 km/h).

To disengage the differential lock after leaving poor
road conditions, press the upper half of the switch,
while maintaining vehicle speed. Let up momentarily
on the accelerator to allow the wheels to fully unlock,
then resume driving at normal speed.

A

B

02/09/96

A. Turning Radius When the Differential Lock is

Engaged (understeer condition).

B. Turning Radius When the Differential Lock is

Disengaged.

Fig. 11.2, Turning Radii

f350079a

also disengage the differential lock function. The
switch will blink until the wheels unlock, and
then go out.

NOTE: If the differential lock system is con­nected with the transmission in its low speed
range, shifting out of the low speed range will

11.2

12

Steering System

Steering Controls ................................................................ 12.1

Steering System

Steering Controls

WARNING

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

When there is no load on the vehicle and the front
tires are pointed straight ahead, the steering wheel
spokes should be at the 9 o’clock and 3 o’clock posi­tions, or within 10 degrees to either side as shown in

Fig. 12.1. See Group 46 of the S2 Chassis Work-

shop Manual for steering adjustment procedures.

10°

1

10°

11/14/2001

1. 9 o’Clock 2. 3 o’Clock

10°

2

10°

f461923

1

2

3

11/14/2001

Push the foot pedal down to adjust the steering column.

1. Steering Wheel

2. Steering Column

Fig. 12.2, Adjustable Steering Column

3. Foot Pedal

f461922

NOTE: For safety, the steering column is locked
at all times unless the foot pedal is pressed
down.

Fig. 12.1, Steering Wheel Centered

On some vehicles, the steering column may be tilted
forward or aft to provide the most comfortable angle
for steering the vehicle. The steering column can
also be telescoped (raised or lowered) to provide the
most comfortable height above the floor.

To tilt the steering column, press down on the foot
pedal located below the steering wheel to release the
steering column lock. Adjust the column to the de­sired position. Release the foot pedal to lock the
steering column in place. See

Fig. 12.2.

To telescope the steering column, press down on the
foot pedal to release the steering column lock. Pull
the steering wheel upwards or push the steering
wheel downwards until it is at the desired height. Re­lease the foot pedal to lock the steering column in
place.

12.1

13

Hydraulic and Air Brake

Systems

Dual Air Brake System ............................................................ 13.1

Air Brake Operation .............................................................. 13.1

Bosch Hydraulic Pin Slide Brakes ................................................... 13.3

Meritor Cam-Master® Q Plus Brakes ................................................ 13.3

Meritor WABCO Pneumatic Antilock Braking System (ABS) .............................. 13.4

Exhaust Brake .................................................................. 13.5

Engine Brake ................................................................... 13.7

Hydraulic and Air Brake Systems

Dual Air Brake System

A dual air brake system consists of two independent
air brake systems that use a single set of brake con­trols. Each system has its own reservoir, plumbing,
and brake chambers. The primary air system oper­ates the service brakes on the rear axle; the second­ary air system operates the service brakes on the
front axle.

Primary Air Brake System

Loss of air pressure in the primary air system causes
the rear service brakes to become inoperative. The
front brakes will continue to be operated by the sec­ondary air system.

Secondary Air Brake System

Loss of air pressure in the secondary air system
causes the front axle brakes to become inoperative.
The rear service brakes will continue to be operated
by the primary air system.

Emergency Braking System

When air pressure is lost in one air system, the air
compressor will operate, but the air supply in the
leaking system will not be replenished. There will be
enough air in the working system to stop the vehicle
safely. The dual air brake system thus provides
emergency braking capability. When the low air pres­sure warning light and emergency buzzer first come
on, stop the vehicle immediately. Do not drive the
vehicle until the cause of the problem is corrected.

Parking Brakes

Pulling out the yellow diamond-shaped knob (parking
brake control valve) on the auxiliary dash panel ap­plies the parking brakes (spring brakes). See

Fig. 13.1.

Air Brake Operation

WARNING

11/21/2006

Fig. 13.1, Parking Brake Control Valve

control, resulting in property damage or personal
injury.

Before driving the vehicle, secure all loose items in
the vehicle so that they will not fly forward during a
full brake application.

f430360a

Parking Brake Interlock, Optional

NOTICE

Do not continually press down on the parking
brake control valve (yellow knob) without press­ing down on the service brake pedal. This will
damage the safety interlock.

The service brakes and parking brakes have a safety
interlock that prevents the unintentional release of
the parking brake. These instructions need to be fol­lowed for the appropriately equipped vehicle to re­lease the parking brake interlock.

Parking Brake Interlock Release

1.

Depress the brake pedal.

2.

Push the parking brake control valve in.

Parking Brake and Ignition Key Release

1.

Turn the ignition key to the ON position.

2.

Depress the brake pedal.

3.

Push the parking brake control valve in.

Do not operate the vehicle with the front brakes
backed off or disconnected. Backing off or dis­connecting the front brakes will not improve ve­hicle handling and may lead to loss of vehicle

13.1

Parking Brake, Ignition Key, Wheel Chair
Lift Interlock Release

1.

Turn the ignition key to the ON position.

Hydraulic and Air Brake Systems

2.

Check to see that the wheel chair lift is in the
stowed position.

3.

Confirm that the wheel chair lift switch is in the
OFF position.

4.

Depress the brake pedal.

5.

Push the parking brake control valve in.

Transmission Shifter Interlock Release

1.

If the vehicle is equipped with a wheel chair lift,
make sure the lift is in the stowed position, and
that the wheel chair lift switch is in the OFF posi­tion.

2.

Depress the service brake pedal to move the
vehicle shifter out of the park position.

Operating the Brakes

To ensure safe operation and minimum brake wear,
follow the steps below when operating the brakes.

1.

When the ignition switch is turned on, the low air
pressure warning light (pressure circle icon) illu­minates and the emergency buzzer sounds.

1.1

Monitor the air pressure system by ob­serving the low air pressure warning light,
the emergency buzzer, and both the pri­mary and secondary air pressure gauges.

1.2

The warning light and buzzer shut off
when air pressure in both systems
reaches 65 to 75 psi (448 to 517 kPa).

2.

Before driving the vehicle, continue to monitor
the air pressure system until the air compressor
has built up a minimum pressure of 95 psi (655
kPa) in both the primary and secondary air sys­tems.

3.

While driving, the low air pressure warning light
and buzzer come on if air pressure drops below
65 to 75 psi (448 to 517 kPa) in either system.

3.1

If this happens, check the air system pres­sure gauges to determine which system
has low air pressure.

3.2

Although vehicle speed can be reduced
using the service brake, either the front or
rear service brakes will not be operating,
causing a longer stopping distance.

3.3

Bring the vehicle to a safe stop and have
the air system repaired before continuing.

4.

During normal brake stops, depress the service
brake until braking action slows down the ve­hicle. Increase or decrease the pressure on the
pedal so that the vehicle comes to a smooth,
safe stop.

IMPORTANT: In the event of a total loss of ser­vice brakes, use the parking brake control valve
to bring the vehicle to a complete stop in the
safest location possible.

5.

When the forward speed of the vehicle has de­creased almost to the idling speed of the engine,
press in the clutch pedal (on manual transmis­sions) and shift the transmission to neutral. Apply
the parking brakes, if the vehicle is to be parked.

NOTICE

Do not use the spring parking brakes if the ser­vice brakes are hot, such as after descending a
steep grade. Also, do not use the spring parking
brakes during freezing temperatures if the ser­vice brakes are wet. To do so could damage the
brakes if hot, or cause them to freeze during cold
weather.

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

Caging the Parking Brakes

WARNING

Do not drive the vehicle with the parking brakes
caged. If the vehicle is driven with the parking
brakes caged, there would be no means of stop­ping the vehicle if a complete loss of air pressure
occurred. This could result in serious personal
injury or vehicle damage.

To move a vehicle with insufficient system air pres­sure, it is necessary to release the parking brake
springs.

There are two ways to do this:

•

Apply an external air source at the gladhands;

•

Cage (manually release) the parking brakes.

13.2

Hydraulic and Air Brake Systems

IMPORTANT: Before caging the parking brakes,
make the connection to a towing vehicle or
chock the tires.

After correcting the brake system problem, uncage
the parking brakes before resuming normal vehicle
operation.

Bosch Hydraulic Pin Slide
Brakes

General Information

The Bosch hydraulic pin slide disc brake is a two­piston sliding caliper brake and is used at both the
front and rear wheel locations. Each pin slide caliper
disc brake wheel installation is made up of a caliper
assembly, anchor plate assembly, and disc brake
pads.

Caliper Assembly

The caliper assembly has two hydraulic piston bores.
The piston bores contain pistons, piston seals, and
piston boots. The caliper assembly attaches and
slides on sealed pins located in the anchor plate.
The caliper housing is the main component of the
caliper assembly. The material of the caliper housing
is ductile iron and has a protective coating to provide
additional environmental protection. The disc brake
caliper housing straddles the rotor, the inner pad,
and the outer pad.

Anchor Plate Assembly

The anchor plate assembly includes lubricated float­ing guide pins sealed by rubber boots. The anchor
plate abutments are protected by stainless steel slip­pers.

Disc Brake Pads

There are two pads per caliper assembly, and they
are the inner and outer pads. The inner pad is lo­cated between the caliper piston and rotor. The outer
pad is located between the rotor and caliper housing
legs. The pads are made of friction material and a
stamped steel backing plate. The pads are referred
to as the shoe and lining assembly. These brake
pads can be removed without removing the caliper.

Operation

Before driving the vehicle, secure all loose items in
the vehicle so that they will not fly forward during a
full brake application. Check that the brake system
warning light is off after releasing the hand brake. If
the warning light does not go off, correct the problem
before continuing operation of the vehicle.

During normal braking stops, depress the foot brake
control pedal until braking action slows down the ve­hicle. Increase or decrease the pressure on the
pedal so that the vehicle comes to a smooth, safe
stop. Apply the hand parking brake if the vehicle is to
be parked.

IMPORTANT: Make sure that the brake fluid in
the master cylinder reservoirs is up to the level
of the ridge that surrounds the reservoir. See

Fig. 13.2. Use only DOT 3 or 4 brake fluid in

the Bosch hyrdraulic pin slide brake system.

Meritor Cam-Master® Q Plus
Brakes

Cam-Master brakes are air-actuated, cam-operated,
foundation brakes. The Q Plus increases service life
and mileage between relines by providing more lining
thickness. A specially designed S-cam and heavy­duty shoe return spring allow additional shoe travel
required to fully wear the thicker lining blocks. An
improved camshaft bushing contributes to longer ser­vice life.

Cam-Master Q Plus Operation

When the brake pedal is depressed, compressed air
enters the brake chamber, causing the diaphragm to
move a pushrod assembly.

The pushrod turns the slack adjuster and brake cam­shaft. As the camshaft turns, the S-type cam head
forces the brake shoes against the brake drum and
braking occurs.

When the brakes are released and air is exhausted
from the brake chamber, the actuator return spring
(within the brake chamber) and the brake shoe return
spring return the camshaft, brake shoes, slack ad­juster, and pushrod to their released positions.

13.3

Hydraulic and Air Brake Systems

AA

05/24/2012

A. Fill level for brake fluid.

Fig. 13.2, Master Cylinder Reservoir

Meritor WABCO Pneumatic
Antilock Braking System (ABS)

Pneumatic ABS is an electronic wheel speed moni­toring and control system that works with the air
brake system. It passively monitors vehicle wheel
speed at all times, but controls wheel speed during
an emergency or reduced-traction stop. In normal
braking applications, the standard air brake system is
in effect.

Pneumatic ABS Operation

The Meritor WABCO ABS is a four-sensor system. It
combines one front-axle control channel with one
rear-axle control channel to form one control circuit.

Example: The sensor and solenoid control valve at
the left front wheel form a control circuit with the sen­sor and solenoid valve at the right rear axle.

ABS includes signal-generating tone wheels and sen­sors located in the wheel hubs of each sensed axle.
The sensors transmit vehicle wheel speed informa­tion to an electronic control unit.

IMPORTANT: For proper ABS system operation,
do not change tire sizes. The sizes of the tires
installed during production are programmed into
the electronic control unit. Installing different

f420477a

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

During emergency or reduced traction stops, fully
depress the brake pedal until the vehicle comes to a
safe stop. Do not pump the brake pedal. With the
brake pedal fully depressed, the ABS system will
control all wheels to provide steering control and a
reduced braking distance.

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

Even if the ABS system is partially or completely in­operative, normal braking ability is usually main­tained.

IMPORTANT: If a solenoid control valve (or
combination solenoid control valve) is damaged
and inoperative, normal braking may be im­paired.

Automatic Traction Control

Vehicles with electronic engines and ABS may have
Automatic Traction Control (ATC). On these vehicles,

13.4

Hydraulic and Air Brake Systems

the ATC system automatically limits wheel spin dur­ing reduced-traction situations. In normal braking ap­plications, the standard air brake system is in effect.

During reduced-traction situations, the ATC solenoid
valve controls air pressure to the modulator valves
and they in turn increase, hold, or reduce pressure to
the appropriate brake chambers to provide better
traction whenever wheel spin occurs.

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

ATC may include a deep snow and mud option to
increase available traction on extra soft surfaces like
snow, mud, or gravel. If so equipped, a momentary
contact rocker switch labeled ATC will be located on
the dash. Pressing the switch will temporarily allow
more wheel spin. The activation of the deep snow
and mud option is indicated by a flashing WHEEL
SPIN lamp. Pressing the switch again will cycle the
system back to normal operation.

NOTICE

The deep snow and mud option is intended to be
used under specific slippery conditions that re­quire momentary increased wheel spin. Using
this option for an extended period of time may
damage the vehicle brake system.

After the ignition switch is turned on, the ABS indica­tor light and the WHEEL SPIN indicator light illumi­nate for about three seconds. After three seconds,
the warning lights go out if all of the ABS compo­nents are working.

During vehicle operation, solid illumination of the
ABS light indicates a problem with the vehicle ABS.
Repair the ABS immediately to ensure full braking
capability.

If equipped with ATC, an amber WHEEL SPIN indica­tor light illuminates if one of the drive wheels spins
during acceleration. When the light illuminates, par­tially release the throttle pedal to stop the spinning
wheel. The light goes out when the wheel stops spin­ning.

If slippery road conditions continue, turn on the differ­ential lock switch. See
structions.

Chapter 11 for axle switch in-

NOTICE

Do not turn the differential lock switch on while
the WHEEL SPIN indicator light is on. To do so
could damage the rear axle.

Automatic Slack Adjusters

NOTICE

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

Automatic slack adjusters should never be manually
adjusted except during routine maintenance of the
foundation brakes (e.g., replacing shoes), during
slack adjuster installation, or in an emergency situa­tion.

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

Visit a repair facility as soon as possible when
brakes equipped with automatic slack adjusters are
determined to be out of adjustment.

Exhaust Brake

General Information

An exhaust brake is an optional auxiliary braking sys­tem that assists, but does not replace, the service
brake system. The driver can use the exhaust brake,
in combination with the accelerator and clutch pedal
(if so equipped), to make maximum use of the ex­haust brake in off-highway and mountain driving as
well as in traffic or high-speed highway driving.

The exhaust brake is controlled by a dash-mounted
rocker switch, shown in
vehicle when the accelerator is released.

To turn the exhaust brake on, press on the upper
part of the rocker switch. When the exhaust brake

Fig. 13.3, to help slow the

13.5

Hydraulic and Air Brake Systems

switch is on, an amber light emitting diode (LED) illu­minates inside the switch. When the panel lights are
on, the EXHST BRK legend is backlit in green.

11/28/2001

Fig. 13.3, Exhaust Brake Switch

The exhaust brake is only active when engine speed
is between 1100 and 2700 rpm. Depressing the ac­celerator or clutch pedal deactivates the exhaust
brake. The ABS system, when active, also deacti­vates the exhaust brake.

The exhaust brake is a butterfly valve mounted in the
exhaust pipe. When the driver’s foot is not on the
accelerator pedal and the upper half of the exhaust
brake switch is pressed in, with the amber light on
the switch illuminated, an air cylinder shuts the but­terfly valve, which restricts the flow of exhaust gases
and retards the engine. This retarding action is car­ried through the engine and drivetrain, slowing the
vehicle and reducing the need for frequent service
brake applications.

Exhaust brakes are not intended for use as the pri­mary braking system during vehicle operation.

f610589

Starting the Engine

Before starting the engine, make sure that the lower
half of the exhaust brake switch is pressed in and
the amber light is not illuminated. Do not turn the ex­haust brake on until the engine has reached normal
operating temperatures.

Operating Characteristics

WARNING

follow this precaution could result in a loss of
vehicle control and possible personal injury or
property damage.

When you remove your feet from both the accelera­tor and clutch pedal (if so equipped), and the upper
half of the exhaust brake switch is pressed in with
the amber LED illuminated, the exhaust brake is ap­plied. The following conditions should exist if the
brake is operating properly:

•

A slight change in the sound of the engine may
be noticed when the exhaust brake is applied.

•

Exhaust smoke should appear as normal.

•

Engine temperature should remain in the nor­mal operating range.

•

Road speed usually decreases when the ex­haust brake is applied during a descent. When
the vehicle is carrying a heavy load or the
grade is extremely steep, the driver may need
to apply the service brakes occasionally.

•

Do not expect a retarding effect similar to sud­den hard application of the service brakes. The
exhaust brake retards the vehicle with a
smooth braking effect.

•

During a descent, the tachometer usually
shows a drop in rpm depending on the grade
and the vehicle load.

•

Depending on the grade and vehicle load, you
may or may not feel the retarding force acting
against your body when the brake is applied.
The retarding force of the brake may not al­ways be noticed, but it is actually preventing
the vehicle from going much faster.

Driving Downhill

While approaching a steep grade, make sure that the
upper half of the exhaust brake switch is pressed in,
with the amber LED illuminated. The exhaust brake
comes on as soon as you remove your foot from the
accelerator pedal. While going down the grade, use
a low enough gear to safely descend with a minimum
application of the service brakes. As a general guide­line, use the same gear as you would to ascend the
hill.

Do not use the exhaust brake when driving on
slippery or low-traction road surfaces. Failure to

13.6

Hydraulic and Air Brake Systems

NOTICE

Do not allow the engine to exceed its governed
speed, or serious engine damage could result.

Apply the service brakes to reduce the engine rpm or
make a slower descent by using a lower gear.

Shutting Down the Engine

Make sure the exhaust brake switch is turned off be­fore shutting down the engine.

Engine Brake

Engine Brake Switch

The engine brake switch controls the degree of en­gine braking. Normally there are two paddle
switches, a two-position On/Off Switch to activate the
engine brake, and a two-position Hi-Lo Switch to
control the amount of engine braking.

To turn the two-position On/Off Switch on, raise the
paddle. When the two-position switch is on, an
amber light-emitting diode (LED) illuminates inside
the switch.

To turn the two-position Hi-Lo Switch on high, raise
the paddle. To turn the two-position Hi-Lo Switch on
low, lower the paddle. See

Fig. 13.4.

When the panel lights are on, the Hi-Lo icon is back­lit in amber on the three-position switch. On both the
three-position switch and the two-position switch, the
ENG BRK legend is backlit in green when the panel
lights are on.

Constant-Throttle Valves

To increase braking performance, Mercedes-Benz
engines are equipped with optional constant-throttle
valves in each combustion chamber. Small valves
built into the cylinder head allow a small amount of
compressed air to escape through the exhaust port
during the combustion stroke. The constant-throttle
valves are open during the entire time that the en­gine brake is activated. Although some braking ability
is lost because the valves are constantly open,
constant-throttle braking is quieter in operation than
other types of engine brakes.

When both the exhaust brake and the constant
throttles are installed, a three-position switch on the
dash controls the amount of engine braking deliv­ered. Like the exhaust brake, the constant throttles
are deactivated when the accelerator or clutch pedal
is depressed. The ABS system, when active, also
deactivates constant-throttle braking.

The engine brake will deactivate if the engine speed
falls below a preset level. This level is program­mable, but is set at the factory at 1100 rpm.

12

10/17/2001

1. On/Off Switch 2. Hi-Lo Switch

Fig. 13.4, Engine Brake Switches

A three-position switch is used on MBE900 engines
equipped with both the regular engine brake and the
constant-throttle (decompression) brake. It works the
same as the two-position Hi-Lo switch, except that
there is a third (off) position when the switch is left at
its normal position.

13.7

f610588

14

Pre- and Post-Trip

Checklists

Pretrip and Post-Trip General Information ............................................ 14.1

Daily Pretrip Inspection and Maintenance Checklist ..................................... 14.1

Weekly Post-Trip Inspection and Maintenance Checklist ................................. 14.3

Monthly Post-Trip Inspection and Maintenance Checklist ................................ 14.3

Pre- and Post-Trip Checklists

Pretrip and Post-Trip General
Information

Regulations in both Canada and the United States
clearly indicate that it is the driver’s responsibility to
perform an inspection and ensure the complete road­worthiness of a vehicle before placing it into service
for the day. Commercial vehicles may be subject to
inspection by authorized inspectors, and an unsafe
vehicle can be put "out of service" until the driver or
owner repairs it.

IMPORTANT: The pre- and post-trip checklists,
and inspections and maintenance procedures
detailed in this chapter, are not all-inclusive.
Also refer to other component and body manu­facturers’ instructions for specific inspection and
maintenance instructions.

Use the pretrip inspection checklist to ensure that
vehicle components are in good working condition
before each trip. Use the weekly and monthly post­trip inspection checklists to note any items that re­quire attention before the next trip. A driver that is
familiar with the vehicle, and drives it regularly, can
perform the daily inspections, then add the weekly
and monthly post-trip inspections as scheduled. If the
driver does not operate the vehicle on a consistent
basis, all three of the inspection procedures should
be performed before the trip.

Pre- and post-trip inspections cannot be done
quickly. However, careful inspections save time by
eliminating stops later to adjust items overlooked or
forgotten.

Numbers in parentheses within each of the checklists
reference the corresponding detailed instructions
found under "Daily (D), Weekly (W), or Monthly (M)
Procedures" in

If any system or component does not pass this in­spection, it must be corrected before operating the
vehicle. Whenever equipment requires adjustment,
replacement, repair, addition of lubricants, or a
change of lubricants, see the S2 Chassis Workshop
Manual for procedures and specifications, or take the
vehicle to an authorized Freightliner dealer.

Chapter 15.

Daily Pretrip Inspection and
Maintenance Checklist

IMPORTANT: Before performing any of these
checks, apply the parking brake and chock the
tires.

For the daily pretrip inspection and maintenance
checklist see Table 14.1.

14.1

Pre- and Post-Trip Checklists

Procedure Performed

(check off)

_______

Check _______ windshield washer reservoir fluid D2
Inspect _______ wheel seal and hub cap (for leakage) —
Check _______ surge tank coolant level D3
Inspect _______ radiator and charge air cooler D4
Check _______ engine for fuel, oil, or coolant leaks —
Inspect _______ engine and chassis wiring D5
Inspect _______ air intake system D6
Check _______ intake-air restriction indicator mounted on air intake D6
Check _______ engine oil level D7
Check _______ power steering fluid level —
Inspect _______ fuel tank(s), fuel lines, and connections D8
Check _______ fuel level D9
Check _______ fuel/water separator D10
Inspect _______ front and rear suspension components D11
Inspect _______ headlights, mirrors, and window glass, and windshield wipers D12
Check _______ doors (open without difficulty and close securely) —

_______ Adjust driver’s seat, then align rearview and downview mirrors —
Check _______ dash-mounted intake-air restriction indicator D6
Check _______ oil- and air-pressure warning systems D13
Check _______ ICU fault codes D14
Check _______ horn, windshield wipers, and windshield washer D15
Check _______ heater, defroster, and optional mirror heat controls D16
Check _______ backup alarm —
Check _______ panel lights and interior lights D17
Check _______ exterior lights and reflectors D18
Check _______ tire pressure D19
Inspect _______ tire condition D20
Inspect _______ rims and wheels D21
Check _______ automatic transmission fluid level —
Inspect _______ air brake chambers and pushrods D22
Inspect _______ air brake lines D23
Inspect _______ slack adjusters D24
Check _______ air brake system operation D25
Check _______ Bendix® Hydro-Max Power Booster D26
Inspect _______ frame rails (missing bolts), crossmembers (bent or loose) —

Check _______

Check _______

_______ Remove chocks and test service brakes D27

Drain manually drained air reservoirs (that are not equipped with automatic drain
valves)

mud flaps (aren’t damaged, at least 10 inches above the ground, and brackets
are secure)

exhaust system (mounted securely, connected tightly, no signs of leaks such as
soot trails)

Daily Pretrip Inspections/Checks

Procedure

Reference

D1

—

—

Inspector___________________________________________________ Date ________________

Table 14.1, Daily Pretrip Inspection and Maintenance Checklist

14.2

Pre- and Post-Trip Checklists

Weekly Post-Trip Inspection

For the weekly post-trip inspection and maintenance
checklist see Table 14.2.

and Maintenance Checklist

IMPORTANT: Before performing any of these
checks, apply the parking brake and chock the
tires.

Procedure Performed

(check off)

_______ Manually drain air reservoirs that are equipped with automatic drain valves —
Inspect _______ batteries and battery cables W1
Check _______ wheel bearing lubricant level W2
Inspect _______ steering components W3
Check _______ serpentine drive belt condition W4
Check _______ drive belt tension W5
Inspect _______ seat belts and tether belts W6

Inspector___________________________________________________ Date ________________

Table 14.2, Weekly Post-Trip Inspection and Maintenance Checklist

Monthly Post-Trip Inspection

Weekly Post-Trip Inspections/Checks

For the monthly post-trip inspection and maintenance
checklist see

Table 14.3.

Procedure
Reference

and Maintenance Checklist

IMPORTANT: Before performing any of these
checks, apply the parking brake and chock the
tires.

Procedure Performed

(check off)

_______ Clean the battery terminals M1
Inspect _______ radiator hoses and heater hoses M2

Check _______

Check _______ steering wheel play M3
Check _______ outer surfaces of the hood and body (for visible surface breaks and damage) —
Check _______ hood tilt damper (attached at both ends) —
Inspect _______ brake lining wear M4
Inspect _______ driveshaft —

Inspector___________________________________________________ Date ________________

14.3

fluid level in the hydraulic clutch reservoir (if applicable, and if necessary, fill with
DOT 4 brake fluid)

Table 14.3, Monthly Post-Trip Inspection and Maintenance Checklist

Monthly Post-Trip Inspections/Checks

Procedure
Reference

—

15

Pre- and Post-Trip

Inspections and

Maintenance

Safety Precautions ............................................................... 15.1

Daily Pretrip Inspection and Maintenance Procedures ................................... 15.1

Weekly Post-Trip Inspection and Maintenance Procedures .............................. 15.11

Monthly Post-Trip Inspection and Maintenance Procedures ............................. 15.13

Pre- and Post-Trip Inspections and Maintenance

1.4

Safety Precautions

DANGER

When working on the vehicle, shut down the en­gine, set the parking brake, and chock the tires.
Before working under the vehicle, always place
jack stands under the frame rails to ensure the
vehicle can not drop. Failure to follow these
steps could result in serious personal injury or
death.

Daily Pretrip Inspection and
Maintenance Procedures

Whenever equipment requires adjustment, replace­ment, and/or repair, see the S2 Chassis Workshop
Manual for procedures and specifications. Specific
references to the manual will be found where appro­priate.

1.

Drain the brake system air reservoirs (reservoirs
without automatic drain valves only).

Water and oil normally enter the air reservoir in
the form of vapor because of the heat generated
during compression. After the water and oil con­dense, drain the resulting emulsion as follows:

1.1

Open the wet tank valve. The drain cock
or pull chain drain is located on the for­ward end of the supply air reservoir, which
is connected directly to the air compres­sor. Block the valve open.

2.

Washer fluids may be flammable and poisonous.
Do not expose washer fluid to an open flame or
any burning material, such as a cigarette. Always
comply with the washer fluid manufacturer’s rec­ommended safety precautions.

3.

If the drained water is cloudy or oily, it
may indicate a problem with the compres­sor. If oil is allowed to contaminate the air
dryer, it will not remove the water from the
air brake system, which could adversely
affect braking.

Check the fluid level in the windshield washer
reservoir.

Add washer fluid as needed. Unscrew the cap to
add fluid.

WARNING

Check the coolant level in the surge tank.

Fig. 15.1. If the coolant is low, add a 50/50

See
mixture of water and the type of antifreeze cur­rently installed in the vehicle. For a list of ap­proved coolants for both diesel and liquid pro­pane gas (LPG) engines, see
surge tank with coolant to the MAX line when the
tank is cool. If the surge tank was empty, start
the engine after refilling and check the level
again when the engine is at operating
temperature.

Table 15.1. Fill the

WARNING

When draining the air reservoir, do not look into
the air jets or direct them toward anyone. Dirt or
sludge particles may be in the airstream and
could cause injury.

1.2

Exhaust the remaining air and moisture
from the system by opening the drain
cocks on the bottoms of the remaining air
reservoirs. Block the valves open.

1.3

Water and oil emulsion often form pockets
that will not drain while compressed air is
in the reservoirs. Because of these pock­ets, leave the valves blocked open during
the first part of the pretrip inspection.

15.1

11/02/2001

Add coolant here (arrow).

Fig. 15.1, Coolant Level Checking

f820382

Pre- and Post-Trip Inspections and Maintenance

Approved Coolants

Engine Type Coolant Manufacturer

Old World Industries Fleet Charge®

Shell

Diesel

Propane Chevron

*

Freightliner-approved antifreeze must meet one of the following condi­tions: A. Ethylene glycol solution that meets GM 6038–M Engineering
Standards. B. Ethylene glycol solution that has less than 0.1% anhydrous
sodium metasilicate and meets either GM 1825–M or GM 1899–M Engi­neering Standards.

†

Chevron Delo coolant is approved for use in LPG engines only.

Texaco JC04 Antifreeze
Van Waters and

Rogers Ltd. (Canada)

Table 15.1, Approved Coolants

Coolant

Designation

Shell HD/N
Antifreeze

Diesel Antifreeze
No. 6038

Chevron Delo
Antifreeze No.

†

275110

*

NOTICE

Coolant must be filled to the full line of the surge
tank. Low coolant could result in engine over­heating, which could cause engine damage.

4.

Inspect the radiator and charge air cooler.

4.1

Inspect the radiator and charge air cooler
for clogged fins. Use compressed air or
water directed from the fan side of the
core to backflush any material restricting
airflow.

4.2

Inspect the radiator and charge air cooler
for damage and accumulated debris.
Straighten bent or damaged fins to permit
airflow across all areas of the cores.

NOTE: When traveling through areas of high
insect concentration, it may be necessary to
clean the exterior of the radiator or the
charge air cooler core as often as every 200
miles (320 km).

4.3

Also inspect and clean the condenser. If
clogged, the condenser can restrict airflow
through the radiator.

4.4

Check the radiator for leaks. If leaks are
found, have the radiator repaired or re­placed. See Group 20 of the S2 Chassis

Workshop Manual for instructions, or take
the vehicle to an authorized Freightliner
dealer.

5.

Inspect the engine and chassis wiring.

Check for loose wiring, chafed insulation, and
damaged or loose hold-down clamps. Tighten
loose wires or hold-down clamps; replace dam­aged wiring or clamps.

6.

Inspect the air intake system for leaks or dam­age.

NOTICE

Failure to maintain a sealed air intake system
could allow entry of dirt and contaminants into
the engine. This could adversely affect engine
performance and result in engine damage.

6.1

Check the intake-air restriction indicator.

6.2

Replace the primary filter element in the
air cleaner if the yellow signal stays
locked at 20 inH
engines and 25 inH
engines. See Group 09 of the S2 Chassis
Workshop Manual for filter element re­placement instructions, or take the vehicle
to an authorized Freightliner dealer. See

Fig. 15.2.

NOTE: After replacing the filter element,
reset the restriction indicator by pressing the
rubber reset button.

6.3

Inspect the secondary or safety filter ele­ment in the air cleaner when replacing the
primary element, and replace it when
clogged or dirty. This element should be
replaced with every third primary element
replacement.

6.4

Check the engine air intake piping from
the air cleaner to the engine intake. In­spect the piping for loose connections,
cracks, torn or collapsed hoses, punc­tures, and other damage. Tighten loose
connections, and have damaged compo­nents replaced. Make sure the piping sys­tem is airtight so that all intake air passes
through the air cleaner.

O for Mercedes-Benz

2

O for Cummins ISB

2

15.2

Pre- and Post-Trip Inspections and Maintenance

7.1

Park the vehicle on a level surface. Allow
several minutes for the oil to drain back
into the oil pan to ensure an accurate
reading.

NOTE: For diesel engines, follow the engine

1

2

09/12/2001

1. Primary Filter Element

2. Secondary or Safety Filter Element

Fig. 15.2, Air Cleaner Filter Elements

f090363

NOTICE

Operating the engine with the oil level below the
minimum fill (or "add") mark or above the maxi­mum fill (or "full") mark could result in engine
damage.

manufacturer’s guidelines for engine shut­down time requirements prior to checking
the oil level.

7.2

Pull out the dipstick and clean it with a
paper towel or cloth, then push the dip­stick back in all the way. Remove it again,
keeping the tip down, and check the oil
level.

7.3

If the oil is below the cross-hatched area,
or the add mark, at the tip of the dipstick,
add at least one quart (liter) of the recom­mended oil. See
for diesel engines, and Fig. 15.5 for pro­pane engines.

For diesel engines that comply with
EPA07 or newer regulations, use CJ-4
engine oil with less than 1% sulfated ash.

For liquid propane gas (LPG) engines, use
SAE 5W–30 oil that meets GM standard
GM6094M and has the American Petro­leum Institute (API) symbol. Do not use
SAE 10W–40 or 20W–50.

FULL ADD 2 QT

Fig. 15.3 and Fig. 15.4

IMPORTANT: On engines that comply with
EPA07 or newer regulations, use CJ-4 engine
oil with less than 1% sulfated ash. Failure to
use CJ-4 oil may void the warranty on emission
aftertreatment components.

7.

Check the engine oil level.

NOTICE

Operating the engine with the oil level below the
minimum fill (or "add") mark or above the maxi­mum fill (or "full") mark could result in engine
damage.

15.3

10/26/2012 f012203

Fig. 15.3, Oil Dipstick (Cummins engine)

1

01/13/99

1. Maximum Fill Level 2. Minimum Fill Level

Fig. 15.4, Oil Dipstick (Mercedes-Benz engine)

2

f011525