Freightliner WALK-IN VAN Operator's Manual

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WALK-IN VAN CHASSIS

STI-471-6

A24-01451-000

Operator’s Manual

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 chassis. If parts on your chassis differ from those shown, they may have been installed by the body builder.

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

Whenever you see instructions in this manual to discard materials, you should ﬁrst attempt to reclaim and recycle them. To preserve our environment, follow appropriate environmental rules and regulations when disposing of materials.

Event Data Recorder

This vehicle is equipped with one or more devices that record speciﬁc vehicle data. The type and amount of data recorded varies depending on how the vehicle is equipped (such as the brand of engine, if an air bag is installed, or if the vehicle features a collision avoidance system, etc.).

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

•

how various systems in the vehicle were operating

•

engine system information

•

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

•

if the driver was depressing the brake pedal

•

how fast the vehicle was traveling

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

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

Emissions and Fuel Efficiency Compliance

This vehicle must be regularly inspected and maintained as indicated in the Walk-In Van Chassis Main-

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

order to continue satisfactory performance and ensure coverage of the vehicle under the manufacturer’s warranty. Many maintenance procedures ensure that the vehicle and engine continue to comply with applicable emissions standards. Maintenance procedures, using components engineered to comply with greenhouse gas emissions and fuel efficiency regulations, may be performed by an authorized Daimler

Foreword

STI-471-6 (11/15)

A24-01451-000

Printed in U.S.A.

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-FTLHELP. Call night or day, weekdays or weekends, for dealer referral, vehicle information, breakdown coordination, or Fleetpack assistance. Our people are knowledgeable, professional, and committed to following through to help you keep your vehicle moving. Please visit

www.Daimler-

TrucksNorthAmerica.com

Reporting Safety Defects

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

www.safercar.gov;or

write to: Administrator, NHTSA, 1200 New Jersey Avenue, SE, Washington, DC 20590. You can also

obtain other information about motor vehicle safety from

www.safercar.gov.

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

For additional road safety information, please visit the Road Safety website at:

www.tc.gc.ca/

roadsafety

company.

No part of this publication, in whole or part, may be translated, reproduced, stored in a retrieval system, or transmitted in any form by any means, electronic, mechanical, photocopying, recording, or otherwise, without the prior written permission of Daimler Trucks North America LLC. For additional information, please contact Daimler Trucks North America LLC, Service Systems and Documentation, P.O. Box 3849, Portland OR 97208-3849 U.S.A. or refer to

www.Daimler-TrucksNorthAmerica.comand www.FreightlinerTrucks.com.

Foreword

Contents

Chapter Page

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

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

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

2 Instruments ............................................................. 2.1

3 Controls ................................................................ 3.1

4 Engines ................................................................ 4.1

5 Transmissions ........................................................... 5.1

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

7 Hydraulic and Air Brake Systems ........................................... 7.1

8 Compressed Natural Gas Fuel System ....................................... 8.1

9 Hybrid Electric Vehicle .................................................... 9.1

10 Pre- and Post-Trip Checklists ............................................. 10.1

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

12 Cleaning and Care ...................................................... 12.1

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

14 Towing ................................................................ 14.1

15 GM Gasoline Engine .................................................... 15.1

16 Hydraulic Hybrid ........................................................ 16.1

17 Propane Fuel System .................................................... 17.1

18 Speciﬁcations .......................................................... 18.1

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

Vehicle Identiﬁcation

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

Vehicle Identiﬁcation Number (VIN) .................................................. 1.1

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

Component Information Label

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

The component information label lists the 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.

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

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

Incomplete vehicles 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 (VIN)

The chassis vehicle identiﬁcation number is permanently attached to the chassis in the engine compartment (depending on vehicle options, usually on the metal panel where the steering driveline enters the engine compartment). See

Fig. 1.2. The last six dig-

its are the chassis serial number. The chassis number is stamped on the left frame rail, over the front axle. A VIN label is also mounted by the body builder. Mounting locations vary, to include the glove box. See

Fig. 1.3.

NOTE: Always include the chassis serial number (last six digits of the VIN) when communicating with 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

09/11/2002 f080123

Fig. 1.1, Component Information Label

GAFFNEY, SOUTH CAROLINA, USA

4UZA4FVC0TC748531

f080061a

04/18/2005

Fig. 1.2, Vehicle Identiﬁcation Number (VIN) Label

Vehicle Identiﬁcation

1.1

have aftertreatment equipment, depending upon local statutory emissions guidelines. See Table 1.1.

A reference label included with the driver’s documentation package contains important warning indicators in the instrument cluster that pertain to the ATS. See

Fig. 1.4.

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

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

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

January 1, 2010–December 31, 2012

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

From March 5, 2012–December 31, 2015

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.

12/04/2001

f080122

Fig. 1.3, Vehicle Identiﬁcation Number Label, Typical

Vehicle Identiﬁcation

1.2

Applicable Emissions System Based on Build Date and EPA Regulations

Build Date Regulation: Emissions Components

From January 1, 2016

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.

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

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.

Certiﬁed Clean Idle Label

The California Air Resources Board (CARB) requires model year 2008 and newer heavy-duty diesel engines to be equipped with a non-programmable engine shutdown system that automatically shuts down the engine after ﬁve minutes of idling in order to limit emissions of particulate matter and NOx.

Certiﬁed vehicles are equipped with a label placed near the bottom edge of the driver-side door. See

Fig. 1.6.

f080156

EXHAUST AFTERTREATMENT SYSTEM INFORMATION

Switch.

Level 1 Level 3Level 2 Level 4

Filter Regeneration Recommended.

Filter is reaching

Bring vehicle to highway speeds to

Filter Regeneration

Filter is now reaching maximum capacity

To avoid engine derate, bring vehicle

Parked Regeneration Required − Engine Derate

Filter has reached maximum capacity

Vehicle must be parked, and a Parked

Service Regeneration Required. Engine Derate To Idle Only.

Filter has exceeded maximum capacity.

Vehicle must be parked, and a Service Regeneration must be

(Solid)

(Flashing) (Flashing)

CHECK

INDICATOR LAMP(S)

Indicator Lamp Message(s)

Diesel Particulate Filter Condition

Required Action

capacity

STOP

allow for an Automatic Regeneration or perform a Parked

to highway speeds to allow for an Automatic Regeneration, or perform a Parked Regeneration as soon as possible.

Regeneration must be performed. Engine will begin derate.

performed. Check engine operator’s manual for details. Engine will shut down.

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

02/20/2009

ARNING

HEST (High Exhaust System Temperature)

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

A regeneration is in progress.

Flashing

Solid

Regeneration.

Necessary

Fig. 1.4, ATS Indicators

03/02/2012 f080183

Fig. 1.5, Vehicle Emission Control Information Label

Vehicle Identiﬁcation

1.3

CERTIFIED

CLEAN IDLE

02/20/2012 f080179

Fig. 1.6, CARB Clean Idle Label

Vehicle Identiﬁcation

1.4

Instruments

Ametek Instrument Panel ........................................................... 2.1

Warning and Indicator Lights ........................................................ 2.9

Speedometer and Tachometer ...................................................... 2.16

Standard Instruments ............................................................. 2.17

Optional Instruments ............................................................. 2.19

Ametek Instrument Panel

The following information describes a typical instrument panel manufactured by Ametek.

Figure 2.1 and

Fig. 2.2 show instrument panels for vehicles that are

compliant with EPA10 and newer regulations, for both diesel and hybrid-electric vehicles (HEV).

Fig-

ure 2.3 and Fig. 2.4 show instrument panels for ve-

hicles that are EPA07-compliant for both diesel and HEV vehicles.

NOTE: These instrument panels are shown with a standard U.S. speedometer, which shows miles per hour (mph) more prominently than kilometers per hour (km/h).

Message Display Center

The message display is a graphical, backlit, liquid crystal display (LCD) that relays information to the vehicle operator. The messages displayed include:

•

Odometer

•

Trip Odometer 1/Trip Odometer 2

•

Chassis Battery Voltage

•

Instantaneous Fuel Rate

•

Average Fuel Rate

•

Gear Attained Status

•

Transmission Temperature

•

Hour Meter

•

Boost Pressure

•

Engine Oil Pressure

•

Coolant Temperature

•

Fuel Level

•

Percent Engine Load

•

Engine RPM

During normal operation, the LCD displays the odometer value and chassis battery voltage on the top line, and driver selected parameters, such as the trip odometer and fuel rate, on the second and third lines.

Priority Messages

Priority messages (including warning messages) are displayed in the LCD due to various inputs or data

messages. Unless noted otherwise, the priority message will take over the whole screen, allowing multiple messages to be displayed in ﬁve second intervals.

Self-Test

When the ignition is turned on, a required self-test automatically begins. Gauge needles will reset to zero during the self-test, and then immediately move to the position dictated by the data received. During this time, the warning lights, alarm (buzzer), and driver display screen will also perform a self-test.

NOTE: The driver can activate or deactivate the start-up self-test by accessing the setup menu.

Menu System

The menu system is shown on the driver display screen once the self-test is ﬁnished. The menu system responds to input from the driver and remains active as long as the ignition is on. In order for the driver to operate the menu system, the ignition must be ON, and the park brake must be set (ON). The main features of the menu system are described below.

•

Setup—this is used to set various parameters, which are saved when the ignition is turned off. Setup has select display units, startup screen, LCD contrast, and reset parameters.

•

Maintenance—shows various maintenance intervals such as engine oil, air ﬁlter, etc.

•

Diagnostics—this is used for setting and reading inputs and outputs and checking the gauges. It also shows the hardware and software version of the instrument panel, and has menus to retrieve active error codes from the engine, transmission, and ABS controllers.

NOTE: No lines can be highlighted in the menu system screen. To get to the sections that can be highlighted, press the right arrow toggle button and hold it for two seconds. The display screen will change and the options shown can then be highlighted. Once a selection has been chosen and changes are made, press the right arrow toggle button to go back to the main message display screen.

Instruments

2.1

Setup Menu

Select Display Units

The set units screen allows the driver to choose between English or metric units of measurement for the displayed values. To navigate to the set units screen, see

Fig. 2.5, screens H, I, and J.

Startup Screen

The startup screen selection allows the driver to turn the startup screen on or off.

LCD Contrast

Select contrast from the menu to set the LCD contrast. Use the down toggle button to set the contrast to the desired level. To navigate to the contrast screen, see

Fig. 2.5, screen M.

Reset Parameters

The reset parameters screen is included with vehicles that have the Allison transmission prognostics feature.

10/13/2009 f611051

1. Fuel Gauge

2. Speedometer

3. Coolant Temperature Gauge

4. Toggle Button, Right

5. Toggle Button, Down

6. Message Display Center

7. Diesel Exhaust Fluid (DEF) Gauge

8. Engine Oil Pressure Gauge

Fig. 2.1, Typical Ametek Instrument Panel (diesel), EPA10 and Newer Engines

Instruments

2.2

Maintenance Menu

The maintenance menu has the following three sub menus:

•

maintenance intervals

•

transmission oil life remaining

•

transmission oil ﬁlter life monitor

Maintenance Intervals

The maintenance intervals menu allows the driver to set the change intervals for engine oil and engine air

ﬁlter. If the intervals are set to zero, the maintenance warnings must be disabled.

Transmission Oil Life Remaining

If transmission prognostics are enabled, this menu indicates how much useful oil life remains.

Transmission Oil Filter Life Monitor

If transmission prognostics are enabled, the transmission oil ﬁlter life monitor tells the driver if the transmission oil ﬁlter is clogged and in need of repair. A message will appear on the display screen as

10/13/2009 f611053

1. HEV Performance Gauge

2. Speedometer

3. HEV Battery Gauge

4. Toggle Button, Right

5. Toggle Button, Down

6. Coolant Temperature Gauge

7. Message Display Center

8. Engine Oil Pressure Gauge

9. Diesel Exhaust Fluid (DEF) Gauge

10. Fuel Gauge

Fig. 2.2, Typical Ametek Instrument Panel (HEV), EPA10 and Newer Engines

Instruments

2.3

TRANS OIL FILTER FUNCTIONAL or TRANS OIL FILTER CLOGGED.

Diagnostic Menu

The diagnostic menu contains the following items:

•

engine faults

•

transmission faults

•

ABS faults

•

check outputs

•

odometer diagnostics

•

check gauges

•

check indicators (warning lamps)

•

check LCD

•

check binary inputs

•

check analog inputs

•

check datalink

•

hardware/software version

All of the items in the diagnostic menu can be accessed by using the toggle buttons and selecting the auxiliary screens. Then navigate to the diagnostic

09/23/2009 f611049

1. Fuel Gauge

2. Speedometer

3. Coolant Temperature Gauge

4. Toggle Button, Right

5. Toggle Button, Down

6. Message Display Center

7. Engine Oil Pressure Gauge

Fig. 2.3, Typical Ametek Instrument Panel (diesel), EPA07-Compliant

Instruments

2.4

sub-menu. Some of the more frequently used diagnostic menus are described further below.

Engine Faults

This screen displays engine fault codes that are received from the engine electronic control unit (ECU). To navigate to the engine fault screen, see

Fig. 2.6,

screen AA.

Transmission Faults

This screen displays transmission fault codes that are received from the transmission ECU. To navigate

to the transmission fault screen, see

Fig. 2.6, screen

AB.

ABS Diagnostics

This screen displays Antilock Brake System (ABS) fault codes that are received from the ABS ECU. To navigate to the ABS diagnostic screen, see

Fig. 2.6,

screen AC.

Check Gauges

The check gauges screen allows the driver to set each gauge as a percentage of scale (either 0, 50, or

09/23/2009 f611050

1. HEV Performance Gauge

2. Speedometer

3. HEV Battery Gauge

4. Toggle Button, Right

5. Toggle Button, Down

6. Coolant Temperature Gauge

7. Message Display Center

8. Engine Oil Pressure Gauge

9. Fuel Gauge

Fig. 2.4, Typical Ametek Instrument Panel (HEV), EPA07-Compliant

Instruments

2.5

100%), as shown in the LCD. To navigate to the check gauges screen, see

Fig. 2.7, AG screens.

SETUP

Down Hold

Or (Right & Exit

highlighted)

Down Press

Current Units

Metric

Down Press

Current Units

English

Current Units

English

Current Units

Metric

Down Press

Startup Screen

Disabled

Down Press

Startup Screen

Enabled

Startup Screen

Enabled

Startup Screen

Disabled

Down Press

Not At Min Contrast /

Decrease Contrast

Down Press

At Min Contrast /

Set Contrast to Max

Right Press

Startup Screen

highlighted

Right Press

Select Display

Units highlighted

Right Press

Display Contrast

highlighted

Right Press

Down Hold

Right Press

Down Hold

Right Press

Down Hold

Right Press

Down Hold

Right Press

Down Hold

Down Press

Highlight next

line of list. At middle,

wrap to top

Right Hold

Reset Parameters

Right Press

Reset Parameters

highlighted

Right Press

Down Hold

Right Press

Down Hold

AUXILIARY

SCREENS

09/23/2009 f040792

Fig. 2.5, Setup Menu Screens

Instruments

2.6

Warning Lamp

The warning lamp screen allows the driver to test each warning lamp (not the vehicle load) on and then off, displaying the lamp name and status in the LCD. To navigate to the warning lamp screen, see

Fig. 2.7, screen AH.

Check LCD

Selecting the check LCD screen displays the Freightliner Custom Chassis Corporation (FCCC) logo in normal and reverse video three times and then returns to the menu. To navigate to the check LCD screen, see

Fig. 2.7, screen AI.

Diagnostics

Note 5: Screen Z scrolls to display the following items: ENGINE FAULTS TRANSMIS

SION FAULTS ABS FAULTS CHECK OUTPUTS CHECK DATA INPUTS ODOMETER DIAGNOSTICS CHECK GAUGES CHECK WARNING LAMPS CHECK LCD CHECK BINARY INPUTS CHECK ANALOG INPUTS CHECK DATA LINK VERSION INFORMATION EXIT The text DIAGNOSTIC MENU remains fixed on the first line.

Down Press

Display Next Fault

Down Press

Display Next Fault

Down Press

Display Next Fault

Right Press

Down Hold

Down Press

Change to

Next Output

Right Press

Down Hold

Right Hold

Toggle Output State Between

Off and On

Right Press

Engine Faults

Highlighted

Right Press

Trans Faults

Highlighted

Right Press

ABS Faults Highlighted

Right Press

Check Outputs

Highlighted

(Right & Exit

highlighted)

Right Press

Down Hold

Right Press

Down Hold

Screens AA,AB,AC Format For J1587

Screen AE For J1587

Down Press

Highlight next

line of list. At bottom,

wrap to top

Right || Hold Down

Right Press

Odometer Diag

Highlighted

09/23/2009 f040795

Fig. 2.6, Diagnostic Menu Screens, Screen 1

Instruments

2.7

Check Binary Inputs

The check binary inputs screen displays the pin number and status of each binary input. The toggle buttons allow the driver to select each binary input. This information is continuously updated to assist in troubleshooting. To navigate to the check binary inputs screen, see

Fig. 2.7, screen AJ.

Check Analog Inputs

The check analog inputs screen displays the pin number and actual value of each analog input deﬁned in the system. The toggle buttons allow the

driver to select each analog input. This information is continuously updated to assist in troubleshooting. To navigate to the check analog input screen, see

Fig. 2.8, screen AK.

Check Datalink

The check datalink screen allows the driver to view

all devices that communicate on the J1939, J1587, and GMLAN datalinks. To navigate to the check datalink screen, see

Fig. 2.8, screen AL.

Down Press

Change to

Next Gauge

Right Hold

Step Gauge to

Next Position

Right || Hold Down

Down Press

Change to

Next Telltale

Right Hold

Toggle State

Between

Off and On

Right || Hold Down

Every 1.5 Seconds /

Invert Video of

Displayed Image

Right ||

9 Seconds Elapsed

|| Hold Down

Down Press

Change to Next Input

Right || Hold Down

Right Press

Check Gauges

Highlighted

Right Press

Warning Lamps

Highlighted

Right Press

Check LCD Highlighted

Right Press

Check Binary Inputs

Highlighted

Other Text for Screen AG

09/23/2009 f040796

Fig. 2.7, Diagnostic Menu Screens, Screen 2

Instruments

2.8

Menu Navigation

The menu navigation road maps are provided to illustrate the screens that are available in the menu system. The paths to speciﬁc screens are shown, along with instructions for using the toggle buttons to move from one screen to another. Refer to the road maps to change items shown in lines one, two, and three of the display screen, view the setup screens, diagnostics, etc. See

Fig. 2.5, Fig. 2.6, Fig. 2.7, Fig. 2.8, Fig. 2.9, Fig. 2.10, Fig. 2.11, Fig. 2.12, Fig. 2.13, Fig. 2.14, Fig. 2.15, Fig. 2.16, and Fig. 2.17.

IMPORTANT: Follow the steps below to change the three items (also known as favorites) shown in the message display center. The message display center is referred to as screen C in

Fig. 2.11.

With the vehicle in park, turn the ignition to ON, and allow the self test to complete.

Press the down toggle button to select an item to change. The selected item will now be highlighted.

Press the right toggle button once to enter the favorites display menu, shown in

Fig. 2.11,as

screen D.

Use the down toggle button to scroll through the available items.

Highlight the new item, then press the right toggle button. The selected item will now appear in the message display center.

Warning and Indicator Lights

General Information

The warning and indicator lights are located in the instrument panel and contain all of the standard and optional warning and indicator lights. See Fig. 2.18 and Fig. 2.19 for diesel and HEV compliant warning and indicator lights respectively.

02/06/2012 f040797

AUXILIARY

SCREENS

SOFTWARE VER: x.yy CONFIG: ccccccc HARDWARE VER: z

Right || Hold Down

Right Press

Version Information

Highlighted

Screen AM

Input Name

Pin pp of 26

xx.x Units

Down Press

Change to Next Input

Right || Hold Down

ECUs on Data Bus

J1939 SA xx J1939 SA yy

Down Press

Scroll Screen Down 1 Line

Right || Hold Down

Right Press

Check Analog Inputs

Highlighted

Right Press

Check Data Link

Highlighted

Screen AK

Screen AL

Fig. 2.8, Diagnostic Menu Screens, Screen 3

Instruments

2.9

Maintenance Warning Light

When the amber maintenance warning light illuminates, the message display center will alert the driver as follows:

•

Oil Change Required—alerts the driver that the engine has reached the recommended oil change interval.

SELF TEST

DISPLAY

MESSAGES

WARNING

MESSAGES

Active Warning

Messages

No Warnings Active or

All Warnings

Acknowledged

Right Hold

Park Brake On

IGNITION ON

IGNITION

OFF

Ignition

Off

Ignition On or

Headlamps On or

Marker Lamps On or

Park Brake Off

Ignition

Ignition Off &

Headlamps Off &

Marker Lamps Off &

Park Brake On

Self Test

Enabled

AUXILIARY

SCREENS

ACTIVE

Ignition Off &

( Headlamps On or

Marker Lamps On or

Park Brake Off )

Ignition On

USB Drive Present &

Park Brake On &

Vehicle Speed = 0 &

Not in Self Test

NORMAL MODE

DOWNLOAD

MODE

09/23/2009 f040788

Fig. 2.9, Ignition On, Normal Mode

Instruments

2.10

•

Air Filter Reminder—the air ﬁlter requires checking or replacement.

•

Transmission Prognostics Warning—if the transmission has prognostics enabled.

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 on.

High Exhaust System Temperature (HEST) Lamp

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.

The amber HEST lamp will illuminate as follows:

•

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

•

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

SELF TEST

DISPLAY

MESSAGES

XXXXXXXXXXXXXXXXXXXXXX XXXXXXXXXXXXXXXXXXXXXX XXXXXXXXXXXXXXXXXXXXXX

Screen Displayed

for 1.5 Seconds

Screen Displayed

for 1.5 Seconds

Startup Screen Enabled

The Self Test screens display the FCCC

logo in normal video (Screen A) and in

reverse video (Screen B)

Startup Screen Disabled

Screen A

Screen B

02/06/2012 f040789

Fig. 2.10, Self Test

Instruments

2.11

Check Engine Indicator

The amber check engine (CHECK) indicator light illuminates when the engine control unit senses a malfunction in the electronic engine control system.

Stop Engine Warning

The red stop engine (STOP) warning light illuminates if a malfunction that could cause engine damage occurs. In most cases, the CHECK engine warning will illuminate before the stop engine warning. When the stop engine warning light illuminates, immediately park the vehicle in a safe location and shut down the engine. Continued operation with the stop engine warning illuminated will lead to automatic engine shutdown and possible engine damage.

Malfunction Indicator Lamp

The amber Malfunction Indicator Lamp (MIL) indicates an engine emissions-related fault. See the engine operators manual for details.

Engine Brake Light

A green engine brake light illuminates when the engine brake is applied.

Wait to Start Warning Light

The amber wait to start indicator light illuminates with the ignition switch in the ON position prior to engine start-up. Do not crank the engine until the wait to start indicator light goes out.

DISPLAY MESSAGES

Selected Line 1 Data Selected Line 2 Data Selected Line 3 Data

Favorites Display Menu Average Fuel Economy Gear Attained Status

Right Press

Highlight First Item in List

Down Press

Move to, and Highlight,

Next Item in List

Right Press

Put Data For Highlighted Item

In Display Line

CurrentLine

Down Hold

Make No Changes

Down Press

Highlight

CurrentLine

HighlightTimer

= 5 sec.

WARNING

MESSAGES

AUXILIARY

SCREENS

New Warning

Message Active

Right Hold

Park Brake On

HighlightTimer

= 0

Right Hold

Reset Highlighted Item

(if resettable)

Screen C

Screen D

11/23/2011 f040790

Fig. 2.11, Display Messages

Instruments

2.12

ABS Indicator

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

Shift Inhibit Indicator

On vehicles equipped with Allison 2100/2200/2500 series transmissions, the amber shift inhibit indicator light illuminates whenever all conditions for safe transmission shifting have not been met.

Check Transmission Indicator

The amber check transmission indicator 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.

AUXILIARY SCREENS

SETUP MAINTENANCE DIAGNOSTICS

Down Press

Highlight next

line of list. At middle,

wrap to top

MAINTENANCE

DIAGNOSTICS

Right Press

Setup

highlighted

Right Press

Diagnostics

highlighted

Right Press

Maintenance

highlighted

SETUP

SETUP.

DISPLAY

MESSAGES

Down Hold

TRIP DATA

Right Press

Trip Data

highlighted

Screen G

02/06/2012 f040791

Fig. 2.12, Auxiliary Screens

Instruments

2.13

Stop Transmission (hybrid only)

The red warning light illuminates when the transmission control unit senses a malfunction.

Diesel Particulate Filter (DPF) Lamp

A solid amber illuminated DPF lamp 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.

A blinking DPF lamp indicates that a stationary regeneration is required immediately. An engine derate and shutdown will occur. See the instructions in the

MAINTENANCE

(Right & Exit

highlighted)

Right Press

Engine Oil

Highlighted

Right Press

Engine Air Filter

Highlighted

Down Press

Highlight next

line of list. At middle,

wrap to top

Maint

Down Press

Display Next

Value of

Air

Change Distance

Air Change Baseline

Air

Change Distance

Odometer

Air Change

Distance

= 0

else

Right Press

Air Change Distance

Current Displayed

Value

Right Hold

Air Change

Baseline

Odometer

Right Hold

Air Change

Baseline

Odometer

Right Press

Down Hold

Right Press

Down Hold

Down Press

Display Next

Value of

Oil

Change Distance

Oil Change Baseline

Oil Change Distance

Odometer

else

Right Press

Oil Change Distance

Current Displayed

Value

Right Hold

Oil Change

Baseline

Odometer

Right Hold

Oil Change

Baseline

Odometer

Right Press

Down Hold

Right Press

Down Hold

Oil Change

Distance

= 0

09/23/2009 f040793

Fig. 2.13, Maintenance Menu Screens, Screen 1

Instruments

2.14

engine manufacturer’s operator’s manual to perform a stationary regeneration.

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 on.

Fasten Seat Belt Warning

The red fasten seat belt warning light (seat belt icon) illuminates for 30 seconds after the ignition switch is turned on.

WARNING

If the vehicle is equipped with an air suspension system, do not move the vehicle with the air suspension deﬂated. Doing so could result in a loss of vehicle control, possibly causing personal injury and property damage.

Air Brake Indicator

The red air brake indicator activates if the pneumatic brake system air is low, or if the air suspension is low.

Hydraulic Brake System Warning

The red brake system warning illuminates if there is a hydraulic brake system failure, or if the vehicle is powered and the engine is not running.

Headlight High-Beam Indicator

The blue high-beam indicator light illuminates when the headlights are switched to the high-beam position.

Parking Brake On Indicator

The red parking brake indicator will ﬂash for two minutes if the parking brake is not set when the ignition is turned off. It will also ﬂash if the park brake is set

02/06/2012 f040794

AUXILIARY

SCREENS

Right Hold

Send SPN 1584 = 39

Right Press

Transmission

Oil Life

Highlighted

Right Press

Transmission

Oil Filter

Highlighted

Right Press

Down Hold

Right Press

Down Hold

Right Press

Down Hold

Maint

Right Hold

Send SPN 1584 = 37

Right Press

Down Hold

Fig. 2.14, Maintenance Menu Screens, Screen 2

Instruments

2.15

and 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 and the driver display screen will show a PARK BRAKE SET message.

Cruise Control Indicator

A green indicator illuminates when the cruise control is activated.

Auxiliary Power Generator (hybrid only)

A green indicator illuminates when the auxiliary power generator is activated.

Speedometer and Tachometer

Standard speedometers are shown in Fig. 2.1,

Fig. 2.2, Fig. 2.3, and Fig. 2.4, item 2 respectively.

Optional speedometer faces are available. The NAFTA version (not shown) of the speedometer face

Trip Data

AUXILIARY

SCREENS

Note 6: Screen AO scrolls to display the following items:

Trip Time Idle Time Max RPM Avg RPM Max Speed Avg Speed Avg Fuel Economy Reset All Exit

Right Press

Reset All

Highlighted

Correct Passcode /

Reset Trip

Data

Right Press

Down Press

Highlight next

line of list. At bottom,

wrap to top

(Right & Exit

highlighted)

Wrong Passcode /

Down Press

Right Press

09/23/2009 f040798

Fig. 2.15, Trip Data

Instruments

2.16

reverses this arrangement, with km/h in larger numbers.

A tachometer is available as an option. See "Optional Instruments."

Standard Instruments

Fuel Level Gauge

The fuel level gauge indicates the amount of fuel in the fuel tank.

Low Fuel Warning Light

The low fuel warning light illuminates when the fuel level in the fuel tank drops to a predetermined level. When the low fuel warning light illuminates, reﬁll the fuel tank as soon as possible.

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. If the engine oil pressure falls below preset levels, the check engine light will illuminate. If the condition does not improve, the CHECK 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.

02/06/2012 f040799

WARNING MESSAGES

DISPLAY

MESSAGES

WARNING Warning Message

No Warning

Messages in List /

Msg Displayed for 5 Sec. /

Display Next Entry in

Warning Message List

Any Button Press

Display 1st Message

in Warning

Message List

Screen AN

Fig. 2.16, Warning Messages

Instruments

2.17

Low Oil Pressure Warning

The low oil pressure (oil can symbol) warning light illuminates and a buzzer sounds when the oil pressure falls below the minimum oil pressure recommended by the engine manufacturer.

High Coolant Temperature Warning

A red high coolant temperature (thermometer symbol) warning light illuminates when the engine is running and the engine coolant temperature exceeds the maximum coolant temperature recommended by the engine manufacturer.

Coolant Temperature Gauge

NOTICE

A sudden increase in coolant temperature may indicate engine or cooling system 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 coolant temperature gauge is mission-critical. If the coolant temperature rises above preset levels, the check engine light will illuminate. If the condition does not improve, the CHECK 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.

Primary and Secondary Air Pressure Gauges

WARNING

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

IGNITION OFF

Park Brake On

Park Brake Off

IGNITION

Headlamps Off &

Marker Lamps Off &

Park Brake On

Ignition On

02/06/2012 f040800

Fig. 2.17, Ignition Off (shown when ignition is keyed OFF)

Instruments

2.18

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 (689 to 827 kPa) in both systems.

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.

Optional Instruments

Air Intake Restriction Gauge

An intake-air restriction indicator, mounted in the engine compartment, measures the vacuum on the engine side of the air cleaner at the air cleaner outlet. See

Fig. 2.20.

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

O). For vehicles equipped with a graduated indicator or a restriction gauge on the dash, check the gauge with the engine off. If restriction reaches 25 inH

O, replace the air cleaner element. Reset the indicator by pressing the button on the bottom.

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

09/21/2009 f611052

345678910111213

1920

1. Maintenance Warning Light

2. Left-Turn Signal Arrow

3. High Exhaust System Temperature (HEST) Lamp

4. Check Engine Indicator

5. Stop Engine Warning

6. Malfunction Indicator Lamp

7. Engine Brake Light

8. Wait to Start Warning Light

9. ABS Indicator

10. Shift Inhibit Indicator

11. Check Transmission Indicator

12. Stop Transmission (hybrid only)

13. Diesel Particulate Filter (DPF) Lamp

14. Right-Turn Signal Arrow

15. Fasten Seat Belt Warning

16. Air Brake Indicator (low air warning)

17. Hydraulic Brake System Warning

18. Headlight High-Beam Indicator

19. Cruise Control Indicator

20. Parking Brake On Indicator

Fig. 2.18, Warning Lights, Diesel

Instruments

2.19

Single Air Pressure Gauge for Hydraulic Brakes with Air Provision

This option is only available with hydraulic brakes with air provision.

Transmission Fluid Temperature Gauge

With an Allison automatic transmission, the transmission ﬂuid temperature gauge reading should not exceed 250°F (121°C) during normal operation. If this occurs, a warning light will activate to alert the driver.

Tachometer

A tachometer indicates engine speed in revolutions per minute (rpm) and serves as a guide for shifting the transmission and for keeping the engine in the appropriate rpm range. For low idle and rated rpm, see the engine identiﬁcation plate.

09/21/2009 f611054

345678910111213

2021

1. Maintenance Warning Light

2. Left-Turn Signal Arrow

3. High Exhaust System Temperature (HEST) Lamp

4. Check Engine Indicator

5. Stop Engine Warning

6. Malfunction Indicator Lamp

7. Engine Brake Light

8. Wait to Start Warning Light

9. ABS Indicator

10. Shift Inhibit Indicator

11. Check Transmission Indicator

12. Stop Transmission Indicator

13. Diesel Particulate Filter (DPF) Lamp

14. Right-Turn Signal Arrow

15. Fasten Seat Belt Warning

16. Air Brake Indicator (low air warning)

17. Hydraulic Brake System Warning

18. Headlight High-Beam Indicator

19. Parking Brake On Indicator

20. Cruise Control Indicator

21. Auxiliary Power Generator

Fig. 2.19, Warning Lights, Hybrid Electric Vehicle

01/18/95

f600148a

Fig. 2.20, Air Intake Restriction Gauge

Instruments

2.20

Controls

Ignition Switch and Key ............................................................ 3.1

Electrical System General Information ................................................ 3.1

Lighting Controls .................................................................. 3.1

Turn Signal Switch ................................................................ 3.3

Horn Controls .................................................................... 3.3

Powertrain Controls ............................................................... 3.3

Braking and Steering Controls ....................................................... 3.5

Dash-Mounted Controls ............................................................ 3.6

Ignition Switch and Key

On most vehicles, the ignition switch can be turned to four positions: ACCESSORY, OFF, ON, and START. See

Fig. 3.1. An optional three-position key-

less ignition switch does not have the ACCESSORY position.

The key can be inserted and removed only from the OFF position. The headlights (low beams), brake lights, fog lights, dome lights, clearance lights, turn signals, hazard warning lights, and the parking lights operate with the ignition switch in the OFF position, regardless of whether the key is inserted.

Turn the key fully clockwise to the START position, only when starting the engine. When the engine starts, release the key. When released, the key will rotate counterclockwise to the ON position.

In the ON position (key turned 45 degrees clockwise), all electrical systems are operable. The warning lights and the buzzer for low engine oil pressure operate until the engine is started and minimum engine oil pressure is achieved.

Electrical System General Information

The Walk-In Van chassis uses multiple electrical signals that 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 should be done only by qualiﬁed technicians. Special skills and equipment are required. 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.

Battery Disconnect Switch (optional)

Some Walk-In Van chassis may be equipped with a battery disconnect switch that can be used to prevent unwanted drain from the vehicle battery when the vehicle is not in use or is in storage. It can also rapidly disconnect from power supplies in the event of an emergency. Mounting locations may vary. See

Fig. 3.2.

Lighting Controls

The lighting controls mentioned under this heading generally operate through switches located on the dash.

07/10/96

f601179

1. Accessory (optional)

2. Off

3. On

4. Start

Fig. 3.1, Ignition Switch Positions

f545041

05/16/2007

1. Power-Off Position

2. Battery Disconnected (red area)

3. Power-On Position (green area)

Fig. 3.2, Battery Disconnect Switch (optional)

Controls

3.1

Headlight and Panel Light Controls

The control knob for the headlights, side marker lights, taillights, parking lights, license plate lights, and panel lights is located on the instrument panel. See

Fig. 3.3 and Fig. 3.4. Control knob positions are

as follows:

•

All lights are off if the knob is pushed all the way in.

•

If pulled out to the ﬁrst stop, all lights are on except the headlights.

•

If pulled all the way out, all lights including the headlights are on.

•

Turn the knob to the right to brighten the panel lights or turn it to the left to dim them.

•

Turn the knob all the way to the left (past the click stop) to operate the courtesy lights.

Headlight High-Beam/Dimmer Switch

The headlight high beams are activated by pulling the turn signal lever toward the driver. When the headlights are on high beam, the high-beam indicator light comes on in the instrument panel.

Hazard Warning Light Tab

The hazard warning light tab is located on the steering column under the turn signal lever. See Fig. 3.5. Pull the tab out to turn on the hazard warning lights. When the hazard warning light tab is pulled out, all of the turn signal lights and both of the indicator lights

on the control panel will ﬂash. To cancel the warning lights, press the tab in.

An additional hazard warning light control knob may be installed on the dash near the headlight controls. To activate the hazard warning lights, pull this knob out.

08/01/96

f601188

A. Off B. All Lights Except Headlights C. All Lights including Headlights D. Panel Light Brightness E. Courtesy Lights

Fig. 3.3, Headlight Control Knob

f601269

02/24/97

1. Windshield Wiper/Washer Control Knob

2. Headlight Control Knob

3. Cargo Light Switch

4. Cab Fan Switch

Fig. 3.4, Left-Hand Dash Panel

11/27/2007 f462122

Fig. 3.5, Hazard Warning Light Tab

Controls

3.2

Turn Signal Switch

The turn signal switch lever is mounted on the steering column. See

Fig. 3.6. Pushing the lever down

turns on the left-turn signal lights; pulling the lever up turns on the right-turn signal lights. When one of the signal lights is on, a green indicator light ﬂashes at the left or right side of the warning and indicator light panel. When the turn is completed, the signal will cancel and the lever will return to the neutral position.

NOTE: The hazard warning light indicator on the turn signal lever is to instruct the driver to pull the hazard warning light tab that is located under the turn signal lever.

Horn Controls

To sound the electric horn, push the horn icon on the steering wheel. See

Fig. 3.7.

Powertrain Controls

Allison Automatic Transmissions

Allison automatic transmissions have either 6 or 7 shift positions on the selector lever. See

Fig. 3.8.

The selector lever is lighted for night driving. Electronically controlled transmissions have a pushbutton selector. See

Chapter 5 for complete trans-

mission operating instructions.

f545174

03/16/2015

1. Headlight High-Beam/Dimmer Switch

2. Hazard Warning Light Indicator

Fig. 3.6, Turn Signal Lever

f462078a

06/28/2007

1. Horn Pad/Icon

Fig. 3.7, Horn Control

09/12/2006

f261381

Fig. 3.8, T-Handle Shift Control (typical)

Controls

3.3

Cruise Control (optional)

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.

NOTE: The maximum cruise control speed allowed is 75 mph (121 km/h). However, some vehicles may have a maximum cruise control speed that is lower than 75 mph (121 km/h), if the vehicle was ordered that way.

The cruise control is activated by two dash switches. See Fig. 3.9.

•

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.

•

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

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 paddle of the Set/ Resume switch to SET/CST.

To disengage the cruise control, do these steps:

2.1

Press down the brake pedal (on automatic or manual transmission) or

Press down the clutch pedal (on manual transmission only)

2.2

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

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.

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.

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.

09/13/2001

f610510

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. 3.9, Cruise Control Switches, Dash-Mounted

Controls

3.4

Manual Dump Valve (optional)

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.

Backup Alarm (optional)

An optional backup alarm, sounds when Reverse ®) gear is engaged. Check the operation of the backup alarm daily, if so equipped.

Braking and Steering Controls

Parking Brake Control

Hand-Operated Parking Brake

On all vehicles, a parking brake control lever is located to the left of the steering column. To apply the parking brake, depress the brake pedal, then pull up on the parking brake lever. To release the parking brake, depress the brake pedal and push the parking brake lever all the way down.

IMPORTANT: Take care to hold on to the parking brake lever while releasing it. Do NOT allow the lever to slam down while releasing it.

NOTICE

Overtightening of the knob can lead to cable breakage and/or damage to the knob and lever.

If the parking brake does not hold the vehicle securely, depress the brake pedal and release the parking brake. Turn the knob on the end of the lever clockwise to increase the parking brake application.

If the parking brake still doesn’t hold the vehicle securely (after adjustment), check the brake lining thickness. For instructions, see Group 42 of the Walk-In Van Chassis Maintenance Manual.

Hydraulic Parking Brake (optional)

To apply the hydraulic parking brake, pull the yellow knob labeled PARKING BRAKE on the dash panel.

In order to release the hydraulic parking brake, the engine must be running (hydraulic pressure is needed to release the brake) and the gear selector must be in the Neutral (N) position. To release the parking brake, push the knob in.

CAUTION

On vehicles with hydraulic parking brakes, loss of all hydraulic pressure will cause the parking brake to automatically engage.

NOTE: If the gear selector is not in the Neutral (N) position and the parking brake is on, a buzzer will sound to let the driver know to place the gear selector in the Neutral (N) position.

If the ignition key is in the OFF position and the parking brake is not applied, a buzzer will sound to let you know that you should apply the parking brake.

With the engine shut down, the hydraulic pump will actuate with your foot on the brake pedal; this could cause the battery to run down. If the engine is inoperable, see the "Emergency Release of Parking Brake" procedure that follows.

Emergency Release of Parking Brake (automatic transmission)

If your engine will not start and you want to release the parking brake, do the following. Block the wheels and turn the ignition switch to the ON position.

NOTICE

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

Use the ignition switch to turn the engine over several times with the gear shift selector in the Neutral (N) position and the parking brake knob in the released (pushed) position.

NOTE: The emergency release will not work in all cases. The system requires hydraulic ﬂuid to provide pressure for the procedure to work. Since the system is pressurized when the brake is released, the parking brake will come back on

Controls

3.5

in 10 minutes, or longer depending on internal pressure.

Tilt/Telescope Steering Column

Lever Adjustment (optional)

To change the position of the steering wheel, pull the lever upward and move the steering wheel to the desired position. See Fig. 3.10. Release the lever to lock the position. The steering wheel can be tilted up to provide easier exit and reentry.

If the chassis is equipped with a telescoping steering column, push the lever down and extend or retract the steering wheel as desired.

Foot Pedal Adjustment (optional)

If the tilt/telescope steering column is equipped with a foot pedal adjustment, depress the foot pedal to move the steering column to the desired position. Release the foot pedal to lock the position. See

Fig. 3.11.

Dash-Mounted Controls

Aftertreatment System (ATS) Regen Switch

A regen switch is located on or under the dash with which the driver can control two states. See

Fig. 3.12. These include:

•

Request regeneration

•

Default (automatic regeneration)

10/12/2007

f462115

1. Tilt/Telescope Lever

Fig. 3.10, Tilt/Telescope Steering Column with Lever

Adjustment

f462016

05/11/2005

1. Tilt/Telescope Foot Pedal

Fig. 3.11, Tilt/Telescope Steering Column with Foot

Pedal Adjustment

f610848

03/09/2012

RGEN

Fig. 3.12, ATS Regen Switch

Controls

3.6

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

Low Idle Adjustment Switch

NOTE: The low idle adjustment switch is not available on hydraulic hybrid units.

On some vehicles equipped with Cummins ISB engines, the engine low idle speed can be adjusted in 25 rpm increments with a low idle adjustment switch. On these vehicles, the engine control unit is programmed to allow low idle speeds between 700 and 875 rpm.

Windshield Wiper Switch

The windshield wipers are controlled by a dashmounted knob. See

Fig. 3.4. For a single wipe cycle,

turn the knob counterclockwise. Hold it in this position until the wipers start, then release the knob. For steady wiping at low speed, turn the knob clockwise one position. For high-speed wiping, turn the knob clockwise to the high-speed position.

NOTE: Heavy snow or ice can overload the wiper motor. A circuit breaker will stop the motor until it cools. Make sure that the windshield is cleared of snow or ice to prevent a circuit overload.

Windshield Washer Switch

Push in and hold the windshield wiper control knob until the desired amount of washer ﬂuid is sprayed on the windshield. See

Fig. 3.4. The wipers will oper-

ate on low speed until they are turned off.

Controls

3.7

Engines

Engine Starting ................................................................... 4.1

Engine Operation ................................................................. 4.2

High Idle Options ................................................................. 4.3

Exhaust Aftertreatment System (ATS) ................................................. 4.3

Engine Shutdown ................................................................. 4.9

Engine Starting

General Information

This engine chapter is to serve as a guide for best practices only. Each make and model engine may have operating characteristics that are unique to that particular engine, and will be documented in the engine manufacturer’s literature. Always refer to speciﬁc instructions and recommendations from the engine manufacturer.

NOTE: Before starting the engine, read Chap-

ter 2

and Chapter 3 of this manual for detailed information on how to read the instruments and operate the controls.

Normal Starting

WARNING

Do not use any starting aid, such as ether, in engines with an air intake heater. This could cause an explosion and serious personal injury or death.

NOTE: Cummins engines are run on a dynamometer before being shipped from the factory. They do not require a break-in period.

IMPORTANT: Special break-in oils are not recommended for new or rebuilt Cummins engines.

NOTICE

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.

IMPORTANT: Ring gear and starter pinion damage caused by improper starting procedures is not warrantable.

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.

NOTICE

If the engine is equipped with a turbocharger, protect the turbocharger during start-up by not depressing the accelerator pedal until normal engine idle oil pressure registers on the gauge.

Before engine start-up, complete the pre- and post-trip inspections and maintenance procedures in Chapter 10.

Set the parking brake.

Place the transmission in neutral.

Turn the key to the ON position and allow the gauge sweep to complete. The audible alert will sound for approximately four seconds.

During cold conditions, the WAIT TO START lamp may illuminate. Wait until the lamp goes out before turning the key to START.

After the gauge sweep has completed, turn the key to the START position.

NOTICE

Do not rev the engine if the oil pressure gauge indicates no oil pressure. Shut down the engine if oil pressure does not build within approximately ten seconds. Check to determine the cause of the problem. Operating the engine with no oil pressure will damage the engine.

Apply load gradually during the warm-up period.

NOTICE

If the oil pressure gauge indicates no oil pressure, shut down the engine within approximately ten seconds to avoid engine damage.

Check the oil pressure gauge for any drop in lubricating oil pressure or mechanical malfunction in the lubricating oil system. Minimum oil pressure at idle is 7 psi (50 kPa).

Engines

4.1

Cold-Weather Starting

See the engine manufacturer’s operation manual for starting aids that are approved for speciﬁc engines.

If the unit is equipped with a block heater, start the block heater two to four hours before travel.

Engine Operation

Normal Operation

WARNING

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

Engines produce high horsepower and peak torque characteristics at low rpm. Because of this, it is not necessary to operate the engine at high rpm to deliver the required horsepower at the wheels. These characteristics may also result in less shifting and make shifting at lower rpm (to peak torque) more practical.

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. 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.

When approaching a hill, accelerate smoothly to start the upgrade at full power (2000 rpm or higher is recommended), then shift down as desired to maintain the optimum vehicle speed.

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.

NOTICE

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

The engine is effective as a brake on downhill grades, but take care not to overspeed the engine going downhill. 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.

Cold-Weather Operation

Satisfactory performance of a diesel engine operating in low ambient temperatures requires modiﬁcation of the engine, surrounding equipment, operating practices, and maintenance procedures. The lower the temperature, the greater the amount of modiﬁcation required. See the engine manufacturer’s operation manual for service products approved for use in cold weather engine operation.

If satisfactory engine temperature is not maintained, maintenance costs will increase due to greater engine wear. If the engine coolant gets too cold, raw fuel will wash the lubricating oil off the cylinder walls and dilute the crankcase oil, causing all moving parts of the engine to suffer from poor lubrication.

If the engine is in good mechanical condition and the precautions necessary for cold-weather operation are taken, ordinary cold weather will not cause difficulty in starting or loss of efficiency.

The following points are important to observe when operating in cold weather.

•

Check for cracks in the battery cases, for corrosion of the terminals, and for tightness of the cable clamps at the terminals.

•

Charge the batteries to full capacity. Replace damaged batteries.

•

If equipped, turn off the battery disconnect switch after the engine is shut down to prevent battery discharge.

•

Have the alternator output checked at an authorized Freightliner dealer.

•

Check the condition and tension of the drive belts.

Engines

4.2

•

Refer to the engine manufacturer’s operation

manual for recommended heaters, low-

viscosity lubricating oils, winter-grade fuels,

and approved coolants.

•

Periodically check the coolant mix ratio (con-

centration of antifreeze in the coolant). Add

more if necessary.

•

At temperatures below -4°F (-20°C), a coolant

preheater is recommended.

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 may cause the bearings to seize or the oil seals to leak.

High Idle with Cruise Control

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

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.

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

Voltage-Based Auto High Idle

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

The idle rpm will automatically increase when the voltage drops below 12.2 volts for 10 seconds. The rpm will incrementally increase every ﬁve seconds until 13.4 volts is achieved and maintained.

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.

Exhaust Aftertreatment System (ATS)

Vehicles and/or engines manufactured after December 31, 2006 and domiciled in the U.S. or Canada are required to meet all EPA and NHTSA regulations effective as of the vehicle build date. Engines manufactured between January 1, 2007 and December 31, 2009 meet EPA07 requirements. Engines manufactured between January 1, 2010 and December 31, 2012 meet EPA10 requirements.

Model year 2013 and later vehicles meet additional requirements as speciﬁed by NHTSA and EPA 2014 fuel efficiency and greenhouse gas emission standards (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.

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.

NOTICE

Follow these guidelines for engines that comply with EPA07 or newer regulations, or damage may occur to the aftertreatment device (ATD) and the warranty may be compromised.

•

Use ultralow-sulfur diesel with 15 ppm sulfur content or less.

•

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 %; currently referred to as CJ-4 oil.

Engines

4.3

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.

EPA07 Engines

Engines built between January 1, 2007 and December 31, 2009 are required to meet EPA07 guidelines for reduced exhaust emissions of particulate matter and nitrogen oxides (NOx). NOx is limited to just over 1 gram per brake horsepower hour (g/bhp-hr), and particulate matter cannot exceed 0.01 g/bhp-hr.

The EPA07 ATS varies according to engine manufacturer and vehicle conﬁguration, but the exhaust mufﬂer is replaced by an aftertreatment device (ATD). Inside the ATD, the exhaust ﬁrst passes over the diesel oxidation catalyst (DOC), then passes through the diesel particulate ﬁlter (DPF), which traps soot particles. The soot is burned to ash during a process called regeneration (regen).

EPA10 and Newer Engines

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 ATS that has, in addition to a DOC/DPF device like that used in an EPA07 ATD, a Selective Catalytic Reduction (SCR) device to reduce NOx downstream of the engine.

After exhaust gases 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. Passive regen occurs when the engine is run-

ning under load and regen occurs without input. 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 reduce it to ash. Both types of regen occur without driver input.

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.

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.

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.

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

) gas. This mixture ﬂows through the SCR device, where the ammonia gas reacts with the NOx in the exhaust, to produce harmless nitrogen (N

) and water vapor (H2O), which then

exits out of the tailpipe.

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 Fig. 4.1.

•

A slow, 10-second ﬂashing of the high exhaust system temperature (HEST) lamp alerts the driver that a parked regen is in progress, but the exhaust temperatures are still relatively

Engines

4.4

cool. It also indicates that the high-idle speed is being controlled by the engine software, not the driver. See Fig. 4.2.

•

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.

•

An illuminated DEF warning lamp in the gauge, indicates that the DEF tank should be reﬁlled at the next opportunity.

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.

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. 4.3.

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

Fig. 4.4.

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

To initiate a parked regeneration, perform the following steps.

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).

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.

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

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.

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

09/25/2006 f610815a

Fig. 4.1, Diesel Particulate Filter (DPF) Lamp

09/25/2006 f610816a

Fig. 4.2, High Exhaust System Temperature (HEST)

Lamp

Engines

4.5

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

f080147

EXHAUST AFTERTREATMENT SYSTEM INFORMATION

Switch.

Level 1 Level 3Level 2 Level 4

Filter Regeneration Recommended

Filter is reaching

Bring vehicle to highway speeds to

Filter Regeneration Necessary

Filter is now reaching maximum capacity

To avoid engine derate bring vehicle

Parked Regeneration Required − Engine Derate

Filter has reached maximum capacity

Vehicle must be parked and a Parked

Parked Regeneration Required − Engine Shut Down

Filter has exceeded maximum capacity

Vehicle must be parked and a Parked Regeneration or Service

(Solid)

(Flashing) (Flashing)

CHECK CHECK

(Flashing)

INDICATOR LAMP(S)

Indicator Lamp Message(s)

Diesel Particulate Filter Condition

Required Action

capacity

. .

STOP

See Engine Operator’s Manual for complete Regeneration Instructions.

allow for an Automatic Regeneration or perform a Parked Regeneration.

to highway speeds to allow for an Automatic Regeneration or perform a Parked Regeneration as soon as possible.

Regeneration must be performed − engine will begin derate.

Regeneration must be performed. Check engine operator’s manual for details −engine will shut down.

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

06/29/2009

24−01583−000B

ARNING

HEST (High Exhaust System Temperature)

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

A regeneration is in progress.

Flashing

Solid

Fig. 4.3, Exhaust-Aftertreatment Warnings Reference Label

f611199

06/19/2012

Fig. 4.4, Regen Switch

Engines

4.6

DEF is frozen; an immersion heater with engine coolant 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 Walk-In Van uses a 10gallon 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.

DEF Gauge

The DEF level is measured in a stand-alone gauge. See Fig. 4.5.

The DEF gauge has a 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

•

One bar illuminated amber—DEF very low, reﬁll DEF

•

One bar ﬂashing red—DEF empty, reﬁll DEF

DEF Warnings and Engine Limits

IMPORTANT: Ignoring the DEF warning lights 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 Operation and Maintenance Manual for further information.

10/13/2009 f611055

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

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

1. Low DEF Warning Lamp

Fig. 4.5, DEF Gauge

Engines

4.7

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. See

Fig. 4.6.

•

The DEF warning lamp illuminates constantly (initial warning).

•

The DEF warning lamp ﬂashes (critical warning).

•

DEF-level lightbar illuminates solid amber.

DEF Empty

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

Fig. 4.7.

•

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

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. 4.8.

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.

DEF Quality or SCR Tampering

NOTICE

Once contaminated DEF 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 light and engine limits.

If contaminated DEF or tampering is detected, the DEF warning light ﬂashes, and engine performance is limited with progressively harsher engine power limits applied. If the fault is not corrected, the CHECK engine lamp illuminates, then the STOP engine lamp illuminates and a 5 mph (8 km/h) speed limit will be applied after the next engine shutdown, or while parked and idling. See

Fig. 4.8.

10/13/2009 f611056

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

Fig. 4.6, DEF Level Low Initial and Critical Warnings

10/13/2009 f611057

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

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

Fig. 4.7, DEF Empty Warning

11/18/2010 f611059b

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. 4.8, DEF Empty and Ignored Warning

Engines

4.8

Engine Shutdown

NOTICE

Except in an emergency, do not shut down the engine when the coolant temperature is above 194°F (90°C). To do so could damage the engine.

With the vehicle stopped, place the transmission in the neutral (N) position and set the parking brake.

It is important to idle an engine for 3 to 5 minutes before shutting it down. This allows the lubricating oil and the coolant to carry heat away from the combustion chambers, bearings, shafts, and seals.

IMPORTANT: 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 piston rings and may result in stuck valves.

Do not idle the engine for excessively long periods.

Turn the ignition key to the OFF position and shut down the engine.

Engines

4.9

Transmissions

Allison Automatic Transmissions ..................................................... 5.1

Allison Automatic Transmissions

General Information

Allison four- and ﬁve-speed automatic transmissions have six or seven shift positions on the selector lever. The selector lever is lighted for night driving. Each forward shift position provides a range of forward gears that are selected automatically according to the speed of the vehicle, engine temperature, and throttle position. The 1000 Series, 2000 Series, and 2500 Series are fully automatic transmissions. See the Allison website for additional information, at

www.allisontransmission.com.

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

Chapter 7 for information on

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.

NOTICE

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.

WARNING

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 "1" (Low) at speeds above 20 mph (32 km/h).

On slippery surfaces, avoid quick movements of the steering wheel. Decrease your speed and allow for extra stopping distance required by these conditions.

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.

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

Series 1000, 2000, and 2500 Transmission Operation

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.

1000 Series

On vehicles with Allison 1000 series transmissions, do the following steps if you have to leave the cab with the engine running (for example, when checking the transmission ﬂuid):

Without Park (P) Position

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

Ensure that the engine is at low idle rpm.

Put the transmission in Neutral (N).

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

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

With Park (P) Position

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

Ensure that the engine is at low idle rpm.

Transmissions

5.1

Put the transmission in Park (P).

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

Engage the Park (P) range by slowly releasing the service brake.

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

2000 Series

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

Without Auto-Apply Parking Brake (PB)

Follow the instructions for vehicles with 1000 series transmissions, under the heading "Without Park (P) Position."

With Auto-Apply Parking Brake (PB)

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

Ensure that the engine is at low idle rpm.

Put the transmission in Auto-Apply Parking Brake (PB).

Ensure that the parking brake is properly engaged.

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

2500 Series

On vehicles with 2500 series transmissions, instructions are as follows.

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

Ensure that the engine is at low idle rpm.

Put the transmission in Park (P).

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

Engage the Park (P) range by slowly releasing the service brake.

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 TCM (transmission control module), the controls will lock the transmission in the current operating range.

Shift inhibits occur under the following conditions:

•

Shifts from Neutral (N) to Reverse (R) or from Neutral (N) to a forward range when the engine is above idle, greater than 900 rpm.

•

Forward/Reverse (R) 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.

Operating Instructions, On-Highway Transmissions

Allison 1000/2000/2500 automatic transmissions are electronically controlled and provide ﬁve or six forward ranges and one Reverse (R) range. Typically, a T-handle shift control is used by the driver to select the ranges. See

Fig. 5.1 and Fig. 5.2.

Park (P) [optional on 1000 and 2500 Series]

Use Park (P) when starting or shutting down the engine, to check vehicle accessories, and to operate the engine in idle for longer than 5 minutes. This position places the transmission in Neutral (N) and engages the park pawl.

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

The Auto-Apply Parking Brake (PB) places the vehicle in Neutral (N) and applies the parking brake.

Transmissions

5.2

Reverse (R)

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

NOTICE

Extended idling in Reverse (R) may cause transmission overheating and damage.

Do not idle in Reverse (R) for more than 5 minutes. Select Park (P), Auto-Apply Parking Brake (PB), or Neutral (N) when time at idle exceeds 5 minutes.

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

Neutral (N)

The Neutral (N) position places the transmission in Neutral (N). This position is used when starting the engine and for stationary operation.

WARNING

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.

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

WARNING

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 (N). If the vehicle is allowed to coast in Neutral (N), you could lose control of the vehicle.

09/12/2006

f261381

Fig. 5.1, T-Handle Shift Control (typical shifter)

07/23/2014 f611243

Fig. 5.2, T-Handle Shift Control (optional shifter)

Transmissions

5.3

NOTICE

Coasting in Neutral (N) can cause severe transmission damage.

Drive (D)

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.

In the Drive (D) position, the transmission will initially go into First (1) range when Drive (D) is selected. As vehicle speed increases, the transmission will upshift automatically through each available range up to Fourth (4) range or Fifth (5) 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 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.

NOTICE

Do not idle in Drive (D) for more than 5 minutes. Extended idling in Drive (D) may cause transmission overheating and damage. Always select Auto-Apply Parking Brake (PB) or Park (P) if time at idle is longer than 5 minutes.

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

Fourth and Third Ranges (4 and 3) [optional]

Use the Fourth (4) or Third (3) range for city traffic and for braking on steep downgrades.

Third and Second Ranges (3 and 2) [standard]

Use the Third (3) or Second (2) range for heavy city traffic and for braking on steeper downgrades.

First Range (1)

Use First (1) range when pulling through mud or deep snow, when maneuvering in tight spaces, or when driving up or down very steep grades. First (1) range provides the vehicle with its maximum driving torque and maximum engine braking effect.

Transmissions

5.4

Steering System

Steering General Information ........................................................ 6.1

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

Tilt/Telescope Steering Column ..................................................... 6.1

Steering General Information

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. See

Fig. 6.1. See Group 46 of the Walk-In Van Chassis

Workshop Manualfor steering adjustment procedures.

Power Steering System

The power steering system consists of a steering gear (which includes a manual steering mechanism, a hydraulic control valve, and a hydraulic power cylinder), hydraulic hoses, power steering pump, reservoir, and other components. The power steering pump, driven by the engine, provides the power assist for the steering system. If the engine is not running, there is no power assist.

If the power-assist feature does not work due to hydraulic ﬂuid loss, steering pump damage, or some other cause, bring the vehicle to a safe stop. Do not drive the vehicle until the cause of the problem has been corrected.

WARNING

Driving the vehicle without the power-assist feature of the steering system requires much greater effort, especially in sharp turns or at low speeds, which could result in an accident and possible injury.

Drivers should use the power available with a power steering system carefully. If the front tires become lodged in a deep chuckhole or rut, drive the vehicle out instead of using the steering system to lift the tires from the hole. Also avoid turning the tires when they are against a curb as this places a heavy load on steering components and could damage them.

Tilt/Telescope Steering Column

Lever Adjustment (optional)

To change the position of the steering wheel, pull the lever upward and move the steering wheel to the desired position. See

Fig. 6.2. Release the lever to lock

the position. The steering wheel can also be tilted up to provide easier exit and reentry.

If the chassis is equipped with a telescoping steering column, push the lever down and extend or retract the steering wheel as desired.

WARNING

Make sure that the control lever is in the locked (neutral) position before driving the vehicle. Never tilt the column while driving the vehicle. Doing so could cause loss of vehicle control and result in personal injury and property damage.

f461923

11/14/2001

10°

1. 9 o’Clock 2. 3 o’Clock

Fig. 6.1, Steering Wheel Centered

10/12/2007

f462115

1. Tilt/Telescope Lever

Fig. 6.2, Tilt/Telescope Steering Column with Lever

Adjustment

Steering System

6.1

Foot Pedal Adjustment (optional)

Fig. 6.3.

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.

f462016

05/11/2005

1. Tilt/Telescope Foot Pedal

Fig. 6.3, Tilt/Telescope Steering Column with Foot

Pedal Adjustment

Steering System

6.2

Hydraulic and Air Brake

Systems

Hydraulic Brake System ............................................................ 7.1

Air Brake System ................................................................. 7.2

Hydraulic Brake System

General Information

The hydraulic brake system includes a power booster, master cylinder, reservoir, hydraulic brake lines, a brake rotor on each wheel hub, and a brake caliper and pad assembly at each rotor. See

Fig. 7.1.

IMPORTANT: Make sure that the ﬂuid in the master cylinder reservoirs is up to the level of the ridge that surrounds the reservoir. Use only heavy-duty brake ﬂuid, DOT 3, in the hydraulic brake system.

The master cylinder controls braking power to the front and rear brakes. The Bendix Hydro-Max® power booster is attached to the rear of the master cylinder and is connected to the power steering system (which provides pressurized power steering ﬂuid). An electrically powered "reserve" pump operates if there is inadequate ﬂuid ﬂow from the power steering pump to the power booster. The brake system warning light comes on if there is a problem within the system. Bring the vehicle to a safe stop and correct the problem before continuing operation of the vehicle. See Group 42 of the Walk-In Van Chassis Workshop Manual for hydraulic brake system troubleshooting and adjustment procedures.

Operation

Before driving the vehicle, secure all loose items in the cab 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. When the forward speed of the vehicle has decreased to almost the idling speed of the engine, push the clutch pedal in (if equipped) and shift the transmission into Neutral (N). Apply the hand parking brake if the vehicle is to be parked.

Meritor WABCO® Antilock Braking System (ABS)

The Meritor WABCO® Antilock Braking System (ABS) is an electronic wheel speed monitoring and control system that works with the hydraulic brake system. ABS passively monitors vehicle wheel speed at all times, but controlswheel speed during an emergency or reduced-traction stop. In normal braking applications, the standard hydraulic brake system is in effect.

IMPORTANT: For proper ABS system operation, the front and rear tires must rotate at speeds within 16% of one another. Installing different sized tires on just the front or rear axle will result in inaccurate wheel speed signals to the ECU resulting in a reduced braking force, which could lead to longer stopping distances.

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 (located on the frame rail) that interprets these signals to calculate wheel speed and a vehicle reference speed. If the calculations indicate wheel lockup, the appropriate control circuit signals the brake pressure modulator to increase or decrease braking pressure until wheel slip has been corrected.

The electronic control unit also has a safety circuit that constantly monitors the wheel sensors, brake pressure modulator, and the electrical circuitry. The dash warning light (ABS) comes on after the ignition

04/26/2012

f460513a

A. Open caps and check ﬂuid level. B. Fill to this level.

Fig. 7.1, Hydraulic Brake Reservoir (MT-45 and MT-55)

Hydraulic and Air Brake Systems

7.1

is switched to the ON position. Once the vehicle moves faster than about 4 mph (6 km/h), the warning light goes out only if all of the vehicle’s ABS components are working properly.

If during vehicle operation, the safety circuit senses a failure in any part of the ABS system (a sensor, brake pressure modulator, wiring connection, short circuit, etc.), the warning light (ABS) comes on and the control circuit where the failure occurred is switched to normal braking action. Even if the ABS system is partially or completely inoperative, normal braking ability is maintained. An exception would be if the brake pressure modulator or hydraulic ﬂuid line is damaged. Since these components are an integral part of the hydraulic brake system, normal braking may be impaired or inoperative.

IMPORTANT: If the ABS warning light does not work as described above or comes on while driving, repair the ABS system immediately to ensure full antilock braking capability.

See the diagnostic menu screens in Chapter 2, and follow the steps to read the fault codes in the instrument panel diagnostic menu.

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.

WARNING

Although the ABS system improves vehicle control during emergency braking situations, the driver still has the responsibility to change driving styles depending on existing traffic and road conditions. Failure to change driving styles to accomodate existing traffic and road conditions could cause an accident, possibly resulting in personal injury or death, or property damage.

Air Brake System

General Information

A dual air brake system consists of two independent air brake systems that use a single set of brake controls. Each system has its own reservoir, plumbing, and brake chambers. The primary system operates

the service brakes on the rear axle; the secondary system operates the service brakes on the front axle.

WARNING

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

Before driving your vehicle, allow time for the air compressor to build up a minimum of 95 psi (655 kPa) pressure in both the primary and the secondary systems. Monitor the air pressure system by observing the dual system air pressure gauges and the low air-pressure warning light and buzzer. The warning light and buzzer shut off when the pressure in both systems reaches 65 to 73 psi (448 to 503 kPa).

The warning light and buzzer comes on if air pressure drops below 65 to 73 psi (448 to 503 kPa) in either system. If this happens, check the air system pressure gauges to determine which system has low air pressure. Although the vehicle’s speed can be reduced using the foot brake control pedal, either the front or the rear service brakes will not be operating, causing a longer stopping distance. Bring the vehicle to a safe stop and have the air system repaired before continuing.

The parking brake will apply when air pressure drops below 38 to 42 psi (262 to 290 kPa). Do not wait for the brake to apply automatically; when the warning light and buzzer ﬁrst come on, immediately bring the vehicle to a safe stop. Before continuing operation of the vehicle, correct the cause of the air loss.

Air Brake System With External Fill (Shrader) Valve

If your engine will not start and it is desirable to release the parking brake, do the following: Block the wheels. Turn the ignition switch to the ON position. Fill the air reservoir for the braking system by external means. The parking brake will not release until air pressure reaches 65 psi (448 kPa). The low air buzzer will sound until air pressure reaches 65 psi (448 kPa) with the ignition switch in the ON position.

IMPORTANT: If the air pressure in the braking system drops back below 38 to 42 psi (262 to 290 kPa) the parking brake will reengage.

Hydraulic and Air Brake Systems

7.2

Operation

Before driving the vehicle, secure all loose items in the cab so that they will not ﬂy forward during a full brake application. Make sure that all occupants are wearing seat belts.

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

The yellow diamond-shaped knob on the control panel actuates the parking brake valve. Pull out the knob to apply the parking brake. See

Fig. 7.2.

WARNING

NOTICE

Do not use the spring 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 (L) or First (1) gear and lightly apply the brakes to heat and dry them.

Allow hot brakes to cool before using the parking brake. Always chock the tires.

Automatic Slack Adjusters

Automatic slack adjusters are required on all vehicles equipped with air brakes manufactured after October 20, 1994. Automatic slack adjusters should never be manually adjusted except during routine maintenance of the foundation brakes (e.g., replacing shoes), during slack adjuster installation, or in an emergency situation.

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

Visit a repair facility as soon as possible when brakes equipped with automatic slack adjusters are determined to be out of adjustment.

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.

03/30/2010 f421624

Fig. 7.2, Parking Brake Control Knob

Hydraulic and Air Brake Systems

7.3

Compressed Natural Gas

Fuel System

CNG General Information .......................................................... 8.1

CNG Fuel Tank Filling Procedure .................................................... 8.1

Engine Starting ................................................................... 8.2

CNG Safety Precautions ........................................................... 8.3

CNG General Information

Natural gas is a mixture of hydrocarbon gasses with a high concentration of methane gas, which burns completely into carbon dioxide and water, resulting in lower emissions than with diesel or gasoline.

Natural gas is less energy dense than diesel, therefore, a larger volume of natural gas is required to produce the same power. This is one reason for the slightly lower maximum power in natural-gaspowered vehicles. The power difference is a reduction in maximum power only and does not affect normal driving. The power reduction is evidenced only in wide-open throttle, high-torque conditions.

IMPORTANT: The natural gas fuel system should be routinely inspected for gas leakage. Use a natural gas detector to check the fuel tanks, fuel ﬁltering and regulating mechanisms, and the fuel lines. If necessary, replace leaking fuel tanks; repair or replace any lines, devices, or connections that are leaking.

Natural gas is nontoxic, but it can cause asphyxiation in certain circumstances. Commercial compressed natural gas normally contains an odor-producing chemical, which enables users to detect gas leaks, but a natural gas detector is recommended for checking for leaks.

A typical natural gas fuel system consists of:

•

Fuel supply containers or tanks storing the gas at high pressure.

•

A pressure relief valve and manual shutoff valves.

•

A ﬁlling connection with a check valve to prevent the gas from ﬂowing back out of the connection.

•

A valve that automatically closes if the engine stops.

•

A high-pressure fuel ﬁlter and a low-pressure fuel ﬁlter.

•

A pressure regulator to reduce the fuel tank pressure to the lower pressure needed for the engine.

•

A gas-air mixer to produce a ﬂammable mixture for the engine.

•

A pressure gauge to indicate the fuel supply in the tanks.

CNG Fuel Tank Filling Procedure

CNG is moved from the fuel station storage tanks to the vehicle cylinders through a metered dispenser. During fueling, as pressure inside of the vehicle cylinders increases, so does the temperature. The dispenser shuts off when it determines the CNG cylinders are full.

CNG fuel cylinders cannot be ﬁlled to their full capacity of 3600 psi (24 821 kPa) in cooler weather. Since temperature change causes gas to expand and contract, less pressure in the cylinders on a cold day is equal to the same amount of gas at a higher pressure on a warm day. The fuel station dispenser has a temperature-pressure compensating device, which accounts for ambient temperature during fueling. See

Table 8.1 for approximate full cylinder pressures at

various temperatures.

CNG Temperature/Pressure Compensation Values

Temperature:

°F (°C)

Fill Station Pressure Set Point

3000 psi (20 684

kPa) Set Point

3600 psi (24 821

kPa) Set Point

100 (37.8) 3415 (23 546) 4086 (28 172)

90 (32.2) 3276 (22 587) 3909 (26 952) 80 (26.7) 3138 (21 636) 3754 (25 883) 70 (21.1) 3000 (20 684) 3600 (24 821) 60 (15.6) 2861 (19 726) 3445 (23 752)

50 (10) 2723 (18 774) 3288 (22 670)

40 (4.4) 2584 (17 816) 3131 (21 587) 30 (-1.1) 2446 (16 865) 2973 (20 498) 20 (-6.7) 2307 (15 906) 2814 (19 402)

10 (-12.2) 2169 (14 955) 2655 (18 306)

0 (-17.8) 2031 (14 003) 2495 (17 202)

-10 (-23.3) 1893 (13 052) 2336 (16 106)

-20 (-28.9) 1755 (12 100) 2180 (15 031)

-30 (34.4) 1616 (11 142) 2024 (13 955)

-40 (-40) 1477 (10 184) 1868 (12 879)

Table 8.1, CNG Temperature/Pressure Compensation

Values

Use the following steps to fuel a CNG vehicle.

Shut down the engine and apply the parking brake.

Compressed Natural Gas Fuel System

8.1

IMPORTANT: Close all windows and doors during the fueling process. Keeping windows and doors closed allows for easier leak detection inside the cab after fueling.

WARNING

Natural gas fuel tanks, lines, and valves are always pressurized. Always observe safety precautions. Failure to do so could lead to loss of control over a ﬁlling hose or to ignition of the natural gas, which could cause serious bodily injury, death, or severe property damage.

Ensure all fuel cylinder shutoff valves are open.

Ensure the vehicle fuel system main shutoff valve is open.

Open the CNG fuel panel access door and remove the dust cap from the vehicle fuel ﬁll port.

Ensure the O-ring is present inside the fuel ﬁll port. If the O-ring has been dislodged or is missing, the station dispensing nozzle will not connect securely to the ﬁll port.

Turn the selector knob on the service pump to the VENT position, if equipped.

Connect the quick coupling on the dispensing nozzle securely to the vehicle fuel ﬁll port.

Turn the selector knob on the service pump to the FILL position, if equipped.

IMPORTANT: If at any time the service pump or vehicle begins to vent CNG uncontrollably, notify a station attendant or activate the service station emergency shut-off switch to cease the ﬂow of CNG.

Switch on the service pump. A slight hissing noise may be heard as the fuel cylinders ﬁll.

10.

Watch the pressure gauge on the service pump. When the gauge reads approximately 3600 psi (24 821 kPa), or when the ﬁll pressure stops climbing, the CNG cylinders are full. The service pump will shut itself down automatically. See

Table 8.1 for pressure compensation values

based on ambient temperatures.

11.

Move the selector knob on the service pump to the VENT position, if equipped. A short hiss will

be heard as a small amount of natural gas is vented into the hose.

WARNING

Do not attempt to remove the ﬁll station nozzle from the tank ﬁll ﬁtting until venting of pressure is noted. If no venting occurs, ask for assistance from the station attendant. Removing an unvented coupling could result in an uncontrolled hose, which could lead to property damage or personal injury.

12.

Remove the station dispensing nozzle from the vehicle ﬁll port.

13.

Install the dust cap on the vehicle fuel ﬁll port and close the fuel panel access door.

Engine Starting

Set the parking brake.

Move the fuel shut-off valve handle to the RUN position.

NOTICE

Protect the turbocharger during engine start-up by not opening the throttle or accelerating the engine above 1000 rpm until normal engine idle oil pressure registers on the gauge.

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

Turn the ignition switch to the START position. See Fig. 8.1 for the four-position ignition switch and

Fig. 8.2 for the three-position ignition switch.

After the engine starts, release the key.

NOTICE

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

Compressed Natural Gas Fuel System

8.2

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 Cummins Operation and Maintenance Manual for minimum idle oil pressure speciﬁcations.

CNG Safety Precautions

DANGER

Natural gas is highly ﬂammable. Failure to observe the following safety precautions could lead to the ignition of the natural gas, which could cause serious bodily injury or death.

CNG General Safety Information

Since compressed natural gas is highly ﬂammable, if you should smell gas, immediately shut off all engines and ignition sources. Avoid causing sparks, and stay away from arcing switches and equipment. Extinguish any cigarettes, pilot lights, ﬂames, or other sources of ignition in the area and adjacent areas. Immediately provide extra ventilation to the area. Do not start the engine or any other type of equipment until the gas leak is corrected and the area cleared of natural gas.

Natural gas is odorless before a scent is added for safety. Natural gas is also colorless and nontoxic. Still, at high enough concentration, natural gas can suffocate a person simply by excluding adequate oxygen to sustain life.

Natural gas is ﬂammable in concentrations ranging from 4 percent to 16 percent by volume in air.

WARNING

When bleeding the dispensing hose after ﬁlling the tank, the handle gets extremely cold. This may freeze the hands if appropriate safety gloves are not used.

When ﬁlling the vehicle tanks with compressed natural gas (CNG), vent the dispensing hose before disconnecting it from the vehicle. The pressure in the hose may cause a disconnected hose to become uncontrollable.

CNG storage tanks have a limited usable life-span, due to the high pressures that they must sustain. Periodic inspections are required by law to ensure continued safety in their use.

If a tank receives an impact or has deep scratches or gouges, it should be inspected before reﬁlling.

07/10/96

f601179

1. Accessory (optional)

2. Off

3. On

4. Start

Fig. 8.1, Four-Position Ignition Switch

05/10/2001

f601179a

1. Off 2. On 3. Start

Fig. 8.2, Three-Position Ignition Switch

Compressed Natural Gas Fuel System

8.3

CNG Workshop Precautions

Because natural gas is less dense than air, it rises. The shop ceiling needs to be equipped with a vent system that will allow the gas to escape and dissipate.

Use only safety ﬂuorescent extension shop lights. Ordinary light bulbs can explode if dropped, possibly causing a ﬁre.

The shop must be equipped with an alarm system that activates when gas concentration in the air becomes dangerous.

Fire extinguishers should be the CO

type (ABC minimum) and should be strategically located, highly visible, and easily accessed.

Permit no smoking or other ignition sources in the shop area.

Servicing the CNG System

Observe the following safety precautions when servicing natural-gas-powered vehicles:

•

Before making non-CNG system repairs on a CNG vehicle, close the shutoff valve at the outlet of the CNG container, and keep it closed throughout the repair procedure. Have the CNG system checked by a qualiﬁed technician before reopening the fuel shutoff valve.

•

Allow only qualiﬁed technicians trained in automotive CNG system repair to perform repairs.

•

Close the fuel shutoff valve(s) before performing maintenance and repairs, and when storing the vehicle inside. Open the valve(s) only if natural gas is needed to operate the engine or to check for leaks.

•

Vent the gas outdoors to a safe location.

•

Always use a natural gas detector to test the system for leaks, whether an odor is present or not. Commercial compressed natural gas normally contains an odor-producing chemical to enable users to detect leaks by smell. But because the odor-producing chemical can fade, a leak detector is necessary.

•

Routinely inspect the fuel tanks, the fuel ﬁltering and regulating mechanisms, and the fuel lines. Use a natural gas detector to check for any leaks. A soap-and-water solution can be used to pinpoint the exact location of leaks.

Replace leaking fuel tanks; repair or replace any lines, devices, or connections that are leaking.

•

Always tighten fasteners and fuel connections to the required torque speciﬁcation, since overtightening or undertightening could cause gas leakage. Tightening to the correct torque speciﬁcation is critical to the system.

Major Repair and Replacement of CNG Parts

When a vehicle is involved in an accident or a ﬁre causing damage to the fuel tank, the fuel tank must be replaced. If damage occurred to other parts of the fuel system, also replace those parts.

Any and all replacement parts (valves, ﬁttings, tubing, etc.) of the CNG fuel system must be designed speciﬁcally for CNG automotive use and must be officially approved and rated for the pressures and conditions that pertain.

Install parts and components in accordance with the manufacturer’s instructions.

Replace (do not repair) damaged fuel lines. When replacing fuel lines, install the lines securely in a protected location, or shield them from heat sources and from contact with unsecured objects. Before assembly, apply a natural gas-impervious pipe thread jointing material to all male pipe threads. Ensure that all lines and ﬁttings are clear and free of cuttings, threading burrs, and scales, and that the ends of all lines are reamed. Protect lines passing through a panel by means of grommets or similar devices. Locate joints and connections so that they are accessible.

Do not use aluminum or copper pipe, tubing, or ﬁttings between the fuel tank and the ﬁrst-stage pressure regulator because of the high pressure involved.

Ensure that shutoff valves have a rated service pressure not less than the rated service pressure of the entire fuel supply system, and that they are capable of withstanding a hydrostatic test of at least four times the rated service pressure.

Compressed Natural Gas Fuel System

8.4

Hybrid Electric Vehicle

Safety Precautions ................................................................ 9.1

Foot Pedal-Operated Parking Brake .................................................. 9.1

Engine Starting and Shutdown ...................................................... 9.1

T-Handle Shifter .................................................................. 9.3

Disabling the Hybrid Electric Vehicle (HEV) System ..................................... 9.4

In Case of an Emergency .......................................................... 9.5

Safety Precautions

The hybrid electric vehicle (HEV) has high-voltage components, including 340-volt Direct Current (DC) batteries and a 500-volt Alternating Current (AC) motor.

Never touch or cut high-voltage cables or connectors. If it is necessary to remove occupants using cutting equipment, avoid high-voltage cables and the Power Electronics Carrier (PEC). See

Fig. 9.1 for the

location of the high-voltage cables and PEC.

DANGER

Unprotected contact with any live high-voltage components can cause serious injury or death.

Foot Pedal-Operated Parking Brake

To set the foot pedal-operated parking brake, place the gear selector in Neutral (N) and depress the parking brake foot pedal down to the ﬂoor. To release the parking brake, press the parking brake release knob located on the dash. See

Fig. 9.2.

Engine Starting and Shutdown

Engine Starting

IMPORTANT: When starting the engine it is recommended that the operator’s foot be ﬁrmly pressing the service brake pedal.

Set the parking brake.

IMPORTANT: The hybrid drive transmission has a parking pawl that engages when Park (P) is selected.

WARNING

The vehicle could roll away if the parking brake is not set, which could result in personal injury or property damage.

Start the engine with the key, or, if equipped with an ignition reader, position the wristband approximately 1 inch (25 mm) above the electronic wristband reader on the ignition pad and press the green button located on the ignition reader for approximately one second. Continue to press and hold the green button to start the engine. See

Fig. 9.3.

05/20/2010 f151096a

Fig. 9.1, Power Electronics Carrier (PEC) Location

Hybrid Electric Vehicle

9.1

Press and hold the service brake pedal.

Release the parking brake. See Fig. 9.2.

While continuing to press the service brake pedal, press Reverse (R), Neutral (N), or Drive (D) on the electronic push-button shifter to put the vehicle into gear.

Engine Shutdown

With the vehicle stopped, press and hold the service brake pedal.

Press Park (P) on the electronic push-button shifter, if so equipped.

WARNING

The vehicle could roll away if the parking brake is not set, which could result in personal injury or property damage.

Apply the parking brake.

Press and hold the red button located on the ignition reader, until the engine shuts down.

Idle-Off Shutdown Procedure

Some vehicles may be equipped with an idle-off option. A warning label like the one shown in Fig. 9.4 will be displayed in vehicles with this option. For the idle-off feature to activate, all of the following conditions must be met for 4 seconds:

•

transmission shifter is in drive (D)

•

vehicle grade sensor range is between –10% to 10%

•

HEV battery charge is more than 30%

•

battery voltage is greater than 12.3V

•

previous vehicle speed (at ﬁrst key start) is above 5 mph (8 km/h)

•

service brake is applied

•

seat belt is fastened

03/14/2006

f430466

1. Parking Brake Foot Pedal

2. Parking Brake Release Knob

Fig. 9.2, Foot Pedal-Operated Parking Brake

f610791

03/09/2006

1. Ignition Off (red) 2. Ignition On (green)

Fig. 9.3, Ignition Reader (optional on some vehicles)

Hybrid Electric Vehicle

9.2

•

ABS/HSA faults are not active

•

engine fault is not active

•

hood is closed

•

air pressure is more than 65 psi (448 kPa)

•

steering pressure is less than 600 psi (4137 kPa)

•

HEV fault is not active

T-Handle Shifter

The hybrid electric vehicle (HEV) is equipped with an Eaton automated manual transmission. A T-handle shift control is used by the driver to select the transmission ranges. See

Fig. 9.5.

P (Park)

Use park 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.

NOTE: This does not apply the parking brake.

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 places the transmission in Neutral and engages the park pawl.

R (Reverse)

The reverse position selects the reverse gear once the vehicle speed is less than 2 mph (3 km/h). 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. Select P (park), or N (neutral) when time at idle exceeds 5 minutes.

N (Neutral)

The neutral position places the transmission in neutral. This position is used when starting the engine and for stationary operation.

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

D (Drive)

The drive position selects the default start gear and automatically upshifts and downshifts. 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 range or

06/03/2010

WARNING

SHIFT TO PARK AND APPLY PARKING BRAKE BEFORE EXITING

THE VEHICLE OR LEAVING THE DRIVER’S SEAT.

ENGINE MAY START AND STOP AUTOMATICALLY RESULTING IN

VEHICLE MOVEMENT IF LEFT UNATTENDED.

SEE OWNER’S MANUAL FOR ADDITIONAL SAFETY INSTRUCTIONS

24−01703−000

f080165

Fig. 9.4, Idle-Off Warning Label

06/25/2010 f270162

Fig. 9.5, T-Handle Shift Control

Hybrid Electric Vehicle

9.3

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

H (Hold)

This hold position on the T-handle shifter holds the transmission in the current gear.

1 (Low Gear)

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

Disabling the Hybrid Electric Vehicle (HEV) System

The following information describes the three methods to disable the HEV system.

Option 1 (preferred method)

Turn off the ignition, or if equipped with an ignition reader, press the red button on the ignition pad. See

Fig. 9.3.

•

The engine will shut down.

•

The dash lights will shut down.

•

The HEV system will shut down.

•

The HEV batteries are still active, but are isolated in the Power Electronics Carrier (PEC).

Option 2

Disconnect the low-voltage (12 volt) vehicle batteries. See Fig. 9.6.

•

The engine will shut down.

•

The HEV system will shut down.

•

The HEV batteries are still active, but are isolated in the Power Electronics Carrier.

Option 3

Push in the service switch in the Power Electronics Carrier and shut down the engine. See

Fig. 9.7.

IMPORTANT: The red service switch on the PEC should only be used for an emergency shutdown or when the service manual or troubleshooting guide directs the Hybrid-Trained Technician to perform work on the high- voltage system.

•

Hybrid system will be disabled

05/26/2006 f151097

1. Passenger Steps 2. Ground Cable

Fig. 9.6, Battery Location

04/22/2009 f545519

Fig. 9.7, Service Switch

Hybrid Electric Vehicle

9.4

•

HEV batteries are still "live" but are isolated in the PEC.

IMPORTANT: These procedures should only be used for an emergency. If service is required on the vehicle, refer to the "Hybrid Services Shutdown" procedure found in TRSM1000 located on

www.roadranger.com.

In Case of an Emergency

When conditions allow, pull the vehicle onto the shoulder of the road and stop.

Apply the parking brake.

WARNING

The vehicle could roll away if the parking brake is not set, which could result in personal injury or property damage.

Push Park (P) on the electronic push-button shifter, if so equipped.

Turn the ignition key off, or, if equipped with an ignition reader, press the red button on the ignition pad to turn off the ignition.

Exit the vehicle.

If the HEV becomes involved in an accident or ﬁre, be aware of the following:

•

Use CO2 or dry chemical extinguishers. Lithium ion batteries are contained in the Power Electronics Carrier (PEC).

•

The high-voltage wiring is covered in orange insulation or convoluted tubing and marked with warning labels at the connectors.

•

All Eaton® Hybrid Electric vehicles will be marked ’Hybrid’ on the outside of the vehicle, along with the shift label on the dash.

•

Do not cut into or open the PEC.

•

Do not cut into or open the DC/AC converter.

•

Do not cut into or open the inverter.

•

Do not cut into high-voltage cables.

•

Do not cut into the passenger side of the body. The PEC is located behind the sheet metal. See

Fig. 9.1.

High-Voltage Safety Features

All high-voltage safety cables are covered in orange insulation and clearly labeled near each connector end. Each high-voltage component is clearly tagged with a warning or danger label. See

Fig. 9.8.

12/04/2007

To reduce risk of possible serious injury (Shock, Burn or Death): Components marked with High Voltage should be avoided. Service must be performed by qualified personnel only.

You will be severely injured or killed if you do not follow the procedure. Components marked with DANGER High Voltage should be avoided. Service must be performed by qualified personnel only.

f080151

DANGERWARNING

Fig. 9.8, High-Voltage Warning and Safety Labels

Hybrid Electric Vehicle

9.5

Pre- and Post-Trip

Checklists

Pretrip and Post-Trip Inspection General Information ................................... 10.1

Daily Pretrip Inspection and Maintenance Checklist ..................................... 10.2

Weekly Post-Trip Inspection and Maintenance Checklist ................................. 10.3

Monthly Post-Trip Inspection and Maintenance Checklist ................................ 10.3

Pretrip and Post-Trip Inspection 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.

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.

Pretrip 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

Chapter 11.

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 Walk-In Van Chassis Workshop Manual for procedures and speciﬁcations, or take the vehicle to an authorized Freightliner dealer.

IMPORTANT: The pretrip and post-trip checklists in this chapter, and the maintenance procedures detailed in

Chapter 11 and in the Walk-In Van

Chassis Maintenance Manual are not all inclu-

sive. Also, refer to the inspection and maintenance instructions of the major component manufacturers and the body manufacturer.

Pre- and Post-Trip Checklists

10.1

Daily Pretrip Inspection and Maintenance Checklist

IMPORTANT: Before performing any checks, apply the parking brake and chock the tires.

See Table 10.1 for a checklist of the procedures that should be performed daily, before the ﬁrst trip.

Procedure Performed

(check off)

Daily Pretrip Inspections/Checks

Procedure

Reference

_______

Drain manually drained air reservoirs (that are not equipped with automatic drain valves)

Check _______ surge tank coolant level D2 Inspect _______ radiator and charge air cooler D3 Check _______ engine for fuel, oil, or coolant leaks D4 Check _______ CNG engines for natural gas leaks, using a natural gas detector D4 Check _______ intake-air restriction indicator and air intake system D5 Check _______ engine oil level D6 Check _______ automatic transmission ﬂuid level, if equipped D7 Check _______ fuel/water separator for contaminants and leaks, if equipped D8 Check _______ fuel tank(s), fuel lines, and connections D9 Check _______ fuel level D10 Check _______ diesel engine fuel cap vent area is clean D10 Check _______ CNG engine pressure gauge mounted in fuel ﬁll box D10 Check _______ front and rear suspension components D11 Check _______ oil- and air-pressure warning systems D12 Check _______ horn D13 Check _______ backup alarm, if equipped – Check _______ headlights, mirrors, and window glass D14 Check _______ air brake chambers and pushrods D15 Check _______ slack adjusters D16 Check _______ tire pressure D17 Check _______ tire condition D18 Check _______ rims and wheels D19 Check _______ air brake system D20 Check _______ parking brakes D21 Inspect _______ frame rails (missing bolts), crossmembers (bent or loose) –

Check _______

mud ﬂaps (aren’t damaged, at least 10 inches above the ground, and brackets are secure)

–

Check _______

exhaust system (mounted securely, connected tightly, no signs of leaks such as soot trails)

–

Check _______ Bendix Hydro-Max® brake booster D22 Inspect _______ engine and chassis wiring D23

_______ remove chocks and test service brakes D24

Inspector___________________________________________________ Date ________________

Table 10.1, Daily Pretrip Inspection and Maintenance Checklist

Pre- and Post-Trip Checklists

10.2

Weekly Post-Trip Inspection and Maintenance Checklist

IMPORTANT: Before performing any checks, apply the parking brake and chock the tires.

See Table 10.2 for a checklist of the procedures that should be performed weekly, post-trip.

Procedure Performed

(check off)

Weekly Post-Trip Inspections/Checks

Procedure Reference

_______ 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 _______ drive belts W4 Check _______ drive belt tension W5 Inspect _______ seat belts and tether belts —

Inspector___________________________________________________ Date ________________

Table 10.2, Weekly Post-Trip Inspection and Maintenance Checklist

Monthly Post-Trip Inspection and Maintenance Checklist

IMPORTANT: Before performing any checks, apply the parking brake and chock the tires.

See Table 10.3 for a checklist of the procedures that should be performed monthly, post-trip.

Procedure Performed

(check off)

Monthly Post-Trip Inspections/Checks

Procedure Reference

_______ Clean the battery terminals M1 Inspect _______ radiator hoses and heater hoses M2

Check _______

ﬂuid level in the hydraulic clutch reservoir (if applicable, and if necessary, ﬁll with DOT 6 brake ﬂuid)

—

Check _______ ﬂuid level in the hydraulic brake ﬂuid reservoir, if equipped M3 Check _______ steering wheel play M4 Check _______ outer surfaces of the hood and body (for visible surface breaks and damage) — Inspect _______ brake lining wear M5 Inspect _______ driveshaft —

Inspector___________________________________________________ Date ________________

Table 10.3, Monthly Post-Trip Inspection and Maintenance Checklist

Pre- and Post-Trip Checklists

10.3

Pre- and Post-Trip

Inspections and

Maintenance

Safety Precautions ............................................................... 11.1

Daily Pretrip Inspection and Maintenance Procedures ................................... 11.1

Weekly Post-Trip Inspection and Maintenance Procedures ............................... 11.9

Monthly Post-Trip Inspection and Maintenance Procedures ............................. 11.11

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, repair, addition of lubricants, or a change of lubricants, see the Walk-In Van Chassis Workshop Manual for repair procedures and speciﬁcations. Speciﬁc references to the manual will be found where appropriate.

Drain manually drained air reservoirs (that are not equipped with automatic drain valves).

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.

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.

Check the coolant level in the surge tank.

See

Fig. 11.1. If the coolant is low, add a 50/50

mixture of water and the type of antifreeze currently installed in your vehicle. Fill the surge tank with coolant to the MAX line when the tank is cool. See

Table 11.1 for approved coolants. If

the surge tank was empty, start the engine after reﬁlling, then check the level again when the engine is at operating temperature.

Approved Coolants

Engine Type Coolant Manufacturer

Coolant

Designation

Diesel

Old World Industries Fleet Charge®

Shell

Shell HD/N

Antifreeze Texaco JC04 Antifreeze Van Waters and

Rogers Ltd. (Canada)

Diesel Antifreeze

No. 6038

Gasoline

Propane

GM DEX-

COOL®

†

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.

†

GM DEX-COOL is approved for use in gasoline and propane engines

only.

Table 11.1, Approved Coolants

05/31/2007

f200705

Fig. 11.1, Surge Tank Fill Cap

Pre- and Post-Trip Inspections and Maintenance

11.1

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.

Inspect the radiator and charge air cooler.

3.1

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.

3.2

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).

3.3

Also inspect and clean the condenser. If clogged, the condenser can restrict airﬂow through the radiator.

3.4

Check the radiator for leaks. If leaks are found, have the radiator repaired or replaced. Take the vehicle to an authorized Freightliner dealer for assistance.

Inspect the engine for fuel, oil, and coolant leaks. On vehicles equipped with a compressed natural gas (CNG) engine, use a natural gas detector to check for natural gas leaks.

Correct any leaks found.

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.

5.1

Check the intake-air restriction indicator, if so equipped.

5.2

Replace the primary ﬁlter element in the air cleaner when ﬁlter restriction reaches

25 inH

O for Cummins engines or 15 inH2O for GM engines. See Group 09 of the Walk-In Van Chassis Workshop Manual for ﬁlter element replacement instructions, or take the vehicle to an authorized Freightliner dealer. See

Fig. 11.2

and Fig. 11.3.

NOTE: After replacing the ﬁlter element, reset the restriction indicator by pressing the rubber reset button, if so equipped.

5.3

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.

5.4

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

09/09/2014 f090509

To replace the ﬁlter, the canister must be replaced.

Fig. 11.2, Farr Air Cleaner Filter Element

Pre- and Post-Trip Inspections and Maintenance

11.2

connections, and have damaged components replaced. Make sure the piping system is airtight so that all intake air passes through the air cleaner.

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.

6.1

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: Follow the engine manufacturer’s guidelines for engine shutdown time requirements prior to checking the oil level.

6.2

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.

6.3

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

Fig. 11.4 for diesel en-

gines and

Fig. 11.5 for gasoline and liquid

propane gas (LPG) engines.

For diesel engines that comply with EPA07 or newer regulations, use CJ-4 engine oil with less than 1% sulfated ash.

For gasoline and 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.

NOTICE

Failure to use the recommended oil can result in engine or aftertreatment component damage and will void the warranty.

Check the oil level in the automatic transmission.

NOTE: The ﬂuid must be warm to ensure an accurate check. The ﬂuid level rises as temperature increases.

09/03/2010 f090481

1. Primary Filter Element

Fig. 11.3, Donaldson Air Cleaner Filter Element

10/26/2012 f012203

FULL ADD 2 QT

Fig. 11.4, Oil Dipstick (diesel engine)

08/05/2010 f012186

Oil should be within the cross-hatched area of the dipstick.

Fig. 11.5, Oil Dipstick (gasoline and propane engines)

Pre- and Post-Trip Inspections and Maintenance

11.3

With the vehicle on a level surface, check the oil level in the transmission using one of the following procedures:

Hot Check

•

Operate the transmission in a Drive (D) range until normal operating temperature, 160 to 200°F (71 to 93°C), is reached.

•

Park the vehicle. Shift to Neutral (N) and apply the parking brake. Let the engine run at idle.

•

Wipe the dipstick clean and check the ﬂuid level. A safe operating level is any level within the HOT-run (upper) band on the dipstick. See

Fig. 11.6.

•

If the ﬂuid is not within this range, add or drain ﬂuid as needed to bring the level to the top of the HOT-run band. See the Walk-In Van Chas- sis Maintenance Manual for ﬂuid types and capacities.

IMPORTANT: Do not drain the fuel/water separator completely. Drain no more than three tablespoons of ﬂuid at a time.

Check the fuel/water separator for contaminants and leaks.

IMPORTANT: When draining ﬂuid from a fuel/ water separator, drain the ﬂuid into an appropriate container and dispose of it properly. Many states now issue ﬁnes for draining fuel/water separators on the ground. On all types of separators, stop draining ﬂuid when you see fuel come out of the separator drain valve.

Inspect the fuel tanks, fuel lines, and connections for leaks.

On vehicles equipped with a compressed natural gas (CNG) engine, inspect the fuel tanks, fuel regulators, fuel ﬁlters, and the fuel lines. Use a natural gas detector to check for any leaks, or spray the components with a soap-and-water solution and check for bubbles.

9.1

Check that the fuel tanks are secured to their mounting brackets and that the mounting brackets are secured to the frame.

9.2

Replace leaking fuel tanks.

9.3

If lines or connections are leaking, have them repaired or replaced.

For repair and/or replacement procedures, see Group 47 of the Walk-In Van Chassis Workshop Manual, or take the vehicle in to an authorized Freightliner dealer.

9.4

If equipped with fuel tank shutoff valves, be sure the valves are fully open.

WARNING

Never operate the engine with the fuel tank shutoff valves partly closed. This could damage the fuel pump, causing sudden loss of engine power, possibly resulting in serious personal injury due to reduced vehicle control.

10.

Check the fuel level in the fuel tank(s).

On vehicles equipped with a diesel engine be sure that the fuel cap vent area is clean. Check the fuel/water separator (if so equipped) for leaks and, if needed, prime the fuel tank system.

On vehicles equipped with a compressed natural gas (CNG) engine, check the pressure gauge mounted in the fuel ﬁll box to determine the amount of fuel in the fuel tanks.

WARNING

Never ﬁll fuel tanks to more than 95 percent of their liquid capacity. This could make them more likely to rupture from impact, possibly causing ﬁre and resulting in serious personal injury or death by burning.

02/27/2002

f270077

A. Hot-Run Band B. Cold-Run Band

Fig. 11.6, Automatic Transmission Dipstick Markings

Pre- and Post-Trip Inspections and Maintenance

11.4

IMPORTANT: Use only ultralow-sulfur diesel (ULSD) fuel with 15 ppm sulfur content or less, based on ASTM D2622 test procedure. Failure to use ultralow-sulfur diesel fuels may void the warranty on emissions components.

10.1

To keep condensation to a minimum, ﬁll diesel fuel tanks at the end of each day, but not to more than 95 percent of liquid capacity. Select the proper grade of fuel, as speciﬁed by the engine manufacturer.

WARNING

Do not mix gasoline or alcohol with diesel fuel. This mixture could cause an explosion, possibly resulting in serious personal injury or death. Do not ﬁll the fuel tanks in the presence of sparks, open ﬂames, or intense heat. These could ignite the fuel, possibly causing severe burns.

10.2

Always strain or ﬁlter diesel fuel before putting it into the tanks. This will lengthen the life of the engine fuel ﬁlter and reduce the chances of dirt entering the engine.

11.

Inspect the front and rear suspension components, including springs, spring hangers, shocks, and suspension brackets.

11.1

Check for broken spring leaves, loose U-bolts, cracks in the suspension brackets, and loose fasteners in the spring hangers and shackles.

11.2

Inspect the shock absorbers for loose fasteners and leaks.

11.3

Tighten all loose fasteners and have any components replaced that are worn, cracked, or otherwise damaged.

11.4

On vehicles with air suspensions, check for leaks. Check air suspension components for cuts and bulges.

WARNING

Do not replace individual leaves of a damaged front or rear suspension leaf spring assembly; replace the complete spring assembly. Visible damage, such as cracks or breaks, to one leaf causes hidden damage to other leaves. Replace-

ment of only the visibly damaged part(s) is no assurance that the spring is safe. If cracks or breaks exist on front spring assemblies in either of the two top leaves, a loss of vehicle control could occur. Failure to replace a damaged spring assembly could cause an accident resulting in serious personal injury or property damage.

12.

Check the oil- and air-pressure warning systems.

When the engine is started, oil- and air-pressure warnings will come on until the oil and air pressure rise above a preset minimum. After starting the engine, make sure the oil- and air-pressure warning systems are operating and that the buzzer stops sounding when the preset minimum is reached.

12.1

If the warning systems do not come on when the ignition is turned on, have the systems repaired.

12.2

If the air pressure in both systems is above the preset minimum when the engine is started, test the low air pressure system by lowering the pressure to below this range, or until the warning system comes on.

NOTE: The air pressure in both the primary and secondary air reservoir systems must be above 65 psi (448 kPa) on most vehicles.

13.

Make sure that the electric horn works.

If a horn is not working, have it replaced before trip departure.

14.

Make sure all the exterior lights are working.Check the high and low beams of the head-

lights. Clean the windshield, side, and rear windows (if equipped) with a long-handled or telescoping window cleaning device and standard cleaning solutions. Stand only on the ground, on a stepladder, or an elevated walkway. The vehicle entry/exit steps and handholds are not designed for this purpose. The tires, fenders, engine, and other under-hood components do not have adequate gripping surfaces and handholds.

DANGER

Do not loosen or remove the parking brake clamp ring for any purpose. See

Fig. 11.7. The parking/

emergency brake section of the brake chamber is

Pre- and Post-Trip Inspections and Maintenance

11.5

not intended to be serviced. Serious injury or death may result from sudden release of the power spring.

Before doing any repairs or adjustments on a service/parking brake chamber, read the applicable warnings and instructions in Group 42 of the Walk-In Van Chassis Workshop Manual.

15.

Inspect the air brake chamber and the air brake chamber pushrods. See

Fig. 11.7.

16.

Inspect the slack adjusters.

16.1

Meritor Slack Adjusters: Check the boot for cuts, tears, or other damage. Have it replaced if necessary.

16.2

Inspect the slack adjuster boot for cuts or tears. If the boot is damaged, have it replaced. See

Fig. 11.8.

17.

Check tire inﬂation pressures using an accurate tire pressure gauge.

Tires should be checked when cool. For inﬂation pressures and maximum loads (per tire) see the tire manufacturer’s guidelines.

17.1

Be sure valve stem caps are on every tire and that they are screwed on ﬁnger-tight.

17.2

Inﬂate the tires to the applicable pressures if needed.

17.3

If a tire has been run ﬂat or underinﬂated, check for possible wheel or tire damage before adding air.

Moisture inside a tire can result in body ply separation or a sidewall rupture. During tire inﬂation, compressed air reservoirs and lines must be kept dry. Use well maintained inline moisture traps and service them regularly.

WARNING

Do not operate the vehicle with underinﬂated or overinﬂated tires. Incorrect inﬂation can stress the tires and make the tires and wheels susceptible to damage, possibly leading to wheel or tire failure and loss of vehicle control, resulting in serious personal injury or death.

IMPORTANT: The load and cold inﬂation pressure must not exceed the wheel manufacturer’s recommendations, even though the tire may be approved for a higher load

02/22/2000

f421352

A. Do not remove this clamp ring.

1. MGM TR-T (TR Series) Brake Chamber shown

Fig. 11.7, Parking Brake Chamber Clamp

f421398

06/17/2003

1. 7/16-inch Adjusting Nut

2. Grease Fitting

3. Boot

4. Link

5. Brake Chamber Piston Rod

6. Clevis

7. ½-inch Clevis Pin

8. 1/4-inch Clevis Pin

9. Grease Relief Opening

10. Slack Adjuster Spline

Fig. 11.8, Automatic Slack Adjuster (typical)

Pre- and Post-Trip Inspections and Maintenance

11.6

inﬂation. Some wheels are stamped with a maximum load and maximum cold inﬂation rating. If they are not stamped, consult the wheel manufacturer for the correct tire inﬂation pressure for the vehicle load. If the load exceeds the maximum wheel capacity, the load must be adjusted or reduced.

IMPORTANT: Low-rolling resistance (LRR) tires minimize wasted energy as a tire rolls, thereby decreasing rolling effort and improving fuel efficiency. If tire replacement is necessary, replacement tires must meet or exceed the rolling resistance of the originally installed tires in order to maintain compliance with greenhouse gas and fuel efficiency regulations (GHG14).

Contact your tire manufacturer/supplier to determine the rolling resistance of the originally installed tires. Visit

www.epa.gov/smartway for

additional information and resources.

18.

Inspect each tire for wear, bulges, cracks, cuts, penetrations, and oil contamination. A weekly

pressure loss of 4 psi (28 kPa) or more in a tire may indicate damage. The tire should be inspected and if necessary, repaired or replaced.

18.1

Check the tire tread depth. If tread is less than 4/32 inch (3 mm) on any front tire, or less than 2/32 inch (1.5 mm) on any rear tire, replace the tire.

18.2

Inspect each tire for bulges, cracks, cuts, and penetrations.

18.3

Inspect each tire for oil contamination. Fuel, oil, gasoline, and other petroleum derivatives, if allowed to contact the tires, will soften the rubber and destroy the tire.

19.

Check the wheel nuts for indications of looseness. Examine each wheel component.

19.1

Remove all dirt and foreign material from the assembly. Dirt or rust streaks from the stud holes, metal buildup around stud holes, or out-of-round or worn stud holes may be caused by loose wheel nuts. See

Fig. 11.9 and Fig. 11.10.

19.2

Examine the wheel components (including studs and nuts) for cracks or other damage.

See Group 33 or Group 35 of the Walk-In Van Chassis Workshop Manual for service procedures on the studs and hubs, and see Group 40 in the same manual for wheel and tire servicing, or take the vehicle to an authorized Freightliner dealer.

WARNING

Have any worn or damaged wheel components replaced by a qualiﬁed person using the wheel manufacturer’s instructions and the wheel industry’s standard safety precautions and equipment. Otherwise a vehicle or workshop accident could occur, possibly resulting in serious personal injury or death.

19.3

Make sure all wheel nuts are tightened 450 to 500 lbf·ft (610 to 678 N·m) for Accuride wheels with unlubricated threads. Use the tightening pattern in

Fig. 11.11 for

10-hole wheels and

Fig. 11.12 for 8-hole

wheels. See Group 40 of the Walk-In Van Chassis Workshop Manual.

NOTICE

Insufficient wheel nut torque can cause wheel shimmy, resulting in wheel damage, stud breakage, and extreme tire tread wear. Excessive wheel nut torque can break studs, damage threads, and crack discs in the stud hole area. Use the recommended torque values and follow the proper tightening sequence.

02/09/95

f400058

Fig. 11.9, Dirt and Rust Streaks from the Stud Holes

Pre- and Post-Trip Inspections and Maintenance

11.7

NOTE: Vehicles operating under severe or adverse conditions should be checked more frequently.

20.

Check the air brake system for proper operation.

20.1

Check the air governor cut-in and cut-out pressures as follows:

Run the engine at fast idle. The air governor should cut out the air compressor at approximately 120 psi (827 kPa). With the engine idling, apply the brake pedal several times. The air governor should cut in the air compressor at approximately 100 psi (689 kPa). If the air governor does not cut in and out as described above, it must be adjusted to these speciﬁcations. If the air governor cannot be adjusted or repaired, replace it before operating the vehicle.

20.2

Check the air pressure buildup times as follows:

With the air system fully charged to 120 psi (827 kPa), make one full brake application and note the air pressure reading on the gauge. Continue to reduce the air pressure by moderate brake applications to a maximum of 90 psi (620 kPa), then run the engine at governed rpm. If the time required to raise the air pressure to 120 psi (827 kPa) (from the pressure noted after one brake application) is more

02/09/95

f400001

Fig. 11.10, Worn Stud Holes

f400081a

08/23/93

Fig. 11.11, Tightening Pattern, 10-Hole Wheels

f400052a

03/08/2012

Fig. 11.12, Tightening Pattern, 8-Hole Wheels

Pre- and Post-Trip Inspections and Maintenance

11.8

than 30 seconds, eliminate any leaks or replace the air compressor before operating the vehicle.

20.3

Check the air pressure reserve as follows:

With the air system fully charged to 120 psi (827 kPa), stop the engine and note the air pressure. Then make one full brake application and observe the pressure drop. If it drops more than 25 psi (172 kPa), all areas of leakage must be eliminated before operating the vehicle.

20.4

Check the air leakage in the system as follows:

With the parking brake (spring brake) applied, the transmission out of gear, and the tires chocked, charge the air system until cut-out pressure of 120 psi (827 kPa) is reached.

With the service brakes released, shut down the engine, wait 1 minute and note the air pressure gauge reading. Observe the air pressure drop in psi (kPa) per minute.

Charge the air system until cut-out pressure of 120 psi (827 kPa) is reached. With the parking brakes released and the service brake applied, shut down the engine, wait 1 minute and note the air pressure gauge reading. Observe the air pressure drop in psi (kPa) per minute.

If leakage exceeds the limits shown in

Table 11.2, repair all areas of leakage be-

fore driving the vehicle.

Maximum Allowable Service Brake Leakage

Brakes Released Brakes Applied

2 psi/min. (14 kPa) 3 psi/min. (21 kPa)

Table 11.2, Maximum Allowable Service Brake

Leakage

21.

Test the parking brake on a 20 percent grade.

Apply the hand brake with the vehicle on a 20 percent grade (or as steep a grade that the vehicle may normally be parked on). The ramp surface should be made of Portland cement or equivalent. If the parking brake does not hold the vehicle, repair the parking brake system.

22.

Check the operation of the Bendix® Hydro-Max brake booster, as follows.

22.1

With ignition off, depress the brake pedal and listen for the back-up motor to engage. Also, note that the pedal force relieves; the pedal should depress easily.

22.2

With the ignition off, engine running, parking brake released, ensure that the BRAKE warning indicator light is not on. This is a dual indicator and indicates that the parking brake is set, and warns if there is a hydro-max failure other than loss of back-up motor power.

23.

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.

24.

Test the service brakes.

When starting to move the vehicle and before picking up speed, test the brakes with the foot pedal and parking brake control valve (yellow knob) to be sure they will bring the vehicle to a safe stop.

Weekly Post-Trip Inspection and Maintenance Procedures

Inspect the batteries and battery cables.

WARNING

Battery posts, terminals, and related accessories contain lead and lead compounds, chemicals known to the State of California to cause cancer and reproductive harm. To prevent possible personal injury, always wash your hands after handling battery parts and related accessories.

1.1

Check the battery cables for chaﬁng and proper routing. Be sure the battery holddown is secure. If it is loose, tighten the hold-down bolts; if it is damaged, replace it. Replace the battery cable if damaged.

1.2

If the battery is equipped with a built-in hydrometer, examine the hydrometer. If a green dot shows in the sight glass, the battery is sufficiently charged.

Pre- and Post-Trip Inspections and Maintenance

11.9

If the sight glass is dark, the charge is low and the battery must be recharged.

If the sight glass is clear, the battery has a low level of electrolyte and must be replaced.

Check the level of the wheel bearing lubricant in the hub cap at each end of the front axle.

If needed, ﬁll the hubs to the level indicated on the hub cap. See

Chapter 15, for recommended

lubricants.

IMPORTANT: Before removing the ﬁll plug, always clean the hub cap and plug.

Examine the steering components.

See Fig. 11.13. If repairs are needed, see

Group 46 of the Walk-In Van Chassis Workshop Manual for instructions, or take the vehicle to an

authorized Freightliner dealer.

3.1

Check the mounting bolts and pitman arm nut, for tightness.

3.2

Check the drag link nuts for missing cotter pins.

3.3

Inspect the steering drive shaft and steering linkage for excessive looseness, or other damage.

3.4

Tighten loose nuts and have damaged parts replaced as needed.

Check the condition of the drive belts.

Check the fan belt(s), alternator belt, and refrigerant compressor belt for signs of glazing, wear (frayed edges), damage (breaks or cracks), or oil contamination. If a belt is glazed, worn, damaged, or oil soaked, replace the belt, following the instructions in Group 01 of the Walk-In Van

Chassis Workshop Manual.

Check the drive belt for proper tension. Use your index ﬁnger to apply approximately 25 pounds (11 kg) of force at the center of the belt freespan. See

Fig. 11.14. Deﬂection should be one

belt thickness per 1 foot (300 mm) of belt freespan. If the tension is more than or less than this value, measure it with a belt-tension gauge and adjust it to the proper tension. See Group 01 of the Walk-In Van Chassis Workshop Manual for instructions.

NOTE: On Cummins engines, a belt tensioner automatically adjusts the fan and alternator belt to correct tension. If the belt slips, repair or replace the tensioner. For instructions, see the

Cummins Engine Operation and Maintenance Manual.

10/11/2001

f461916

1. Steering Gear Mounting Bolt

2. Pitman Arm Pinch Bolt Nut

3. Drag Link Nut

Fig. 11.13, Steering Gear Fasteners

10/31/94

f200036a

A. Deﬂection B. Belt Free-Span

Fig. 11.14, Checking Belt Tension

Pre- and Post-Trip Inspections and Maintenance

11.10

Monthly Post-Trip Inspection and Maintenance Procedures

WARNING

Clean the batteries.

1.1

Remove any corrosion from the hold-down and the top of the battery.

NOTICE

Take care to keep the vent plugs tight so that the neutralizing solution does not enter any of the battery cells and damage the battery.

1.2

Use a soda solution to neutralize the acid present, then rinse off the soda solution with clean water.

1.3

If the battery posts or cable terminals are corroded, disconnect the terminals from the posts. Clean them with a soda solution and a wire brush. After cleaning, connect the terminals to the battery posts, then apply a thin coat of petroleum jelly to the posts and terminals to help retard corrosion.

Inspect the radiator and heater hoses, including the clamps and support brackets.

2.1

Make sure the radiator inlet and outlet hoses are pliable and are not cracking, weakening, or ballooning.

2.2

Make sure the heater hoses are pliable and are not cracking or ballooning. Replace hoses that show signs of cracking, weakening, or ballooning.

2.3

Tighten hose clamps as necessary, but do not overtighten, as hose life can be adversely affected.

2.4

Be sure the hose support brackets are securely fastened. Make sure the hoses are not located near sources of wear, abrasion, or high heat.

IMPORTANT: Replace all hoses, including heater hoses, at the same time. Service-type knitted or braided yarn-reinforced neoprene hose is acceptable. Silicone hoses having an extended service life can be substituted for the reinforced neoprene type. See the Freightliner Service Parts Catalog or contact your Freightliner Dealer.

Check the ﬂuid level in the hydraulic brake ﬂuid reservoir, if so equipped.

If needed, ﬁll the reservoir up to the ridge that surrounds the reservoir. Use only heavy-duty brake ﬂuid, DOT 6. See

Fig. 11.15.

Check the steering wheel for excessive play.

With the front tires pointing straight ahead, turn the steering wheel until motion is observed at the front wheels. Align a reference mark on a ruler, then slowly turn the steering wheel in the opposite direction until motion is again detected at the wheels. Measure the lash (free play) at the rim of the steering wheel. See

Fig. 11.16.

04/26/2012

f460513a

A. Open caps and check ﬂuid level. B. Fill to this level.

Fig. 11.15, Check the Hydraulic Brake Fluid Level (MT-

45/55 reservoir shown)

Pre- and Post-Trip Inspections and Maintenance

11.11

Excessive lash exists if steering wheel movement exceeds 4-3/4 inches (121 mm) with an 18-inch (470 mm) steering wheel. If there is excessive lash, check the steering system for wear or incorrect adjustment of the linkage and steering gear before operating the vehicle.

Check the brake lining wear on vehicles equipped with air brakes. Proper brake operation is dependent on periodic maintenance and inspection of the brake linings.

5.1

Apply the parking brakes, and chock the tires to prevent vehicle movement.

5.2

If the axle assembly is not equipped with a dust shield or backing plate, measure the axle brake lining thickness. If any of the brake linings are worn to less than 3/16 inch (4.8 mm) at the thinnest point, replace the linings on all brake assemblies on that axle. See Group 42 of the Walk-In Van Chassis Workshop Manual for lining replacement instructions and camshaft end play inspection.

5.3

If the axle assembly is equipped with a dust shield or backing plate, remove the inspection plugs to inspect the brake lining thickness. If any of the brake linings are worn to less than approximately 3/16 inch (4.8 mm) at the thinnest point, replace the linings on all brake assemblies on that

axle. See Group 42 of the Walk-In Van Chassis Workshop Manual for lining replacement instructions and camshaft end play inspection.

5.4

Install the inspection plugs in the dust shields or backing plates, if so equipped.

5.5

Remove the chocks from the tires.

10/10/95 f461057

A. Lash Area

Fig. 11.16, Measuring Lash at the Steering Wheel

Pre- and Post-Trip Inspections and Maintenance

11.12

Cleaning and Care

Washing and Polishing ............................................................ 12.1

Care of Chrome Parts ............................................................ 12.1

Dashboard and Instrument Panel Care ............................................... 12.1

Washing and Polishing

To extend the life of your vehicle’s ﬁnish, follow these guidelines:

•

Rinse the undercarriage regularly during the winter months to protect it from mud and road salt corrosion.

•

Do not let diesel fuel or antifreeze stand on a painted chassis surface. If either should occur, rinse the surface off with water.

•

To prevent frame corrosion, have any nicks or other damage on the frame ﬁnish touched up as soon as possible.

To prevent delamination and deterioration of labels and stickers on the cab, follow these guidlines carefully:

•

Do not pressure wash the label or sticker or surfaces near it.

•

Do not use strong alkaline soaps on or near the label or sticker.

Care of Chrome Parts

To prevent rust, keep chrome parts clean and protected at all times. This is especially important during winter driving and in coastal areas where there is exposure to salt air.

When cleaning chrome parts, use clean water and a soft cloth or sponge. A mild detergent may also be used.

Sponge gently, then rinse. If necessary, use a nonabrasive chrome cleaner to remove stubborn rust or other material. Do not use steel wool.

To help protect the chrome after cleaning, apply a coat of polishing wax to the surface. Never use wax on parts that are exposed to high heat, such as exhaust pipes.

Dashboard and Instrument Panel Care

NOTICE

When cleaning the dashboard, instrument panel, or gauge lens covers, do not use Armor-All Protectant®, STP Son-of-a-Gun®, window cleaner, or

other equivalent treatments. These cleaners contain vinyl plasticizers which can cause stress crazing in the interior plastic panels and can result in cracking of the panels. Some cleaners can also have an adverse effect on the clear plastic of instrument panels and gauge lens covers, resulting in a foggy or cloudy appearance. This type of damage is not covered by vehicle warranty.

To clean the dashboard, instrument panel, and gauge lens covers, use a cloth dampened with warm soapy water. Make certain to wring the cloth out well before cleaning, as excess water will damage the electrical components.

Cleaning and Care

12.1

In an Emergency

Hazard Warning Lights ............................................................ 13.1

Towing ......................................................................... 13.1

Emergency Starting With Jumper Cables ............................................. 13.1

Changing a Flat Tire .............................................................. 13.3

Running Out of Fuel .............................................................. 13.3

Hazard Warning Lights

The hazard warning light tab is located on the steering column. See

Fig. 13.1. Pull the tab out to acti-

vate the hazard warning lights. When the hazard warning light tab is pulled out, all of the turn signal lights and both of the indicator lights on the instrument panel will ﬂash. To cancel the hazard warning lights, push the tab in.

An additional hazard warning light control knob may be installed on the dash near the headlight controls. To activate the hazard warning lights, pull the knob out.

Towing

See Chapter 14 for towing information.

Emergency Starting With Jumper Cables

When using jumper cables, follow the instructions below.

WARNING

Batteries release explosive gas. Do not smoke when working around batteries. Put out all ﬂames and remove all sources of sparks or intense heat in the vicinity of the battery. Do not allow the ve-

hicles to touch each other. Do not lean over the batteries when making connections, and keep all other persons away from the batteries. Failure to follow these precautions could lead to severe personal injury as a result of an explosion or acid burns.

NOTICE

Make sure that both starting systems are the same voltage. Electronic devices on both vehicles can be damaged when connected to a vehicle with a different operating voltage.

Apply the parking brakes and turn off all lights and other electrical devices.

IMPORTANT: Do not attempt to jump start a damaged battery.

Access the batteries under the passenger steps.

NOTICE

Always connect the batteries and jumper cables correctly (positive-to-positive and negative-tonegative). Connecting a charging device backwards (positive-to-negative) can severely damage the vehicle electrical content and cause nonwarrantable failures.

Connect the positive (+) jumper cable to the positive terminal on the discharged battery. See

Fig. 13.2.

Connect the other end of the positive jumper cable to the positive terminal on the booster battery providing the charge.

WARNING

Do the next step exactly as instructed and do not allow the clamps of one cable to touch the clamps of the other cable. Otherwise, a spark could occur near a battery, possibly resulting in severe personal injury from explosion or acid burns.

Connect the negative (-) jumper cable to the negative terminal on the booster battery.

Connect the other end of the negative jumper cable to the negative ground stud on the vehicle requiring the jump start.

11/27/2007 f462122

Fig. 13.1, Hazard Warning Light Tab

In an Emergency

13.1

Start the engine of the vehicle providing the jump start and let the engine run for a few minutes to charge the batteries of the other vehicle.

NOTICE

Do not crank the engine for more than 30 seconds at a time during any of the following procedures. Wait two minutes after each try to allow

the starter to cool. Failure to do so could cause starter damage.

Attempt to start the engine of the vehicle with the batteries receiving the charge.

When the engine starts, let it idle for a few minutes.

01/07/2011 f545725

−

Disconnect jumper cables in the REVERSE order that they were connected.

A. Discharged Battery B. Negative Ground Stud

C. Positive Jumper Cable D. Negative Jumper Cable

E. Booster Battery

1. 1st Connection: Positive Jumper Cable to Discharged Battery

2. 2nd Connection: Positive Jumper Cable to Booster Battery

3. 3rd Connection: Negative Jumper Cable to Booster Battery

4. 4th Connection: Negative Jumper Cable to Negative Ground Stud (discharged battery)

Fig. 13.2, Jumper Connections (three battery system shown for clarity)

In an Emergency

13.2

WARNING

10.

Disconnect the negative jumper cable from the negative cable stud on the jump started vehicle.

11.

Disconnect the negative jumper cable from the booster battery.

12.

Disconnect the positive cable from the booster battery.

13.

Disconnect the other end of the positive jumper cable from the jump started vehicle.

14.

Close the battery access door at the passenger steps.

Changing a Flat Tire

IMPORTANT: If a ﬂat tire occurs while driving, gradually decrease vehicle speed. Holding the steering wheel ﬁrmly, move the vehicle to a safe location as quickly as possible.

If possible, stop the vehicle on a level surface away from traffic.

Apply the parking brake and place the transmission in Park (P). Turn the ignition switch to the OFF position.

Turn on the hazard warning lights.

Remove the spare wheel, jack, jack handle, and lug wrench (if so equipped) from storage.

Block the wheel diagonally opposite the wheel being changed.

NOTICE

The jacking point for the front and rear wheels is directly under the axle. Insert a wooden block between the axle and the jack. Do not jack directly on the axle housing.

Place the jack on a solid surface. Insert the jack handle and pump the handle to slightly raise the vehicle. Do not raise the wheel off of the ground.

Loosen the wheel lug nuts, but do not remove them.

NOTE: Dual stud-piloted rear wheels are attached using inner and outer (2-element) lug nuts. The larger nut retains the outer dual (studpiloted), 2-piece wheel. The inner square nut retains the inner dual (stud-piloted) wheel. Remove and install these nuts separately. The rear dual outer lug nut must be removed and loosened to check and retighten the inner nut. Hubpiloted wheels use a single outer lug nut that holds both discs on the hub pilot.

Raise the vehicle until the wheel is off of the ground. Remove the lug nuts and the wheel.

Install the spare wheel and lug nuts. Make sure that the beveled sides of the nuts face inward.

In a star pattern, tighten the nuts evenly until snug.

10.

Lower the vehicle until the wheel touches the ground. Tighten the nuts in the same pattern 450 to 500 lbf·ft (610 to 678 N·m).

11.

Finish lowering the vehicle to the ground, then remove the jack.

12.

Remove the block, then stow the jack, jack handle, and lug wrench (if so equipped).

13.

After operating the vehicle for 50 to 100 miles (80 to 161 km), retighten the nuts (for studpiloted dual discs, all inner, then all outer) 450 to 500 lbf·ft (610 to 678 N·m).

Running Out of Fuel

Diesel Engines

WARNING

Diesel fuel is ﬂammable. When you approach a vehicle and the smell of diesel fuel is present, immediately shut off all engines and ignition sources. Avoid causing sparks and stay away from arcing switches and equipment. Extinguish cigarettes, pilot lights, ﬂames, or other sources of ignition in the area and adjacent areas. Immediately provide extra ventilation to the area. Do not start the vehicle or any other type of equipment until the fuel leak is corrected and the area

In an Emergency

13.3

cleared of fuel. Failure to perform these actions could lead to the ignition of the fuel, which could cause personal injury or death, or severe property damage.

If the vehicle runs out of fuel, try to stop the vehicle on a level location away from traffic. Add at least 2 gallons (8 liters) of fuel to the fuel tank in order to restart the engine. If the vehicle is not level, up to 4 gallons (16 liters) of fuel may be required. Prolonged engine cranking may be required to pump fuel from the fuel tank to the engine before the engine will start.

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.

If the vehicle will not start by cranking the engine, the fuel system may need to be primed. See the applicable engine manufacturer’s operation and maintenance manual.

Compressed Natural Gas (CNG) Engines

WARNING

Compressed natural gas is highly ﬂammable. When inspecting or servicing a vehicle, avoid causing sparks or using arcing switches and equipment. Extinguish cigarettes, pilot lights, ﬂames, or other sources of ignition. Failure to perform these actions or to take other precautions could lead to the ignition of the natural gas, which could cause serious bodily injury, death, or severe property damage.

If the vehicle runs out of fuel, park on a level location away from traffic. Restart the engine after adding at least 30 psi (207 kPa) of fuel.

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.

In an Emergency

13.4

Towing

Front Towing Hookup ............................................................. 14.1

Rear Towing Hookup ............................................................. 14.1

Front Towing Hookup

WARNING

Do not tow an unbraked vehicle if the combined weight of both vehicles is more than the sum of the gross axle weight ratings (GAWR) of the towing vehicle. Otherwise brake capacity will be inadequate, which could result in personal injury or death.

IMPORTANT: When it is necessary to tow the vehicle, make sure the instructions below are closely followed to prevent damage to the vehicle.

NOTE: Towing rules and regulations vary from federal, state, local, and transit authority. These laws must be followed when towing the vehicle.

Front Towing Hookup

Disconnect the battery ground cables.

NOTICE

Failure to remove the axle shafts when towing the vehicle with the rear wheels on the ground could result in damage to the transmission and other parts.

Remove the rear driveshaft before towing a vehicle equipped with a hydraulic hybrid system. Failure to do so will damage the hydraulic hybrid components. Once the driveshaft has been removed, do not attempt to start a vehicle equipped with a hydraulic hybrid drive system. Doing so will damage the hydraulic hybrid system components.

Remove the drive axle shafts.

On a vehicle equipped with a hydraulic hybrid system, remove the rear driveshaft.

IMPORTANT: Cover the ends of the hubs with metal plates or plywood cut to ﬁt the axle opening, and drilled to ﬁt the axle shaft studs. This prevents lubricant from leaking out, and will keep contaminants from getting into the axle lubricant and damaging the wheel bearings.

If additional clearance is needed for towing, remove the bumper.

Attach the towing device. Due to the many variables that exist in towing, positioning the lifting and towing device is the sole responsibility of the towing-vehicle operator.

NOTICE

Failure to protect the frame rails from the chains could cause damage, leading to eventual frame failure.

Lift the vehicle and secure the safety chains. If extra towing clearance is needed, remove the front wheels.

Connect the clearance lights, taillights, and signal lights. Connect any special towing lights required by local regulations.

WARNING

Failure to chock the tires or connect the tow truck’s air brake system before releasing the spring parking brakes could allow the disabled vehicle to suddenly roll. This could cause property damage or personal injury.

NOTICE

Before attempting to tow a vehicle with an air suspension (and during the towing operation), ensure that the air suspension is properly charged. Charge the suspension through the Schrader valve on the air dryer. Attempting to tow a vehicle with an improperly charged air suspension may result in damage to the chassis and body.

Chock the tires on the disabled vehicle and connect the towing vehicle’s air brake system to the vehicle being towed. Then, release the spring parking brake and remove the chocks.

On vehicles equipped with hydraulic disc brakes be sure the parking brake is released before starting the towing process.

Rear Towing Hookup

Position the front tires pointing straight ahead, and secure the steering wheel in this position.

Towing

14.1

Disconnect the battery ground cable.

WARNING

Due to the many variables that exist in towing, positioning the lifting and towing device is the sole responsibility of the tow vehicle operator. The operator must be familiar with standard towing industry safety measures. Improper procedures could result in personal injury or death.

Attach the towing device.

Lift the vehicle, and secure the safety towing chains. If additional clearance is needed, remove the bumper extension, if so equipped.

Connect the clearance lights, taillights, and signal lights. Also connect any special towing lights required by local regulations.

Towing

14.2

GM Gasoline Engine

Starting the Engine ............................................................... 15.1

Engine Break-In ................................................................. 15.3

Fast Idle System ................................................................. 15.3

Engine Coolant .................................................................. 15.4

Fuel ........................................................................... 15.4

Engine Oil ...................................................................... 15.5

Ametek Instrument Panel .......................................................... 15.5

Warning and Indicator Lights ...................................................... 15.11

Speedometer and Tachometer ..................................................... 15.18

Standard Instruments ............................................................ 15.18

Starting the Engine

IMPORTANT: For service issues and questions, call 1-800-FTL-HELP and follow the prompts for gasoline engines. Representatives will be able to answer questions and diagnose mechanical issues, as well as provide detailed service repair information.

General Information

NOTE: Before starting the engine, read Chap-

ter 2

and Chapter 3 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 10 and Chapter 11 of this manual.

NOTICE

IMPORTANT: Ring gear and starter pinion damage caused by improper starting procedures is not warrantable.

NOTICE

Never attempt to start any electronic engine using ether or any other starting ﬂuid. Serious engine damage could result.

Set the parking brake.

Turn the ignition switch to the ON position. See

Fig. 15.1 for the four-position ignition switch and Fig. 15.2 for the three-position ignition switch.

Make sure that the transmission shift control is in Neutral (N) or Park (P), and that the park brake is set.

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

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.

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

07/10/96

f601179

1. Accessory (optional)

2. Off

3. On

4. Start

Fig. 15.1, Four-Position Ignition Switch

05/10/2001

f601179a

1. Off 2. On 3. Start

Fig. 15.2, Three-Position Ignition Switch

GM Gasoline Engine

15.1

Freightliner WALK-IN VAN Operator's Manual

Specifications and Main Features

Frequently Asked Questions

User Manual