Foreword - sd95d2cbd361a0b8d.jimcontent.com · Foreword. Contents Chapter Page Introduction, Environmental Concerns and Recommendations, Event Data Recorder, Customer Assistance Center,

IntroductionThis manual provides information needed to operateand understand the vehicle and its components.More detailed information is contained in the Owner’sWarranty Information for North America booklet, andin the vehicle’s workshop and maintenance manuals.

Custom-built Sterling vehicles are equipped with vari-ous chassis and cab components. Not all of the infor-mation contained in this manual applies to every ve-hicle. For details about components in your vehicle,refer to the chassis specification pages included in allnew vehicles and to the vehicle specification decallocated inside the vehicle.

For your reference, keep this manual in the vehicleat all times.

IMPORTANT: Descriptions and specifications in thismanual were in effect at the time of printing. SterlingTruck Corporation reserves the right to discontinuemodels and to change specifications or design at anytime without notice and without incurring obligation.Descriptions and specifications contained in this pub-lication provide no warranty, expressed or implied,and are subject to revisions and editions without no-tice.

Environmental Concerns andRecommendationsWhenever you see instructions in this manual to dis-card materials, you should first attempt to reclaimand recycle them. To preserve our environment, fol-low appropriate environmental rules and regulationswhen disposing of materials.

Event Data RecorderThis vehicle is equipped with one or more devicesthat record specific vehicle data. The type andamount of data recorded varies depending on howthe vehicle is equipped (such as the brand of engine,if an air bag is installed, or if the vehicle features acollision avoidance system, etc.).

Customer Assistance CenterHaving trouble finding service? Call the CustomerAssistance Center at 1-800-785-4357 or 1-800-STL-HELP. Call night or day, weekdays or weekends, fordealer referral, vehicle information, breakdown coor-

dination, or Fleetpack assistance. Our people areknowledgeable, professional, and committed to fol-lowing through to help you keep your truck moving.

Reporting Safety DefectsIf you believe that your vehicle has a defect whichcould cause a crash or could cause injury ordeath, you should immediately inform the NationalHighway Traffic Safety Administration (NHTSA) inaddition to notifying Sterling Truck Corporation.

If the NHTSA receives similar complaints, it mayopen an investigation and if it finds that a safetydefect exists in a group of vehicles, it may order arecall and remedy campaign. However, NHTSAcannot become involved in individual problemsbetween you, your dealer, or Sterling Truck Corpo-ration.

To contact NHTSA, you may call the VehicleSafety Hotline toll-free at 1-888-327-4236 (TTY:1-800-424-9153); go to www.safercar.gov; or writeto: Administrator, NHTSA, 1200 New JerseyAvenue, SE, Washington, DC 20590. You can alsoobtain other information about motor vehicle safetyfrom www.safercar.gov.

Canadian customers who wish to report a safety-related defect to Transport Canada, Defect Investi-gations and Recalls, may telephone the toll-freehotline 1-800-333-0510, or contact TransportCanada 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 visitthe Road Safety website at:www.tc.gc.ca/roadsafety/menu.htm.

Foreword

STI-401-1 (3/09P)A24-00993-000

Printed in U.S.A.

© 2000–2009 Daimler Trucks North America LLC. All rights reserved. Daimler Trucks North America LLC is a Daimlercompany.

No part of this publication, in whole or part, may be translated, stored in a retrieval system, or transmitted in any formby any means, electronic, mechanical, photocopying, recording, or otherwise, without the prior written permission ofDaimler 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 towww.Daimler-TrucksNorthAmerica.com and www.SterlingTrucks.com.

Foreword

ContentsChapter Page

Introduction, Environmental Concerns and Recommendations,Event Data Recorder, Customer Assistance Center, ReportingSafety Defects . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Foreword

1 Vehicle Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.12 Instruments and Controls Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.13 Vehicle Access and Features . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.14 Heater and Air Conditioner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.15 Seats and Seat Belts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.16 Steering and Brake Systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.17 Engines and Clutches . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.18 Transmissions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.19 Rear Axles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.1

10 Fifth Wheels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.111 Pretrip and Post-Trip Inspections and Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11.112 Cab Appearance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12.113 In an Emergency . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13.1

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

1

Vehicle IdentificationVehicle Specification Decal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.1Federal Motor Vehicle Safety Standard (FMVSS) Labels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.1Canadian Motor Vehicle Safety Standard (CMVSS) Labels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.2Tire and Rim Labels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.2EPA Emission Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.2

Vehicle Specification DecalThe vehicle specification decal lists the vehiclemodel, identification number, and major componentmodels. It also recaps the major assemblies and in-stallations shown on the chassis specification sheet.The specification decal is inside the rear cover of theOwner’s Warranty Information for North Americabooklet. An illustration of the decal is shown inFig. 1.1 .

NOTE: Labels shown in this chapter are ex-amples only. Actual specifications may vary fromvehicle to vehicle.

Federal Motor Vehicle SafetyStandard (FMVSS) LabelsNOTE: Due to the variety of FMVSS certificationrequirements, not all of the labels shown willapply to your vehicle.

Tractors with or without fifth wheels purchased in theU.S. are certified by means of a certification label(Fig. 1.2 ) and the tire and rim labels (Fig. 1.3 ).These labels are attached to the left side rear doorjamb, as shown in Fig. 1.4 .

If purchased for service in the U.S., trucks built with-out a cargo body have a certification label (Fig. 1.5 )attached to the left side rear door jamb. See Fig. 1.4 .In addition, after completion of the vehicle, a certifi-cation label similar to that shown in Fig. 1.2 must beattached by the final-stage manufacturer. This labelwill be located on the left side rear door jamb andcertifies that the vehicle conforms to all applicable

04/23/99

USE VEHICLE ID NO.WHEN ORDERING PARTS

WHEELBASEENGINE NO.TRANS NO.FRT AXLE NO.

REAR AXLE NO.RATIO

FOR COMPLETE PAINT INFORMATIONSEE VEHICLE SPECIFICATION SHEET

MANUFACTURED BY

MODELVEHICLE ID NO.

DATE OF MFR

ENGINE MODEL

TRANS MODEL MAINFRONT AXLE MODELREAR AXLE MODEL

PAINT MFRPAINT NO.

PART NO. 045−9904BB60−CA

COMPONENT INFORMATION

1ST INT AXLE MODEL2ND INT AXLE MODEL3RD INT AXLE MODEL4TH INT AXLE MODEL5TH INT AXLE MODEL

1ST INT AXLE MODEL2ND INT AXLE MODEL3RD INT AXLE MODEL4TH INT AXLE MODEL5TH INT AXLE MODEL

f080090

Fig. 1.1, Vehicle Specification Decal, Canadian-BuiltVehicle Shown

11/21/96 f080053

1 2 3

Fig. 1.2, Certification Label, U.S.

f080079

24−00273−040TIRES AND RIMS LISTED ARE NOT NECESSARILY THOSE INSTALLED ON THE VEHICLE.

VEHICLE ID NO.DATE OF MFRGVWR

FRONT AXLEFIRST INTERMEDIATE AXLESECOND INTERMEDIATE AXLETHIRD INTERMEDIATE AXLEREAR AXLE

GAWR TIRES RIMS PSI COLD

1 2 3

02/12/98

1. Date of manufacture by month and year.2. Gross vehicle weight rating; developed by taking the

sum of all the vehicle’s gross axle ratings.3. Gross axle weight ratings; developed by considering

each component in an axle system, includingsuspension, axle, wheels, and tires. The lowestcomponent capacity is the value for the system.

Fig. 1.3, Tire and Rim Label

1

2

04/23/99 f080092

1. Tire and Rim Labels 2. Certification Label

Fig. 1.4, Labels Location

Vehicle Identification

1.1

FMVSS regulations in effect on the date ofcompletion.

Canadian Motor Vehicle SafetyStandard (CMVSS) LabelsIn Canada, tractors with fifth wheels are certified bymeans of a "Statement of Compliance" label and theCanadian National Safety Mark (Fig. 1.6 ), which areattached to the left side rear door jamb. Tire and rimlabels (Fig. 1.3 ) are also attached to the left siderear door jamb.

If purchased for service in Canada, trucks built with-out a cargo body and tractors built without a fifthwheel are certified by a "Statement of Compliance"label, similar to Fig. 1.2 . This label must be attachedby the final-stage manufacturer after completion ofthe vehicle. The label is located on the left side reardoor jamb, and certifies that the vehicle conforms toall applicable CMVSS regulations in effect on thedate of completion.

Tire and Rim LabelsTire and rim labels certify suitable tire and rim combi-nations that can be installed on the vehicle for thegiven gross axle weight rating. Tires and rims in-stalled on the vehicle at the time of manufacture mayhave a higher load capacity than that certified by thetire and rim label. If the tires and rims currently onthe vehicle have a lower load capacity than thatshown on the tire and rim label, then the tires and

rims determine the load limitations on each of theaxles.

See Fig. 1.3 for U.S. and Canadian tire and rim la-bels.

EPA Emission ControlVehicle Noise Emission Control LabelA vehicle noise emission control label (Fig. 1.7 ) isattached to the left side rear door jamb.

IMPORTANT: Certain Sterling incomplete ve-hicles may be produced with incomplete noisecontrol hardware. Such vehicles will not have avehicle noise emission control information label.For such vehicles, it is the final-stage manufac-turer’s responsibility to complete the vehicle inconformity to U.S. EPA regulations (40 CFR Part205) and label it for compliance.

EPA07 Exhaust EmissionsTo meet January 2007 emissions regulations, ve-hicles with engines manufactured after January 1,2007, are equipped with an emission aftertreatmentdevice. There is a warning label on the driver’s sun-visor, explaining important new warning indicators inthe driver’s message display, that pertain to the after-treatment system. See Fig. 1.8 .

It is a violation of federal law to alter exhaust plumb-ing or after-treatment in any way that would bring theengine out of compliance with certification require-ments. (Ref: 42 U.S.C. S7522(a) (3).) It is theowner’s responsibility to maintain the vehicle so thatit conforms to EPA regulations.

09/28/98 f080023

Fig. 1.5, Incomplete Vehicle Certification Label, U.S.

f08002410/10/2006

Fig. 1.6, Canadian National Safety Mark

f08009124−00273−020

VEHICLE NOISE EMISSION CONTROL INFORMATION

THIS VEHICLE CONFORMS TO U.S. EPA REGULATIONS FOR NOISE EMISSIONAPPLICABLE TO MEDIUM AND HEAVY TRUCKS.THE FOLLOWING ACTS OR THE CAUSING THEREOF BY ANY PERSON ARE PROHIBITED BYTHE NOISE CONTROL ACT OF 1972:A. THE REMOVAL OR RENDERING INOPERATIVE, OTHER THAN FOR PURPOSES OF MAINTENANCE, REPAIR, OR REPLACEMENT, OF ANY NOISE CONTROL DEVICE OR ELEMENT OF DESIGN (LISTED IN THE OWNER’S MANUAL) INCORPORATED INTO THIS VEHICLE IN COMPLIANCE WITH THE NOISE CONTROL ACT.B. THE USE THIS VEHICLE AFTER SUCH DEVICE OR ELEMENT OF DESIGN HAS BEEN REMOVED OR RENDERED INOPERATIVE.

DATE OF MANUFACTURE 01/99STERLING TRUCK CORPORATION

04/23/99

Fig. 1.7, Vehicle Noise Emission Control Label


1.2

f080147

EXHAUST AFTERTREATMENT SYSTEM INFORMATION

Switch.

Level 1 Level 3Level 2 Level 4Filter RegenerationRecommended

Filter is reaching

Bring vehicle tohighway speeds to

Filter RegenerationNecessary

Filter is nowreaching maximumcapacity.

To avoid enginederate bring vehicle

Parked RegenerationRequired − EngineDerate

Filter has reachedmaximum capacity.

Vehicle must beparked and a Parked

Parked Regeneration Required −Engine Shut Down

Filter has exceededmaximum capacity

Vehicle must be parked and aParked Regeneration or Service

(Solid) (Flashing) (Flashing)

CHECK CHECK

(Flashing)

INDICATORLAMP(S)

Indicator LampMessage(s)

Diesel ParticulateFilter Condition

Required Action

capacity. .

STOP

See Engine Operator’s Manual for complete Regeneration Instructions.

allow for an AutomaticRegeneration orperform a ParkedRegeneration.

to highway speedsto allow for anAutomaticRegeneration orperform a ParkedRegeneration assoon as possible.

Regeneration mustbe performed −engine will beginderate.

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

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

02/20/2009

24−01583−000B

WARNING

HEST (High ExhaustSystem Temperature)

Exhaust Componentsand exhaust gas areoperating at hightemperature. Whenstationary, keep awayfrom people andflammable materials,vapors, or structures.

A regeneration is inprogress.

Flashing

Solid

Fig. 1.8, Sunvisor Warning Label


1.3

2

Instruments and ControlsIdentification

Instrument and Control Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.1Warning and Indicator Lights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.10Instruments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.13Instrumentation Control Unit 4 (ICU4) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.16Instrumentation Control Unit 3 (ICU3 and ICU3 ’07) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.21NGI Instrument Cluster, Optional . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.23

Instrument and Control PanelFigure 2.1 represents a typical instrument and con-trol panel equipped with all of the standard and manyof the optional instruments and controls.

Ignition Switch and KeyThe ignition switch has four positions: OFF, START,ON, and accessory (ACC). See Fig. 2.2 . The ignitionkey can be inserted and removed only in the OFFposition. The ignition key also locks and unlocks thecab doors from the outside.

With the ignition switch in the OFF position, whetherthe ignition key is inserted or not, the low-beamheadlights, hazard warning lights, marker lights,clearance lights, dome lights, parking lights, and thebrake lights will operate.

To start the engine, turn the ignition key 90 degreesclockwise to the START position. After the enginehas started, release the key and it will return to theon position.

In the ON position, the key is turned 45 degreesclockwise. With the ignition switch in the ON position,all the electrical systems are operable. The warninglights and buzzer indicating low air pressure and lowoil pressure will operate until the engine is startedand the minimum pressures are built up.

In the ACC position, the key is turned 45 degreescounterclockwise. With the ignition switch in the ac-cessory position, the radio, windshield wipers, heatedmirrors, power mirrors, and power windows areoperable.

Power Window Switch, OptionalThe power window switch is located on the driver’sdoor and controls the passenger window if there is amanual window regulator for the driver’s door. Ifthere are two power window switches on the driver’sdoor, one switch controls the driver’s window andone switch controls the passenger’s window. SeeFig. 2.3 . The passenger’s door also has a power

1

2

3

4

5

11

1314 f610338

05

5

1015

1520 25

253035 45 55

6575

85

10/06/99

67 8 9

10

1617 16

1512

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

1. Ignition Switch2. Headlight and Parking Light Switch3. Turn Signal/Windshield Wiper Lever4. Marker Blink Switch5. Control Panel Dimmer and Dome Light Switch6. Instrument Cluster7. Dash Message Center8. Trailer Brake Valve Control9. Instrument Panel Gauges

10. Instrument Panel Switches11. Parking Brake Valve Control12. Hot Posts13. Trailer Air-Supply Valve Control14. Electronic Sound System15. Climate Control Panel16. Cruise Control Switch17. Horn

Fig. 2.1, Instrument and Control Panel Layout

Instruments and Controls Identification

2.1

window switch if both doors are controlled electri-cally.

Push the dimpled end of the power window switch tolower the window; push the raised end of the switchto raise the window.

Power Lock Switch, OptionalThe power lock switch (Fig. 2.3 ) is located below thedoor handle on the driver’s side and the passenger’sside of the cab. Press the L to lock the doors. Pressthe U to unlock the doors.

Mirror ControlsPower Mirror Switch, OptionalThe position of the door-mounted mirrors is con-trolled by the power mirror switch (Fig. 2.4 ) locatednear the door handle on the driver’s side of the cab.Move the lever toward the L to control the left mirror,and toward the R to control the right mirror. Move thebutton to the left or right to control the position of themirror.

Heated Mirror Switch, OptionalOne or both door-mounted mirrors can be heated tokeep them defrosted. Press the upper end of theheated mirror switch (Fig. 2.5 ) to heat the mirrors.When the heated mirror switch is pressed, the MIRHEAT indicator on the dash message center comeson.

Lighted Mirrors, OptionalThe lights on the door-mounted mirrors act asmarker lights. Push the paddle on the marker blink(MARK BLNK) switch (Fig. 2.7 ) down to turn on themirror lights.

09/30/99 f610344

1

2

3

4

1. Accessory2. Off

3. On4. Start

Fig. 2.2, Ignition Switch Positions

f72036710/06/99

1 2

3

3

4A B

A. Push here to lower window.B. Push here to raise window.1. Door Handle2. Power Mirror Switch

3. Power Window Switch4. Power Lock Switch

Fig. 2.3, Power Lock, Window, and Mirror Switches

f61036309/15/99

Fig. 2.4, Power Mirror Switch

f61036209/15/99

Fig. 2.5, Heated Mirror Switch


2.2

Headlight and Parking Light SwitchThe headlight and parking light switch (Fig. 2.6 ) islocated above the ignition switch. Turn the switch 45degrees clockwise to turn on the parking lights. Turnthe switch 90 degrees clockwise to turn on theheadlights.

Daytime Running Lights, Optional

WARNINGWhen the daytime running lights are on, only theheadlights are illuminated at a reduced intensity.The marker lights, taillights, and trailer lights arenot illuminated. Turn the headlights ON at dusk.Using the daytime running lights at night couldcause an accident resulting in personal injury orproperty damage.

The daytime running lights are turned on when theengine is started, the parking brake is released, andthe headlight switch is in the OFF position. The day-time running lights illuminate the headlights at a re-duced intensity during daytime driving. These lightsare not to be used in place of the headlights duringreduced visibility or nighttime driving conditions.

For vehicles built to operate in Canada, daytime run-ning lights are required.

Marker Blink SwitchThe marker blink (MARK BLNK) switch (Fig. 2.7 ) is apaddle switch located above and to the left of theheadlight and parking light switch. Push the paddledown to turn on the marker lights. Push the paddleup to blink the marker lights. When the paddle is inthe center position, the marker lights are off.

Instrument and Control Panel DimmerSwitchThe instrument and control panel dimmer switch(Fig. 2.8 ) is located above and to the right of theheadlight and parking light switch. The instrumentand control panel lights can be brightened by movingthe lever up, or dimmed by moving the lever down.The dome light can be turned on by moving theswitch all the way up.

Turn Signal Lever, UnitedTechnologiesTurn SignalsThe turn signal lever (Fig. 2.9 ) is located on the leftside of the steering column. Push the lever up to turnon the right-turn signal. Pull the lever down to turn onthe left-turn signal. The turn signal lever will return tothe neutral position after the turn has beencompleted.

High-Beam HeadlightsPush the turn signal lever away from you to changethe headlights from low beam to high beam.

09/22/1999 f610367

Fig. 2.6, Headlight and Parking Light Switch

09/22/1999 f610366

Fig. 2.7, Marker Blink Switch

f610365 09/22/1999

Fig. 2.8, Instrument and Control Panel Dimmer Switch


2.3

Flash to PassPull the turn signal lever toward you and release thelever to momentarily flash the high-beam headlightswhen the headlights are off.

Windshield Wipers

CAUTIONDo not move the wiper arms manually. Wipermotor damage will occur if the arms are moved.

To turn on the windshield wipers, turn the knob onthe end of the turn signal lever. There are seven in-termittent wiper speeds from slow to fast, a lowspeed, and a high speed. See Fig. 2.9 .

Windshield WasherTo turn on the windshield washer, push in the buttonat the end of the turn signal lever. Windshield washerfluid will continue to spray as long as the button ispushed in. See Fig. 2.9 .

Hazard Warning LightsPush the hazard warning lights switch (Fig. 2.10 ) ontop of the steering column to turn on the hazardwarning lights. Push the switch again to turn off thehazard warning lights.

Turn Signal Lever, Signal-StatTurn SignalsThe turn signal lever (Fig. 2.11 ) is located on the leftside of the steering column. Push the lever up to turnon the right-turn signal. Pull the lever down to turn onthe left-turn signal. Return the turn signal lever to theneutral position after the turn has been completed.

High-Beam HeadlightsPull the turn signal lever toward you to change theheadlights from low beam to high beam.

Flash to PassPull the turn signal lever toward you and release thelever to momentarily flash the high-beam headlightswhen the headlights are off.

Windshield Wipers

CAUTIONDo not move the wiper arms manually. Wipermotor damage will occur if the arms are moved.

To turn the windshield wipers on, turn the knob onthe end of the turn signal lever. There are five inter-mittent wiper speeds, a low speed, and a highspeed. See Fig. 2.11 .

Windshield WasherTo turn the windshield washer on, push in the buttonat the end of the turn signal lever. Windshield washerfluid will continue to spray as long as the knob ispushed in. See Fig. 2.11 .

10/06/99 f610361

12

1. Windshield Washer Button2. Windshield Wiper Knob

Fig. 2.9, Turn Signal Lever, United Technologies

09/22/1999 f610359

Fig. 2.10, Hazard Warning Lights Switch

10/06/99 f610360

2

1

1. Windshield Wiper/Washer Knob2. Hazard Warning Lights Switch

Fig. 2.11, Turn Signal Lever, Signal-Stat


2.4

Tilt, or Tilt and Telescoping SteeringWheel, Optional

WARNINGMake sure that the steering column is locked be-fore driving the vehicle. Never tilt or telescopethe steering wheel while driving the vehicle.Doing so could cause loss of vehicle control,personal injury, and property damage.

To tilt the steering wheel, push down on the lever(Fig. 2.12 ) below the steering wheel, and tilt the col-umn to the desired position. Release the lever to lockthe steering wheel in place.

To telescope the steering wheel, pull the lever upand pull the steering wheel closer to you or push thesteering wheel farther away. Release the lever tolock the steering wheel in place.

HornYour vehicle is equipped with an electric horn andmay have an optional air horn.

To use the electric horn, press the center of thesteering wheel. To use the air horn, pull the cablelocated on the ceiling above the driver’s seat.

Trailer-Brake Hand-Control-ValveLeverThe trailer-brake hand-control-valve lever (Fig. 2.13 )is used to apply the trailer brakes without applyingthe truck or tractor brakes, and is mounted on theinstrument and control panel. Pull the lever down toapply the brakes. When the lever is released, thelever will return to the upper position.

Heater and Air-Conditioner ControlsRefer to Chapter 4 for detailed operating instructionsof the heater and air conditioner.

Parking-Brake-Control ValveThe yellow diamond-shaped knob (Fig. 2.14 ) oper-ates the parking-brake-control valve. Pulling the knobout applies both the tractor and the trailer springbrakes. Pushing the knob in releases the tractorspring brakes. Before the spring brakes can be re-leased, the air pressure in either air brake systemmust be at least 65 psi (448 kPa).

Refer to Chapter 6 under the heading "Air BrakeSystem" for instructions regarding the use of theparking-brake-control valve.

Trailer-Air-Supply ValveThe red octagonal-shaped knob (Fig. 2.14 ) operatesthe trailer-air-supply valve. After the vehicle is con-nected to a trailer, and the air hoses are connected,and the pressure in the air system is at least 65 psi(448 kPa), the trailer-air-supply valve can be pushedin (and should stay in) to charge the trailer-air-supplysystem and release the trailer spring brakes. Beforedisconnecting a trailer, or when operating a vehicle

09/25/99 f601857

1

1. Tilt and Telescoping Lever

Fig. 2.12, Tilt, or Tilt and Telescoping Steering Wheel

09/25/99

TRAILERBRAKE

NOT FORPARKING

f610343

Fig. 2.13, Trailer-Brake Hand-Control-Valve Lever


2.5

without a trailer, the trailer-air-supply valve must bepulled out.

Refer to Chapter 6 under the heading "Air BrakeSystem" for instructions regarding the use of thetrailer-air-supply valve.

Hot PostsHot posts (Fig. 2.1 ) are provided as a source ofpower within the cab to operate 12-volt electrical ac-cessories. A power and ground jack are included inthe hot post.

Mode/Reset Switch, OptionalThe mode/reset switch (Fig. 2.15 ) is located on theright side of the instrument cluster. The mode/resetswitch is used to scroll through the displays on themessage display screen, and to reset the trip dis-tance and trip hours values to zero. When the mode/reset switch is pressed for one second or less, theswitch acts as a mode switch. When the switch ispressed for more than one second, the switch actsas a reset switch.

To reset the value of the selected display to zero,press the mode/reset switch for one second orlonger. To toggle between MI (miles) or KM (kilome-ters), press the mode/reset switch while in the SE-LECT screen.

When the odometer reading is displayed and theparking brake is released:

• Press the mode/reset switch once and the tripdistance will display.

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

• Press the mode/reset switch a third time andthe SELECT screen and the current units, MIor KM, will display.

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

Axle ControlsWheel Lock Switch, OptionalThe wheel lock switch locks together the wheels onthe same axle. Push the wheel lock switch(Fig. 2.16 ) up to engage the wheel lock. Move theswitch to the center position to disengage the wheellock. Refer to Chapter 9 for complete operatinginstructions.

Axle Lock Switch, OptionalThe axle lock switch is installed on vehicles with tan-dem rear drive axles. It locks the rear drive axles to-gether. Push the axle lock switch (Fig. 2.17 ) up toengage the axle lock. Move the switch to the centerposition to disengage the axle lock.

f610291

1 2

03/10/99

1. Trailer-Air-Supply Valve2. Parking-Brake-Control Valve

Fig. 2.14, Brake Valve Knobs

09/25/99

PUSH− MODE HOLD− RESET

f610340

Fig. 2.15, Mode/Reset Switch

f61037610/01/99

Fig. 2.16, Wheel Lock Switch


2.6

All-Wheel-Drive Switches, OptionalAll-wheel-drive (AWD) allows the driver to directdriveline power to all four axles, front and rear. Twoswitches are used to control AWD: an AWD operationswitch used to activate all-wheel-drive, and an AWDrange switch used to select the high or low range.

The AWD operation switch is a two-position rockerswitch with a light-emitting diode (LED) that illumi-nates when AWD is engaged. The legend LOCKEDis underneath the LED on the upper half of theswitch. On the lower half is the legend AWD. SeeFig. 2.18 . When the panel lights are on, the AWDlegend is backlit in green.

To engage AWD, press the upper half of the rockerswitch. The LED illuminates to indicate that AWD isengaged. To turn off AWD, press the lower half of theswitch. The LED goes out to indicate the AWD is nolonger engaged.

When AWD is engaged, the LOCKED legend isbacklit in red. In addition, a red indicator with the leg-end FR AXLE ENGAGE displays on the dash mes-sage center.

CAUTIONTo prevent damage to the transfer case and thedriveline, stop the vehicle and apply the parkingbrake before using the range switch.

The AWD range switch is used under similar condi-tions to those of the axle shift switch on a two-speedrear axle. Use the high range when driving at normalspeeds under off-road conditions, or on non-pavedsurfaces. Use the low range when extra traction isneeded at low speeds; for example, under conditionsof mud, snow, or ice. This switch should be usedonly when AWD has been engaged.

In most cases, the AWD range switch is a two-position rocker switch with the legends LO RANGEat the upper end and HIGH RANGE at the lowerend. On vehicles with a power takeoff unit (PTO), thethree-position switch has a neutral (N-TRL) positionin the middle. See Fig. 2.19 .

On vehicles without a PTO, high range is consideredstandard operation. To activate the low range, pressthe upper half of the switch. When the low range isactivated, the LO RANGE legend is backlit in red. Inaddition, a red indicator with the legend T-CASE LORANGE displays on the dash message center. Toswitch back to HIGH RANGE, press the lower half ofthe switch.

IMPORTANT: Always use the N-TRL switch po-sition when operating the PTO.

On vehicles with a PTO, neutral is considered stan-dard operation (switch in the middle position). An

f61037710/01/99

Fig. 2.17, Axle Lock Switch

08/10/2006 f610807

LOCKED

AWD

Fig. 2.18, AWD Operation Switch

1

f610808

LO

RANGEHIGH

RANGELO

RANGEHIGH

N−TRL

07/21/2006

2

1. Two-Position Switch2. Three-Position Switch

Fig. 2.19, AWD Range Switches


2.7

amber indicator with the legend T-CASE NEUTRLdisplays on the dash message center.

To activate the high range, press the lower half of theswitch. No indicator displays on the dash messagecenter with the high range activated. Press the upperhalf to return to N-TRL.

To activate the low range, press the upper half of theswitch. A red indicator with the legend T-CASE LORANGE displays on the dash message center. Onthe switch, the LO N-TRL legend is backlit in red.Press the lower half to return to N-TRL, and thenpress the lower half again to select HIGH RANGE.

Traction in Mud or Snow Switch,OptionalIf the vehicle is equipped with Automatic TractionControl, the traction in mud or snow (TRAC MUD/SNOW) switch (Fig. 2.20 ) is used to provide in-creased traction on soft surfaces such as snow, mud,or gravel by slightly increasing the permissible wheelspin.

Engine Brake ControlsExhaust Brake Switch, OptionalThe exhaust brake restricts the flow of exhaust gas-ses, which slows the engine. Push the exhaust brakeswitch (Fig. 2.21 ) up to engage the exhaust brake.Move the switch to the center position to disengagethe exhaust brake. Refer to Chapter 7 under theheading "Exhaust Braking System, Optional" for addi-tional information.

Engine Brake Switch, OptionalThe three-position engine brake switch is availableonly on Mercedes-Benz MBE900 engines. Press theupper half of the engine brake switch to apply both

the engine brake and exhaust brake. When theswitch is in the center position, only the exhaustbrake is applied. When the lower half of the switch ispressed, the switch is off.

Aftertreatment System (ATS)Request/Inhibit Regen SwitchA parked regen of the ATS can be initiated with therequest/inhibit regen switch. See Fig. 2.22. It mayalso be used to inhibit the vehicle from performing anautomatic regen.

The style and function of switch will vary with the en-gine make and model. See the engine operationmanual for operation details.

ABS Diagnostic Switch, OptionalThe ABS diagnostic switch (Fig. 2.23 ) is a momen-tary switch that turns on the blink code diagnosticcapabilities. For information on troubleshooting withblink code diagnostics, see Group 42 in the Acterra®

Workshop Manual.

f61038310/26/99

TRACMUD/

SNOW

Fig. 2.20, Traction in Mud or Snow Switch

f61037810/06/99

EXHBRK

Fig. 2.21, Exhaust Brake Switch

f61084810/02/2006

Fig. 2.22, Request/Inhibit Regen Switch


2.8

Cruise ControlTo turn on the cruise control, press the ON switchlocated on the steering wheel. See Fig. 2.24 .

To Set a Speed— press the set/coast (SET/CST)switch located on the steering wheel, after you havereached the desired speed. See Fig. 2.25 . The ve-hicle will travel at the set speed until the brake pedalor clutch pedal is depressed, or until the cruise con-trol OFF switch is pressed.

The speed control may not operate until a minimumvehicle speed is reached. For more information, referto your diesel engine operation and maintenancemanual.

When driving up a steep hill, the speed control maynot be able to maintain the preset speed in the trans-mission gear position selected. To maintain a presetspeed in this situation, downshift the transmission toa lower gear.

To Set a Higher Set Speed— choose one of threeways to set a higher set speed.

• Press and hold the resume/accelerate (RSM/ACCL) switch (Fig. 2.25 ) located on the steer-ing wheel until the higher set speed is reached.Then release the switch.

• Press and release the resume/accelerateswitch. Each press of the switch will increasethe set speed by 1 mph (1.6 km/h).

• Press and release the resume/accelerateswitch and depress the accelerator pedal untilthe desired speed is reached. Then press theset/coast (SET/CST) switch.

You can accelerate with the throttle pedal at any timeduring cruise control usage. Releasing the throttlepedal will return the vehicle to the previously pro-grammed set speed.

To Set a Lower Set Speed— choose one of threeways to set a lower set speed.

• Press and hold the set/coast (SET/CST) switchlocated on the steering wheel until the lowerset speed is reached. Then release the switch.

• Press and release the set/coast switch. Eachpress of the switch will decrease the set speedby 1 mph (1.6 km/h).

• Press and release the set/coast switch anddepress the brake pedal until the desiredspeed is reached. Then press the set/coastswitch.

To Disengage the Speed Control— depress thebrake pedal or the clutch pedal. Disengaging the

f61038410/26/99

ABSDIAG

Fig. 2.23, ABS Diagnostic Switch

09/25/99

OFF

ON

f610342

Fig. 2.24, Cruise Control On/Off Switch

09/25/99 f610341

SET/CST

RSM/ACCL

Fig. 2.25, Speed Control Switch


2.9

speed control will not erase the previously pro-grammed set speed. Pressing the OFF switch willerase the previously programmed set speed.

To Return to a Set Speed— press the resume/accelerate (RSM/ACCL) switch for about three sec-onds.

IMPORTANT: The use of radio transmittingequipment that is not FCC approved may causethe speed control to malfunction. Therefore, useonly properly installed FCC approved radiotransmitting equipment in your vehicle.

To Turn Off Cruise Control— press the OFF switch(Fig. 2.24 ) located on the steering wheel. Once thecruise control is turned off, the previously pro-grammed set speed will be deleted.

Stationary Throttle Control OperationOn all engines except CAT 3126, the cruise controlmay also be used as a throttle control for PTO appli-cations under the following conditions:

• the parking brake is set

• the clutch and accelerator pedals are released

To operate the cruise control:

• Press the ON switch located on the steeringwheel;

• Press and hold the set/coast (SET/CST) switchlocated on the steering wheel until the desiredrpm has been reached;

• Adjust the rpm by alternately pressing the set/coast and resume/accelerate (RSM/ACCL)switches.

The cruise control now functions as a throttle control.

To turn off the throttle control:

• Press the OFF switch located on the steeringwheel, or depress the throttle pedal or theclutch pedal.

On CAT 3126 engines, the PTO will only operate ifthe vehicle is in neutral. This feature can be overrid-den by a special service tool. See your dealer or ser-vice representative for more information.

Battery-Isolation SwitchThe battery-isolation switch (see Fig. 2.26 ) is locatedon the cab floor at the left of the driver’s seat, or in-

side the battery box. The battery-isolation switch re-duces the power to the cab and engine power wiring.Use it whenever the vehicle is to be put out of ser-vice for extended periods.

IMPORTANT: The battery-isolation switch doesnot completely disconnect the batteries from theelectrical system. For service operations thatrequire that the batteries be disconnected, al-ways shut down the engine and remove thenegative battery cables.

NOTE: Whenever battery power is discon-nected, clocks and electronically tuned radiosmust be reset.

Transmission ControlsIf so equipped, the transmission range control valveand splitter valve are attached to the gearshift knob.Transmission shift pattern labels are located insidethe cab.

Refer to Chapter 8 for complete manual transmis-sion operating instructions.

Refer to Chapter 8 for information on the automatictransmission controls.

Warning and Indicator LightsDash lightbars have warning and indicator lights thatmay be lettering or icons. Up until December 31,

11/02/1999 f150991

Fig. 2.26, Battery-Isolation Switch


2.10

2006, the warning and indicator lights were a mixtureof ISO icons and lettering. Since January 2007, ISOicons are used for all standard warning and indicator

lights on the dash lightbar. See Table 2.1 for descrip-tions of the icons.

Warning and Indicator Light Icons

CHECK Check Engine (amber)

Indicates an undesirable engine condition is detected orrecorded. The vehicle can still be driven. If the condition getsworse, the stop engine or engine protection light willilluminate.

STOP Stop Engine or Engine Protect (red)

Indicates a serious fault that requires the engine shut downimmediately. The engine ECU will reduce the maximumengine torque and speed, and, if the condition does notimprove, will shut down the engine within 30 seconds of thelight illuminating. The driver must safely bring the vehicle toa stop on the side of the road and shut down the engine assoon as the red light is seen. If the engine shuts down whilethe vehicle is in a hazardous location, the engine can berestarted after turning the key to the OFF position for a fewseconds.

High Exhaust System Temperature(HEST) Lamp (amber)

Slow (10-second) flash indicates a regeneration is inprogress, and the driver is not controlling the engine idlespeed.

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

Diesel Particulate Filter (DPF) Lamp(amber)

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

Blinking indicates that a parked regeneration is requiredimmediately. An engine derate and shutdown will occur. Seethe engine operation manual for details on how to perform astationary regeneration.

Malfunction Indicator Lamp (MIL) (amber)Indicates an engine emissions-related fault, including, but notlimited to the aftertreatment system. See the engineoperation manual for details.

Tractor ABS Lamp (amber)Indicates a problem with the ABS is detected. Repair thetractor ABS immediately to ensure full antilock brakingcapability.

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

Left-Turn Signal (green) Flashes on and off whenever the outside turn signal lightsare flashing.


2.11

Warning and Indicator Light Icons

Right-Turn Signal (green) Flashes on and off whenever the outside turn signal lightsare flashing.

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

Low Air Pressure Warning Lamp (red)Activates with a buzzer when air pressure in the primary orsecondary air reservoir falls below 64 to 76 psi (440 to 525kPa).

High Coolant Temperature Warning Lamp(red)

Activates with a buzzer when the coolant temperature goesabove a maximum level specified by the enginemanufacturer (see the engine manual).

Low Engine Oil Pressure Warning Lamp(red)

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

BRAKE

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

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

Fasten Seat Belt Lamp (red) Illuminates for 15 seconds when the ignition key is turned tothe ON position.

Intake Heater Lamp (amber) Indicates the intake air heater is active.

Water in Fuel Lamp (amber) Indicates that the fuel could contain water.

Low Battery Voltage Lamp (red) Indicates battery voltage is 11.9 volts or less.

Table 2.1, Warning and Indicator Light Icons

Engine Protection Warning LightsIMPORTANT: Drivers of electronically controlledengines should know the extent of the warning/warning-shutdown system for their vehicle be-fore operating it. This information can be ob-tained from their Sterling dealer.

Amber Check Engine Warning LightWhen the amber Check Engine warning lamp comeson for any reason, the vehicle can still be operated,and the driver can proceed to the required destina-

tion. This condition should be reported to an autho-rized service center as soon as possible. See theengine manufacturer’s engine operation and mainte-nance manual for details of the engine protectionsystem in the vehicle. See Fig. 2.27 .

Red Stop Engine LightWhen the red Stop Engine lamp comes on, the com-puter has detected a major malfunction in the enginethat requires immediate attention.

IMPORTANT: It is the operator’s responsibility toshut down the engine to avoid serious damage.


2.12

See the engine manufacturer’s engine operationand maintenance manual for details of the en-gine protection system in the vehicle.

If the engine shuts down while the vehicle is in ahazardous location, the engine can be restarted afterturning the key to the OFF position for a few sec-onds, to allow the driver to move the vehicle to asafe location.

Stop Engine Override Switch

CAUTIONUsing the override button so the engine operatesfor an extended period may result in engine dam-age. The operator has the responsibility to takeaction to avoid engine damage.

The vehicle may be equipped with a Stop EngineOverride (SEO) switch, that can be used to overridethe shutdown sequence. This override resets theshutdown timer, restoring power to the level whenthe red stop engine lamp was illuminated. The switchmust be recycled after five seconds to obtain a sub-sequent override.

InstrumentsTachometer, OptionalThe tachometer (Fig. 2.28 ) indicates the enginespeed in hundreds of revolutions per minute (rpm)and serves as a guide for shifting the transmissionand keeping the engine in the appropriate rpm range.

SpeedometerThe speedometer (Fig. 2.28 ) registers speed in bothmiles per hour (mph) and kilometers per hour (km/h).

Engine Oil Pressure Gauge

CAUTIONA sudden decrease or absence of oil pressuremay indicate mechanical failure. Bring the vehicleto a safe stop and investigate the cause to pre-vent further damage. Do not operate the engineuntil the cause has been determined and cor-rected.

Refer to the engine operation manual for the specificsafe-operating range for your vehicle. See Fig. 2.29 .

03/20/2008 f6110001 2 3

CHECK STOP

1. Stop Engine Override Switch2. Amber Check Engine Warning Lamp3. Red Stop Engine Lamp

Fig. 2.27, Engine Protection Warning Lights

0

5

10

1520

30

RPM5

15

25

3545 55

65

75

85

MPHkm/h

25

X 100

30

50

70

130

110

10

90

f61035610/06/99

1 2

1. Tachometer 2. Speedometer

Fig. 2.28, Tachometer/Speedometer

09/10/99

100

50

OIL

0

f610350

PSI

Fig. 2.29, Engine Oil Pressure Gauge


2.13

Coolant Temperature GaugeDuring normal operation, the coolant temperaturegauge should read 180 to 210°F (82 to 99°C). Referto the engine operation manual for the specific safe-operating range for your vehicle. See Fig. 2.30 . If thetemperature remains below normal or exceeds themaximum, inspect the cooling system to determinethe cause. Refer to Group 20 in the Acterra® Work-shop Manual for troubleshooting and repairprocedures.

Voltage Reading

CAUTIONGel cell batteries can be damaged if the batteryvoltage is allowed to drop below 12.0 volts or ifthe charging voltage is more than 14.1 volts.Start the engine to recharge the gel cell beforethe battery becomes fully discharged. If an exter-nal charger is needed, disconnect the gel cellbattery and use only an external battery chargerthat has been approved for gel cell batteries.

The voltage reading indicates the vehicle chargingsystem voltage when the engine is running, and thebattery voltage when the engine is stopped. By moni-toring the voltage reading, you can be aware of po-tential charging system problems and have themfixed before the batteries discharge enough to createstarting difficulties.

The voltage reading will normally show approximately13.7 to 14.1 volts when the engine is running. Thevoltage of a fully charged battery is 12.7 to 12.8 voltswhen the engine is stopped. A completely dischargedbattery will produce only about 12.0 volts. The volt-age reading will indicate lower voltage as the vehicle

is being started or when electrical devices in the ve-hicle are being used.

If the voltage reading shows an undercharged orovercharged condition for an extended period, havethe charging system and batteries checked at a re-pair facility.

On a vehicle equipped with a battery isolator system,the voltage reading shows the average voltage of allthe batteries when the engine is running. When theengine is stopped, the voltage reading shows onlythe gel cell battery voltage and does not indicate thevoltage of the engine-starting batteries.

Primary and Secondary Air PressureGaugesAir pressure gauges (Fig. 2.31 and Fig. 2.32 ) regis-ter the pressure in the primary and secondary airsystems. Normal pressure, with the engine running,is 100 to 120 psi (689 to 827 kPa) in both systems. Alow air pressure warning light comes on and abuzzer sounds when air pressure in either the pri-mary or secondary system drops below a minimumpressure of 60 psi (414 kPa). When the engine isstarted, the warning light and buzzer remain on untilair pressure in both systems exceeds minimumpressure.

Fuel GaugeThe fuel gauge (Fig. 2.33 ) indicates the level of fuelin the fuel tank(s).

09/28/1999

250

WATER

100

f610369

150

F

200

Fig. 2.30, Coolant Temperature Gauge

09/10/99

150

AIR

0

f610353

10050

PSIP

Fig. 2.31, Primary Air Pressure Gauge


2.14

Transmission Oil Temperature Gauge,Optional

CAUTIONA sudden increase in oil temperature that is notcaused by a load increase may indicate mechani-cal failure. Bring the vehicle to a safe stop andinvestigate the cause to prevent further damage.Do not operate the engine until the cause hasbeen determined and corrected.

During normal operation, the transmission oil tem-perature gauge (Fig. 2.34 ) reading should not ex-ceed 250°F (121°C).

Forward and Rear Axle OilTemperature Gauges, Optional

CAUTIONA sudden increase in oil temperature that is notcaused by a load increase may indicate mechani-cal failure. Bring the vehicle to a safe stop and

investigate the cause to prevent further damage.Do not operate the engine until the cause hasbeen determined and corrected.

During normal operation, forward and rear axle oiltemperature gauges (Fig. 2.35 and Fig. 2.36 ) shouldread between 150 and 230°F (65 and 110°C).

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

09/10/99

150

AIR

0

f610354

10050

PSIS

Fig. 2.32, Secondary Air Pressure Gauge

09/10/99

F

1/2

FUEL

E

f610351

Fig. 2.33, Fuel Gauge

09/10/99

350

TRANS

100

f610352

275175

F

Fig. 2.34, Transmission Oil Temperature Gauge

f61034603/09/98

FWDREARAXLE

125

175 250

325F

OILTEMP

Fig. 2.35, Forward Rear Axle Oil Temperature Gauge

f61034709/10/99

REARREARAXLE

125

175 250

325F

OILTEMP

Fig. 2.36, Rearmost Axle Oil Temperature Gauge


2.15

Application Air Pressure Gauge,OptionalAn application air pressure gauge (Fig. 2.37 ) regis-ters the air pressure being used to apply the brakes,and should be used for reference only. The gaugewill not register air pressure until the foot brake pedalis depressed or the trailer hand brake is applied.

Intake Air Restriction IndicatorThe intake air restriction indicator (Fig. 2.38 ) mea-sures the vacuum on the engine side of the aircleaner at the air cleaner outlet. Vacuum is mea-sured in inH2O (inches of water). If the intake air re-striction indicator stays locked at or above the ser-vice values shown in Table 2.2 , the air cleanerneeds to be serviced. After the air cleaner is ser-viced, push the reset button on the intake air restric-tion indicator to reset the indicator.

NOTE: Rain or snow can wet the filter, whichcan temporarily cause a higher than normalreading.

Intake Air Restriction Indicator ValuesEngine Type Initial inH 2O Service inH 2O

Caterpillar 15 25Cummins 10 25Mercedes-Benz 10 22Detroit Diesel 12 20

Table 2.2, Intake Air Restriction Indicator Values

Intake Air Restriction Indicator, Dash-Mounted, OptionalThe intake air restriction indicator (Fig. 2.39 ) mea-sures the vacuum on the engine side of the aircleaner at the air cleaner outlet. Vacuum is mea-sured in inH2O (inches of water). If the intake air re-striction indicator stays locked at or above the ser-vice values shown in Table 2.2 , the air cleanerneeds to be serviced. After the air cleaner is ser-viced, push the reset tab on the intake air restrictionindicator to reset the indicator.

NOTE: Rain or snow can wet the filter, whichcan temporarily cause a higher than normalreading.

Instrumentation Control Unit 4(ICU4)The ICU4 instrument cluster is an individual gaugecluster, with a lightbar with a driver message displayscreen, and integrated warning and indicator lights.See Fig. 2.40 for a typical layout of the gauges.

Standard gauges are:

• speedometer

• engine-coolant temperature gauge

f61034809/10/99

PSI

APPL AIRPRESS0

30

60 90

120

150

Fig. 2.37, Application Air Pressure Gauge

08/31/99 f090301

1

2

1. Intake Air Restriction Indicator2. Air Cleaner

Fig. 2.38, Intake Air Restriction Indicator


2.16

• engine-oil pressure gauge

• voltmeter

• fuel gauge

• air gauges

The following gauges have a warning light on thegauge:

• engine-coolant temperature (high)

• engine-oil pressure (low)

• fuel level (low)

Buzzer and ChimeA buzzer sounds for three seconds during the self-test at start-up, and when the following conditionsexist:

• low air pressure

• low oil pressure

• high coolant temperature

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

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

Ignition SequenceWhen the ignition key is turned on, the ICU4 beginsa self-test. During this process, all gauges controlledby the cluster sweep to full scale and return, thebuzzer sounds for 3 seconds, the fasten seat beltwarning light illuminates for 15 seconds, and the bat-tery voltage, low air pressure, and parking brakewarning lights illuminate then turn off. Then the soft-ware revision level of the ICU4 is displayed, followedby active faults, if any, then the odometer display.

Mode/Reset SwitchThe mode/reset switch controls the display of theodometer, trip miles and hours, engine miles andhours, service cycle screens, fault code screens, andoil level screens (on some Mercedes-Benz engines;if equipped and enabled).

With the parking brake released, only the basic func-tion screens, which include odometer, trip miles, andtrip hours, can be accessed. Park the vehicle and setthe parking brake to access additional screen func-tions.

Basic Function ScreensWhen the odometer is displayed, push the mode/reset switch once to display trip distance, and push itagain to display trip hours. Both numbers are calcu-lated from the last time the value was reset. Hold theswitch when either number is displayed, to reset thevalue to zero. See Fig. 2.41 .

f61034909/10/99

AIR FILTER RESTRICTIONRESET

22

15118

5.5

3.72.72.0

IN kPaH O2

6.225

Fig. 2.39, Intake Air Restriction Indicator, Dash-Mounted

10/06/2008

0 160

10060

PSI

AIR

S

0 160

10060

PSI

AIR

P

100 250

200150

F

WATER

E F

1/2

FUEL8 16

12

VOLTS

0 100

40

OIL

PSI

75

6555

5

15

2535 45

8510

30

5070 90

110

130

km/hMPH

RPMX 100

1520

25

10

5

0 30

CHECK STOP ABS ABS

12

3

4

5

6 7 8

9

1011

f611017

1. Tachometer2. Voltmeter3. Engine-Coolant

Temperature Gauge4. Engine-Oil Pressure

Gauge5. Lightbar6. Dash Message Center

7. Mode/Reset Switch8. Primary-Air Pressure

Gauge9. Secondary-Air

Pressure Gauge10. Fuel Level Gauge11. Speedometer

Fig. 2.40, ICU4 Instrument Cluster


2.17

Diagnostic ScreensDuring vehicle start-up, with the parking brake on,the ICU4 displays any active fault codes for threeseconds each, until the parking brake is released.While the active fault codes are on display, push themode/reset switch once to display the initial diagnos-tic screen (DIAG) and the total number of activefaults. See Fig. 2.42 .

If service cycle screens are enabled, and service dis-tance or time has been exceeded, the text SERVICEwill be displayed with the other fault messages. Thisinforms the driver that the service interval has beenexceeded, and vehicle service is required.

Specific fault code information can be displayed onlywhile the vehicle is parked and the parking brake set.When the odometer screen is displayed, push themode/reset switch until the DIAG screen is displayed,then hold the switch to enter the fault code screensequence. Once the initial fault code is displayed,push the switch to cycle through additional diagnostic

codes relating to the first fault. Hold the switch to dis-play additional faults or return to the DIAG screen. Ifservice cycle screens are enabled, service intervalinformation is displayed before fault code informationis displayed.

When the word SERVICE appears on the DIAG mes-sage display screen, service cycle screens are en-abled. Hold the mode/reset switch at the DIAGscreen to display miles or hours remaining until thenext scheduled service. When MI appears on theDIAG screen, service miles are enabled; whenHOURS appears on the screen, service hours areenabled. Either service miles or hours can be en-abled, but not both. When service miles or hours hasbeen exceeded, the number flashes to indicate ser-vice is overdue.

Engine ScreensPush the mode/reset switch once following the DIAGscreen and the word ENGINE is displayed in thelower right corner of the digital display. Hold the

f040693

Push

With

par

k br

ake

off

Go to the Diagnostic and Engine Display Screens figure.

Hold

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

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

Default OdometerDisplay Screen

To Reset Trip Miles

To Reset Trip Hours

Hold

Hold

Hold

Push

Push

Push

Push

Push

Hold For setup screens.

Go to the Diagnostic and Engine Display Screens figure.

With park brake on

06/01/2004

Fig. 2.41, ICU4 Basic Function Screens


2.18

switch to display total engine miles. Push then hold itagain to display total engine hours. If OIL LVL is dis-played earlier with ENGINE (only on vehicles withMercedes-Benz engines; if equipped and enabled)hold the switch again to access oil level screens.

Setup ScreensSee Fig. 2.43 for setup screens.

Press the mode reset switch while in the engine dis-play screen, to sequence to the SETUP screen. Holdthe mode switch while in the SETUP screen, to se-quence to the SELECT screen. Hold the modeswitch while in SELECT, to toggle between MI or KMas a display preference. Release the mode switch atthe desired selection, then press again to reset.

Push the mode switch again to display the tempera-ture warning screen. Hold the mode switch to togglebetween ON and OFF. Release the button, thenpress it again to reset to the desired setting.

Push the mode switch again to sequence to the LCDbrightness screen. Hold the mode switch to togglebetween ON and OFF. Release the button at the de-sired setting, then push again to reset.

Push the mode switch again to sequence to the ser-vice SETUP screen.

To reset the service intervals, hold the mode switchwhile in the service SETUP screen, to display theRESET screen. Hold the mode switch while in theRESET screen, to display the interval select screen.Hold the mode switch while in the interval selectscreen, to toggle between MI (KM), or HOURS forselection of the service interval mode. Release thebutton at the desired setting, then push again toreset.

When MI (KM) is selected, push the mode switch tosequence to the service miles distance select screen.Holding the mode switch for approximately 1-1/2 sec-onds will display table values. Holding the mode/reset switch for 3 seconds will speed up scrolling

To display totalengine miles.

To display tolalengine hours.

To display OIL LVLscreens (if equippedand enabled).

To display specific OIL LVL amountover or under full.

For additional faults,if any, or return toDIAG screen.

04/28/2004 f040695

Push

Hold

Push

Push

Push

Hold

Hold

Hold

Push

HoldHold

Hold

Push

Then

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

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

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

If Service Cycle screens not enabled

Or

Fig. 2.42, ICU4 Diagnostic and Engine Screens


2.19

through the tables. Release the mode switch whenthe desired interval flashes, then push the mode/reset switch to select it. When completed, the displaywill sequence to the odometer display.

When HOURS is selected, push the mode switch tosequence to the service hours time select screen.

Holding the mode switch for approximately 1-1/2 sec-onds will display table values. Holding the mode/reset switch for 3 seconds will speed up scrollingthrough the tables. Release the mode switch whenthe desired interval flashes, then push the mode/reset switch to select it. When completed, the displaywill sequence to the odometer display.

Selection?

To toggle betweenlook−up tablehours

To toggle betweenlook−up tablemiles

To toggle betweenMI > HOURS > no >

NOTE:* Flash screen text**Display active mode

The no selection will disable the Service Interval

Hold will reset all Service Interval counters

Metric version screens are similar to English version screens

To toggle betweenMI > KM >

To toggle betweenON > OFF >

Push

To toggle betweenON > OFF >

HRSMI

no

Push

PushPush

Push Push Push

Push

Push

PushPush

Hold

Hold

Hold

Hold

Hold Hold Hold

HoldHold

Hold

SET UP SELECT*MI

SET UP

WARN°T

*on

LCD LMP

*on

**MI **HOURS**no

RESET**MI **HOURS

*no

SELECT*MI *HOURS

*noSERVICE SERVICE SERVICE

*12345MI

SERVICE

*12345HOURS

SERVICE

RESET

EE

DONE

f04075506/21/2007

Fig. 2.43, ICU4 Setup Screens


2.20

If NO is selected, the display will sequence to theodometer display.

The last screen in the SETUP menu, RESET EE isfor resetting certain parameters to the original set-tings. Hold the mode switch to reset the ABS rollcall,sensor fault codes, and engine oil level screens.Push the mode switch to sequence the display to theodometer setting.

Instrumentation Control Unit 3(ICU3 and ICU3 ’07)The instrumentation control unit (ICU) houses mostwarning and indicator lights, most gauges, and amessage display screen. Warning messages anddiagnostic fault codes will appear in the messagedisplay screen. The dash lightbars have warning andindicator lights that may be lettering or icons. Up untilDecember 31, 2006, the warning and indicator lightsare a mixture of ISO icons, and lettering. Since Janu-ary 2007, ISO icons are used for all standard warn-ing and indicator lights on the dash lightbar. SeeTable 2.1 for an explanation of the icons.

There can be up to eight gauges on the ICU3 instru-ment cluster, six electronic gauges and two mechani-cal gauges. See Fig. 2.44 . Only air gauges operatemechanically. The ICU3 cannot drive gauges locatedon the control panel.

The dash message center is the heart of the ICU3. Ithas two parts, a set of up to 26 warning and indica-tor lights and a message display screen. The mes-sage display screen is a one-line by seven-characterliquid crystal display (LCD) that normally shows theodometer reading. Below the odometer reading is asmaller one-line by three-character LCD that showsthe voltmeter reading.

The message display screen will also display the tripdistance, trip hours (engine hours), and service diag-nostics if the vehicle has this option.

Use the instrument and control panel dimmer switchto increase or decrease the brightness of the mes-sage display screen.

There can be up to 26 warning and indicator lightsinstalled in the ICU3. See Fig. 2.45 and Fig. 2.46 .

There are four rows of lights in the dash messagecenter. Lights installed in the top row are optionaland their positions may vary. The lights in the bottom

three rows are installed in fixed positions on all ve-hicles. Most are standard, but a few are optional.

ICU3 Ignition SequenceIf the headlights are turned on, the message displayscreen displays the odometer reading. When the ig-nition is turned on, all the electronic gauges completea full sweep of their dials, the warning and indicatorlights light up, and the buzzer sounds for three sec-onds.

NOTE: The air gauges do not sweep.

The following lights come on during the ignition se-quence:

• high coolant temperature warning

• low engine oil pressure warning

• low air pressure warning

• parking brake indicator

• engine protection warning

• check engine warning

• tractor ABS

• trailer ABS

10/06/2008

CHECK STOP ABS ABS

1

2

3

4

5 6

7

8

9

1011

12

f611022

1. TransmissionTemperature Gauge

2. Engine CoolantTemperature Gauge

3. Engine Oil PressureGauge

4. Lightbar5. Tachometer6. High Beam Indicator

Light

7. Dash Message Center8. Speedometer9. Fuel Level Gauge10. Primary Air Pressure

Gauge11. Mode/Reset Switch12. Secondary Air

Pressure Gauge

Fig. 2.44, ICU3 (’07 shown)


2.21

f610379

1 1 16512 3 47 8 9 10 11 12

13 14 1519 20 21

2223 24

16 17 18

12/01/99

Typical installation shown. Location of icons installed in the top row may vary, and other icons may be specified.

1. Optional Warning and Indicator Lights2. Axle Lock3. Low Water (coolant)4. Wheel Lock5. Range Inhibit6. Check Transmission7. Check Engine8. Engine Protection Warning9. No Charge10. Tractor ABS11. Transmission Temperature12. Trailer ABS

13. Low Oil Pressure14. High Coolant Temperature15. Fasten Seat Belt16. Brake System Warning and Parking Brake Indicator17. Recirculated Air18. Air Filter Restriction19. Left-Turn Signal20. Low Battery Voltage21. Message Display Screen22. High-Beam23. Low Air Pressure24. Right-Turn Signal

Fig. 2.45, ICU3 Dash Message Center

f61083608/31/2006

1 2 3 4

8 9 1014 15

5 6 7

11 12 1318 191716

ABS ABS

OPT OPT OPT OPT OPT OPT OPT OPT OPT

BRAKE

1. Optional Indicator2. Check Engine3. Stop Engine4. Malfunction Indicator Light (MIL)5. Tractor ABS6. Transmission Temperature7. Trailer ABS8. Low Oil Pressure

9. High Coolant Temperature10. Fasten Seat Belt11. Parking Brake ON12. Diesel Particulate Filter (DPF)

Status Lamp13. High Exhaust System

Temperature (HEST)

14. Left-Turn Signal15. Low Battery Voltage16. Driver Display Screen17. High Beams18. Low Air Pressure19. Right-Turn Signal

Fig. 2.46, ICU3 ’07 Dash Message Center


2.22

NOTE: Although the engine and ABS warninglights come on during the ignition sequence,they are not controlled by the ICU3 or ICU3 ’07but by their own system ECU (electronic controlunit).

Once the ignition switch has been turned on, theICU3 or ICU3 ’07 performs a self-test to look for ac-tive faults. During the first half of the self-test, allsegments of the message display screen display888888.8. The voltmeter display also comes on withthe value 18.8. During the second half of the self-test, the software revision level is displayed.

If there are no active faults, the screen displays theodometer reading.

If the ICU3 or ICU3 ’07 has received active faultcodes from other devices, it displays them, one afterthe other, until the parking brake is released or theignition switch is turned off.

A list of fault codes and definitions can be found inGroup 54 of the Acterra® Workshop Manual. Oncethe parking brake is released, the ICU3 or ICU3 ’07displays the odometer reading again.

Mode/Reset SwitchThe mode/reset switch (Fig. 2.47 ) is located on theright side of the instrument cluster. The mode/resetswitch is used to scroll through the displays on themessage display screen, and to reset the trip dis-tance and trip hours values to zero.

See Fig. 2.48 for the state diagram for the LCD dis-play cycle.

NOTE: The systems diagnostics test is used bytrained personnel to retrieve fault codes andother diagnostic information pertaining to thevehicle.

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

• Press the mode/reset switch once and the tripdistance will display.

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

• Press the mode/reset switch a third time andthe SELECT screen and the current units, MIor KM, will display.

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

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

NGI Instrument Cluster,OptionalInstrumentsThe NGI instrument cluster became an option inJanuary of 2002.

Each of its gauges is an individually replaceable unit.The instrument control unit (ICU) is located in thespeedometer and receives information from the vari-ous sensors installed on the vehicle and feeds it tothe electronic gauges. Only the air gauges operatemechanically.

LightbarThe lightbar has 3 rows of 7 warning lights. SeeFig. 2.49 . The 7 telltales on the top row of the light-bar will vary depending on the vehicle configurationand customer preference. The 2 lower rows contain14 standard telltales as shown in Table 2.3 .

09/25/99

PUSH− MODE HOLD− RESET

f610340

Fig. 2.47, Mode/Reset Switch


2.23

NGI Lightbar Standard TelltalesLight LED Color

Left Turn Signal GreenCheck Engine AmberEngine Protection RedFasten Seat Belt Symbol Red

NGI Lightbar Standard TelltalesLight LED Color

High Beam Headlamps BlueTractor ABS (Antilock Brake System) AmberParking/Emergency Brake RedAir Intake Filter Restriction AmberRight Turn Signal GreenTrailer ABS AmberWater in Fuel AmberIntake Heater AmberCheck A/C AmberLow Air Red

Table 2.3, NGI Lightbar Standard Telltales

Message CenterThe NGI message center is a one row, seven char-acter liquid crystal display (LCD), located on thespeedometer, that displays the following information:

03/26/2004 f040636a

Push

Push

123456.7TRIP MI 12.3 VOLTS

Push

123456.7MI 12.3 VOLTS

Push

123456.7TRIP HOURS

12.3 VOLTS

SELECtMI

dIAGMI HOURS

n

Push

Push

123456.7MI

EC

Push

CLEAr

Push

123456.7HOURS

EC

EnG oIL *Lo

SEtUP **MI **HOURS**no

Default OdometerDispay Screen

To Reset Trip MilesHold

To Reset Trip HoursHold

To Toggle between UnitsHold

Dispay DiagnosticsHold

Dispay Oil LevelHold

Dispay Service IntervalCycle Screens

Hold

To Dispay Total Engine HoursEC = Engine Control

To Dispay Total Engine MilesEC = Engine Control

Clear DefaultsHold

Push Push

n = Number of Active Fault CodesMI = CYCLE Miles EnabledHOURS = Cycle Hours Enabled

*Lo = Oil Level LowHI = Oil Level HighBlank = Oil Level OK− − = No Message

MI<−−−−>KM

**MI = CYCLE Miles Active Mode**HOURS = CYCLE Hours Active Mode**no = Service CYCLE Inactive

Fig. 2.48, ICU3 Mode Reset LCD Display Cycle

f61050604/28/2003

Fig. 2.49, NGI Lightbar


2.24

• Odometer

• Trip Odometers (two)

• Engine Hour Meter

• System Diagnostic Menu

• NGI-specific warning messages

The odometer, hour meter, and trip odometers areprimary screens. When a primary screen is displayedfor 3 seconds or more it becomes the default screen.The default screen is displayed at ignition and willremain so until manually adjusted using the Modeand Set buttons.

Mode and Set ButtonsThe Mode and Set buttons are located in the lowerright corner of the instrument cluster. See Fig. 2.50 .Pressing the Mode button cycles through the variousfunctions. Pressing the Set button selects the desiredfunction. See Fig. 2.51 . In the Odometer mode, theSet button toggles to MI or KM. In the Trip 1 and 2Odometer modes, the Set button resets the Tripmeter to zero. In the Engine hours mode, total en-gine hours are displayed. This is not resetable. In theSystem mode, the Set button initiates the SystemDiagnostics test and will display any warning mes-sages that are present in the system.

NOTE: The systems diagnostics test is used bytrained personnel to retrieve fault codes andother diagnostic information pertaining to the ve-hicle.

To run the system diagnostics, the following condi-tions must be met:

• ignition on;

• parking brake set;

• road speed below 2 mph;

• engine rpm at or below 1000;

• no low air pressure warning in effect.

25

155 85

75

6535 45 55

MPH

150PSI

0S

1/2

3/41/4

E F

km/h

12/19/2002 f610635

1 2

1. Mode Button 2. Set Button

Fig. 2.50, Mode and Set Buttons


2.25

12/11/2002 f040637a

Odometer

Clear Trip1Odometer

Clear Trip2Odometer

System DiagnosticsTest Loop

NGI Specific WarningMessage Loop

Main Loop

Kilometersor

No

Yes

No

Entry via Ignition is ODOdefault?

is Trip 1default?

is Trip 2default?

Yes

No

Entry via panellamp power

Entry via MODEbutton press

Yes

LOW AIRinactive?

No

No

Mode Yes Mode

Mode

Yes

Mode

Set

Yes

Set

Yes Yes

No

TripOdometer

Trip2Odometer

EngineHoursMode

Park BrakeSet?

Road Speed< 25 MPH?

No

No

No

RPM<1000?

SystemDiagnosis

Test

Anywarning

messages?

Ignitionon?

SetSet

Miles

Yes

Fig. 2.51, State Diagram for LCD Display


2.26

3

Vehicle Access and FeaturesCab Door Locks and Handles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.1Door Windows . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.1Cab Entry and Exit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.2Hood Tilting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.4Back-of-Cab Grab Handles, Steps, and Deck Plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.4Fuse, Relay, and Circuit Breaker Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.5

Cab Door Locks and HandlesThe key that operates the ignition switch also locksand unlocks the cab doors from the outside. The lockcannot be operated when the door is open.

To unlock the driver’s door from outside the cab, in-sert the key in the lockset and turn the key counter-clockwise (Fig. 3.1 ). Pull the handle out to open thedoor. To lock the driver’s door, insert the key in thelockset and turn the key clockwise.

To unlock the passenger’s door from outside the cab,insert the key in the lockset and turn the key clock-wise. Pull the handle out to open the door. To lockthe passenger’s door, insert the key in the locksetand turn the key counterclockwise.

To lock the door from inside the cab, close the door,then push the lock button down or push the L on thepower lock switch. See Fig. 3.2 and Fig. 3.3 .

To open the door from the inside, pull the doorhandle toward you. This will unlatch the door whetheror not it was locked. To unlock the door without un-latching it, pull up the lock button or press the U onthe power lock switch.

Door WindowsIf the vehicle has manual window regulators, lowerthe driver’s door window by turning the window regu-lator handle clockwise. To lower the passenger’s

f720361

12

09/22/99

1. Unlock 2. Lock

Fig. 3.1, Driver’s Door Lock and Handle

09/25/99 f720360

1

2

3

4

5

1. Door Grab Handle2. Lock Button3. Door Handle

4. Window RegulatorHandle

5. Door Light

Fig. 3.2, Door Interior

f72036710/06/99

1 2

3

3

4A B

A. Push here to lower the window.B. Push here to raise the window.1. Door Handle2. Power Mirror Switch

3. Power Window Switch4. Power Lock Switch

Fig. 3.3, Power Switches

Vehicle Access and Features

3.1

door window, turn the window regulator handlecounterclockwise.

If the vehicle is equipped with power windowswitches, they are located on the door (Fig. 3.3 ).Push the dimpled end of the power window switch tolower the window. Push the raised end of the powerwindow switch to raise the window.

Cab Entry and Exit

WARNINGWet or dirty shoe soles greatly increase thechance of slipping or falling. If your soles are wetor dirty, be especially careful when climbingonto, or down from, the back-of-cab area.

Always maintain three-point contact with theback-of-cab access supports while entering andexiting the back-of-cab area. Three-point contactmeans both feet and one hand, or both handsand one foot, on the grab handles, steps, anddeck plates. Other areas are not meant to sup-port back-of-cab access, and grabbing or step-ping in the wrong place could lead to a fall, andpersonal injury.

Be careful not to get hands or feet tangled inhoses or other back-of-cab equipment. Careless-ness could cause a person to trip and fall, withpossible injury.

When entering or exiting the cab, use the grabhandles and cab access steps as indicated in thefollowing instructions. See Fig. 3.4 and Fig. 3.5 .

Entering the Driver’s Side WhenThere are Two Cab Access Steps1. Open the driver’s door and place anything that

you are carrying in the cab.

2. Grasp the door grab handle with your left handand the cab grab handle with your right hand.

3. Place your right foot on the bottom step and pullyourself up.

4. Place your left foot on the top step.

5. Grasp the steering wheel with your left hand andstep into the cab with your right foot first.

6. Grasp the steering wheel with your right handand pull yourself into the seat.

Exiting the Driver’s Side When Thereare Two Cab Access Steps1. Do not attempt to exit the cab while carrying any

items in your hands.

2. Grasp the steering wheel with both hands andplace your left foot on the top step. Pivot yourbody so you’re facing in to the cab.

3. Grasp the cab grab handle with your right hand.

4. Move your right foot to the bottom step.

5. Grasp the door grab handle with your left hand.

6. Step to the ground with your left foot first.

f72036210/08/99

1

2

3

4

1. Cab Grab Handle2. Top Cab Access Step3. Bottom Cab Access Step4. Door Grab Handle

Fig. 3.4, Driver’s Side Cab Access Steps and GrabHandles


3.2

Entering the Passenger’s Side WhenThere are Two Cab Access Steps1. Open the passenger’s door and place anything

that you are carrying in the cab.

2. Grasp the cab grab handle with your left handand the door grab handle with your right hand.

3. Place your left foot on the bottom step and pullyourself up.

4. Place your right foot on the top step.

5. Grasp the seat with your left hand and step intothe cab with your left foot first.

6. Pull yourself into the seat.

Exiting the Passenger’s Side WhenThere are Two Cab Access Steps1. Do not attempt to exit the cab while carrying any


2. Grasp the door grab handle with your right handand place your right foot on the top step.

3. Grasp the grab handle with your left hand.

4. Move your left foot to the bottom step.

5. Step to the ground with your right foot first.

Entering the Driver’s Side WhenThere is One Cab Access Step1. Open the driver’s door and place anything that

you are carrying in the cab.

2. Grasp the door grab handle with your left handand the grab handle with your right hand.

3. Place your right foot on the cab access step.

4. Bring your left foot up to the cab floor and stepup, bringing your right foot into place in the cab.

5. Grasp the steering wheel with your left hand andpull yourself into the seat.

Exiting the Driver’s Side When Thereis One Cab Access Step1. Do not attempt to exit the cab while carrying any


2. Grasp the door grab handle with your left hand.

3. Move your left foot to the cab access step andgrasp the grab handle with your right hand.

4. Bring your right foot down to the ground, thenbring your left foot down to the ground.

Entering the Passenger’s Side WhenThere is One Cab Access Step1. Open the passenger’s door and place anything

that you are carrying in the cab.

2. Grasp the grab handle with your left hand andthe door grab handle with your right hand.

3. Place your right foot on the cab access step.

4. Bring your left foot up to the cab floor and stepup, bringing your right foot into place in the cab.

5. Grasp the seat with your left hand and pull your-self into the seat.

f72036310/08/99

1

2

3 4

1. Bottom Cab Access Step2. Top Cab Access Step3. Cab Grab Handle4. Door Grab Handle

Fig. 3.5, Passenger’s Side Cab Access Steps and GrabHandles


3.3

Exiting the Passenger’s Side WhenThere is One Cab Access Step1. Do not attempt to exit the cab while carrying any


2. Grasp the door grab handle with your right hand.

3. Move your right foot to the cab access step, andgrasp the grab handle with your left hand.

4. Bring your left foot down to the ground, thenbring your right foot down to the ground.

Hood TiltingA grab handle at the front of the hood provides ahand-hold for hood tilting. Stop cables prevent thehood from overtravel. In the operating position, thehood is secured to the lower cab half-fenders by ahold-down latch on each side of the hood.

To Tilt the Hood1. Apply the parking brakes.

2. Release both hood hold-down latches by pullingthe ends up. See Fig. 3.6 .

3. Using the front bumper step and the hoodhandle, slowly tilt the hood until the stop cablessupport it. See Fig. 3.7 .

CAUTIONDo not let the hood free-fall to the full-open posi-tion. To do so could cause damage to the hoodor hood straps.

To Return the Hood1. Grasp the hood handle and lift the hood to the

45-degree position.

2. As the hood goes over center, use the bumperstep and the hood handle to control the rate ofdescent to the operating position.

3. Make sure the hood is flush with the cowl, thensecure the hood by engaging both hood hold-down latches.

IMPORTANT: Make sure that both hold-downlatches are fully engaged before operating thevehicle.

Back-of-Cab Grab Handles,Steps, and Deck PlateWhen trailer air and electrical connections cannot becoupled from the ground, Federal Motor Carrier

10/01/93 f720073

Fig. 3.6, Unlatch the Hood

10/28/99 f880474

Fig. 3.7, Tilting the Hood


3.4

Safety Regulations require commercial carriers toprovide back-of-cab access (Fig. 3.8 ).

A grab handle is mounted either on the exhaustshield, the cab, or the sleeper. Steps are mounted onthe fuel tank, battery box, or frame; depending on theavailable space. When an optional deck plate is in-cluded, it is mounted across the top of the framerails.

WARNINGWet or dirty shoes, steps, or grab rails greatlyincrease the chance of slipping or falling. If yourshoes or the contact areas are wet or dirty, beespecially careful when entering or exiting thevehicle, or back-of-cab access.

Always maintain three-point contact with the ve-hicle, when accessing the back of the cab. Three-point contact means both feet and one hand, orboth hands and one foot.

When steps are mounted on battery box covers,make sure that the cover is latched and secure,before using the steps.

Do not step on the fuel tank, battery box, frame,etc., unless adequate slip resistant surfaces andhandholds are provided.

Do not jump from the vehicle.

Accessing Back-of-Cab AreaWhen climbing onto the deck plate, use the grabhandle and access steps as follows:

1. Grasp the grab handle with both hands. Reachup as far as is comfortable.

2. Place one foot on the bottom step and pull your-self up.

3. Place your other foot on the top step.

4. Move your lower hand to a higher position on thegrab handle.

5. Step onto the deck plate.

Exiting the Back-of-Cab AreaWhen climbing down from the deck plate, use thegrab handle and access steps as follows:

1. Grasp the grab handle with both hands.

2. Step one foot at a time to the top step.

3. Move your upper hand to a lower position on thegrab handle.

4. Move one foot to the bottom step.

5. Move your upper hand to a lower position on thegrab handle.

6. Step to the ground with your upper foot first.

Fuse, Relay, and CircuitBreaker IdentificationThere are two power distribution modules (PDM) inthe vehicle. The internal PDM is located below theright-side dash or the passenger-side dash. The ex-ternal PDM is located under the hood on the front-wall. Refer to Fig. 3.9 and Table 3.1 for the internalPDM fuse, relay, and circuit breaker identification.Refer to Fig. 3.10 and Table 3.2 for the externalPDM fuse, relay, and circuit breaker identification.

Internal PDM Fuse, Relay, and Circuit BreakerIdentification

Pos.No.

Description Part Number Rating

1 — D9ZB-14A094-CA andF6HT-14526-CA 10A

03/22/2001

1 1

2

3f602080

1. Grab Handle2. Deck Plate3. Step

Fig. 3.8, Back-of-Cab Access


3.5


Pos.No.


2 Power Door Lock D9ZB-14A094-CA andF6HT-14526-CA 10A

3 Horn/Buzzer D9ZB-14A094-CA andF6HT-14526-CA 10A

4 WindshieldWasher/Wiper

F6HT-145264-NA andF6HT-14526-NA 11/CB

5 — D9ZB-14A094-DA andF6HT-14526-DA 15A

6 Air Dryer Heater D9ZB-14A094-CA andF6HT-14526-CA 10A


8 Axle Shift D9ZB-14A094-DA andF6HT-14526-DA 15A


10 Backup Lamp D9ZB-14A094-CA andF6HT-14526-CA 10A

11 Open D9ZB-14A094-CA andF6HT-14526-CA 10A




15 Radio System D9ZB-14A094-EA andF6HT-14526-EA 20A

16 Radio System D9ZB-14A094-CA andF6HT-14526-CA 10A

17 Mirror, Heated,Power

D9ZB-14A094-FA andF6HT-14526-FA 25A

18 Accessory Supply D9ZB-14A094-DA andF6HT-14526-DA 15A

19 — D9ZB-14A094-BA andF6HT-14526-BA 5A



22 Ignition Run D9ZB-14A094-CA andF6HT-14526-CA 10A


24 CB Radio Post D9ZB-14A094-DA andF6HT-14526-DA 15A


Pos.No.


25 Start, Ignition D9ZB-14A094-FA andF6HT-14526-FA 25A

26 ABS HydraulicPump

D9ZB-14A094-CA andF6HT-14526-CA 10A

27 Open — —28 Open — —29 Open — —30 Open — —

31 Interior Light D9ZB-14A094-DA andF6HT-14526-DA 15A

32 Marker ClearanceLamp

D9ZB-14A094-DA andF6HT-14526-DA 15A

33 Cluster DiagramConnector

D9ZB-14A094-DA andF6HT-14526-DA 15A

34 Left Side PowerWindow

F6HT-14526-MA andF6HT-14526-MA 18A/CB

35 Right Side PowerWindow

F6HT-14526-MA andF6HT-14526-MA 18A/CB

36 Utility/Trailer Lamp — —

37 Head Lamp D9ZB-14A094-DA andF6HT-14526-DA 15A

38 Open D9ZB-14A094-CA andF6HT-14526-CA —

39 Fog/Road Lamp D9ZB-14A094-CA andF6HT-14526-CA 10A

40 Open — —41 Open — —

42 Stop Lamp/HazardWarning Lamp

D9ZB-14A094-GA andF6HT-14526-GA 30A

43 Engine D9ZB-14A094-CA andF6HT-14526-CA 10A

44 — D9ZB-14A094-CA andF6HT-14526-CA —

45 ABS D9ZB-14A094-BA andF6HT-14526-AA 5A


47 ABS D9ZB-14A094-BA andF6HT-14526-AA 5A

48 — D9ZB-14A094-BA andF6HT-14526-BA —

R1 Right Side PowerWindow Relay 23-11276-011 —

R2 Left Side PowerWindow Relay 23-11276-011 —

R3 2-Speed AxleRelay 23-11276-011 —


3.6


Pos.No.


R4 Ignition Run Relay 23-11276-011 —

R5 Ignition Run/Accessory Relay 23-11276-011 —

R6 Ignition Run Relay 23-11276-011 —R7 Fog/Road Lamp 23-11276-011 —R8 HVAC Blower — —

R9 Hazard WarningLamps — —

R10 Open — —

R11 Windshield Wiper/Washer 23-11276-011 —

R12 ABS Power 23-11276-011 —R13 Transmission 680 545 00 05 —R14 Brake Cut Out 680 545 00 05 —


Pos.No.


R15 Open — —R16 Open — —

R17 Hydraulic BrakePump 680 545 00 05 —

R18 Engine Brake 680 545 00 05 —R19 ABS Lamp 680 545 00 05 —

R20 2-Speed Axle,MBE 680 545 00 05 —

R21 Electronic EngineService Brake 680 545 00 05 —

R22 Trans ABS 680 545 00 05 —

Table 3.1, Internal PDM Fuse, Relay, and CircuitBreaker Identification

External PDM Fuse, Relay, and Circuit Breaker IdentificationPos. Description Part Number RatingR–A Fuel Heater Relay (optional) F0AB-14B192-AA —R–B Tail/Brake Lamp Relay (body builder) F0AB-14B192-AA —R–C Marker Lamp Relay (body builder) F0AB-14B192-AA —R–D Transmission, Backup Light Relay F0AB-14B192-AA —R–E Trailer ABS ECU Constant Relay F80B-14B192-AA —R–F Transmission Neutral Relay F0AB-14B192-AA —R–G Not Used — —R–H Not Used — —R–J Not Used — —R–K Not Used — —R–L Not Used — —R–M Not Used — —R–N Trailer Left-Turn Relay F0AB-14B192-AA —R–P Trailer Right-Turn Relay F0AB-14B192-AA —R–R Trailer Park Lamp Relay F0AB-14B192-AA —R–U Trailer Marker Lamp Relay F0AB-14B192-AA —R–V Trailer Brake Lamp Relay F80B-14B192-AA —R–W Not Used — —

A Power to R–A Fuel Heater (optional) E97B-14A094-BA and F6HT-14526-JA 40A Fuse 40A CBB Feed F1, F2 (PDM electrical center) E97B-14A094-AA and F6HT-14526-LA 30A Fuse 30A CBC Feed to R–B, R–C (body builder) E97B-14A094-BA and F6HT-14526-JA 40A Fuse 40A CBD Feed F13, F14, F15 (PDM electrical center) E97B-14A094-BA and F6HT-14526-JA 40A Fuse 40A CBE Power to R–2 (PDM electrical center) Left Door E97B-14A094-BA and F6HT-14526-JA 40A Fuse 40A CBF Feed F36 (PDM electrical center) E97B-14A094-BA and F6HT-14526-JA 40A Fuse 40A CB

G Power to R–8 (PDM electrical center) HVACBlower Motor E97B-14A094-BA and F6HT-14526-JA 40A Fuse 40A CB

H Power to R–6 (PDM electrical center) Ignition Run E97B-14A094-BA and F6HT-14526-JA 40A Fuse 40A CB


3.7

External PDM Fuse, Relay, and Circuit Breaker IdentificationPos. Description Part Number Rating

J Ignition to R–5 (PDM electrical center) E97B-14A094-DA 60A Fuse 60A CBK Feed F31, F32, F33 (PDM electrical center) E97B-14A094-BA and F6HT-14526-JA 40A Fuse 40A CBL Feed F37 (PDM electrical center) Head Lamps E97B-14A094-BA and F6HT-14526-JA 40A Fuse 40A CBM Feed F26 (PDM electrical center) ABS Power E97B-14A094-BA and F6HT-14526-JA 40A Fuse 40A CBN Open — —P Open — —R Open — —

S Feed F3, F4 (PDM electrical center) WindshieldWipers E97B-14A094-BA and F6HT-14526-JA 40A Fuse 40A CB

T Power to R–N, R–P Trailer Left and Right TurnSignals E97B-14A094-BA and F6HT-14526-JA 40A Fuse 40A CB

U Feed F23, F24 (PDM electrical center) CB Radio E97B-14A094-BA and F6HT-14526-JA 40A Fuse 40A CBV Power to R–1 (PDM electrical center) Right Door E97B-14A094-BA and F6HT-14526-JA 40A Fuse 40A CBW Power to R–R, R–U Trailer Park/Marker E97B-14A094-BA and F6HT-14526-JA 40A Fuse 40A CBX Open — 30A Fuse 30A CBY Open — 30A Fuse 30A CB

Z Feed F42 (PDM Electrical Center) Brake Lamp/Flash E97B-14A094-BA and F6HT-14526-JA 40A Fuse 40A CB

AA Feed PDM Electrical Center (A) Custom AccessPanel E97B-14A094-BA and F6HT-14526-JA 40A Fuse 40A CB

BB Open — 30A Fuse 30A CBCC Power to R–V Trailer Brake Lamp E97B-14A094-BA and F6HT-14526-JA 40A Fuse 40A CBDD Open — —EE Power to R–E Trailer E97B-14A094-BA and F6HT-14526-JA 40A Fuse 40A CBFF Open — —GG Open — —

Table 3.2, External PDM Fuse, Relay, and Circuit Breaker Identification


3.8

R22

484746454443424140393837

25 26 27 28 29 30

31 32 33 34 35 36

1

2

3

4

5

6

7

8

9

10

11

12

13 14 15 16 17 18

19 20 21 22 23 24

A

B

C

D

EF

G

H J K L M N P R1 R2 R3

R4 R5 R6 R7 R8 R9

R10 R11 R12 R13 R14 R15 R16 R17

R18 R19 R20 R21

11/02/1999 f542977

Fig. 3.9, Internal PDM Fuse, Relay, and Circuit Breaker Panel

f542976 11/02/1999

R−W R−V R−U R−R R−P R−N

S T U V W EE DD CC BB AA Z Y X GG FF

R P N M L K J H G F E D C B A

R−M R−L R−K R−J R−H R−G

R−F R−E R−D R−C R−B R−A

Fig. 3.10, External PDM Fuse, Relay, and Circuit Breaker Panel


3.9

4

Heater and Air ConditionerHVAC General Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.1Defogging and Defrosting Using Fresh Air . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.1Heating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.2Air Conditioning, Optional . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.2Fresh Air . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.2

HVAC General InformationA dash-mounted climate control panel (Fig. 4.1 orFig. 4.2 ) allows you to control all of the heating, airconditioning, defrosting, and ventilating functions.

A four-speed fan forces fresh or recirculated airthrough the air outlets at the windshield, door win-dows, dash panel, and cab floor.

A temperature control switch is used to select thedesired temperature. Turn the switch counterclock-wise for cool air, or clockwise for warm air.

An air selection switch controls the direction of warmor cool air either through the dash panel louvers, thedash panel louvers and floor outlets, the floor outlets,the floor and defrost (windshield) outlets, or the de-frost outlets.

The dash panel louvers can be adjusted left andright, and up and down. Close the louver by movingthe control toward the solid circle; open the louver bymoving the control toward the open circle (Fig. 4.3 ).

Fresh air is forced through the air outlets when theair selection switch is in the A/C (air conditioning),PANEL, PANEL & FLOOR, FLR (floor), FLR & DEF(defrost), and DEF positions. Recirculated air isforced through the air outlets when the air selection

switch is in the MAX A/C (maximum air conditioning)position. Dusty or smoky outside air is preventedfrom being drawn inside the cab when the air selec-tion switch is in the OFF position.

IMPORTANT: To prevent the buildup of fumes orodors (for example from smoking) and to pre-vent oxygen depletion inside the cab, do notoperate the air conditioning system in the MAXA/C mode for more than 20 minutes.

NOTE: An engine heater supply gate valve isoptional on the Acterra. Shutting off the heatersupply gate valve limits the ability to control theair conditioning temperature in the cab. With thevalve shut off, warm coolant is no longer avail-able from the engine and the controls on theclimate control panel can’t be used to changethe air temperature.

Defogging and DefrostingUsing Fresh Air1. Turn the temperature control switch all the way

clockwise for warm air, and turn the fan switch toLO before starting the engine.

2. Remove any ice or snow from the outside of thewindshield, door windows, and fresh air inletgrille.

3. With the engine at operating temperature, turnthe fan switch to the highest speed. Leave it inthis position for 30 seconds. This will clear thesystem of moist air.

09/21/1999 f610372

1 2

3

1. Fan Switch2. Temperature Control Switch3. Air Selection Switch

Fig. 4.1, Climate Control Panel With Air Conditioning

f610371

1 2

310/04/99

1. Fan Switch2. Temperature Control Switch3. Air Selection Switch

Fig. 4.2, Climate Control Panel Without AirConditioning

09/28/99 f6103451 2

1. Closed Position 2. Open Position

Fig. 4.3, Dash Panel Louver

Heater and Air Conditioner

4.1

4. Move the air selection switch to the defrost(DEF) position. In this position warm, dry air isdirected to the windshield.

NOTE: If your vehicle is equipped with air condi-tioning, the air conditioner automatically comeson in the defrost mode. Operating in this modedries the air.

Heating1. With the engine at operating temperature, move

the temperature control switch all the way clock-wise for heat.

2. Turn on the fan switch to the desired speed.

3. Move the air selection switch to the desired set-ting.

IMPORTANT: If the windows start to fog, movethe air selection switch to defrost (DEF) andmake sure the fan is on.

NOTE: In mild weather the fan switch can bekept in the LO position since forward motion ofthe vehicle will provide airflow through theheater.

4. When a comfortable temperature has beenreached, adjust the fan switch setting and tem-perature control switch as needed to maintainthe temperature.

Air Conditioning, OptionalIMPORTANT: Operate the air conditioner atleast five minutes each month, even during coolweather. This helps prevent drying and crackingof tubing seals, reducing refrigerant leaks in thesystem. Operate the air conditioner only afterthe engine compartment is warm, and the inte-rior of the cab is 70°F (21°C) or higher. Duringcold weather, the heater can be operated at thesame time to prevent discomfort.

1. If the cab is hot inside, temporarily open the win-dows to let the hot air out.

2. Move the air selection switch to a non-air condi-tioning panel position and turn the fan switch toLO before starting the engine.

3. Start the engine.

4. Move the air selection switch to either one of theair conditioning settings. With the switch at theA/C setting, fresh air is drawn into the cab. Withthe switch at MAX A/C, the air inside the cab isrecirculated. A recirculated air (RECIRC AIR) in-dicator on the dash message center illuminateswhen the air inside the cab is recirculated.

IMPORTANT: To prevent the buildup of fumes orodors (for example from smoking) and to pre-vent oxygen depletion inside the cab, do notoperate the air conditioning system in the MAXA/C mode for more than 20 minutes.

5. Move the temperature control switch counter-clockwise for cool air. In this position, no heat isgiven off by the heater.

6. Turn the fan switch to the highest speed.

7. As soon as cool air is flowing from the dashpanel louvers, close the windows. Adjust the fanswitch setting as desired.

8. If the air from the outlets is too cold, move thetemperature control switch clockwise for warmerair flow.

IMPORTANT: If the outside air is dusty orsmoky, set the air selection switch to MAX A/Cand keep the windows and vent closed to pre-vent drawing in dust or smoke. The air selectionswitch can also be set to OFF to prevent draw-ing in dust or smoke.

Fresh Air1. Move the air selection switch to the desired posi-

tion.

2. Move the temperature control switch counter-clockwise for no heating, or move it clockwise forheat.

3. Set the fan switch at the desired speed.

Heater and Air Conditioner

4.2

5

Seats and Seat BeltsSeats . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.1Seat Belts and Tether Belts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.5

SeatsGeneral InformationUnless otherwise noted, all seat adjustments shouldbe made while seated and before the engine isstarted.

WARNINGKeep hands, tools, and other objects away fromthe scissor points under the seats. Failure to doso could cause personal injury.

Seat AdjustmentThe following is a description of adjustments that canbe made to various Sterling-installed seats. Not allseats have all of the adjustments listed below. SeeFig. 5.1 for illustrations of the seat adjustments.

1. Back Cushion Tilt: This adjustment tilts the backcushion forward or backward.

2. Lumbar Support: Lumbar support changes theshape of the back of the seat to give more orless support to the occupant’s lumbar (lowerback) area. This adjustment is either mechanicalor air controlled depending on the type of seat.

3. Isolator: This feature (also referred to as back-slap isolator or Chugger-Snubber®) reduces theamount of road shock by isolating the occupantfrom the motion of the vehicle and allowing theupper seat to move in a simple pendulum mo-tion. A lockout feature is used when the isolatoris not desired.

4. Height Adjustment: The entire seat moves up ordown when adjusting the height. The adjustmentis either manually controlled or air controlled de-pending on the type of seat.

5. Bottom Cushion Angle or Fore and Aft BottomCushion Height: This feature lets the occupantraise or lower the front or back of the bottomcushion. This adjustment is easier to performwhen all weight is removed from the seat.

10/27/99 f910429

1

2

3 4

56

7

1. Back Cushion Tilt2. Lumbar Support3. Isolator Feature4. Height Adjustment

5. Bottom Cushion Angle (fore and aft cushion height)6. Fore and Aft Seat Adjustment (seat track adjustment)7. Head Rest Adjustment

Fig. 5.1, Seat Adjustments

Seats and Seat Belts

5.1

6. Fore and Aft Seat or Seat Track Adjustment: Theentire seat moves forward or backward when thisadjustment is made.

7. Head Rest Adjustment: When this adjustment ismade, the angle of the head rest changes to pro-vide support to the head.

8. Weight Adjustment: On seats with weight adjust-ment, the feature is fully automatic. When you siton the seat, a leveling valve places you in thecenter of the ride zone. Additional adjustmentsare possible by using the height adjustmentfeature.

EzyRider® SeatFor seat adjustment controls on vehicles built beforeNovember 28, 2005, see Fig. 5.2 . For seat adjust-ment controls on vehicles built on or after November28, 2005, see Fig. 5.3 .

Back Cushion TiltTo tilt the back cushion, raise the back cushion tiltlever and lean forward or backward. Release thelever to lock the cushion in place.

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

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

Fore and Aft Seat AdjustmentPull the fore and aft seat adjustment lever out to thesecond stop and slide the seat forward or backwardto the desired position.

f9104561

2

3

4

5

6

03/12/20017

1. Isolator and Fore/Aft Seat Adjustment Lever2. Bottom Cushion Angle Guide3. Armrest Adjustment Knob4. Back Cushion Tilt Position Indicator5. Back Cushion Tilt Lever6. Height Adjustment and Lumbar Support Lever7. Fore/Aft Seat Position Indicator

Fig. 5.2, EzyRider Seat Adjustment Controls (VehiclesBuilt Before November 28, 2005)

f9105651

3

4

5

6

2

2

01/06/2006

1. Isolator and Fore/Aft Seat Adjustment Lever2. Armrest Adjustment Knob3. Bottom Cushion Angle Guide4. Back Cushion Tilt Lever5. Lumbar Support Switch6. Height Adjustment Switch

Fig. 5.3, EzyRider Seat Adjustment Controls (VehiclesBuilt on or After November 28, 2005)


5.2

Height AdjustmentTo raise or lower the seat, use the height adjustmentswitch or lever on the side of the seat.

Bottom Cushion AngleTo adjust the bottom cushion angle, pull the bottomcushion up and forward or down and back. The bot-tom cushion angle is controlled by the guides oneach side of the seat.

Seat Position IndicatorsSeats installed in vehicles built before November 28,2005 are equipped with seat position indicators. Aback cushion tilt position indicator and a fore/aft seatposition indicator allow the driver to see where theseat is adjusted within the adjustment ranges.

Armrest Angle (optional armrests)To adjust the vertical angle of the armrest, turn theadjustment knob on the underside of the armrest.

National Nonsuspended SeatSee Fig. 5.4 for seat adjustment controls.

Back Cushion TiltTo tilt the back cushion, turn the back cushion tiltknob and lean forward or backward.

Fore and Aft Seat AdjustmentTo adjust the fore and aft position of the entire seat,move the fore and aft seat adjustment lever to theleft and slide the seat forward or backward to thedesired position.

Fore and Aft Bottom Cushion AdjustmentTo adjust the fore and aft position of the bottomcushion only, pull the fore and aft bottom cushionadjustment handle out and slide the bottom cushionforward or backward to the desired position.

National 2000 Series SeatSee Fig. 5.5 for seat adjustment controls.

Back Cushion TiltTo tilt the back cushion, turn the back cushion tiltknob until the desired position is reached.

Height AdjustmentTo raise or lower the height of the seat, use theheight adjustment switch on the side of the seat.

Fore and Aft Seat AdjustmentTo adjust the fore and aft position of the entire seat,move the fore and aft seat adjustment lever to theleft and slide the seat forward or backward to thedesired position. Move the lever back to its originalposition to lock the seat in place.

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

IsolatorAlso called a Chugger Snubber®, the isolator reducesthe amount of road shock by isolating the occupantfrom the motion of the vehicle and allowing the seatto move in a simple pendulum motion. To use the

10/07/99 f910430

1

2

3

1. Back Cushion Tilt Knob2. Fore and Aft Seat Adjustment Lever3. Fore and Aft Bottom Cushion Adjustment Handle

Fig. 5.4, National Nonsuspended Seat AdjustmentControls


5.3

isolator feature, turn the isolator handle to the hori-zontal position. Turn the isolator handle down whenthe isolator feature is not desired.

Lumbar SupportTo adjust the lumbar support, use the lumbar supportswitch on the side of the seat to give more or lesssupport to your lower back.

Bottom Cushion Front HeightTo adjust the height of the front of the bottom cush-ion, lift the bottom cushion front height adjustmenthandle, and pull forward or push back to the desiredsetting.

Bostrom Talladega™ 915 SeatSee Fig. 5.6 for seat adjustment controls.

Back Cushion TiltTo tilt the back cushion, lean forward slightly to re-move pressure from the cushion and hold the backcushion tilt lever down. Lean backward slowly to thedesired position and release the lever to lock thecushion in place.

Height AdjustmentTo raise the seat, push up on the height adjustmentswitch. To lower the seat, push down on the heightadjustment switch.

Fore and Aft Seat AdjustmentMove the fore and aft seat adjustment lever to theside to adjust the seat to the desired fore-aft position.Move the lever back to its original position to lock thefore-aft position.

Bottom Cushion Tilt AdjustmentTurn the bottom cushion tilt adjustment knob to in-crease or decrease the bottom cushion tilt.

11/14/2000

1

234

5

f910445

6

7

1. Back Cushion Tilt Knob2. Lumbar Support Switch3. Height Adjustment Switch4. Fore and Aft Seat Adjustment Lever5. Bottom Cushion Front Height Adjustment Handle6. Isolator Handle7. Rear Cushion Adjustment Knob

Fig. 5.5, National 2000 Series Seat Adjustment Controls

09/24/1999 f910428

1

2 3

4

5

1. Back Cushion Tilt Lever2. Upper and Lower Lumbar Support Switches3. Height Adjustment Switch4. Bottom Cushion Tilt Adjustment Knob5. Fore and Aft Seat Adjustment Lever

Fig. 5.6, Bostrom Talladega 915 Seat AdjustmentControls


5.4

Lumbar SupportFor seats with air lumbar support, use the upper andlower lumbar support switches to adjust the top lum-bar and bottom lumbar supports.

Two-Passenger Bench SeatThe two-passenger bench seat is stationary. The bot-tom seat cushion lifts up to access an additional stor-age area under the seat.

Seat Belts and Tether BeltsGeneral InformationSeat belt assemblies are designed to secure personsin the vehicle to help lessen the chance of injury orthe amount of injury resulting from accidents or sud-den stops. For this reason, Sterling Truck Corpora-tion urges the driver and all passengers, regardlessof age or physical condition, to use seat belts whenriding in the vehicle.

Seat belt assemblies in the vehicle meet FederalMotor Vehicle Safety Standard 209, "Type 1" and"Type 2" requirements. They are recommended forall persons weighing over 50 pounds (23 kg).

A child restraint system should also be provided foreach child weighing 50 pounds (23 kg) or less. Itshould meet the requirements of Federal Motor Ve-hicle Safety Standard 213, "Child Restraint Systems."When providing such a restraint system, carefullyread and follow all instructions pertaining to installa-tion and usage for the child. Make certain the childremains in the restraint system at all times when thevehicle is in motion.

In addition to seat belt assemblies, tether belts areinstalled on suspension-type seats. Tether belts helpsecure the seat to the floor and are intended to re-strain the seat and seat belt in case of an accident orsudden stop.

IMPORTANT: Seat belts have a finite life whichmay be much shorter than the life of the vehicle.Regular inspections and replacement as neededare the only assurance of adequate seat beltsecurity over the life of the vehicle.

See Chapter 11 for the seat belt inspection proce-dure.

Seat Belt OperationThree-Point Seat Belt With Komfort ®

LatchWhile your vehicle is in motion, the combination lapand shoulder belt adjusts to your movement. How-ever, if you brake hard, corner hard or if your vehiclereceives an impact of 5 mph (8 km/h) or more, thelap and shoulder belt locks and prevents you frommoving.

WARNINGWear three-point seat belts only as describedbelow. Three-point seat belts are designed to beworn by one person at a time. In case of an acci-dent or sudden stop, personal injury or deathcould result from misuse.

WARNINGFasten the seat belts before driving. Fastening athree-point seat belt while driving creates a haz-ard.

1. Pull the lap-shoulder portion of the belt from theretractor so that the shoulder portion of the beltcrosses your shoulder and chest. Insert the belttongue into the proper buckle until you hear asnap and feel it latch.

2. Tighten the lap portion of the belt, pull up on theshoulder piece until it fits you snugly. The beltshould rest as low on your hips as possible.

3. If desired, engage the Komfort latch as follows:

Pull on the shoulder strap to lessen the pressureof the strap on your shoulder and chest. Allow nomore than one inch (2.5 cm) of slack betweenyour chest and the shoulder harness. SeeFig. 5.7 . More slack can significantly reduce theseat belt’s effectiveness in an accident or a sud-den stop. While holding the belt slack, press theKomfort latch lever up, clamping the belt’s web-bing. See Fig. 5.8 .

4. To unbuckle the three-point seat belt, push thebutton on the buckle as shown in Fig. 5.9 . If theKomfort latch was used, release it by giving theshoulder belt a quick tug. If you lean forwardagainst the shoulder belt, the Komfort latch willautomatically release and will need to be reset.


5.5

NOTE: The Komfort Latch does not have to bereleased in an emergency situation. The Kom-fort Latch will release by itself under rough roador other abnormal conditions. Make sure thethree-point seat belt is completely retractedwhen it is not in use.

Lap Belt Without a RetractorThe center lap belt on a two-passenger seat doesnot have a retractor and therefore should be short-ened and fastened when being used. To lengthen thebelt, tip the belt tongue at a right angle to the beltand pull the belt over your lap until the tonguereaches the buckle.

1. Pull the belt across your hips and insert thetongue into the correct buckle on your seat untilyou hear a snap and feel it lock.

2. Make sure the buckle is securely fastened.

3. Adjust the belt so that it fits snugly around yourhips. If you need to lengthen the belt, unfasten itand repeat the previous steps. If you need toshorten the belt, pull on the loose end of the belt.

A

01/06/95 f910048a

A. 1 Inch (2.5 cm) Maximum

Fig. 5.7, Adjusting Shoulder Harness Clearance

11/02/95 f910144

Fig. 5.8, Locking the Komfort Latch

01/18/95 f910049a

Fig. 5.9, Releasing the Three-Point Seat Belt


5.6

6

Steering and Brake SystemsSteering System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.1Air Brake System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.1Hydraulic Brake System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.5

Steering SystemGeneral InformationWhen there is no load on the vehicle and the fronttires are pointed straight ahead, the steering wheelspokes should be at the 4 o’clock and 8 o’clock posi-tions, or within 10 degrees of these positions. SeeFig. 6.1 . For steering wheel adjustment procedures,see Group 46 of the Acterra® Workshop Manual.

Power Steering SystemThe power steering system consists of a steeringgear (which includes a manual steering mechanism,a hydraulic control valve, and a hydraulic power cyl-inder), hydraulic hoses, power steering pump, powersteering reservoir, and other components. Somemodels are also equipped with a separate hydraulicpower cylinder on the right side of the front axle. Thepower steering pump, driven by the engine, providesthe power assist for the steering system. If the en-gine is not running, there is no power assist.

If the power-assist feature does not work due to hy-draulic fluid loss, steering pump damage, or someother cause, bring the vehicle to a safe stop. Do notdrive the vehicle until the cause of the problem iscorrected.

WARNINGDriving the vehicle without the power-assist fea-ture of the steering system requires much greatereffort, especially in sharp turns or at low speeds,

which could result in an accident and possibleinjury.

Drivers should use the power available with a powersteering system carefully. If the front tires becomelodged in a deep chuckhole or rut, drive the vehicleout instead of using the steering system to lift thetires from the hole. Also, avoid turning the tires whenthey are against a curb as this places a heavy loadon steering components and could damage them.

Air Brake SystemGeneral InformationA dual air brake system operates two independent airbrake systems through one set of brake controls.Each system has its own reservoir, plumbing, andbrake chambers. The primary air system operatesthe service brakes on the rear axles; the secondaryair system operates the service brakes on the frontaxle. Either or both the primary and secondarysytems can operate the trailer brakes.

WARNINGDo not operate the vehicle with the front brakesbacked off or disconnected. Backing off or dis-connecting the front brakes will not improve ve-hicle handling and may lead to loss of vehiclecontrol resulting in property damage or personalinjury.

If the primary air system loses pressure, the rear ser-vice brakes will not work but the secondary air sys-tem will continue to operate the front axle and trailerbrakes.

If the secondary air system loses air pressure, thefront brakes will not work but the primary air systemwill continue to operate the rear service brakes andtrailer brakes.

IMPORTANT: When air pressure is lost in one ofthe air systems, the air compressor will operatebut will not replenish the air supply in the sys-tem that is not leaking. There will only beenough air in the non-leaking system to get thevehicle stopped. Therefore, it is important tobring the vehicle to a safe stop as soon as pos-sible. Do not attempt to drive the vehicle againuntil the problem is corrected.

f461750 01/04/2000

1 2

10°

10° 10°

10°

1. 8 o’Clock 2. 4 o’Clock

Fig. 6.1, Steering Wheel Centered

Steering and Brake Systems

6.1

Trucks are equipped with spring brake modulation. Ifan air pressure loss occurs in the primary air system,the rear spring brakes will be modulated (applied andreleased) according to how hard the brake pedal isbeing pushed. There will only be enough air in thesecondary system for two to four brake applications,then the park brake valve will pop out and lock thebrakes.

Before driving your vehicle, allow time for the aircompressor to build up a minimum pressure of 95 psi(655 kPa) in both air systems. Monitor the air pres-sure system by observing the primary and secondaryair pressure gauges and the low air pressure warninglight and buzzer. The warning light and buzzer shutoff when air pressure in both systems reaches 64 to76 psi (441 to 524 kPa).

The low air pressure warning light and buzzer comeon if air pressure drops below 64 to 76 psi (441 to524 kPa) in either system. If this happens, check theair system pressure gauges to determine which sys-tem has low pressure. Although the service brakeswill still slow the vehicle, one set of the servicebrakes will not be operating and the vehicle will re-quire a longer distance to stop. Bring the vehicle to asafe stop and have the air system repaired beforecontinuing.

If if a tractor-trailer loses pressure in both the primaryand secondary air systems, the trailer service brakesor spring parking brakes will automatically activatewhen the air pressure drops below 35 to 45 psi (241to 310 kPa). The tractor spring parking brakes willautomatically activate when the air pressure dropsbelow 20 to 30 psi (138 to 207 kPa). On trucks,spring parking brakes will come on when the airpressure drops below 20 to 30 psi (138 to 207 kPa).The activation is gradual but irreversible. Do not waitfor automatic activation of the brakes. When the lowair pressure warning light and buzzer first come on,immediately bring the vehicle to a safe stop. Correctthe cause of the air loss before attempting to drivethe vehicle again.

WARNINGDo not drive the vehicle with the parking brakescaged. If the vehicle is driven with the parkingbrakes caged, there would be no means of stop-ping the vehicle if a complete loss of air pressureoccurred. This could result in serious personalinjury or vehicle damage.

IMPORTANT: Connect to a towing vehicle orchock the tires before caging the spring parkingbrakes.

NOTE: Before a vehicle with insufficient systemair pressure can be moved, the spring parkingbrakes must be released by connecting an ex-ternal air source at the gladhands, or by manu-ally caging (manually releasing) the parkingbrake springs.

OperationBefore driving the vehicle, make sure all occupantsare wearing seat belts. Secure all loose items in thecab so that they will not fly forward during a fullbrake application.

In a normal stop, push in the clutch pedal (if the ve-hicle has one) as the vehicle approaches a halt andshift the transmission to neutral. Set the spring park-ing brakes after coming to a stop, if the vehicle is tobe parked.

IMPORTANT: In the event of a total loss of ser-vice brakes with full system air pressure, usethe parking brake control valve (the yellowknob) to bring the vehicle to a complete stop inthe safest location possible.

The yellow diamond-shaped knob (Fig. 6.2 ) on thecontrol panel activates the parking brake valve. Pull-ing out the knob puts on both the tractor and thetrailer spring parking brakes and causes the trailer airsupply valve knob to pop out.

f610291

1 2

03/10/99

1. Trailer Air Supply Valve Knob2. Parking Brake Control Valve Knob

Fig. 6.2, Parking Brake Control Valve and Trailer AirSupply Valve Knobs


6.2

Pulling the red octagonal knob (Fig. 6.2 ) on the con-trol panel opens the trailer air supply valve, exhaust-ing the pressurized air from the system and settingthe parking spring brakes. When the air hoses fromthe vehicle are connected to the trailer and the pres-sure in both air systems reaches at least 65 psi (448kPa), the red knob must be pushed in. It should re-main pushed in to keep the supply valve open, re-leasing the trailer spring parking brakes and chargingthe trailer air supply system .

The red knob should be out to block the trailer airsupply before disconnecting a trailer. If pressure inboth air systems drops to 35 to 45 psi (241 to 310kPa) the red knob automatically pops out, exhaustingthe trailer air supply and applying the trailer serviceor spring parking brakes. Braking increases as pres-sure falls, until as pressure approaches zero, thebrakes are fully set.

CAUTIONDo not use the spring parking brakes if the ser-vice brakes are hot, such as after descending asteep grade. Also, do not use the spring parkingbrakes during freezing temperatures if the ser-vice brakes are wet. To do so could damage thebrakes if hot, or cause them to freeze during coldweather.

If the brakes are wet, drive the vehicle in lowgear and lightly apply the brakes to heat and drythem. Allow hot brakes to cool before using thespring parking brakes. Always chock the tires.

If the brakes are wet, drive the vehicle in low gearand lightly apply the brakes to heat and dry them.

Allow hot brakes to cool before using the springparking brakes.

If the trailer is not equipped with spring parkingbrakes, pulling out the yellow knob applies the tractorspring parking brakes and the trailer service brakes.When the tractor and trailer parking brakes (or trailerservice brakes) are both applied, the trailer brakescan be released by pushing in the red knob, leavingthe tractor parking brakes applied. Air pressure in theprimary or secondary reservoir must be at least 64psi (441 kPa) before the tractor spring parkingbrakes, or the trailer service or spring parkingbrakes, can be released.

On trailers without spring parking brakes, chock thetrailer tires before disconnecting the tractor when

parking just the trailer. When parking a tractor with atrailer, if the trailer is not equipped with spring park-ing brakes, set the tractor spring parking brakes.

WARNINGDo not use the trailer service brakes for parking;they are not designed for this purpose. If airbleeds out of the trailer air tank during parking,the vehicle could roll causing serious personalinjury or property damage.

Meritor™ WABCO® Antilock BrakingSystem (ABS), Air Brake SystemsThe Meritor WABCO Antilock Braking System (ABS)is an electronic wheel speed monitoring and controlsystem that works with the air brake system. ABSpassively monitors vehicle wheel speed at all times,but controls wheel speed during an emergency orreduced-traction stop. In normal braking applications,the standard air brake system works as they alwayshave and ABS has no active role.

IMPORTANT: For proper ABS system operation,use tires of the factory installed size. The sizesof the tires installed during production are pro-grammed into the electronic control unit. Install-ing different size tires could result in reducedbraking ability leading to longer stopping dis-tances.

ABS reads from signal-generating tone wheels andsensors located in the wheel hubs of each sensedaxle. The sensors transmit vehicle wheel speed infor-mation to an electronic control unit (ECU). The maincircuit of the ECU interprets the speed sensor signalsand constantly compares wheel speeds, wheel brak-ing rates, and vehicle speed. If it senses a wheel isbeginning to lock, the ECU signals the appropriatesolenoid control valve to reduce braking in thatwheel, preventing a skid. During emergency braking,the solenoid control valve prevents wheel lockup bycontroling air pressure in the brake chambers.

The ECU also has a safety circuit which constantlymonitors the wheel sensors, solenoid control valvesand the electrical circuitry. In a vehicle equipped onlywith a tractor ABS system, when the ignition switch isturned on the TRACTOR ABS warning light comeson. The warning light goes out only if all of the trac-tor ABS components are working properly.


6.3

CAUTIONAn accumulation of road salt, dirt, or debris onthe ABS tone wheels and sensors can cause theABS warning light to come on. If the ABS lightdoes come on, the tone rings and sensorsshould be inspected for corrosion and serviced ifnecessary. The service should include cleaningof the tone rings and sensors. If any tone ring ona vehicle shows severe corrosion, all tone ringson that vehicle should be replaced.

During winter months in areas where corrosivematerials are used on the highways, periodicallyclean the underside of the vehicle, including thetone rings and sensors, to ensure proper ABSfunction and to protect the components from cor-rosion. Clean more frequently when unusuallycorrosive chemicals are being used.

The dash-mounted TRAILER ABS light will operateas follows when a compatible trailer is properly con-nected to a tractor:

• When the ignition key is turned to the on posi-tion, the trailer ABS lamp will illuminate briefly,then turn off.

• If the lamp comes on momentarily during ve-hicle operation then shuts off, a fault was de-tected and corrected.

• If the lamp comes on and stays on during ve-hicle operation, there is a problem with thetrailer ABS. Repair the trailer ABS system im-mediately to ensure full antilock braking capa-bility.

The Trailer ABS lamp will not light up unless a com-patible trailer is connected to the tractor.

IMPORTANT: If a compatible trailer is connectedand the lamp does not flash on briefly when theignition key is turned on, it is possible that thelamp is burnt out.

Automatic Traction Control is an option available onABS-equipped vehicles with air brake systems. Ithelps improve traction when vehicles are on slipperysurfaces by keeping drive wheels from spinning. ATCworks automatically in two ways.

• If a drive wheel starts to spin, ATC decreasesair pressure to brake the wheel. This transfersengine torque to the wheels with better trac-tion.

• If all of the drive wheels spin, ATC reduces en-gine torque to provide improved traction.

If the vehicle is equipped with Automatic TractionControl (ATC), any wheel spin during accelerationturns on the WHEEL SPIN indicator light. The lightgoes out when the wheel stops spinning. When thelight comes on, partially release the throttle pedaluntil the light goes out. If slippery road conditionscontinue, turn the axle lock switch on. See Chap-ter 9 for axle lock instructions.

CAUTIONDo not turn the differential lock switch on whilethe WHEEL SPIN indicator light is on. To do socould damage the rear axle.

ATC turns itself on and off. Drivers do not have toselect this feature. If drive wheels spin during accel-eration, the WHEEL SPIN indicator comes on, indi-cating ATC is active. It goes out when the drivewheels stop spinning.

The ATC option includes a mud or deep snow (TRACMUD/SNOW) switch. This switch is used to improvetraction on soft surfaces such as snow, mud, orgravel by slightly increasing the permissible wheelspin. When the mud or deep snow switch is pressed,the WHEEL SPIN indicator comes on.

The ABS diagnostic (ABS DIAG) switch is a momen-tary switch that turns on the blink code diagnosticcapabilities. It may also be used to disable the trac-tion control for dynamometer testing as described inthe next paragraph. For information on troubleshoot-ing with blink code diagnostics, see Group 42 of theActerra® Workshop Manual.

WARNINGFailure to disable the ATC before dynamometertesting could result in serious personal injuryand damage to the vehicle.

Vehicles with ATC must have the ATC disabled totest the vehicle on a dynamometer. To disable theATC, press and hold the ABS diagnostic switch for atleast three seconds. Once the system configurationcode begins, ATC has been disabled. The WHEELSPIN indicator comes on and stays on while dis-abled.

The Meritor WABCO ABS system combines onefront-axle control channel with either one rear axle


6.4

(the four-sensor system), or two rear axles (the six-sensor system) to form one control circuit. For ex-ample, the sensor and solenoid control valve at theleft-front axle form a control circuit with the sensor(s)and solenoid valve(s) on the right rear axle(s). Duringvehicle operation, if the safety circuit senses a failurein any part of the ABS system (a sensor, solenoidcontrol valve, wiring connection, short circuit, etc.),the TRACTOR ABS warning light comes on and thecontrol circuit where the failure occurred is switchedto normal braking action. ABS will continue to workon the remaining control circuit. Even if the ABS sys-tem is not working to some degree, normal brakingability is maintained. A possible exception would be ifa solenoid control valve or combination solenoid con-trol valve is damaged or not working. Since thesevalves are an integral part of the air brake system,normal braking may be reduced or may not work atall and if they are malfunctioning the vehicle must beparked as quickly and safely as possible.

IMPORTANT: If any of the ABS warning lightsdo not work as described above or come onwhile driving, repair the ABS system immedi-ately to ensure full antilock braking capability.

During emergency or reduced-traction stops, pushthe brake pedal steadily until the vehicle comes to asafe stop. Do not pump the brake pedal. If the driverpushes the brake pedal hard enough to lock thewheels, the ABS system will control braking to pro-vide steering control and the shortest possible stop-ping distance.

Although the ABS system improves vehicle controlduring emergency braking situations, the driver stillhas the responsibility to drive appropriately for theexisting traffic and road conditions. For example, theABS system cannot prevent an accident if the driveris speeding or following too closely, or going too fastin slippery road surfaces.

Automatic Slack AdjustersAutomatic slack adjusters are required on all vehiclesequipped with air brakes manufactured after October20, 1994. Automatic slack adjusters should never bemanually adjusted except during routine maintenanceof the foundation brakes (e.g., replacing shoes), dur-ing slack adjuster installation or in an emergencysituation.

When the brake pushrod stroke exceeds the legalbrake adjustment limit on a vehicle, there is likely a

mechanical problem with the foundation brake com-ponents or the adjuster is improperly installed.

Visit a repair facility as soon as possible whenbrakes equipped with automatic slack adjusters aredetermined to be out of adjustment.

WARNINGManually adjusting an automatic slack adjuster tobring the pushrod stroke within legal limits islikely masking a mechanical problem. Adjustmentis not repairing. In fact, continual adjustment ofautomatic slack adjusters may result in prema-ture wear of the adjuster itself. Further, the im-proper adjustment of some automatic slack ad-justers may cause internal damage to theadjuster, thereby preventing it from properlyfunctioning.

Hydraulic Brake SystemGeneral InformationThe hydraulic brake system includes a Hydro-Max®

power booster, master cylinder, hydraulic brake res-ervoir (Fig. 6.3 ), hydraulic lines, a brake rotor oneach wheel hub, and a brake caliper and pad assem-bly at each rotor.

10/31/94 f460513a

A

B

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

Fig. 6.3, Hydraulic Brake Reservoir


6.5

IMPORTANT: Fill the master cylinder reservoirto the bottom of the narrow ring of the fillerneck. Use only heavy-duty DOT 3 brake fluid inthe hydraulic brake system.

The master cylinder supplies hydraulic pressure tothe brakes. It is attached to the front of the Hydro-Max power booster. The power booster receivespressurized automatic transmission fluid (ATF) fromthe power steering system. (The power steering sys-tem contains ATF, not the product specifically calledpower steering fluid.) An electrically powered "re-serve" pump cuts in, if fluid pressure falls betweenthe power steering pump and the power booster. Thebrake system warning light comes on if there is aproblem within the system.

If the light comes on, bring the vehicle to a safestop and correct the problem immediately. Donot attempt to drive until the problem is foundand corrected.

For hydraulic brake system troubleshooting and ad-justment procedures, see Group 42 of the Acterra®

Workshop Manual.

OperationBefore driving the vehicle, secure all loose items inthe cab so that they will not fly forward during a fullbrake application. Make sure all occupants are wear-ing seat belts. Check that the brake system warninglight is off after releasing the parking brake. If thewarning light does not go off, find and correct theproblem before continuing to operate the vehicle.

During normal brake stops, pushing the brake pedalslows the vehicle. As the vehicle slows almost to astop, push in the clutch pedal if there is one, andshift the transmission to neutral. After coming to astop, apply the parking brake if the vehicle is to beparked.

Meritor™ WABCO® Antilock BrakingSystem (ABS), Hydraulic BrakeSystemsThe Meritor WABCO Antilock Braking System (ABS)is an electronic wheel speed monitoring and controlsystem which works with the hydraulic brake system.ABS watches each braking wheel’s speed at alltimes, then controls wheel speed during an emer-gency or reduced-traction stop. In normal braking the

standard hydraulic brake system is in effect, the ABSdoes nothing.

IMPORTANT: For proper ABS system operation,do not change tire sizes. The sizes of the tiresinstalled during production are programmed intothe electronic control unit (SUV). Installing differ-ent sized tires could result in inaccurate wheelspeed signals to the ECU, reduced brakingforce and longer stopping distances. This couldlead to an accident, property damage and per-sonal injury.

ABS uses signal-generating tone wheels and sensorslocated in the wheel hubs of each sensed axle tomeasure their speeds. The sensors transmit thewheel speed information to the ECU which compareswheel speeds and a vehicle reference speed. If thecalculations indicate a wheel is about to lock, theECU signals the brake pressure modulator to in-crease or decrease braking pressure.

The ECU also has a safety circuit which constantlymonitors the wheel sensors, brake pressure modula-tor, and the electrical circuitry. The TRACTOR ABSwarning light comes on after the ignition is switchedon. The warning light goes out only if all the tractorABS components are working properly.

The ABS warning light comes on and stays lit whenthe ignition is switched on. It should go off when thevehicle exceeds four miles per hour. If it does not gooff over four miles per hour, there may be an activefault in the hydraulic ABS. If the ABS warning lightcomes on and stays on, then goes off after the ve-hicle goes over four miles per hour, there may be astored fault in the hydraulic ABS. Have the ABS sys-tem checked if either situation occurs.

If during vehicle operation the safety circuit senses afailure in any part of the ABS system (a sensor,brake pressure modulator, wiring connection, shortcircuit, etc.) the TRACTOR ABS warning light comeson and the control circuit where the failure occurredis switched to normal braking action. Even if the ABSsystem is partially or completely inoperative, normalbraking ability is maintained. An exception would beif the brake pressure modulator, or hydraulic fluid lineis damaged. As these components are an integralpart of the hydraulic brake system, normal brakingmay be impaired or inoperative.


6.6

CAUTIONAn accumulation of road salt, dirt, or debris onthe ABS tone wheels and sensors can cause theABS warning light to come on. If the ABS lightdoes come on, the tone rings and sensorsshould be inspected for corrosion and serviced ifnecessary. The service should include cleaningof the tone rings and sensors. If any tone ring ona vehicle shows severe corrosion, all tone ringson that vehicle should be replaced.

During winter months in areas where corrosivematerials are used on the highways, periodicallyclean the underside of the vehicle, including thetone rings and sensors, to ensure proper ABSfunction and to protect the components from cor-rosion. Clean more frequently when unusuallycorrosive chemicals are being used.

Before ignition, the dash mounted TRAILER ABSlamp will operate as follows when a compatible traileris properly connected to a tractor:

• When the ignition key is turned to the on posi-tion, the trailer ABS lamp will illuminate mo-mentarily, then turn off.

• If the lamp comes on momentarily during ve-hicle operation, then shuts off, a fault was de-tected and corrected.

• If the lamp comes on and stays on during ve-hicle operation, there is a fault with the trailerABS. Repair the trailer ABS system immedi-ately to ensure full antilock braking capability.

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

IMPORTANT: If any of the ABS warning lightsdo not work as described above or come onwhile driving, repair the ABS system immedi-ately to ensure full antilock braking capability.

During emergency or reduced-traction stops, fullydepress the service brake until the vehicle comes toa safe stop. Do notpump the pedal. With the servicebrake pedal depressed, the ABS system will controlall wheels to provide steering control and a reducedbraking distance.

Although the ABS system improves vehicle controlduring emergency braking situations, the driver stillhas the responsibility to change driving styles de-pending on the existing traffic and road conditions.

For example, the ABS system cannot prevent an ac-cident if the driver is speeding or following tooclosely on slippery road surfaces.

The ABS diagnostic (ABS DIAG) switch is a momen-tary switch that turns on the blink code diagnosticcapabilities. It may also be used to disable the trac-tion control for dynamometer testing. For informationon troubleshooting with blink code diagnostics, seeGroup 42 of the Acterra® Workshop Manual.

WARNINGFailure to disable the ATC before dynamometertesting could result in serious personal injuryand damage to the vehicle.

Vehicles with ATC must have the ATC disabled totest the vehicle on a dynamometer. To disable theATC, press and hold the ABS diagnostic switch for atleast three seconds. Once the system configurationcode begins, ATC has been disabled. The WHEELSPIN indicator comes on and stays on while dis-abled.


6.7

7

Engines and ClutchesEPA07 Aftertreatment System (ATS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.1Engine Starting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.2Cold-Weather Starting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.5Starting After an Extended Shutdown or Oil Change . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.6Engine Break-In . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.6Engine Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.6Cold-Weather Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.9Engine Shutdown . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.11High-Altitude Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.13Exhaust Braking System, Optional . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.13Engine Braking System, Optional . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.15Clutches . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.15

EPA07 Aftertreatment System(ATS)On-road diesel engines built after December 31,2006, are required to meet EPA07 guidelines for re-duced exhaust emissions of particulate matter andnitrogen oxides (NOx). NOx is limited to just over 1gram per brake horsepower hour (g/bhp-hr), and par-ticulate matter cannot exceed 0.01 g/bhp-hr.

EPA07-compliant engines require ultralow-sulfur die-sel (ULSD) fuel, and they should never be run onfuel with sulfur content higher than 15 ppm. In addi-tion, they require low-ash engine oil. The followingguidelines must be followed, or the warranty may becompromised.

• Use ultralow-sulfur diesel (ULSD) with 15 ppmsulfur content or less, based on ASTM D2622test procedure.

• Do not use fuel blended with used engine lubeoil.

• Engine lube oil must have a sulfated ash levelless than 1.0 wt %, meeting the API CJ-4 indexspecifications.

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

The "exhaust system" in EPA07-compliant vehicles iscalled the aftertreatment system (ATS). The ATS var-ies according to engine manufacturer and vehicleconfiguration, but instead of a muffler, an aftertreat-ment system has a device that outwardly resemblesa muffler, called the aftertreatment device (ATD).

IMPORTANT: See your engine operation manualfor complete details and operation of the after-treatment system.

Inside the ATD on Mercedes-Benz, Detroit Diesel,and Cummins engines, the exhaust first passes overthe diesel oxidation catalyst (DOC), then it passesthrough the diesel particulate filter (DPF), which trapssoot particles. If exhaust temperature is high enough,the trapped soot is reduced to ash, in a processcalled passive regeneration (regen). Passive regen-

eration occurs as the vehicle is driven normallyunder load; the driver is not even aware that it ishappening. The harder an EPA07 engine works, thebetter it disposes of soot, as the exhaust heat aloneis enough to burn the soot to ash. Over the course ofa workday, however, passive regeneration cannotalways keep the ATD filter clean, so the filter mustundergo active regeneration . In active regeneration,extra fuel is injected into the exhaust stream to su-perheat the soot trapped in the DPF and turn it toash. Active regeneration happens only when the ve-hicle is moving above a certain speed, determined bythe engine manufacturer. Consult manufacturers’documentation for details.

Both active and passive regeneration happen auto-matically, without driver input.

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

If conditions do not provide for at-speed active re-generation, the vehicle will need a driver-activatedparked regeneration . The vehicle must be standingstill, and the driver must initiate parked regen. Com-pleting a parked regen takes 20 minutes to an hour,depending on ambient conditions.

DANGERDuring parked regeneration, exhaust tempera-tures are very high, and could cause a fire, heatdamage to objects or materials, or personal in-jury to persons near the exhaust outlet.

Before a parked regeneration, make certain theexhaust outlets are directed away from struc-tures, trees, vegetation, flammable materials, andanything else that may be damaged or injured byprolonged exposure to high heat.

There are three warning lamps in the driver messagecenter that alert the driver of the need to perform aparked regen, clean the filter, or of an engine faultthat affects the emissions.

A slow (10-second) flash of the high exhaust systemtemperature (HEST) lamp, indicates a regeneration isin progress, and the driver is not controlling the en-gine idle speed.

Engines and Clutches

7.1

A solid illuminated high exhaust system temperature(HEST) lamp, alerts the operator of high exhausttemperature during the regeneration process, whenthe speed is below 5 mph (8 km/h). The HEST lampdoes not signify the need for any kind of vehicle orengine service; it only alerts the vehicle operator ofhigh exhaust temperatures. Make sure the engineexhaust pipe outlet is not directed at any person, orat any surface or material that will melt, burn, or ex-plode. See Fig. 7.1 .

A solid yellow diesel particulate filter (DPF) lamp indi-cates that a parked regen is required soon, andshould be scheduled for the earliest convenient time.See Fig. 7.2 . A blinking yellow DPF lamp indicatesthat a parked regen is required immediately, or anengine derate may occur.

A solid yellow malfunction indicator lamp (MIL) indi-cates an engine fault that affects the emissions. SeeFig. 7.3 .

Diesel particulate filter servicing must be performedby an authorized technician, and a record must bemaintained for warranty purposes. The record mustinclude:

• date of cleaning or replacement;

• vehicle mileage;

• particulate filter part number and serial number.

The request/inhibit regen switch (Fig. 7.4 ), locatedon the dash, may have three selectable positions:

• request regeneration;

• default (can include appropriate normal statecondition—either in an automatic regenerationor inhibit state);

• inhibit regeneration.

NOTE: The regen switch can start an activeregen only when at least one of two conditionsexists: either the DPF light is lit, or the enginesoftware calls for it. If neither of those conditionsexist, the regen switch cannot cause a regen-eration to happen.

The function of the switch will vary by the enginemake and model in the vehicle. See the engine op-eration manual for switch operation details.

Engine StartingNOTE: Before starting the engine, read Chap-ter 2 for detailed information on how to read theinstruments and operate the controls.

09/25/2006 f610816a

Fig. 7.1, High Exhaust System Temperature (HEST)Lamp

09/25/2006 f610815a

Fig. 7.2, Diesel Particulate Filter (DPF) Status Lamp

09/25/2006 f610814a

Fig. 7.3, Malfunction Indicator Lamp (MIL)


7.2

CAUTIONWhen starting a vehicle equipped with a manualtransmission and clutch lockout switch, theclutch pedal must be fully depressed during theentire start sequence. Failure to do so can causethe pinion to release and re-engage, which couldcause ring gear and starter pinion damage.

If a vehicle does not start on the first attempt,make sure that the engine has completelystopped rotating before reapplying the starterswitch. Failure to do so can cause the pinion torelease and re-engage, which could cause ringgear and starter pinion damage.

Moving a vehicle with the starter and/or using thestarter to bump the engine for maintenance pro-cedures is strictly prohibited. Use of these meth-ods to bump the engine over or move the vehiclecan cause the pinion to release and re-engage,which could cause ring gear and starter piniondamage.

IMPORTANT: Ring gear and starter pinion dam-age caused by improper starting procedures isnot warrantable.

Whenever you start an engine, watch for any signsof engine problems. If the engine vibrates, misfires,or makes unusual noises, turn the engine off as soonas possible and determine the cause of the problem.Frequently, engine damage may be avoided by aquick response to early indications of problems.

Pre-StartNOTE: These pre-start steps apply to all en-gines.

1. Perform the engine pretrip inspection and dailymaintenance checks in Chapter 11 .

2. Set the parking brake.

3. For manual transmissions, place the transmis-sion in neutral and disengage the clutch.

For automatic transmissions, make sure thetransmission shift control is in neutral or park.

NOTE: On vehicles equipped with a neutral startswitch, the transmission must be in neutral be-fore the engine can be started. For air start sys-tems, check the air supply before starting theengine. There must be 100 psi (689 kPa) of airpressure available.

Starting Precautions, All Engines

WARNINGDo not use any starting aid, such as ether, in en-gines with an intake air preheater. This couldcause an explosion, resulting in serious personalinjury or death.

CAUTIONDo not crank the engine for more than 30 sec-onds at a time. Wait two minutes after each try toallow the starter to cool. Failure to do so couldcause starter damage.

NOTE: Some starters are equipped with op-tional overcrank protection. If overcranking oc-curs, a thermostat breaks the electrical circuit tothe starter motor until the motor has cooled.

CAUTIONProtect the turbocharger during the start-up bynot opening the throttle or accelerating the en-gine above 1000 rpm until normal engine idle oilpressure registers on the gauge.

f61084810/02/2006

Fig. 7.4, Request/Inhibit Regen Switch


7.3

Mercedes-BenzNOTE: Before doing these steps, do the stepsin "Pre-Start."

CAUTIONNever attempt to start any Mercedes-Benz elec-tronic engine using ether or any other startingfluid. Serious engine damage could result.

1. Turn the ignition switch to the on position(Fig. 7.5 ). All the electronic gauges on the instru-ment and control panel complete a full sweep oftheir dials, the warning and indicator lights lightup, and the buzzer sounds for three seconds.

IMPORTANT: On vehicles equipped with an in-take air preheater, wait until the INTAKEHEATER indicator goes out before attempting tostart the engine.

2. Turn the ignition switch to the start position.Without touching the throttle pedal, start the en-gine.

3. Idle the engine for one to three minutes at 600rpm (700 rpm for 4-cylinder engines) before op-erating the engine under load.

4. Check the oil pressure gauge for any drop in lu-bricating oil pressure or mechanical malfunctionin the lubricating oil system. Minimum oil pres-sure at idle is 7 psi (50 kPa).

CAUTIONDo not rev the engine if the oil pressure gaugeindicates no oil pressure. Shut down the engineif no oil pressure appears within approximatelyten seconds. Check to determine the cause of theproblem. Operating the engine with no oil pres-sure will damage the engine.

CaterpillarNOTE: Before doing these steps, do the stepsin "Pre-Start."

1. Turn the ignition switch to the on position(Fig. 7.5 ). The CHECK ENGINE indicator comeson for five seconds. The INTAKE HEATER indi-cator comes on for a minimum of two seconds,regardless of coolant temperature.

IMPORTANT: If the INTAKE HEATER indicatorstays on for more than two seconds, wait untilthe indicator goes out before attempting to startthe engine.

2. Turn the ignition switch to the start position. Re-lease the switch the moment the engine starts.

2.1 If the engine does not start after 15 to 20seconds of cranking, turn the ignitionswitch off.

2.2 Wait two minutes to allow the startermotor to cool. Turn the ignition switchback to the on position and try to start theengine again.

2.3 As soon as the engine starts, release theignition switch, allowing the engine to runat a slow idle.

CAUTIONIf the oil pressure is too low, shut down the en-gine immediately to prevent serious damage. Ifthe vehicle is equipped with an automatic shut-down system, the engine will shut down after 30seconds.

3. The engine may be operated at low load andspeed once the engine oil pressure has reached10 psi (69 kPa) and air pressure (if applicable)has reached 64 to 76 psi (441 to 524 kPa).

09/30/99 f610344

1

2

3

4

1. Accessory2. Off

3. On4. Start

Fig. 7.5, Ignition Switch Positions


7.4

4. When the engine has reached the minimum op-erating temperature of 160°F (71°C), the enginemay be operated at full load.

Cummins

CAUTIONNever attempt to start any Cummins IS serieselectronic engine (ISB, ISC, ISL) using ether orany other starting fluid. Serious engine damagecould result.

NOTE: Before doing these steps, do the stepsin "Pre-Start."

1. Turn the ignition switch to the on position(Fig. 7.5 ). The CHECK ENGINE indicator willcome on. The INTAKE HEATER indicator comeson for a minimum of two seconds, regardless ofcoolant temperature. Leave the ignition switch onuntil the CHECK ENGINE indicator goes out.

IMPORTANT: If the INTAKE HEATER indicatorstays on for more than two seconds, wait untilthe indicator goes out before attempting to startthe engine.

2. Turn the ignition switch to the start position. Afterthe engine starts, release the key.

3. Bring the engine up to operating speed graduallyas it warms up and develops stable oil pressure.

NOTE: When the engine is started, it takes ashort time to build up a lubricating oil film be-tween the shafts and bearings, and between thepistons and liners. The oil pressure gauge indi-cates any drop in lubricating oil pressure within15 seconds of engine start-up.

4. If minimum engine oil pressure at idle of 10 psi(69 kPa) does not register within 15 seconds,shut down the engine.

CAUTIONProtect the turbocharger during the start-up bynot opening the throttle or accelerating the en-gine above 1000 rpm until minimum engine idleoil pressure registers on the gauge. Failure to doso could damage the turbocharger.

5. Idle the engine for three to five minutes at 1000rpm before operating the engine under load.

Cold-Weather Starting

WARNINGDo not use any starting aid, such as ether, in en-gines with an intake air preheater. This couldcause an explosion, resulting in serious personalinjury or death.

Modern electronic engines do not normally requirespecial starting aids. At low temperatures, intake airpreheaters, manifold preheaters, or water jacketheaters are sometimes used to assist in starting.

Mercedes-BenzThe intake air preheater is activated by turning theignition switch to the on position (Fig. 7.5 ). If the en-gine is at normal temperature, the INTAKE HEATERindicator goes out after two seconds.

If the temperature is low enough to require theheater, the INTAKE HEATER indicator stays on whilethe intake air preheater warms up. After the indicatorgoes out, start the engine. If the engine doesn’t startafter about 30 seconds of cranking, turn the key tothe off position and wait two minutes, then repeat thestarting procedure.

NOTE: If the engine doesn’t start on the secondtry, wait at least five minutes before using theintake air preheater again.

CaterpillarCaterpillar truck engines with direct injection are de-signed to start at temperatures above 32°F (0°C)without using start systems. If the temperature isbelow 32°F (0°C), startability will be improved by theuse of an automatic ether injection system and/or ajacket water heater.

CAUTIONDirecting ether at the heater element in the intakeair preheater could cause extensive engine dam-age.


7.5

The intake air preheater is activated by turning theignition switch to the on position (Fig. 7.5 ). If the en-gine is at normal temperature, the INTAKE HEATERindicator goes out after two seconds.

If the temperature is low enough to require theheater, the INTAKE HEATER indicator stays on whilethe intake air preheater warms up. After the indicatorgoes out, start the engine.

IMPORTANT: Attempting to start the engine be-fore the INTAKE HEATER indicator has gone offcould result in excessive white smoke at start-up.

If the engine doesn’t start after 15 to 20 seconds ofcranking, turn the key to the off position and wait twominutes; then repeat the starting procedure.

CumminsThe cold-start system approved for use on Cumminsengines has been based upon starting aid capabili-ties to –25°F (–32°C).

Turn the ignition switch to the on position (Fig. 7.5 ).If the engine is at normal temperature, the INTAKEHEATER indicator goes out after two seconds.

If the temperature is low enough to require theheater, the INTAKE HEATER indicator stays on whilethe intake air preheater warms up. After the indicatorgoes out, start the engine.

Run the engine slightly above idle until oil pressureshows on the gauge. If oil pressure doesn’t show onthe gauge within 30 seconds of starting, turn the keyto the off position and wait one minute; then repeatthe starting procedure.

Starting After an ExtendedShutdown or Oil ChangeDo the following steps after an oil change or after theengine has been shut down for more than threedays:

1. Disconnect the electrical connector from the fuelpump solenoid valve.

2. Crank the engine until oil pressure shows on thegauge.

3. Connect the electrical connector to the fuel pumpsolenoid valve.

4. Start the engine. After one minute, shut down theengine and check for leaks.

5. Allow five minutes for the oil to settle, then checkthe engine oil level and add oil if needed. Do notoverfill.

Engine Break-InEvery engine is tested on a dynamometer beforeshipment, eliminating the need for a break-in period.Before running the engine for the first time, follow theinstructions in the engine operator’s manual for thevehicle.

Engine Operation

DANGERDo not operate the engine in an area where flam-mable vapors such as gasoline or diesel fumesare present. Shut down the engine when in anarea where flammable liquids or gases are beinghandled. Failure to observe these precautionscould result in serious injury or death.

All diesel engines have been built to comply with therequirements of the Federal (U.S.) Clean Air Act.Once an engine is placed in service, the responsibil-ity for meeting both state and local regulations is withthe owner/operator. Good operating practices, regularmaintenance, and correct adjustments are factorswhich will help to stay within the regulations.

Proper maintenance of the engine, which is the re-sponsibility of the owner/operator, is essential tokeep the emission levels low.

Engine ProtectionOn electronic engines, an engine-protection systemmonitors all engine sensors and electronic compo-nents, and recognizes system malfunctions. If a criti-cal fault is detected, an amber check-engine warninglamp and a red stop-engine lamp illuminate.

The standard parameters that are monitored for en-gine protection are: low coolant level, high coolanttemperature, low oil pressure, high soot level (DPF),and uncontrolled DPF regeneration.


7.6

Amber Check-Engine Warning LampWhen the amber check-engine warning lamp comeson for any reason, the vehicle can still be operated,and the driver can proceed to the required destina-tion. This condition should be reported to an autho-rized service center as soon as possible.

Red Stop-Engine Lamp

WARNINGWhen the red stop-engine light illuminates, mostengines are programmed to shut down automati-cally within 30 seconds. The driver must immedi-ately move the vehicle to a safe location at theside of the road to prevent causing a hazardoussituation that could cause bodily injury, propertydamage, or severe damage to the engine.

The red stop-engine lamp illuminates to indicate thatthe engine-protection system has been activated.The conditions that will cause the red stop-enginelamp to come on are:

• high coolant temperature

• loss of coolant

• low oil pressure

• high soot level (DPF)

• uncontrolled DPF regeneration

On some engines, the engine ECU will derate theengine, allowing it to run at low rpm and slow vehiclespeed, until the vehicle can be driven to a safe loca-tion or to a service facility. On other engines, the en-gine ECU will first derate the engine, then if the con-dition does not improve, shut it down completely 30seconds after the light comes on. The driver mustsafely bring the vehicle to a stop on the side of theroad before the engine shuts down.

To restart the engine (override the shutdown com-mand) turn the ignition switch to OFF, leave it there afew seconds, and turn the switch to START. The en-gine will run for a short period and shut down again ifthe condition does not improve.

IMPORTANT: Do not attempt to restart the en-gine while the vehicle is moving. Bring the ve-hicle to a safe stop and restart the engine withthe vehicle stopped.

Stop-Engine Override SwitchIf the vehicle is equipped with a stop-engine override(SEO) switch, it can be used to override the shut-down sequence. This override resets the shutdowntimer, restoring power to the previous level before thered stop-engine lamp was illuminated. The switchmust be recycled after five seconds to obtain a sub-sequent override.

CAUTIONUsing the override button so the engine operatesfor an extended period may result in engine dam-age. The operator has the responsibility to takeaction to avoid engine damage.

Mercedes-BenzWhile you are driving, watch for any signs of engineproblems. If the engine overheats, uses excessivefuel or lubricating oil, vibrates, misfires, makes un-usual noises, or shows an unusual loss of power,turn the engine off as soon as possible and deter-mine the cause of the problem. Frequently, enginedamage may be avoided by a quick response toearly indications of problems.

1. Use the tachometer to determine when to shift.Follow the pattern on the shift lever when movingthrough the gears.

2. Depending on the vehicle gearing, the postedspeed limit can sometimes allow operation in ei-ther of the top two gears; however, for improvedoperating efficiency (fuel economy and enginelife), operate in the top gear at reduced rpmrather than in the next lower gear at the maxi-mum rpm.

3. Cruise at partial throttle whenever road condi-tions and speed requirements permit. This driv-ing technique permits operating within the mosteconomical power range of the engine.

4. Use lower gears in steep downhill driving. Nor-mally, the gear used to descend a hill is thesame gear used to climb a hill of the samegrade.

5. Never allow the engine to exceed the ratedspeed. Use the exhaust brake and the optionalconstant-throttle brake, if installed, to lower en-gine rpm below the rated speed.


7.7

6. Never allow the engine to idle for more than 30minutes. Excessive idling can cause oil to leakfrom the turbocharger.

CAUTIONStop the engine at the first sign of malfunction.Almost all malfunctions give some warning to theoperator before significant damage occurs. Manyengines are saved because alert operators heedthe warning signs (sudden drop in oil pressure,unusual noises, etc.) and immediately shut downthe engine.

NOTE: Long periods of idling are not good foran engine because the combustion chambertemperatures drop so low the fuel may not burncompletely. This will cause carbon to clog theinjector spray holes and piston rings, and mayresult in stuck valves.

If the engine coolant temperature becomes toolow, raw fuel will wash the lubricating oil off thecylinder walls and dilute the crankcase oil, caus-ing all moving parts of the engine to suffer frompoor lubrication.

CaterpillarProper operation and maintenance are key factors inobtaining the maximum life and economy of a vehicleengine. Follow the directions in the Caterpillar Opera-tion and Maintenance Manualand this manual fortrouble-free, economical engine operation.

1. Operate the engine at low load. After normal oilpressure is reached and the temperature gaugeneedle begins to move, the engine may be oper-ated at full load.

Caterpillar electronic engines automatically idleat 900 to 1000 rpm for the correct warm-up timeafter a cold engine start when the air tempera-ture is lower than 40°F (5°C). These electronicengine systems will reduce the idle speed to 600rpm when the engine has warmed sufficiently tooperate the vehicle.

IMPORTANT: Fuel heaters used on vehicleswith Caterpillar electronic engines could causeexcessive fuel temperatures that affect engineperformance and operation of the electronic en-gine controls. If a fuel heater is used, make sure

it has thermostatic controls. If the fuel heaterhas a timer, set the timer to activate only for alimited period of time before the engine starts.Make sure the fuel heater is used only for start-ing the engine.

2. Select a gear that allows a smooth, easy startwithout increasing engine speed above low idleor slipping the clutch. Engage the clutchsmoothly. Jerky starts waste fuel and put stresson the drivetrain.

It is not necessary to accelerate Caterpillar elec-tronic engines to governed speed in the lowergears to get the vehicle moving, except in a highpower demand situation such as starting on agrade.

3. Continue to upshift until cruising speed isreached. Use only the rpm needed to make anupshift into the next gear. The engine speedneeded to make an upshift increases as thetruck speed increases. If the truck can be oper-ated in a higher gear after reaching the desiredspeed, select the highest gear available that willpull the load. Experience with your vehicle willshow you what rpm is needed to make upshiftsunder various conditions. This progressive shift-ing technique will lower fuel costs because theengine will be operating at the lowest rpmneeded to pull the load.

Caterpillar electronic engines can be pro-grammed to limit engine rpm while the vehicle isoperated in the lower and higher gears. This fea-ture assists the driver in following progressiveshifting techniques.

4. On uphill grades, begin downshifting when theengine rpm falls to 1200 rpm. Fuel economy willbe best if you let the engine lug back to aroundthis speed before you downshift. Downshift untila gear is reached in which the engine will pullthe load. Let the engine lug down if you canmake it to the top of a hill without downshifting.

IMPORTANT: Do not allow Caterpillar electronicengines to exceed 2300 rpm (2100 rpm ifequipped with an exhaust brake).

5. On a downhill grade, do not coast or put thetransmission in neutral. Select the correct gearthat does not allow the engine to exceed itsmaximum speed. Use the brakes to limit thetruck speed.


7.8

A simple rule to follow is to select the same gear(or one gear lower) that would be needed to goup the grade.

6. As with any engine, prolonged idling of Caterpil-lar engines is not recommended. An idling en-gine wastes fuel and, if left unattended, is alsounsafe.

Caterpillar engines can be programmed to shutoff automatically after a specified idling time. Thevehicle transmission must be in neutral and theparking brake must be set for the automatic shut-off option to work.

CumminsFollow the directions in the Cummins Operation andMaintenance Manual and in this manual for trouble-free, economical vehicle engine operation.

1. Cummins diesel engines produce high horse-power and peak torque characteristics at lowrpm. Because of this, it is not necessary to keepthe engine "wound up" to deliver the requiredhorsepower at the wheels. These characteristicsmay also result in less shifting and make shiftingat lower rpm (to peak torque) more practical.

2. Depending on the vehicle gearing, the postedspeed limit can sometimes allow operation in ei-ther of the top two gears; however, for improvedoperating efficiency (fuel economy and enginelife), operate in the top gear at reduced rpmrather than in the next lower gear at the maxi-mum rpm.

3. Cruise at partial throttle whenever road condi-tions and speed requirements permit. This driv-ing technique permits operating within the mosteconomical power range of the engine.

4. When approaching a hill, open the throttlesmoothly to start the upgrade at full power, thenshift down as desired to maintain the optimumvehicle speed. The high torque of Cummins en-gines may permit topping some grades withoutshifting.

5. Cummins engines are designed to operate overa wide speed range. More frequent shifting thannecessary does not allow proper utilization of thisflexibility. The driver who stays in top gear anduses the wider speed range will achieve the bestfuel economy.

6. The Cummins diesel engine is effective as abrake on downhill grades, but care must be usednot to overspeed the engine going downhill. Thegovernor has no control over engine speed whenthe engine is being pushed by the loaded ve-hicle.

Never turn off the ignition switch while goingdownhill. With the engine still in gear, fuel pres-sure will build up against the shutdown valve andmay prevent it from opening when the ignitionkey is turned on.

CAUTIONDo not allow the engine to exceed its governedspeed, or serious engine damage could result.

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

Cold-Weather OperationIMPORTANT: If a winterfront is used on a ve-hicle with an electronic engine equipped with acharge air cooler, make sure that there are slitopenings distributed across the face of the win-terfront to allow airflow through the entirecharge-air-cooler core. Do not use a winterfrontwith closed areas that block uniform air flowacross any sections of the charge-air-coolercrossflow tubes. This will adversely affect theoperation and durability of the charge air cooler.

Mercedes-BenzSpecial precautions must be taken during coldweather. For service products to use in cold weather,see Chapter 5 of the MBE900 Engine Operator’sManual.

IMPORTANT: At outside air temperatures below–4°F (–20°C), a coolant preheater is recom-mended.

1. Check for cracks in the battery cases, for corro-sion of the terminals, and for tightness of thecable clamps at the terminals. Run a load test todetermine full or partial charging. Charge the bat-teries to full capacity. Replace any battery that isunable to hold full charge or is physically dam-aged.


7.9

2. Check the alternator output. Check the conditionand tension of the poly-V belt.

3. Periodically check the coolant mixing ratio (con-centration of antifreeze in the coolant). Add moreif necessary. The coolant mixing ratio shouldnever rise above 55 percent antifreeze.

4. Use low-viscosity lubricating oils for adequatelubrication.

5. At temperatures below 32°F (0°C), do not usesummer-grade (2-D) diesel fuel. To avoid fuelproblems due to paraffin separation, use winter-grade (1-D or winterized 2-D) diesel fuel only.

6. If the use of unblended summer-grade diesel fuelin winter cannot be avoided, install a thermostati-cally controlled fuel heater to prevent wax fromclogging the fuel filters, and formation of ice crys-tals from water in the fuel. If a fuel heater isused, make sure it has thermostatic controls toprevent excessive heating of the fuel in warmweather. Excessive heating of fuel can cause aloss of engine power.

CaterpillarIf the engine is in good mechanical condition and theprecautions necessary for cold-weather operation aretaken, ordinary cold weather will not cause difficultyin starting or loss of efficiency.

If the engine does not start, prime the fuel system.

For cold-weather operation, use the following guide-lines:

1. When starting the engine in temperatures below32°F (0°C), use engine lubricants of lower vis-cosity. See the engine operation and mainte-nance manual for specifications.

2. When operating in temperatures below 32°F(0°C), use sufficient antifreeze solution in thecooling system to prevent freezing.

3. During cold weather, give more attention to thecondition of the batteries. Test them frequently toensure sufficient power for starting. Inspect allswitches and connections in the electrical systemand keep them in good condition to preventlosses through poor contacts. See Group 15 ofthe Acterra® Workshop Manual for detailed infor-mation.

4. If so equipped, turn off the battery disconnectswitch after the engine is stopped to prevent bat-tery discharge while the starter motor is cooling.

For starting below 0°F (–18°C), an optional cold-weather starting assist is recommended. Fortemperatures below –10°F (–23°C), consult yourCaterpillar dealer for recommendations.

WARNINGDo not use any starting aid, such as ether, in en-gines with a cold start manifold heater. Thiscould cause an explosion and serious personalinjury or death.

5. Customer parameters may include cold modeoperation. When the coolant temperature isbelow 64°F (18°C), the system puts the engine incold mode, limiting engine power, advancing tim-ing, and adjusting the low idle to 600 rpm to im-prove warm-up time. The system will keep theengine in cold mode until coolant temperaturerises above 64°F (18°C) or until the engine hasbeen running for 12 minutes. The system willthen stop the cold mode and allow the engine tooperate normally.

6. Fuel cloud point is the temperature at which waxcrystals become visible, which is generally abovethe pour point of the fuel. To keep the fuel filterelements from plugging with wax crystals, thecloud point should be no higher than the lowestambient temperature at which the engine muststart.

CumminsSatisfactory performance of a diesel engine operatingin low ambient temperatures requires modification ofthe engine, surrounding equipment, operating prac-tices, and maintenance procedures. The lower thetemperatures the greater the amount of modificationrequired, and yet with the modifications applied, theengines must still be capable of operation in warmerclimates without extensive changes.

The following information is provided to engine own-ers, operators, and maintenance personnel on howthe modifications can be applied to get satisfactoryperformance from their diesel engines.

There are three basic objectives:


7.10

1. Reasonable starting characteristics, followed bypractical and dependable warm-up of the engineand equipment.

2. A unit or installation which is as independent aspossible from external influences.

3. Modifications which maintain satisfactory operat-ing temperatures with a minimum increase inmaintenance of the equipment and accessories.

If satisfactory engine temperature is not maintained,higher maintenance cost will result due to increasedengine wear.

Special provisions to overcome low temperatures aredefinitely necessary, whereas a change to a warmerclimate normally requires only a minimum of revision.Most of the accessories should be designed in sucha way that they can be disconnected so there is littleeffect on the engine when they are not in use.

The two most commonly used terms associated withpreparation of equipment for low-temperature opera-tion are "winterization" and "arctic specifications."

Winterization of the engine and/or components sothat starting and operating are possible in the lowesttemperature to be encountered requires:

• Proper lubrication with low-temperature lubri-cating oils.

• Protection from the low-temperature air. Themetal temperature does not change, but therate of heat dissipation is affected.

• Fuel of the proper grade for the lowest tem-perature.

• Heat to raise the engine block and componenttemperatures to at least –25°F (–32°C) forstarting in lower temperatures.

• Electrical equipment capable of operating inthe lowest expected temperature. All switches,connections, and batteries in the electrical sys-tem should be inspected and kept in good con-dition to prevent losses through poor contacts.

Arctic specifications refer to the design of ma-terial and specifications of components neces-sary for satisfactory engine operation in ex-tremely low temperatures to –64°F (–53°C).Contact the nearest Sterling dealer or Cum-mins engine dealer, to obtain the special itemsrequired.

CAUTION"Antileak" antifreezes are not recommended foruse in Cummins engines. Although these anti-freezes are chemically compatible with DCAwater treatment, the "antileak" agents may clogthe coolant filters.

IMPORTANT: Fuel heaters used on vehicleswith Cummins CELECT engine systems couldcause high fuel temperatures that affect engineperformance and operation of the electronic en-gine controls. If a fuel heater is used, make sureit has thermostatic controls. If the fuel heaterhas a timer, set the timer to activate only for alimited period of time before the engine starts.Make sure the fuel heater is used only for start-ing the engine.

Engine ShutdownMercedes-BenzIf any the following occur, shut down the engine im-mediately.

• The oil pressure swings back and forth or fallssharply.

• Engine power and rpm fall, even though theaccelerator pedal remains steady.

• The exhaust pipe gives off heavy smoke.

• The coolant and/or oil temperature climb ab-normally.

• Abnormal sounds suddenly occur in the engineor turbocharger.

1. With the vehicle stopped, apply the parkingbrakes and put the transmission in neutral.

CAUTIONIdle the engine one to two minutes before shut-ting it down, if this can be done without damageto the engine. After hard operation, shuttingdown the engine without idling may cause dam-age to the turbocharger.

2. Allow the engine to idle one to two minutes be-fore shutting it down. This allows the lubricatingoil and the coolant to carry heat away from the


7.11

combustion chambers, bearings, shafts, andseals. The extreme heat may cause bearings toseize or oil seals to leak.

IMPORTANT: Bearings and seals in the turbo-charger are subjected to the high heat of com-bustion exhaust gases. While the engine is run-ning, this heat is carried away by oil circulation,but if the engine is stopped suddenly the turbo-charger temperature may rise as much as 115°F(61°C).

CAUTIONExcept in emergency, do not shut down theMBE900 engine when the coolant temperature isabove 194°F (90°C). To do so could damage theengine.

3. Turn off the ignition switch and shut down theengine.

Caterpillar

CAUTIONStopping the engine immediately after it has beenworking under load can result in overheating andaccelerated wear of the engine components. Ex-cessive temperatures in the turbocharger center-housing will cause oil coking problems. Followthe procedure, outlined below, to allow the en-gine to cool.

1. With the vehicle stopped, apply the parkingbrakes.

2. Reduce the engine speed to low idle.

3. Place the transmission shift lever in neutral.

NOTE: If the engine has been operating at lowloads, run it at low idle for 30 seconds beforestopping. If the engine has been operating athighway speed or at high loads, run it at lowidle for three minutes to reduce and stabilizeinternal engine temperatures before stopping.

4. Turn off the ignition key to shut down the engine.

5. If equipped with an idle shutdown timer, it can beset to shut the engine down after a presetamount of time. Ninety seconds before the pre-set shutdown time, the CHECK ENGINE indica-

tor will begin to flash at a rapid rate. If the posi-tion of the clutch pedal or service brake changesduring this final ninety seconds (diagnostic lampflashing) the idle shutdown timer will be disableduntil reset.

6. After stopping the engine, fill the fuel tank.

7. Check the crankcase oil level while the engine isstopped. Maintain the oil level between the ADDand FULL marks on the dipstick.

8. If temperatures below 32°F (0°C) are expected,allow the engine water jacket expansion tank tocool, then check the coolant for proper antifreezeprotection. The cooling system must be protectedagainst freezing to the lowest expected outsidetemperature. Add permanent-type antifreeze ifrequired.

9. Repair any leaks, perform minor adjustments,tighten loose bolts, etc. Observe the vehicle mile-age or the service meter reading, if so equipped.Perform periodic maintenance as instructed inthe Lubrication and Maintenance Chart in theCaterpillar Operation and Maintenance Manage-ment manual.

Cummins1. With the vehicle stopped, apply the parking

brakes and put the transmission in neutral.

2. It is important to idle an engine three to five min-utes before shutting it down. This allows the lu-bricating oil and the water to carry heat awayfrom the combustion chambers, bearings, shafts,etc. This is especially important with turbo-charged engines.

Bearings and seals in the turbocharger are sub-jected to the high heat of combustion exhaustgases. While the engine is running this heat iscarried away by oil circulation, but if the engineis stopped suddenly, the turbocharger tempera-ture may rise as much 115°F (61°C). The ex-treme heat may cause bearings to seize or oilseals to leak.

3. Do not idle the engine for excessively long peri-ods. Long periods of idling are not good for anengine because the combustion chamber tem-peratures drop so low the fuel may not burncompletely. This will cause carbon to clog theinjector spray holes and piston rings and mayresult in stuck valves.


7.12

If the engine coolant temperature becomes toolow, raw fuel will wash the lubricating oil off thecylinder walls and dilute the crankcase oil caus-ing all moving parts of the engine to suffer frompoor lubrication.

4. If the engine is not being used, shut it down byturning the ignition switch off.

CAUTIONStop the engine at the first sign of malfunction.Almost all malfunctions give some warning to theoperator before significant damage occurs. Manyengines are saved because alert operators heedthe warning signs (sudden drop in oil pressure,unusual noises, etc.) and immediately shut downthe engine.

High-Altitude OperationEngines lose horsepower when operated at high alti-tude because the air is too thin to burn as much fuelas at sea level. This loss is about three percent foreach 1000 feet (300 m) altitude above sea level for anaturally aspirated engine. Most turbocharged en-gines are rated for higher altitudes than naturally as-pirated engines.

An engine will have smoky exhaust at high altitudesunless a lower gear is used. The engine will not de-mand full fuel from the fuel system unless the engineis altitude-compensated by the use of a turbocharger.Shift gears as needed to avoid excessive exhaustsmoke.

Exhaust Braking System,OptionalGeneral InformationAn exhaust brake is an optional auxiliary braking sys-tem that assists but does not replace the servicebrake system. The exhaust brake switch, located onthe control panel, in combination with the acceleratorand clutch pedals, allows the driver to make maxi-mum use of the exhaust brake in off-highway andmountain driving as well as in traffic or high-speedhighway driving.

The exhaust brake is a butterfly-type valve mountedin the exhaust pipe. When the driver’s foot is not onthe accelerator pedal and the exhaust brake switch is

in the on position, an air cylinder shuts the butterflyvalve which restricts the flow of exhaust gases andretards the engine. This retarding action is carriedthrough the engine and drivetrain, slowing the vehicleand reducing the need for frequent service brake ap-plications.

Exhaust brakes are not intended for use as the pri-mary braking system during vehicle operation.

Starting the EngineBefore starting the engine, make sure that the ex-haust brake switch is in the off position. Do not turnthe exhaust brake on until the engine has reachednormal operating temperatures.

Driving DownhillWhile approaching a steep grade, make sure that theexhaust brake switch is in the on position. The ex-haust brake comes on as soon as you remove yourfoot from the accelerator pedal. While going downthe grade, use a low enough gear to safely descendwith a minimum application of the service brakes. Asa general guideline, use the same gear as you wouldto ascend the hill.

WARNINGDo not use the exhaust brake when driving onslippery or low-traction road surfaces. Failure tofollow this precaution could result in a loss ofvehicle control and possible personal injury orproperty damage.

Exhaust Brake Operating CharacteristicsWhen you remove your feet from both the accelera-tor and clutch pedals and the exhaust brake switch isin the on position, the exhaust brake is applied. Thefollowing conditions should exist if the brake is oper-ating properly:

• A slight change in the sound of the engine maybe noticed when the exhaust brake is applied.

• Exhaust smoke should appear normal.

• Engine temperature should remain in the nor-mal operating range.

• Road speed usually decreases when the ex-haust brake is applied during a descent. Whenthe vehicle is carrying a heavy load or the


7.13

grade is extremely steep, you may need toapply the service brakes occasionally.

• Do not expect a retarding effect similar to sud-den hard application of the service brakes. Theexhaust brake retards the vehicle with asmooth braking effect.

• During a descent, the tachometer usuallyshows a drop in rpm depending on the gradeand the vehicle load.

• Depending on the grade and vehicle load, youmay or may not feel the retarding force actingagainst your body when the brake is applied.The retarding force of the brake may not al-ways be noticed, but it is actually preventingthe vehicle from going much faster.

Shutting Off the EngineMake sure the exhaust brake is turned off beforeshutting off the engine.

Pacbrake® Exhaust BrakeThe Pacbrake exhaust brake is intended as asupplement to the service brakes and will not bringthe vehicle to a complete stop. The Pacbrake willassist in the control or reduction of road speed inconjunction with, or independent of, the servicebrakes. The amount of retarding or braking force iscontrolled by the driver.

Pacbrake OperationThe Pacbrake is controlled by the exhaust brakeswitch and the throttle pedal. All applications are ad-ditionally affected, controlled, or governed by enginespeed through transmission gear selection. The Alli-son MD3060 transmission has automatic downshift-ing when the exhaust brake is requested. See theinformation on the "Allison World Transmission" laterin this chapter.

On some applications, when the Pacbrake is in use,it may be necessary to check that the cruise controlis not set and that the throttle is in the idle position.

On some applications the engine, transmission,cruise control, and the Pacbrake exhaust brake mayelectronically interact with each other, which auto-matically operates their functions. Following aresome examples of the programmed options that maybe available with the cruise control in the on position:

• The coast mode engages the Pacbrake whenthe service brake is applied and disengageswhen the service brake is released.

• The latch mode engages the Pacbrake whenthe service brake is applied and the Pacbrakeremains on after the service brake is released.The Pacbrake is disengaged when anotherinput (depressing the throttle or clutch, enginespeed drops below 800 rpm, or the exhaustbrake switch is turned off) is supplied.

• The manual mode does not require the cruisecontrol switch to be on and operates thePacbrake manually at the driver’s discretion.

The amount of braking power the engine will developis related to the speed (rpm) of the engine. Thehigher the engine rpm, the greater the retardingpower.

Certain conditions may require that the transmissionbe downshifted in order to generate adequate rpmfor the amount of retarding power required. Pacbrakeexhaust brakes are designed and approved for safeuse at 300 rpm above the engine’s maximum gov-erned rpm. Refer to individual engine manufacturer’sspecifications.

The Pacbrake will function best if it is used all of thetime. However, if the vehicle is used inconsistently orseasonally, it may be necessary to perform a preven-tive maintenance procedure.

1. With the engine shut down, use any oil-free ornonpetroleum based high-heat lubricant andspray or coat a sufficient amount on the restrictervalve shaft and the attaching locations at eachend of the actuation cylinder. See Fig. 7.6 .

2. With your hands or a pair of pliers, motion thevalve several times to distribute the lubricantdown the shaft and the attaching locations.

NOTE: Starting the engine and idling for shortperiods of time is not recommended. During acold engine start-up, enough moisture is devel-oped within the engine and the exhaust systemto create a corrosion hazard that could affectthe future operation of the Pacbrake. The brakehousing may trap water in the valve shaft borecausing corrosion in an improper or nonfunction-ing brake. If it is necessary to periodically start


7.14

the engine, it is recommended that normal oper-ating temperatures be attained before shuttingdown the engine.

Allison World TransmissionPacbrake exhaust brakes on engines that are usedwith the Allison World Transmission MD series, areinterfaced with the transmission electronic controlmodule (ECM). An exhaust-brake-enabled transmis-sion ECM will usually provide converter lockup ingears two through six. Effective exhaust braking be-gins when the transmission automatically downshiftsinto fifth gear (62 mph or less). Once on, thePacbrake exhaust brake will control road speedand/or slow the vehicle sufficiently that the transmis-sion will automatically downshift, if necessary, to Alli-son’s preselect mode.

The preselect mode is normally assigned to secondgear; however, the transmission can be repro-grammed by an Allison Transmission Distributor tothird or fourth gear should the operator desire. If ad-ditional retarding power is required before the auto-matic downshifting occurs, you can select a lowertransmission gear on the Allison shift selector.

Engine Braking System,OptionalMercedes-Benz Engine Brake/Constant-Throttle ValvesTo increase braking performance, the MBE900 en-gine can be equipped with constant throttles in eachcombustion chamber. Small valves built into the cyl-inder head allow a small amount of compressed airto escape through the exhaust port during the com-bustion stroke. The constant-throttle valves are openduring the entire time that the engine brake is acti-vated.

When a vehicle is equipped with both an exhaustbrake and an engine brake, a three-position enginebrake switch is used to apply the exhaust and/or en-gine brakes. When the top of the engine brakeswitch is pressed, both the engine brake and exhaustbrakes are applied. Using the engine brake and ex-haust brake provides the best braking performance.With the switch in the center position, only the ex-haust brake is applied. When the bottom of theswitch is pressed, the switch is off.

ClutchesGeneral InformationThe major reason clutches wear out too soon is ex-cessive heat. Clutches are designed to absorb anddissipate more heat than encountered in typical op-eration. The temperatures developed in typical op-eration will not break down the clutch friction sur-faces. However, if a clutch is slipped excessively orrequired to do the job of a fluid coupling, high tem-peratures develop quickly and destroy the clutch.Temperatures generated between the flywheel,driven discs, and pressure plates can be highenough to cause the metal to flow and the frictionfacing material to char and burn.

CAUTIONDo not allow sustained slippage of the clutch;this could severely damage the clutch disc, pres-sure plate, or flywheel. Damage caused by clutchslippage due to improper break-in is not warrant-able.

Slipping and excessive heat are practically nonexist-ent when a clutch is fully engaged. But during the

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AA

A

A. Lubrication Point

Fig. 7.6, Pacbrake Exhaust Brake and Air Cylinder


7.15

moment of engagement, when the clutch is pickingup the load, it generates considerable heat. An incor-rectly adjusted or slipping clutch will rapidly generatesufficient heat to destroy itself.

The most important items that a driver should beaware of to ensure long service life of the clutch in-clude: starting in the right gear, recognizing clutchmalfunctions, and knowing when to adjust a clutch.

Clutch OperationGear Shifting TechniquesMany drivers upshift into the next gear or even skip-shift into a higher gear before the vehicle hasreached the correct speed. This type of shifting isalmost as bad as starting off in a gear that is toohigh since the engine rpm and vehicle speeds aretoo far apart, requiring the clutch to absorb the speeddifference by generating heat. For transmission oper-ating instructions, see Chapter 8 .

Apply the clutch brake by fully depressing the clutchpedal. The purpose of the clutch brake is to stop thetransmission gears from rotating in order to engagethe transmission gears quickly in making an initialstart.

CAUTIONNever apply the clutch brake when making down-shifts or upshifts. The clutch pedal should neverbe fully depressed before the transmission is putin neutral. If the clutch brake is applied with thetransmission still in gear, a reverse load will beput on the gear. At the same time, it will have theeffect of trying to stop or decelerate the vehiclewith the clutch brake. Rapid wear of the frictiondiscs will take place necessitating frequent re-placement. Considerable heat will be generated,which will be detrimental to the release bearingsand transmission front bearings.

Vehicle Overload, or Overloading theClutchClutches are designed for specific vehicle applica-tions and loads. These limitations should not be ex-ceeded.

CAUTIONOverloading will not only result in damage to theclutch, but also to the entire powertrain.

Riding the Clutch PedalRiding the clutch pedal is destructive to the clutchsince partial clutch engagement permits slippage,generating excessive heat. Riding the clutch pedalwill also put a constant thrust load on the releasebearing which can thin out the lubricant. Releasebearing failures can be attributed to this type of mis-use.

Holding the Vehicle on an Incline With aSlipping ClutchA slipping clutch accumulates heat faster than it canbe dissipated, resulting in early clutch failures. Neveruse the clutch as a hill holder.

Coasting With the Clutch Released(Pedal Depressed) and the Transmissionin GearDo not allow the vehicle to coast with the clutch re-leased and the transmission in gear. If the transmis-sion remains in a low gear and the vehicle gainsspeed, which may occur on a downgrade, the inputshaft and clutch driven disc will turn at speeds thatare higher than normal. This occurs because the rearwheels and the driveline become the input for thetransmission, and a higher-than-normal speed for agiven transmission gear translates to a higher rpmvalue for the clutch driven disc.

WARNINGDo not coast with the clutch released (pedal de-pressed) and the transmission in gear. Highdriven-disc rpm could cause the clutch facing tobe thrown off the disc. Flying debris could causeinjury to persons in the cab.

Engaging the Clutch While CoastingEngaging the clutch while coasting can result in tre-mendous shock loads and possible damage to theclutch as well as to the entire drivetrain.


7.16

Reporting Erratic Clutch OperationPromptlyReporting erratic clutch operation as soon as pos-sible will give maintenance personnel a chance toinspect the clutch components.

On mechanical clutch linkages, free-pedal travelshould be included and commented on daily in thedriver’s report, since clutch free-pedal travel is themaintenance department’s guide to the condition ofthe clutch and the release mechanism.

CAUTIONOperating the vehicle with incorrect clutch pedalfree-travel could result in clutch damage. SeeGroup 25 of the Acterra ® Workshop Manual forfree-pedal adjustment procedures and specifica-tions.

Clutch AdjustmentsSome clutches have an internal adjustment. See theapplicable section in Group 25 of the Acterra® Work-shop Manual for clutch adjustment procedures andspecifications.

CAUTIONOperating the vehicle with the clutch incorrectlyadjusted could result in clutch or clutch brakefailure.

LubricationThe release bearing should be lubricated at frequentintervals. See Group 25 of the Acterra® MaintenanceManual for intervals and procedures.

CAUTIONFailure to lubricate the release bearing as recom-mended could result in release bearing damageand damage to the clutch.


7.17

8

TransmissionsFreightliner SmartShift Shift Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.1Eaton Fuller AutoShift Automated Transmissions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.1Eaton Fuller UltraShift™ . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.5Eaton Fuller Straight-Shift Transmissions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.10Eaton Fuller Range-Shift Transmissions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.11Eaton Fuller Deep-Reduction Transmissions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.13Mercedes-Benz Manual Transmissions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.15TTC Manual Transmissions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.16Allison On-Highway Transmissions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.16Allison MD Series Transmissions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.19Allison AT/MT Series Transmissions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.22Mercedes-Benz Automated Transmissions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.24

Freightliner SmartShift ShiftControlThe SmartShift transmission control is an electronictransmission control device. It is installed with thefollowing transmissions:

• Eaton® Fuller® AutoShift™

• Eaton Fuller UltraShift™

• Mercedes-Benz Automated Gear Shift (AGS)

It replaces either the typical floor-mounted shift leveror dash-mounted push button control.

SmartShift accepts driver requests for transmissionfunctions and transmits them through hard wiring tothe transmission control unit (TCU). SmartShift is atrue shift-by-wire system.

SmartShift offers two main advantages over conven-tional transmission control devices. Without a floor-mounted shift control, usable cab space is increased.The SmartShift control mounts to the right-hand sideof the steering column and is operated by the fingersof the driver’s right hand, allowing both hands to re-main on the steering wheel.

A two-position slide switch (Fig. 8.1 ) is mounted onthe body of the control lever just before the paddlewidens out. The slide switch allows the driver tochoose automatic (AUTO) or manual (MAN) mode.

In AUTO mode, gears shift automatically, withoutdriver interaction. Manual gear shifts are accom-plished by a momentary pull or push on the control inthe plane perpendicular to the steering wheel. Pullupward (toward you) on the control to upshift andpush downward (away from you) to downshift. Thecontrol is spring-loaded and returns to mid-positionwhen released after an upshift or downshift.

For the Eaton Fuller automated transmissions(Fig. 8.1 ), a four-position (R, N, D, L) selector switchis located at the end of the lever. For the Mercedes-Benz AGS (Fig. 8.2 ), a three-position (R, N, D) se-lector switch is located at the end of the lever.

Embedded in the selector switch is a small neutrallock button to prevent accidental shifts into gear fromneutral. Any time you shift through N, press down onthe neutral lock button to move the switch from neu-tral (N) to another gear, such as drive (D), low (L), orreverse (R). When shifting to N, it is not necessary topress the neutral lock button.

Eaton Fuller AutoShiftAutomated TransmissionsRefer to the Eaton website for additional information,www.roadranger.com.

IMPORTANT: Before starting the vehicle, alwaysdo the following:

• Be seated in the driver’s seat.

• Place the transmission in neutral.

• Set the parking brakes.

• Press the clutch pedal down to the floor.

General Information, AutoShiftThe AutoShift ASX is a partially automated 6-speedor 7-speed Eaton Fuller transmission. The AutoShiftAS2 is a partially automated 10-speed Eaton Fullertransmission. On all models, the driver must use theclutch and put the transmission in neutral to start and

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3 4

5 6

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9

10

1112

f270120

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To upshift manually, pull the lever up (towards you). Todownshift manually, push the lever down (away fromyou).1. SmartShift Control Lever2. Slide Switch (forward driving mode switch)3. MAN Mode (of slide switch)4. AUTO Mode (of slide switch)5. Upshift Direction6. Reverse Position (of selector switch)7. Selector Switch8. Neutral Lock Button9. Neutral Position (of selector switch)10. Drive Position (of selector switch)11. Low Position (of selector switch)12. Downshift Direction

Fig. 8.1, SmartShift Control (with Eaton Fuller AutoShiftand UltraShift)

Transmissions

8.1

stop the vehicle. The SmartShift transmission shiftcontrol (Fig. 8.3 ) is used with the AutoShifttransmission.

The driver does not need to break torque or increaseor decrease engine speed to synchronize the shift.The transmission signals the engine controller whento break torque and the engine controller automati-cally increases or decreases engine speed. Whenengine speed is correct, the transmission engagesthe next gear and signals the engine controller toresume operation.

The AutoShift transmission can be operated in anautomatic (AUTO) mode or a manual (MAN) mode.Select the mode you want to use by moving the slideswitch on the shift control.

Gear information is presented to the driver on a geardisplay module mounted on the dashboard (Fig. 8.4 ).In automatic mode, the number of the forward gearcurrently selected appears continually on the displaywhen in drive.

The display also flashes the next gear to be engagedwhile the transmission is in neutral during a gear

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To upshift manually, pull the lever up (towards you). Todownshift manually, push the lever down (away fromyou).1. SmartShift Control Lever2. Slide Switch3. MAN Position (of slide switch)4. AUTO Position (of slide switch)5. Upshift Direction6. Reverse Position (of selector switch)7. Selector Switch8. Neutral Lock Button9. Neutral Position (of selector switch)10. Drive Position (of selector switch)11. Downshift Direction

Fig. 8.2, SmartShift Control (with Mercedes-Benz AGS)

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A1

B3

2

A. Pull the shift control in this direction to upshift.B. Push the shift control in this direction to downshift.1. Steering Wheel2. Shift Control

3. Steering Column

Fig. 8.3, SmartShift Control Operation

1

4

5

SOLID

SOLID

FLASHING

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3

2

SOLID

A

BA. Gear Display Module B. Module Detail1. Current Gear2. 9th Gear Engaged3. In 9th Gear, Preselected Toward 10th4. Out Of Gear, Waiting For Engine/Transmission rpm

To Synchronize5. 10th Gear Engaged

Fig. 8.4, Gear Display Module

Transmissions

8.2

change. In manual mode, the current gear is dis-played until a new gear is requested. When neutral isselected, N will appear on the display.

If the gear display continues to flash after releasingthe clutch pedal, gear engagement is not complete.Press down the clutch again and wait for the gearsto fully engage.

When reverse (R) is engaged on 10-speed AutoShifttransmissions, either "RL" or "RH" will appear on themessage display screen. AutoShift transmissions withfewer speeds do not have a dual range reverse gear."R" will appear when reverse is engaged.

IMPORTANT: The information shown on thedigital display indicates the state of the trans-mission only, not the state of the SmartShiftcontrol.

Operation, SmartShift With EatonFuller AutoShift

WARNINGIf the engine cranks in any gear other than neu-tral, have the vehicle serviced immediately. If thevehicle is started in gear it will suddenly moveforward or backward, which could result in per-sonal injury and damage to property and thetransmission.

Automatic and Manual ModesA two-position slide switch (forward driving modeswitch) is located near the end of the control. SeeFig. 8.1 . The switch positions are labelled MAN(manual shift mode) and AUTO (automatic drivemode).

NOTE: In automatic drive mode, upshifts anddownshifts require no driver interaction. Movethe selector switch to the drive (D) position, dis-engage the clutch to engage the gear selected,engage the clutch and drive the vehicle. Inmanual shift mode, upshifts and downshifts re-quire either a pull upward or push downward onthe control.

Start-Up1. With the parking brake applied, press the clutch

all the way down to the floor.

2. Check to make sure the transmission is in neu-tral.

IMPORTANT: To start the engine, the transmis-sion must be in neutral.

3. Start the engine.

4. With the transmission in neutral, release theclutch pedal.

NOTE: This allows the speed sensor on theinput shaft to get a reading.

5. Press down on the clutch again and release theparking brake.

6. Select the desired starting gear.

7. Release the clutch.

IMPORTANT: If you have to leave the cab withthe engine running:

• Place the transmission in neutral.

• Set the parking brakes.

• Chock the tires.

Reverse1. To engage reverse (R), slide the selector switch

upward to the next position above the neutralposition and disengage the clutch.

NOTE: AutoShift 10-speed transmissions have adual-range reverse. Reverse low (RL) is the de-fault reverse gear.

2. Select reverse high (RH) by pulling upward onthe control.

NOTE: Reverse may be engaged below a pro-grammable forward speed in order to rock thevehicle. If reverse is selected above the pro-grammed forward speed, an audible warning willsound and a message indicating that the gear isnot available will appear on the message dis-play screen.

NeutralNeutral (N) is used for starting, parking, or any sta-tionary operation. No gear is selected. The transmis-sion must be in neutral before the engine can bestarted.

Transmissions

8.3

Select neutral by moving the mode selector switch toN while depressing the clutch pedal. Verify that theletter N appears on the auxiliary display. Set theparking brakes and slowly release the clutch pedal.

NOTE: Neutral is always available during ve-hicle operation. When in neutral, upshift anddownshift requests are ignored. If the mode se-lector switch is moved from N to D (drive) whilethe vehicle is moving, the transmission will se-lect an appropriate gear for the road speed.

Selecting a Starting Gear1. In automatic mode, select drive (D) by sliding the

selector switch downward to the next positionbelow the neutral position.

2. Disengage the clutch to engage the gear se-lected. Engage the clutch and drive the vehicle.

NOTE: To select a starting gear other than thedefault starting gear, either pull upward or pushdownward on the control while the vehicle isstopped and in drive (either manual or auto-matic mode).

Each pull upward on the control increases thestarting gear by one gear, but no higher than4th gear. The number of the gear selected willflash on the message display screen until thedriver engages the clutch.

This gear will be stored in memory as the de-fault starting gear until either a different startinggear is selected by the driver or the engine isshut down. The transmission may also be pro-grammed so that it is not possible to select astarting gear other than the preprogrammed de-fault starting gear.

UpshiftingIn drive (D), the transmission selects the startinggear and automatically selects gears between thestarting gear and the top gear.

1. To select drive, move the selector switch to Dwhile depressing the clutch pedal. Slowly releasethe clutch pedal and drive the vehicle.

NOTE: With the transmission in drive (D) in theautomatic mode, upshifts require no driver inter-action.

2. With the transmission in drive in the manualmode, request an upshift by pulling upward onthe control. See Fig. 8.3 . If the requested gear isavailable, the transmission will upshift.

NOTE: A single, momentary pull upward on thecontrol selects the next higher gear when it isavailable. Two consecutive, momentary upwardpulls will cause a skip shift when the next twohigher gears are available and conditions areright.

3. To skip shift, move the control two times in lessthan 1/2 second. The number of the gear en-gaged will appear on the message displayscreen.

NOTE: If a requested gear is not available, anaudible warning will sound and the messagedisplay screen will indicate that the gear is notavailable. An unavailable requested upshift isnot stored in memory. The upshift must be re-quested again.

Downshifting

NOTE: With the transmission in drive (D) in theautomatic mode, downshifts require no driverinteraction.

1. With the transmission in drive in the manualmode, request a downshift by pushing downwardon the control. If the requested gear is available,the transmission will downshift.

NOTE: A single, momentary push downward onthe control selects the next lower gear when it isavailable. Two consecutive, momentary down-ward pushes will cause a skip shift, when thenext two lower gears are available and condi-tions are right.

2. To skip shift, move the control two times in lessthan 1/2 second. The number of the gear en-gaged will appear on the message displayscreen.

NOTE: If a requested gear is not available, anaudible warning will sound and the messagedisplay screen will indicate that the requestedgear is not available. Unlike upshifting, an un-available requested downshift is stored inmemory and the shift will be made when the

Transmissions

8.4

gear is available. The time limit for this memoryis a programmable parameter.

Low Gear OperationUse low (L) when descending steep hills and usingcompression braking. Engine speed will be increasedby 200 rpm and shift points will be offset by 200 rpm.The efficiency of the exhaust brake will be maxi-mized.

Select low by moving the mode switch selector whiledepressing the clutch pedal if the vehicle is stopped.If L is selected while the vehicle is moving, the trans-mission downshifts at the earliest opportunity formaximum engine braking.

Using the ClutchUse the clutch to start and stop the vehicle. Be sureto put the transmission in neutral and apply the park-ing brake before shutting down the engine.

Eaton Fuller UltraShift ™

General Information, UltraShift ASWUltraShift ASW is a fully-automated six-speedmedium-duty transmission. No clutch pedal is re-quired to operate the vehicle. This transmission usesa "wet" clutch system in which the drive and drivendiscs rotate in a bath of automatic transmission fluid(Dexron III).

The UltraShift transmission uses the four-positionSmartShift control lever on the steering column toselect gears. To know what gear the transmission isin, look at the round current gear indicator on theright-hand control panel as shown in Fig. 8.5 . All for-ward shifts can be made either manually or automati-cally, at the driver’s choice.

Operation, UltraShift ASWPower Up1. With the parking brake set, select neutral (N) by

moving the selector switch to the N position.

2. With the transmission in neutral, turn on the igni-tion switch. The "CHECK TRANS" and "TRANSTEMP" telltale lights come on and go out again(bulb check). See Fig. 8.6 .

3. After the ignition is turned on, the current gearindicator shows the dot display, arranged in a

square pattern. All dots in the pattern should lightup, without gaps or spaces. See Fig. 8.7 .

4. Wait for the current gear indicator to show a solid"N." When the "N" is solid, rather than flashing,the UltraShift ASW transmission control unit(TCU) is powered up. Start the engine and applythe service brake.

5. Select drive (D) by pressing in the neutral lockbutton and moving the selector switch downward

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1

2

To know what gear the transmission is in, look at thecurrent gear indicator.1. Current Gear Indicator2. SmartShift Control

Fig. 8.5, Shift Controls and Indicators, UltraShiftTransmissions

BRAKE

CHECKTRANS

f610677

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TRANSTEMP

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1. "CHECK TRANS" Light2. "TRANS TEMP" Light

Fig. 8.6, Telltale Lights

Transmissions

8.5

to the position below neutral. Release the park-ing brake. The gear is displayed on the currentgear indicator.

NOTE: When D is selected, the transmissionstarts up in default starting gear, either first orsecond.

6. On a level grade, release the service brake andpress down on the throttle pedal to allow the ve-hicle to move forward.

WARNINGWhen starting or stopping on hills and grades,use extra care to prevent the vehicle from rollingback. A rollback accident could cause death, seri-ous personal injury, or property damage.

7. Prevent the vehicle from rolling backwards whenstopped on a hill or grade, or when the vehicle isstarting from a stop on a hill or grade.

7.1 To start from a full stop on hill or grade,quickly move your foot from the brakepedal and press firmly on the throttlepedal.

On steep hills, set the parking brake andrelease it only when there is enough en-gine power to prevent rollback.

7.2 To stop on a hill or grade, press and holdthe brake pedal to keep the vehicle frommoving.

On steep hills, set the parking brake andchock the tires, front and/or rear. Neverhold a hill with the throttle pedal. This willcause the clutch to overheat.

Power Down1. Apply the service brakes.

2. Select neutral (N) by moving the selector switchto N. When the "N" on the current gear indicatoris solid, rather than flashing, the ASW TCU isready to power down.

3. With the transmission in neutral, set the parkingbrake.

4. Turn off the ignition key and shut down the en-gine.

Automatic and Manual ModesThe SmartShift control has a slide switch located onthe body of the control lever just before the paddlewidens out. See Fig. 8.8 . The slide switch controlsthe forward driving mode, automatic or manual.

To change mode at any time, move the slide switchin the desired direction. This allows the driver to re-spond flexibly to a wide range of driving conditions,such as blind corners, tight curves, and steep hills.

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Fig. 8.7, Power Up Dot Display

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1 2

3

1. Slide Switch (controls forward driving mode)2. Selector Switch (controls gear selection)3. Neutral Lock Button (prevents accidental shift into

gear)

Fig. 8.8, Switches, UltraShift Transmissions

Transmissions

8.6

IMPORTANT: Whatever the mode, it is alwayspossible to shift manually by moving the leverup or down as needed. When the engine speedis within 75 revolutions per minute (rpm) of theload-based shift point for an automatic shift, theASW TCU will advance the shift.

In either mode, the gear indicator displays the cur-rent gear. See Fig. 8.9 .

At the start of a shift, the current gear continues todisplay until the transmission has been pulled intoneutral. At this point, as the transmission is synchro-nizing for the new (target) gear, the gear indicatorflashes the number of the new gear.

When the shift is complete, the new gear displayssolid, without flashing.

Automatic Mode (AUTO)In automatic drive mode (AUTO), upshifts and down-shifts are made by the transmission without driverintervention. Press in the neutral lock button, movethe selector switch to drive (D), and press down onthe throttle pedal. The transmission will shift auto-matically.

If driving conditions require, it is still possible to re-quest a manual shift. The transmission will make theshift if the engine speed is within 75 rpm of the load-based shift point for that gear.

If the driver presses down on the throttle pedal aftera manual downshift in automatic mode, the transmis-sion will upshift again if the ASW TCU requires it.

Manual Mode (MAN)In manual drive mode (MAN), upshifts and down-shifts are made by the driver:

• To shift up, pull the lever up (towards you).

• To shift down, push the lever down (away fromyou).

The system will hold the current gear until the driverrequests a shift. In downhill situations in particular,the driver must be alert to vehicle speed by down-shifting and/or using the service brakes as needed.

A shift request will still be refused if the selected gearwould cause engine overspeed or excessive lugging.

Selecting GearsReverseReverse (R) is at the upper end of the four-positionselector switch located at the end of the SmartShiftcontrol lever. To select R, press in the neutral lockbutton and move the selector switch upward to theposition above neutral. When reverse is selected, theletter "R" displays on the current gear indicator. SeeFig. 8.10 .

IMPORTANT: Under normal conditions, do notselect reverse with the vehicle moving forward.

The vehicle must be moving at less than two milesper hour (3 km/h) before selecting reverse. If reverse

10/13/2003 f610680

NOTE: The gear indicator displays the current gear. Inthis example, it displays first gear.

Fig. 8.9, Current Gear Display

10/14/2003 f610681

Fig. 8.10, Reverse Gear Display

Transmissions

8.7

is selected when the vehicle is moving faster, an au-dible warning will sound and continue sounding atthree-second intervals until the control lever is re-turned to the D position. When the vehicle is movingat the proper speed, reverse can be engaged.

Neutral

IMPORTANT: Always start the engine with thetransmission in neutral, the parking brake set,and the service brakes applied.

Neutral (N) is directly below R on the four-positionselector switch located at the end of the SmartShiftcontrol lever. To select N, move the selector switch tothe position below R. When neutral is selected, theletter "N" displays on the current gear indicator. SeeFig. 8.11 .

WARNINGDo not coast in neutral. Coasting in neutral cancause an accident, possibly resulting in severepersonal injury or death.

Neutral is always available during operation, what-ever the vehicle speed. When in neutral, requests toupshift or downshift are ignored. If the selector switchis moved from neutral to drive while the vehicle ismoving, the transmission will shift into a gear withinthe engine’s operating torque range.

Before shutting down the engine, return the selectorswitch to N. When the ignition is turned off, the trans-mission will reset to neutral in a few minutes regard-less of the position of the shift lever.

DriveDrive (D) is directly below N on the four-position se-lector switch located at the end of the SmartShiftcontrol lever. To select D, press in the neutral lockbutton and move the selector switch to the positionbelow N. When drive is selected, the number of thecurrently selected forward gear (1, 2, 3, 4, 5, or 6)displays on the gear indicator. See Fig. 8.9 .

When in drive, requests to upshift or downshift areenabled. Either manual or automatic mode can beselected on the slide switch.

The vehicle starts up in either first or second gear,depending on load and grade.

The ASW UltraShift controller adapts to the workingconditions of each vehicle and its driver. After powerup or a load change, it needs to learn the new condi-tions. While learning, it may hold a gear too long be-fore upshifting. Start the upshift manually. It may takethree or four shifts before ASW succeeds in learningthe new load-based shift points, but after that it willhandle the shifting automatically.

LowLow (L) is located at the lower end of the four-position selector switch located at the end of theSmartShift control lever. To select L, press in theneutral lock button and move the selector switch tothe position below D.

When in low, the current gear is maintained. Re-quests to upshift are not enabled.

IMPORTANT: If the engine is approaching over-speed, the ASW TCU will override the currentgear setting and upshift to prevent engine dam-age.

To enhance engine braking, downshifts are per-formed at higher rpm than normal.

If L is selected from neutral while stopped, the ve-hicle starts up in first gear and stays there until theengine approaches overspeed.

UpshiftingTo request an upshift with the transmission in drive,pull the control lever up (towards you). If the gear isavailable, the transmission upshifts and the new geardisplays on the gear indicator. No skip shifts areavailable while upshifting.

10/13/2003 f610679

Fig. 8.11, Neutral Display

Transmissions

8.8

No upshifts are available in low, except to preventengine overspeed.

If the transmission does not upshift quickly enoughafter power-up or a load change, begin the shiftmanually. The ASW TCU will learn the new load-based shift conditions after three or four shifts.

If the gear requested is unavailable, a tone willsound. An unavailable request to upshift is not storedin memory. The upshift must be requested again.

Downshifting

NOTE: The driver can manually downshift atany time, even when the slide switch is set toAUTO mode.

To request a downshift with the transmission in driveor low, push the control lever down (away from you).If the gear is available, the transmission downshiftsand the new gear displays on the gear indicator. Skipshifts are available while downshifting.

For best engine braking, select low while moving. Inlow, downshifts are performed at higher rpm than indrive.

IMPORTANT: If the engine is approaching over-speed, the ASW TCU will override the currentgear setting and upshift to prevent engine dam-age.

If the gear requested is unavailable, a tone willsound. An unavailable request to downshift is notstored in memory. The downshift must be requestedagain.

When coasting to a stop, the ASW TCU does notfinish the downshift until the driver presses down onthe throttle pedal again.

IMPORTANT: A downshift request can neverresult in a shift into neutral, even if the vehicle isin the drive position in the lowest possible gear.

Before starting down a hill, slow down. Downshift toa speed that you can control without hard pressureon the service brakes.

Before entering a curve, slow down to a safe speed.Downshift if necessary. This lets you use somepower through the curve to help the vehicle be morestable on the turn. It also allows you to regain speedfaster as you come out of the curve.

Ultrashift DiagnosticsClutch CalibrationThe ASW TCU automatically adjusts for clutch wear.The calibration takes place whenever the followingconditions are met:

• The engine is at normal operating temperature

• The vehicle is stopped

• The engine is at idle speed

• The selector switch on the controller is in neu-tral

Calibration may take up to two minutes to complete.The engine may slow and return to normal idle sev-eral times during calibration.

To stop calibration at any time, select one of thedrive positions on the selector switch (R, D, or L).

Clutch Protection FaultExcessive clutch slippage creates heat and reducesthe life of the clutch. These are some conditionswhich lead to clutch abuse:

• Using the throttle to hold the vehicle on agrade

• Starting the vehicle in too high a gear

• Overloading the vehicle

• Using high idle with the vehicle in gear

The ASW TCU is programmed to prevent clutchabuse. When the clutch overheats, the followingalerts take place:

• The "TRANS TEMP" light comes on

• The current gear indicator displays "CA"

• A warning tone sounds at one-second intervals

The alerts continue until the clutch cools, the throttleis released, or the clutch is fully engaged.

System ProblemIn the event of a problem, do the following steps:

1. Note the driving conditions at the time the prob-lem occurred.

Transmissions

8.9

2. Record the status of the transmission at the timeof the problem (AUTO or MAN mode, gear set-ting R, N, D, or L, current gear, engine speed,etc.)

3. Reset the system, using the procedure below.

Reset ProcedureTransmission operation can sometimes be restoredby doing the following reset procedure:

1. Stop the vehicle when it is safe to do so. Set theparking brake.

2. Place the selector switch in neutral and turn offthe ignition.

3. Check all harness connectors as described inChapter 11 .

4. Wait at least two minutes with the engine shutdown.

5. Restart the engine.

If the problem continues, contact an authorizedFreightliner or Eaton service facility.

Locked In GearIf the transmission becomes locked in gear, a dash(-) will appear on the current gear indicator when thevehicle is restarted during the reset procedure.

NOTE: If the transmission becomes locked ingear while the vehicle is moving, increasedbraking effort may be required to stop the ve-hicle.

If the current gear indicator displays a dash duringpower-up with the selector switch in neutral, do thefollowing steps:

1. Make sure the parking brake is set. Turn off theignition and wait at least two minutes.

2. Apply the service brakes.

3. With the service brakes applied, release theparking brake.

4. Make sure the selector switch is in neutral andturn on the ignition key. Do not attempt to startthe engine at his time.

5. If necessary to get the transmission to shift intoneutral, release the pressure on the brake pedalslightly.

6. Once the ASW TCU reaches neutral, a solid "N"will appear on the current gear indicator and thevehicle will start. Make sure the service brakesare applied and the parking brake is set.

If the current gear indicator continues to display adash, contact an authorized Freightliner or Eaton ser-vice facility.

Eaton Fuller Straight-ShiftTransmissionsRefer to the Eaton website for additional information,www.roadranger.com.

General Information, Straight-ShiftEaton Fuller 5-speed FS models are fully synchro-nized. They have five forward speeds and one re-verse. See Fig. 8.12 for the shift pattern.

Eaton Fuller 6-speed FS and FSO models are fullysynchronized. They have six forward speeds and onereverse. See Fig. 8.13 for the shift pattern.

Eaton Fuller 7-speed T models are not synchronized.They have seven forward speeds and one reverse.See Fig. 8.14 for the shift pattern.

These transmissions are designed for use with on-highway, fuel economy engines where a minimum ofshifting is desired and less gear reduction is accept-able.

Operation, Straight-Shift1. Always use 1st gear when starting to move the

vehicle forward.

2. Accelerate to build up the engine speed (rpm)needed to shift into 2nd gear. Disengage the

1

2

3

R 4

5

05/21/2008 f261049

N

Fig. 8.12, Shift Pattern, 5-Speed FS Models

Transmissions

8.10

clutch and move the shift lever to 2nd gear. En-gage the clutch and accelerate again. This isknown as progressive shifting.

3. Continue upshifting using the same progressivesequence described in the previous step. Followthe pattern on the shift lever.

4. When downshifting, shift progressively downthrough each successive lower gear as follows:

When the engine speed drops to the same rpmto which it fell immediately after upshifting to thatsame gear, press the clutch pedal down andmove the shift lever to the next lower gear. En-gage the clutch smoothly.

Continue downshifting as required using thesame sequence described above.

CAUTIONIf the vehicle is moving when shifting, depressthe clutch pedal just far enough to disengage theclutch. Pressing it to the floor will engage theclutch brake, if so equipped, causing prematureclutch brake wear.

IMPORTANT: Do not rest your foot on the clutchpedal while driving. This causes partial clutchdisengagement which could cause prematureclutch wear.

NOTE: On synchronized models, disengage theclutch completely when shifting gears. Double-clutching is unnecessary. On unsynchronizedmodels, use double-clutching to engage 1stgear or reverse.

Eaton Fuller Range-ShiftTransmissionsRefer to the Eaton website for additional information,www.roadranger.com.

General Information, Range-ShiftEaton Fuller 9-Speed RT ModelsEaton Fuller 9-speed RT models have nine forwardspeeds and two reverse speeds, consisting of a5-speed front section and a 2-speed auxiliary sec-tion. The first position in the front section is usedonly as a starting gear. The other four ratios areused once in LO range and once again in HI range.See Fig. 8.15 for the shift patterns.

After shifting out of the first position, use theRoadranger® repeat H shift pattern. LO range and HIrange are selected with the range knob or rangelever. It is used once during the upshift sequenceand once during the downshift sequence.

1

2

3 5

4 6

05/21/2008 f261048

N

R

Fig. 8.13, Shift Pattern, 6-Speed FS and FSO Models

1

4

3 5

6

7

05/21/2008 f261051

N

R 2

Fig. 8.14, Shift Pattern, 7-Speed T Models

1

4

5

86

73

2

A

B

N

LO

LO

HI

11/23/99 f261047

A. High Range B. Low Range

Fig. 8.15, Shift Pattern, 9-Speed RT Models

Transmissions

8.11

Always preselect the range shift. After preselection,the transmission will automatically make the synchro-nizer range shift as the shift lever passes throughneutral.

Eaton Fuller 10-Speed RT ModelsEaton Fuller Roadranger 10-speed RT and FRmodels have ten forward speeds and two reversespeeds. The gear shift lever mechanically engagesand disengages five forward gears and one reversegear in the transmission front section. The rangelever on the roadranger valve allows the driver tocontrol an air shifted auxiliary section to provide a LOand HI range. The five forward gears selected in LOrange are used again in HI range to provide the 10progressive forward gear ratios. See Fig. 8.16 for theshift patterns. See Table 8.1 for the shiftprogressions.

Eaton Fuller Shift Progressions

ModelLO Range

HI RangeOff-Highway On-Highway

9-SpeedDirect orOverdrive

(RT)

1

2

3

4

f260322

R

LOW

1

2

3

4

f260323

R

7

6 8

5

f260324

R

10-SpeedDirect orOverdrive

(RT)

2

3

4

1

f260329

R

5

2

3

4

1

f260329

R

5

9

8 10

7

f260330

R

6

Table 8.1, Eaton Fuller Shift Progressions

Once the highest shift lever position (5th gear) isreached in LO range, the driver preselects the range

shift lever for HI range. The range shift occurs auto-matically as the shift lever is moved from 5th gearposition to the 6th gear position.

When downshifting, the driver preselects the rangelever for LO range and the range shift occurs auto-matically during the shift lever movement to the nextgear position.

Operation, Range-Shift1. When operating off-highway or under adverse

conditions, always use the low gear when start-ing to move the vehicle.

When operating on-highway, with no load orunder ideal conditions, use 1st gear when start-ing to move the vehicle.

For all conditions, use the highest gear that isstill low enough to start the vehicle moving withthe engine idling and without excessively slippingthe clutch.

2. Use the clutch brake to stop gear rotation whenshifting into low (or 1st) or reverse when the ve-hicle is stationary. The clutch brake is applied bydepressing the clutch pedal all the way to thefloor.

For normal upshifts and downshifts, only a partialdisengagement of the clutch is necessary tobreak engine torque.

3. Do not make range shifts with the vehicle movingin reverse gear.

4. Never attempt to move the range preselectionlever with the gear shift lever in neutral while thevehicle is moving. Preselection with the rangepreselection lever must be made prior to movingthe shift lever out of gear into neutral.

5. Do not shift from high range to low range at highvehicle speeds.

6. Double-clutch between all upshifts and down-shifts.

7. After your shifting ability improves, you may wantto skip some of the ratios. This may be doneonly when operating conditions such as load,grade, and road speed permit.

4

N

7 2

9

6 1

8 3

10 5

R HI

LO

f261053

A

B

12/15/1999

A. High Range B. Low Range

Fig. 8.16, Shift Pattern, 10-Speed RT and FR Models

Transmissions

8.12

Upshifting1. Position the gear shift lever in neutral. Start the

engine and bring the air system pressure up to100 to 120 psi (689 to 827 kPa).

2. Position the range preselection lever down intolow range.

3. Press the clutch pedal to the floor. Shift into lowor 1st gear, then engage the clutch with the en-gine at or near idle speed to start the vehiclemoving. Accelerate to 80 percent of engine gov-erned speed.

4. Shift progressively up from low or 1st gear to thetop gear in low range, double-clutching betweenshifts and accelerating to 80 percent of enginegoverned speed.

5. While in the top gear of the low-range shift pat-tern and ready for the next upshift, flip the rangepreselection lever up into high range. Double-clutch through neutral and shift into the bottomgear in high range. As the shift lever passesthrough neutral, the transmission will automati-cally shift from low range to high range.

6. With the transmission in high range, shift pro-gressively up through each of the high rangegears, double-clutching between shifts.

Downshifting1. With the transmission in high range, shift pro-

gressively down to the bottom gear in highrange, double-clutching between shifts.

2. When in the bottom gear of the high-range shiftpattern and ready for the next downshift, pushthe range preselection lever down into low range.Double-clutch through neutral and shift into thetop gear of the low-range shift pattern. As theshift lever passes through neutral, the transmis-sion will automatically shift from high range tolow range.

3. With the transmission in low range, downshiftthrough the low range gears as conditions re-quire.

Never use the clutch brake when downshifting oras a brake to slow the vehicle.

Eaton Fuller Deep-ReductionTransmissionsRefer to the Eaton website for additional information,www.roadranger.com.

General Information, Deep ReductionIMPORTANT: Not all lever positions are used ineach range and the shift patterns vary betweentransmissions. Be sure to read the shift patterndecal on the dash for the operating instructionsfor the specific transmission installed in your ve-hicle.

9-Speed RT–L ModelsEaton Fuller 9-speed deep-reduction transmissionshave a 5-speed front section, and a 2-speed rear-range section, with a deep reduction button. Thedeep reduction (low-low) gear is used only when op-erating under adverse conditions. Low gear in thefront section is used only for rough, off-highway con-ditions, as a starting ratio. Both the low gear and 1stgear in the low range can be split, using the deepreduction button, for another reduction ratio in thoseshift lever positions. The remaining four forward posi-tions are used once in the low range and once in thehigh range. Reverse in the low range can also besplit with the deep reduction button for a lower ratio.

10-Speed RT–LL ModelsEaton Fuller 10-speed deep-reduction transmissionshave a 5-speed front section, and a 2-speed rearrange section, with a deep reduction button. Thedeep reduction (low-low) gear is used only when op-erating under adverse conditions. Low gear in thefront section is used only for rough, off-highway con-ditions, as a starting ratio. The remaining four for-ward positions are used once in the low range andonce in the high range. See Fig. 8.17 for the shiftpattern.

Operation, Deep ReductionIMPORTANT: The shifter knob has an interlockfeature that prevents the deep reduction buttonfrom being moved forward when the range pre-selection lever is up (in high range); when in lowrange and the deep reduction button is in the

Transmissions

8.13

forward position, the range preselection levercannot be moved up.

1. For all driving conditions, use the highest gearthat is still low enough to start the vehicle movingwith the engine idling, and without slipping theclutch excessively.

2. Use the clutch brake to stop gear rotation whenshifting into low-low, low-1st (whichever is usedas a starting ratio) or reverse, when the vehicleis stationary. The clutch brake is actuated by de-pressing the clutch pedal all the way to the floor.

For normal upshifts and downshifts, only a partialdisengagement of the clutch is necessary tobreak engine torque.

3. Double-clutch between all upshifts and down-shifts.

4. Never move the shift lever into low gear while inhigh range.

5. Do not preselect with the deep reduction button.When making the shift from a deep reductionratio to a low range ratio, move the deep reduc-tion button from a forward position to a rearwardposition, then complete the shift immediately.

6. Never move the deep reduction button from arearward position to a forward position when thetransmission is in high range.

7. Do not shift from high range to low range at highvehicle speeds.

8. Do not make range shifts with the vehicle movingin reverse gear.

9. Never attempt to move the range preselectionlever with the gear shift lever in neutral while thevehicle is moving. Preselection with the rangepreselection lever must be made prior to movingthe shift lever out of gear into neutral.

10. After your shifting ability improves, you may wantto skip some of the ratios. This may be doneonly when operating conditions permit, depend-ing on the load, grade, and road speed.

UpshiftingThere are several patterns of upshifting, dependingon the vehicle load and the road conditions. Deepreduction gears are best suited for heavy loads andsteep inclines. Low gear (in 10-speed transmissions)is best suited for off-highway use.

The following instructions are recommended for start-ing a loaded vehicle moving, under adverse condi-tions.

1. Position the gear shift lever in neutral. Start theengine, and bring the vehicle air system pressureup to 100 to 120 psi (689 to 827 kPa).

2. Position the range preselection lever down, intolow range.

3. Move the deep reduction button to the forwardposition, to engage the deep reduction gears.

4. Depress the clutch pedal to the floor; shift intolow-low gear; then engage the clutch, with theengine at or near idle speed, to start the vehiclemoving. Accelerate to 80 percent of engine gov-erned speed.

5. When ready for the next upshift, move the deepreduction button rearward, then break the torqueon the gears by momentarily releasing the accel-erator or depressing the clutch pedal. Do notmove the shift lever.

6. From low gear, shift upward to the top gear inlow range, double-clutching between shifts, andaccelerating to 80 percent of engine governedspeed.

7. While in the top gear of the low range shift pat-tern, and ready for the next upshift, flip the rangepreselection lever up into high range. Double-clutch through neutral, and shift into the bottom

1 3 5 7

2 6 8

4

1

12/14/1999 f261055

N A

B

C D

A. High RangeB. Low RangeC. Deep Reduction IN (forward)D. Deep Reduction OUT (rearward)1. Deep Reduction Button

Fig. 8.17, Eaton Fuller 10-Speed Deep-ReductionTransmission Shift Patterns

Transmissions

8.14

gear in high range. As the shift lever passesthrough neutral, the transmission will automati-cally shift from low range to high range.

8. With the transmission in high range, shift pro-gressively upward through each of the highrange gears, double-clutching between shifts.

Downshifting1. With the transmission in high range, shift pro-

gressively downward to the bottom gear in highrange, double-clutching between shifts.

2. When in the bottom gear of the high range shiftpattern, and ready for the next downshift, pushthe range preselection lever down into low range.Double-clutch through neutral, and shift into thetop gear of the low range shift pattern. As theshift lever passes through neutral, the transmis-sion will automatically shift from high range tolow range.

3. With the transmission in low range, downshiftthrough the low range gears, as conditions re-quire.

IMPORTANT: Never use the clutch brake whendownshifting, or as a brake to slow the vehicle.

Mercedes-Benz ManualTransmissions

CAUTIONOperating a manual transmission with the fluidlevel higher or lower than recommended can re-sult in transmission damage.

Mercedes-Benz transmissions use a simple 6-speedgear pattern as shown in Fig. 8.18 .

Always use first gear when starting to move the ve-hicle forward.

IMPORTANT: Do not rest your foot on the clutchpedal while driving. This causes partial clutchdisengagement which could cause prematureclutch wear.

While traveling, check the tachometer regularly to besure the engine speed is within the most economicalrange (1400 to 2000 rpm).

On level roads, drive in the highest usable gear,keeping engine speed down.

CAUTIONDo not rest your hand on the gear shift leverwhile driving. This can cause synchronizer dam-age.

When approaching an uphill grade, shift down aheadof time to prevent loss of engine rpm. When ap-proaching a downhill grade, shift down ahead of timeto prevent runaway speed. For information aboutshift points and "progressive shifting," see Chap-ter 7 .

Change gears only when absolutely necessary. Skipgears if needed.

When shifting, always press the clutch pedal all theway down. Do not force the gear lever.

Before shifting into reverse, be sure the engine isidling and the vehicle is not moving.

CAUTIONIf the transmission locks up while driving, mak-ing further shifting impossible, continue drivingin the gear already selected to reach service as-sistance, as circumstances allow. Or, safely parkthe vehicle off the roadway and contact yournearest Sterling dealer or other qualified serviceprovider for roadside assistance. To prevent fur-ther transmission damage, do not move the ve-hicle from a standing start unless this can be ac-complished safely, taking into account the gearthat is engaged and the load on the vehicle.

f261098

1

62 4

3 5

R

05/03/2001

N

05/03/2001

Fig. 8.18, Shift Pattern, M-B Transmissions

Transmissions

8.15

TTC Manual TransmissionsRefer to the TTC website for additional information,www.ttcautomotive.com.

General Information, TTCTTC (Spicer) 7-speed series transmissions are syn-chronized in all gears except 1st and reverse. Theyhave seven forward gears and one reverse gear. SeeFig. 8.19 for the shift pattern.

Operation, TTC1. Always use 1st gear when starting to move the

vehicle forward.

2. To save fuel, use progressive shifting techniques.It is usually not necessary to go all the way togoverned speed before upshifting.

3. Double-clutch only when shifting out of neutral,or when shifting down into 1st.

NOTE: 1st gear, like reverse, is not synchro-nized.

Upshifting1. Position the gear shift lever in neutral, then start

the engine. Bring the air system pressure up to100 to 120 psi (689 to 827 kPa).

2. To shift, press down on the clutch and wait forthe clutch to release completely. Move the shiftlever into 1st gear and engage the clutch (re-move your foot from the lever).

3. Accelerate until your rpm is high enough to shiftinto 2nd. Press down on the clutch and move theshift lever to second gear. Engage the clutch andcontinue driving.

4. Use this progressive shifting technique to shiftinto each higher gear. See Fig. 8.19 for the shiftpattern.

IMPORTANT: As you approach top speed, it willbe necessary to accelerate closer and closer togoverned speed before allowing the engine rpmto drop down at the next shift point.

DownshiftingWhen downshifting, shift progressively down througheach successive lower gear, as follows:

1. Depress the clutch pedal enough to release thetorque, shift into the next lower gear, and engagethe clutch smoothly while accelerating the engineto keep the vehicle moving at the desired speed.

2. Continue downshifting, as conditions require,using the same sequence described above.When shifting down into 1st gear, remember that1st gear isn’t synchronized. Double-clutch whenshifting down into 1st gear.

Allison On-HighwayTransmissionsThe Allison on-highway transmissions are fully auto-matic and include the 1000 Series™, 2000 Series™,and 2400 Series™. Refer to the Allison website foradditional information, www.allisontransmission.com.

Safety Precautions, On-HighwayTransmissions

WARNINGDo not leave the vehicle unattended with the en-gine running. If you leave the vehicle and the en-gine is running, the vehicle can move suddenly,which could result in personal injury or propertydamage.

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

f260118

R

51 3

2 4

7

6

03/12/96

N

Fig. 8.19, TTC 7-Speed Transmission Shift Pattern

Transmissions

8.16

Without Park Position1. Bring the vehicle to a complete stop using the

service brake.

2. Ensure that the engine is at low idle rpm.

3. Put the transmission in neutral.

4. Apply the parking brake, and make sure it isproperly engaged.

5. Chock the rear tires and take any other stepsnecessary to keep the vehicle from moving.

With Park Position1. Bring the vehicle to a complete stop using the

service brake.


3. Put the transmission in P (park).

4. Apply the parking brake (if equipped), and makesure it is properly engaged.

5. Engage the park range by slowly releasing theservice brake.


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

Without Auto-Apply Parking BrakeFollow the instructions for vehicles with 1000 seriestransmissions, under the heading "Without Park Posi-tion."

With Auto-Apply Parking Brake1. Bring the vehicle to a complete stop using the

service brake.


3. Put the transmission in PB (auto-apply parkingbrake).

4. Apply the parking brake (if equipped), and makesure it is properly engaged.


2400 SeriesOn vehicles with 2400 series transmissions, followthe instructions for vehicles with 1000 series trans-missions.

Range Inhibit Indicator, 2000 and2400 SeriesA RANGE INHIBIT indicator is a standard feature ofthe 2000 series and 2400 series transmissions. TheRANGE INHIBIT indicator comes on to alert thedriver that transmission operation is being inhibitedand that the range shifts being requested by thedriver may not occur. When certain operating condi-tions are detected by the TCM (transmission controlmodule), the controls will lock the transmission in thecurrent operating range.

Shift inhibits occur under the following conditions:

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

• Forward/reverse directional shifts are typicallynot permitted if appreciable output shaft speedis detected.

• When some types of unusual transmission op-erating conditions are detected by the TCM,the TCM temporarily limits transmission opera-tion until the vehicle can be driven to a servicelocation. When this type of situation is de-tected, the TCM will lock the transmission in asafe gear range.

• The TCM will prevent shifts from park or neu-tral to range when auxiliary equipment, such asa power takeoff unit (PTO), is in operation.

Operating Instructions, On-HighwayTransmissionsAllison automatic transmissions are electronicallycontrolled. The shift selector provides five or six for-ward ranges and one reverse range. A lever shift se-lector (Fig. 8.20 ) is used by the driver to select theranges.

Transmissions

8.17

P (Park, optional on 1000 and 2400Series)Use park when turning the engine on or off, to checkvehicle accessories, to operate the engine in idle forlonger than 5 minutes, and for stationary operation ofthe power takeoff, if equipped. This position placesthe transmission in neutral and engages the parkpawl of the transmission.

NOTE: This does not apply the parking brake.

PB (Auto-Apply Parking Brake, optionalon 2000 Series)The auto-apply parking brake places the transmis-sion in neutral and applies the parking brake.

R (Reverse)Reverse is used to back the vehicle. When the selec-tor is in reverse, the reverse warning signal willsound. Always bring the vehicle to a complete stopbefore shifting from a forward range to reverse, orfrom reverse to a forward range.

CAUTIONExtended idling in reverse may cause transmis-sion overheating and damage.

Do not idle in reverse for more than 5 minutes. Se-lect P (park), PB (auto-apply parking brake), or N(neutral) when time at idle exceeds 5 minutes.

NOTE: The shift into reverse may not succeed ifa range inhibitor is active. Check for illuminationof the RANGE INHIBIT indicator.

N (Neutral)The neutral position places the transmission in neu-tral. This position is used when starting the engineand for stationary operation.

WARNINGFailure to apply the vehicle parking brakes whenthe transmission is in neutral may allow the ve-hicle to move unexpectedly, possibly causingproperty damage or personal injury.

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


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

CAUTIONCoasting in neutral can cause severe transmis-sion damage.

D (Drive)

WARNINGWhen going downhill, use a combination ofdownshifting, braking, and other retarding de-vices to control vehicle speed and the engine’srated governed speed. Failure to do so could re-duce vehicle braking, possibly causing loss ofvehicle control and resulting in personal injury orproperty damage.

In the drive position, the transmission will initially gointo first range when drive is selected. As vehiclespeed increases, the transmission will upshift auto-matically through each available range up to fourthrange or fifth range. As the vehicle slows, the trans-mission will downshift automatically.

f270115

R

N D 3 2

1

PB

N D 3 2

1

R

N D 3 2

1

R

P

12/09/99

Fig. 8.20, Lever Shift Selectors

Transmissions

8.18

When going downhill, downshift to a lower transmis-sion range to increase engine braking and to helpmaintain control. The transmission has a feature toprevent automatic upshifting above the lower rangeselected. However, during downhill operation, thetransmission may upshift to the next higher range, ifthe engine is exceeding its governed speed in thelower range.

CAUTIONDo not idle in drive for more than 5 minutes. Ex-tended idling in drive may cause transmissionoverheating and damage. Always select PB (auto-apply parking brake) or P (park) if time at idle islonger than 5 minutes.

NOTE: The shift into drive may not succeed if arange inhibitor is active. Check for illuminationof the RANGE INHIBIT indicator.

4 and 3 (Fourth and Third Ranges,optional)Use the fourth or third range for city traffic and forbraking on steep downgrades.

3 and 2 (Third and Second Ranges,standard)Use the third or second range for heavy city trafficand for braking on steeper downgrades.

1 (First Range)Use first range when pulling through mud or deepsnow, when maneuvering in tight spaces, or whendriving up or down very steep grades. First rangeprovides the vehicle with its maximum driving torqueand maximum engine braking effect.

NOTE: To have the transmission select theseranges automatically, leave the selector lever inD (drive).

Allison MD SeriesTransmissionsRefer to the Allison website for additional information,www.allisontransmission.com.

Safety Precautions


On vehicles with MD series transmissions, do thefollowing steps if you have to leave the cab with theengine running (for example, when checking thetransmission fluid):

1. Bring the vehicle to a complete stop using theservice brake.

2. Put the transmission in N (neutral).

3. Ensure that the engine is at low idle rpm (500 to800 rpm).

4. Apply the parking brake and emergency brakes,and make sure they are properly engaged.


Operating Instructions, MD SeriesThe Allison MD transmission is electronically con-trolled and comes with a push-button shift controlthat provides five or six forward ranges and one re-verse range. The push-button shift selector has an R(reverse), an N (neutral), a D (drive), an up arrow, adown arrow, a mode button, and a digital display.

New shift controls — known as "fourth generation" —were introduced in mid-2006. They replaced the pre-vious units that are commonly referred to as "WTECIII". See Fig. 8.21 and Fig. 8.22 .

R (Reverse)Press the R button to select reverse. The digital dis-play will show R when reverse is selected. Alwaysbring the vehicle to a complete stop and let the en-gine return to idle before shifting from a forwardrange to reverse, or from reverse to a forward range.

CAUTIONExtended idling in reverse may cause transmis-sion overheating and damage.

Transmissions

8.19

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

NOTE: The shift into reverse may not succeed ifa range inhibitor is active. When reverse is se-lected, always be sure that R is not flashing.

N (Neutral)

WARNINGWhen starting the engine, make sure that the ser-vice brakes are applied. Failure to apply the ser-vice brakes may result in unexpected vehiclemovement, which could cause severe personalinjury or death. Failure to apply the vehicle park-ing brakes when the transmission is in neutralmay allow the vehicle to move unexpectedly, pos-sibly causing property damage or personal injury.

Press the N button to select neutral. The digital dis-play will display N when neutral is selected. It is notnecessary to press neutral before starting the ve-hicle. The ECU (electronic control unit) or TCM(transmission control module) automatically placesthe transmission in neutral at start-up.

WARNINGFailure to apply the vehicle parking brakes whenthe transmission is in neutral may allow the ve-hicle to move unexpectedly, possibly causingproperty damage or personal injury.

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


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

Always select neutral before turning off the engine.Neutral is also used during stationary operation ofthe power takeoff if your vehicle is equipped with aPTO.

D (Drive)When the D button is pushed, the highest forwardrange will appear in the display. The transmission willnormally go into first range when drive is selected

N

R

D

f270113

1

2

3

07/27/2006

4

1. Digital Display2. Mode Identification

Label

3. Mode Indicator LED4. Mode Button

Fig. 8.21, WTEC III Push-Button Shift Selector

1

2

3

f61080407/27/2006

4

1. Digital Display2. Mode Identification

Label

3. Mode Indicator LED4. Mode Button

Fig. 8.22, Fourth Generation Push-Button Shift Selector

Transmissions

8.20

(except for those units programmed to start in sec-ond range). As vehicle speed increases, the trans-mission will upshift automatically through each range.As the vehicle slows, the transmission will downshiftautomatically.

CAUTIONDo not idle in drive for more than 5 minutes. Ex-tended idling in drive may cause transmissionoverheating and damage. Always select neutral iftime at idle is longer than 5 minutes.

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

5, 4, 3, and 2 (Fifth, Fourth, Third, andSecond Ranges)Occasionally, road conditions, load, or traffic condi-tions will make it desirable to restrict automatic shift-ing to a lower range. Lower ranges provide greaterbraking for going down grades. The lower the range,the greater the braking effect.

Push the up or down arrows on the push-button shiftselector to select individual forward ranges. The digi-tal display will display your choice of range. When alower range is selected, the transmission may notdownshift until the vehicle speed or engine RPM (en-gine governed speed) is reduced.


When going downhill, downshift to a lower transmis-sion range to increase engine braking and to helpmaintain control. The transmission has a feature toprevent automatic upshifting above the lower rangeselected. However, during downhill operation, if theengine governed speed is exceeded in the lowerrange, the transmission may upshift to the nexthigher range.

1 (First Range)Use the first range when pulling through mud ordeep snow, when maneuvering in tight spaces, orwhen driving up or down steep grades. First rangeprovides the vehicle with its maximum driving torqueand maximum engine braking effect. Push the downarrow until the first range appears on the display.

Up and Down ArrowsWhen a lower range is desired, after D has beenpressed, press the down arrow until the desiredrange is shown on the display. Pressing the downarrow continuously causes the range position to con-tinue to go down until the button is released or thelowest range is attained.

When the transmission is in drive and the downarrow has the transmission in a lower range position,press the up arrow to shift to a higher selector posi-tion. Pressing the up arrow continuously causes therange position to continue to rise until the button isreleased or the highest available position is attained.

Pressing the up or down arrows does not overridethe transmission automatic shifting operation. If ahigher or lower position is selected, the transmissioncontinues shifting through the ranges according tothe vehicle operating characteristics until the highestor lowest selected position is reached.

Mode ButtonThe MODE button starts a specialized input or outputfunction that has been previously programmed intothe ECU or TCM. Pressing the MODE buttonchanges transmission operation for a specific func-tion.

Mode Indicator LEDWhen the MODE button is pressed, the mode indica-tor LED illuminates. A mode identification label, lo-cated above the MODE button, identifies the functionassociated with a mode change.

Digital DisplayThe dual digital display shows both the selectedrange (SELECT) and actual range attained (MONI-TOR). The single digital display shows the selectedrange.

Transmissions

8.21

Oil Level SensorAllison MD Series transmissions have an electronicoil level sensor to read fluid level information. Thefluid level diagnostic will display whether the oil levelis OK, too low, or too high. It will also display a de-fault code and indicate if the preconditions (of receiv-ing the fluid level information) are not met.

IMPORTANT: Maintain the the proper fluid levelat all times. If the fluid level is too low, the con-verter and clutch do not receive an adequatesupply of fluid. If the level is too high, the trans-mission may shift erratically or overheat.

To access the oil level display mode, park the vehicleon a level surface, shift to N (Neutral), apply theparking brake, and idle the engine. Then simulta-neously press both the up and down arrows once.The oil level will display at the end of a two-minutecountdown.

Diagnostic CodesDiagnostic codes are numerical indications relating toa malfunction in transmission operation. These codesare logged in the TCM/ECU memory. The most se-vere or most recent code is listed first. A maximum offive codes (numbered d1-d5) may be listed inmemory at one time. If the mode indicator LED isilluminated, the displayed code is active. If it is notilluminated, the displayed code is not active.

NOTE: During normal operation, an illuminatedmode indicator LED signifies the specializedmode operation is in use.

To enter diagnostics mode, first park the vehicle andapply the parking brake. Then simultaneously pressboth the up and down arrows twice.

Allison AT/MT SeriesTransmissionsRefer to the Allison website for additional information,www.allisontransmission.com.

Allison AT 500 SeriesThe Allison AT 500 Series transmissions provide fourforward ranges and one reverse range. A lever shiftselector (Fig. 8.20 ) is used by the driver to select theranges.


If you must leave the engine running, do not leavethe vehicle until you do the following.

• Put the transmission in neutral.

• Apply the parking brake and emergency brakesand make sure they are properly engaged.

• Chock the rear tires and take any other stepsnecessary to keep the vehicle from moving.

PB (Auto-Apply Parking Brake, optional)When the shift selector does not have an auto-applyparking brake, always put the shift selector in neutraland apply the parking brake to hold the vehicle whenit is unattended and before turning off the engine.

R (Reverse)Reverse is used to back the vehicle. Completely stopthe vehicle before shifting from a forward range toreverse, or from reverse to a forward range. The re-verse warning signal will sound when the selector isin reverse.

N (Neutral)Place the shift selector in neutral before starting theengine. When the shift selector has no park provi-sion, always put the shift selector in neutral andapply the parking brake to hold the vehicle when it isunattended and before turning off the engine. Theneutral position is also used during stationary opera-tion of the power takeoff if your vehicle is equippedwith a PTO.

WARNINGDo not let the vehicle coast in neutral. If the ve-hicle is allowed to coast in neutral, the enginebrake will not work and you could lose control ofthe vehicle. This can cause an accident possiblyresulting in personal injury or property damage.Coasting in neutral can also cause severe trans-mission damage.

Transmissions

8.22

D (Drive)In the drive position, the transmission will initially at-tain 1st range and as the vehicle speed increases,the transmission will upshift to second range, thirdrange, and fourth range automatically. As the vehicleslows down, the transmission will downshift to thecorrect range automatically.

3 and 2 (Third and Second Ranges)Third range and second range are used when road,load, or traffic conditions make it desirable to restrictthe automatic shifting to a lower range. When condi-tions improve, return the selector to the drive posi-tion. The third and second ranges also providegreater engine braking for going down grades. Thelower the range, the greater the braking effect.


IMPORTANT: When descending a hill, downshiftto a lower transmission range to increase en-gine braking and to help you maintain control.The transmission has a feature to prevent auto-matic upshifting above the lower range selected.However, during downhill operation, if the en-gine governed speed is exceeded in the lowerrange, the transmission may upshift to the nexthigher range.

1 (First Range)The first range is used when pulling through mud orsnow, or when driving up and down steep grades.This range provides the vehicle with maximum driv-ing power and maximum braking power.

Allison MT 600 ModelsThe Allison MT 643 transmission provides four for-ward ranges and one reverse range. The Allison MT653DR transmission provides five forward rangesand one reverse range. A lever shift selector(Fig. 8.20 ) is used by the driver to select the ranges.


If you must leave the engine running, do not leavethe vehicle until you do the following.

• Put the transmission in neutral.

• Apply the parking brake and emergency brakesand make sure they are properly engaged.

• Chock the rear tires and take any other stepsnecessary to keep the vehicle from moving.

R (Reverse)Reverse is used to back the vehicle. Completely stopthe vehicle before shifting from a forward range toreverse or from reverse to a forward range. The re-verse warning signal will sound when the selector isin reverse.

N (Neutral)Place the shift selector in neutral before starting theengine. Shift to neutral and set the parking brake anytime the vehicle is parked with the engine running.The neutral position is also used during stationaryoperation of the power takeoff if your vehicle isequipped with a PTO.

WARNINGDo not let the vehicle coast in neutral. If the ve-hicle is allowed to coast in neutral, the enginebrake will not work and you could lose control ofthe vehicle. This can cause an accident possiblyresulting in personal injury or property damage.Coasting in neutral can also cause severe trans-mission damage.

D (Drive)In the drive position, the MT 643 transmission willinitially attain first range and, as vehicle speed in-creases, the transmission will upshift to secondrange, third range, and fourth range. In the drive po-sition, the MT 653DR transmission will initially attainsecond range and as the vehicle speed increases,

Transmissions

8.23

the transmission will upshift to third range, fourthrange, and fifth range automatically. As the vehiclespeeds slows down, the transmission will downshiftto the correct range automatically.

4, 3, and 2 (Fourth, Third, and SecondRanges)On the MT 643 transmission, the third range andsecond range are used when road, load, or trafficconditions make it desirable to restrict the automaticshifting to a lower range. When conditions improve,return the selector to the drive position. The third andsecond ranges also provide greater engine brakingfor going down grades. The lower the range, thegreater the braking effect.

On the MT 653DR transmission, the fourth, third, andsecond ranges are used when road, load, or trafficconditions make it desirable to restrict the automaticshifting to a lower range. When conditions improve,return the selector to the drive position.

On the MT 653DR transmission, the third and sec-ond ranges are used for vehicle speed control up ordown steep grades or for undesirable road condi-tions.


IMPORTANT: When going downhill, downshift toa lower transmission range to increase enginebraking and to help you maintain control. Thetransmission has a feature to prevent automaticupshifting above the lower range selected. How-ever, during downhill operation, if the enginegoverned speed is exceeded in the lower range,the transmission may upshift to the next higherrange.

1 (First Range)On the MT 643 transmission, the first range is usedwhen pulling through mud or snow, or when drivingup and down steep grades. This range provides the

vehicle with maximum driving power and maximumbraking power.

On the MT 653DR transmission, the first range isused for off-highway operation or when pullingthrough mud or snow. It is recommended that fullpower shifts not be made from first range to secondrange, or from second range to first range.

Mercedes-Benz AutomatedTransmissionsGeneral Information, AGSThe AGS Automated Gear Shift is a fully automated6-speed medium-duty transmission. The clutch is ac-tivated by a hydraulic system that is integral to thetransmission. No clutch pedal is needed to operatethe vehicle.

AGS transmissions use the SmartShift control leveron the steering column to select gears. A manualshift is possible at any time by moving the SmartShiftlever up or down as needed.

The transmission control unit (TCU) can direct allforward shifts in response to driving conditions andthe driver’s pressure on the brake and throttle ped-als. To know which gear the transmission is in, lookat the round current gear indicator on the right-handcontrol panel as shown in Fig. 8.23 .

The TCU always selects first gear to start the vehiclein motion. It is possible, in manual mode, to start anunloaded vehicle in second gear. In most cases, sec-ond gear is acceptable for downhill starts. In othersituations, for best results always start moving in firstgear. Loaded vehicles, or vehicles on substantialgrades, must start moving only in first gear.

CAUTIONAt the first sign of a transmission malfunction,take the vehicle out of service immediately. De-pending on the type of problem, further shiftingmay not be possible, and driveline torque may beinterrupted.

Transmissions

8.24

Operation, AGSPower Up1. With the parking brake set and/or the brake

pedal pressed down, select neutral (N) by mov-ing the selector switch to the center position.

2. With the transmission in neutral, turn on the igni-tion switch. The "CHECK TRANS" and "TRANSTEMP" telltale lights come on and go out again(bulb check). See Fig. 8.24 .

3. On power up, the current gear indicator showsthe dot display, arranged in a square pattern. Alldots in the pattern should light up, without gapsor spaces. See Fig. 8.25 .

4. When the current gear indicator shows "N," startthe engine.

NOTE: No matter what the circumstances, donot start the engine unless the current gear indi-cator shows "N." See Chapter 13 for jump start-ing information.

5. Select drive (D) by pressing in the neutral lockbutton and moving the selector switch downwardto the position below neutral. Release the park-

ing brake and/or service brake pedal. The gear isdisplayed on the current gear indicator.

NOTE: When D is selected, the transmissionstarts up in first gear. To start up in second gear(downhill start, vehicle unloaded or lightlyloaded), pull up on the SmartShift lever whenthe current gear indicator displays "1."

6. On a level grade, press down on the throttlepedal to allow the vehicle to move forward. Thevehicle will not move until the pedal is de-pressed.

WARNINGWhen starting or stopping on hills and grades,use extra care to prevent the vehicle from rolling

10/13/2003 f270079

1

2

To know which gear the transmission is in, look at thecurrent gear indicator.1. Current Gear Indicator2. SmartShift Control

Fig. 8.23, Shift Controls and Indicators, AGSTransmissions

BRAKE

CHECKTRANS

f610677

1

TRANSTEMP

10/27/2003

2

1. "CHECK TRANS" Light2. "TRANS TEMP" Light

Fig. 8.24, Telltale Lights

10/13/2003 f610678

Fig. 8.25, Power-Up Dot Display

Transmissions

8.25

back. A rollback accident could cause death, seri-ous personal injury, or property damage.

7. Prevent the vehicle from rolling backwards whenstopped on a hill or grade, or when the vehicle isstarting from a stop on a hill or grade.

7.1 To start from a full stop on a hill or grade,quickly move your foot from the brakepedal and press firmly on the throttlepedal.

On steep hills, set the parking brake andrelease it only when there is enough en-gine power to prevent rollback.

7.2 To stop on a hill or grade, press and holdthe brake pedal to keep the vehicle frommoving.

On steep hills, set the parking brake.Never hold a hill with the throttle pedal.This will cause the clutch to overheat.

Power Down1. Bring the vehicle to a complete stop.

2. Set the parking brake.

3. Move the selector switch to N. Wait until "N" ap-pears on the current gear indicator.

WARNINGAlways apply the parking brake before shuttingdown the engine. AGS will shift into neutral aftershutdown, regardless of the position of the shiftlever. If you do not set the parking brake, the ve-hicle could roll and cause an accident resultingin death, serious personal injury, or propertydamage.

4. Turn the ignition switch off and shut down theengine.

5. If the current gear indicator flashes "PB" whenthe engine is shut down, set the parking brakeand move the selector switch to "N."

Automatic and Manual ModesThe SmartShift control has a slide switch located onthe body of the lever just before the paddle widensout. See Fig. 8.26 . The slide switch controls the for-ward driving mode, automatic or manual.

To change mode at any time, move the slide switchin the desired direction. This allows the driver to re-spond to a wide range of driving conditions, such asblind corners, tight curves, and steep hills.

IMPORTANT: Whatever the mode, it is alwayspossible to shift manually by moving the leverup or down as needed.

In either mode, the gear indicator displays the cur-rent gear. See Fig. 8.27 .

Automatic Mode (AUTO)Automatic drive mode (AUTO) is recommended formost driving conditions. For the best fuel economy,always use AUTO mode.

In AUTO mode, upshifts and downshifts are made bythe transmission without driver intervention. Press inthe neutral lock button, move the selector switch todrive (D), and press down on the throttle pedal. Thetransmission will shift automatically through the for-ward gears.

If driving conditions require, it is still possible to re-quest a manual shift. The transmission will make theshift unless the selected gear would cause engineoverspeed.

01/19/2004 f270079b

1 2

3

1. Slide Switch (controls forward driving mode)2. Selector Switch (controls gear selection)3. Neutral Lock Button (prevents accidental shift into

gear)

Fig. 8.26, Switches, AGS Transmission

Transmissions

8.26

If the driver presses down on the throttle pedal aftera manual downshift in automatic mode, the transmis-sion will upshift again if the TCU requires it.

On downgrades, the transmission holds the currentgear until the driver requests a shift, or presses thethrottle pedal.

WARNINGWhile driving off-road or with locked differentialin AUTO mode, use extra caution. Shifts of theAGS could interrupt power to the drive wheels,causing a rollback accident while climbing steepgrades at low speeds. A rollback accident couldcause death, serious personal injury, or propertydamage.

Manual Mode (MAN)Manual mode may be required under certain condi-tions, such as:

• In difficult or slippery conditions

• On hills, steep grades, or other situationswhere driveline torque interruption is not desir-able

• During off-road driving or driving with a lockeddifferential

• In downhill driving where control of enginebraking is needed

• If necessary to hold a specific gear on a down-grade

In manual drive mode (MAN), upshifts and down-shifts are made by the driver:

• To shift up, pull the lever up (towards you).

• To shift down, push the lever down (away fromyou).

The system will hold the current gear until the driverrequests a shift. In downhill situations in particular,the driver must be alert to vehicle speed and main-tain vehicle control by downshifting and/or using theservice brakes as needed.

When braking or slowing in MAN, downshift as nec-essary to prevent lugging the engine when speed isresumed. If the vehicle comes to a complete stop,the TCU resets the transmission to neutral.

NOTE: A downshift request will be refused if theselected gear would cause engine overspeed.

Cruise ControlCruise control is fully functional with AGS transmis-sion in either AUTO or MAN mode.

In AUTO, the TCU will adjust the gear selections tomaintain the speed settings as desired. No driveraction is necessary.

In MAN, the vehicle speed settings must be withinthe engine speed range for the gear selected. If theengine cannot maintain set speed due to changes inroad grade, the driver must downshift or upshift asnecessary.

For vehicles equipped with a power take-off (PTO)unit, two modes of operation are possible, stationaryand mobile. For PTO operation, see Chapter 7 .

Selecting GearsReverseReverse (R) is at the upper end of the three-positionselector switch located at the end of the SmartShiftcontrol lever. To select reverse (R), press in the neu-tral lock button and move the selector switch upwardto the position above neutral. When reverse is se-lected, the letter "R" displays on the current gear in-dicator. See Fig. 8.28 .

IMPORTANT: The vehicle must come to a com-plete stop before selecting reverse. If reverse is

10/13/2003 f610680

NOTE: The gear indicator displays the current gear. Inthis example, it displays first gear.

Fig. 8.27, Current Gear Display

Transmissions

8.27

selected with the vehicle moving forward, anaudible alert will sound and continue soundingat three-second intervals until the selectorswitch is returned to N or D.

Once the vehicle has come to a complete stop, re-verse can be engaged.

NeutralNeutral (N) is in the center of the three-position se-lector switch located at the end of the SmartShiftcontrol lever. Always start the engine in neutral. Toselect neutral, move the selector switch to the centerposition. When neutral is selected, the letter "N" dis-plays on the current gear indicator. See Fig. 8.29 .


Neutral is always available during operation, what-ever the vehicle speed. When in neutral, requests toupshift or downshift are ignored. If the selector switchis moved from neutral to drive while the vehicle ismoving, the transmission will shift into a gear withinthe operating torque range of the engine.

WARNINGAlways apply the parking brake before shuttingdown the engine. AGS will shift into neutral aftershutdown, regardless of the position of the shiftlever. If you do not set the parking brake, the ve-hicle could roll and cause an accident resultingin death, serious personal injury, or propertydamage.

Before shutting down the engine, return the selectorswitch to "N." When the ignition is turned off, thetransmission will reset to neutral during power down.

Drive

IMPORTANT: The vehicle must come to a com-plete stop before selecting drive. If drive is se-lected with the vehicle moving in reverse, anaudible alert will sound and continue soundingat three-second intervals until the selectorswitch is returned to N or R.

Drive (D) is at the lower end of the three-position se-lector switch located at the end of the SmartShiftcontrol lever. To select drive, press in the neutral lockbutton and move the selector switch to the positionbelow N. When drive is selected, the number of thecurrently selected forward gear (1, 2, 3, 4 , 5, or 6)displays on the gear indicator. See Fig. 8.27 .

Upshifting

NOTE: The driver can manually upshift at anytime, even when the slide switch is set to AUTOmode.

To request an upshift with the transmission in drive,pull the control lever up (towards you). If the gear is

10/14/2003 f610681

Fig. 8.28, Reverse Gear Display

10/13/2003 f610679

Fig. 8.29, Neutral Display

Transmissions

8.28

available, the transmission upshifts and the new geardisplays on the gear indicator.

As in a manual transmission, upshifting too earlycauses engine lugging and uneven operation.

To achieve smooth operation in MAN mode, upshiftwhen the engine speed reaches approximately 2000revolutions per minute (rpm). Heavy loads or steepgrades require higher rpm; lighter loads require lowerrpm.

An unavailable request to upshift is not stored inmemory. The upshift must be requested again.

Downshifting

NOTE: The driver can manually downshift atany time, even when the slide switch is set toAUTO mode.

To request a downshift with the transmission in drive,push the control lever down (away from you). If thegear is available, the transmission downshifts andthe new gear displays on the gear indicator.

Downshifts are not available if the engine speed afterthe shift would exceed 2700 rpm. If the gear re-quested is unavailable, an audible alert will sound.An unavailable request to downshift is not stored inmemory. The downshift must be requested again.

IMPORTANT: A downshift request can neverresult in a shift into neutral, even if the vehicle isin the drive position in the lowest possible gear.

To achieve smooth operation in MAN mode, down-shift when the engine speed reaches approximately1200 rpm.

Before starting down a hill, slow down. Downshift toa speed that you can control without hard pressureon the service brakes.

Before entering a curve, slow down to a safe speed.Downshift if necessary. This lets you use somepower through the curve to help the vehicle be morestable on the turn. It also allows you to regain speedfaster as you come out of the curve.

AGS Diagnostics

CAUTIONAt the first sign of a transmission malfunction,take the vehicle out of service immediately. De-

pending on the type of problem, further shiftingmay not be possible, and driveline torque may beinterrupted.

System MalfunctionIf the "CHECK TRANS" telltale light comes on whiledriving, the audible alert sounds, and the currentgear indicator begins to flash between the currentgear and "SM" (system malfunction), there is a prob-lem which may or may not be apparent to the driver.Bring the vehicle at once to a safe stopping placeand call an authorized Freightliner service facility forassistance.

Clutch OverloadIf the "TRANS TEMP" telltale light comes on whiledriving and the current gear indicator begins to flashbetween the current gear and "CO" (clutch overload),the clutch has begun to overheat.

The clutch overload may have been caused by im-proper driving practices such as frequent and rapidstart/stop driving, or hillholding with the throttle pedal.In this case, allow the clutch to cool, and continueon, but cease the improper driving practices.

If the clutch overload message returns or continues,the clutch is worn or damaged. Bring the vehicle atonce to a safe stopping place and call an authorizedFreightliner service facility for assistance.

Low Hydraulic Fluid Level

IMPORTANT: The only hydraulic fluid permittedin this system is Pentosin CHF 11S. No otherfluid can be substituted.

If the "CHECK TRANS" telltale light comes on whiledriving and the current gear indicator begins to flashbetween the current gear and "FL" (fluid level), therehas been an unusual loss of hydraulic fluid. Bring thevehicle at once to a safe stopping place and call anauthorized Freightliner service facility for assistance.The hydraulic reservoir holds about 1.05 quarts (oneliter) of Pentosin CHF 11S.

NOTE: After hydraulic fluid loss, a special pro-cedure is required to fill the hydraulic reservoir.This procedure must be carried out by an autho-rized Freightliner service facility.

Transmissions

8.29

9

Rear AxlesMeritor™ Drive Axles With Wheel Lock . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.1Meritor™ Wheel Lock Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.1Meritor™ Tandem Drive Axles With Axle Lock . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.2Meritor™ Axle Lock Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.2

Meritor ™ Drive Axles WithWheel LockThe Meritor wheel lock is a driver-controlled tractiondevice operated from the vehicle cab. The wheel lockswitch (Fig. 9.1 ) allows the driver to lock the wheelson the same axle together. The wheel lock indicatorlight comes on when the wheel lock is turned on.

The wheel lock provides maximum traction underslippery conditions. When the wheel lock is engaged,the clutch collar completely locks the differentialcase, gearing, and axle shafts together, maximizingthe traction of both wheels and protecting againstspinout.

Under normal traction conditions, do not use thewheel lock feature.

WARNINGBe especially careful when driving under slipperyconditions with the differential locked. Thoughforward traction is improved, the vehicle can stillslip sideways, causing possible loss of vehiclecontrol, personal injury, and property damage.

Meritor ™ Wheel LockOperationTo lock the wheels and obtain maximum tractionunder slippery conditions, push the wheel lock switchup.

WARNINGLock the wheels only when the vehicle is stand-ing still or moving less than 25 mph (40 km/h).Never lock the wheels when the vehicle is travel-

ing down steep grades or when the wheels areslipping. This could damage the differential orlead to loss of vehicle control, causing personalinjury and property damage.

NOTE: On some vehicles, the wheel lock sys-tem is connected through the low speed rangeof the transmission. If this system is used, thetransmission must be in the low speed range forthe wheels to fully lock.

If the vehicle is moving, maintain a constant vehiclespeed when the wheel lock is turned on. Briefly letup on the accelerator to relieve torque on the gear-ing, allowing the wheels to fully lock. The wheel lockindicator comes on when the wheel lock is turned on.When the wheels are fully locked, the turning radiuswill increase because the vehicle understeers. SeeFig. 9.2 . Drive cautiously and do not exceed 25 mph(40 km/h).

To disengage the wheel lock, move the wheel lockswitch to the center position. Briefly let up on the ac-celerator to relieve torque on the gearing, allowingthe wheels to fully unlock.

NOTE: If the wheel lock system is connectedthrough the low speed range of the transmis-sion, shifting out of low speed range will alsodisengage the wheel lock.

When the wheel lock is disengaged, the wheel lockindicator will turn off.

f61037610/01/99

Fig. 9.1, Wheel Lock Switch

02/09/96 f350079a

A

B

A. Turning Radius When the Wheel Lock is Engaged(understeer condition)

B. Turning Radius When the Wheel Lock isDisengaged

Fig. 9.2, Turning Radii

Rear Axles

9.1

Meritor ™ Tandem Drive AxlesWith Axle LockMeritor tandem drive axles have an axle lock feature.The axle lock is controlled by the axle lock switch(Fig. 9.3 ) on the control panel.

When the axle lock is not engaged, there is differen-tial action between the two axles. The differentialcompensates for different wheel speeds and varia-tions in tire size. Keep the axle lock disengagedwhen driving on roads where traction is good.

When the axle lock is engaged, the axles are lockedtogether and the driveshaft becomes a solid connec-tion between the two axles. Power entering the for-ward axle is transmitted straight through to the rearaxle so that both axles turn together at the samespeed. The axle lock should be used when the ve-hicle encounters poor traction conditions; however, italso increases drivetrain and tire wear and should beused only when improved traction is required.

Meritor ™ Axle Lock OperationTo engage the axle lock and achieve maximum pull-ing power when approaching slippery or poor roadconditions, push the axle lock switch up while main-taining vehicle speed. Let up momentarily on the ac-celerator to engage the axle lock. Proceed over poorroad conditions with caution. Do not wait until tractionis lost and the tires are spinning before engaging theaxle lock.

CAUTIONDo not turn the differential lock switch on whilethe WHEEL SPIN indicator light is on. To do socould damage the rear axle.

To disengage the axle lock after leaving poor roadconditions, move the axle lock switch to the centerposition while maintaining vehicle speed. Let up mo-mentarily on the accelerator to allow the shift, thenresume driving at normal speed.

f61037710/01/99

Fig. 9.3, Axle Lock Switch

Rear Axles

9.2

10

Fifth WheelsHolland Fifth Wheels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.1Fontaine® Fifth Wheels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.3

Holland Fifth Wheels3500 Series Stationary ModelsHolland 3500 Series stationary fifth wheels are bestsuited for applications where the axle loading, king-pin setting, and vehicle combination length all remainconstant throughout the fleet. The stationary fifthwheel can be a plate mount or an angle mount. SeeFig. 10.1 .

The Type B kingpin lock mechanism (Fig. 10.2 ) uti-lizes two spring-loaded lock halves. The final forwardmotion of the kingpin into the open lock halves forcesthe locks to close around the kingpin. The kingpincan be released only by pulling the release handle allthe way out. The lock adjustment nut will compen-sate for wear on the lock or kingpin.

Fifth Wheel Locking OperationLocking the Fifth Wheel Mechanism1. Make sure the coupling area is level and clear of

persons and obstacles.

2. The fifth wheel plate must be completely lubri-cated with chassis grease. For lubrication in-structions, see Group 31 of the Acterra® Mainte-nance Manual.

WARNINGKeep the fifth wheel plate lubricated to preventbinding between the tractor and trailer. A bindingfifth wheel could cause erratic steering and lossof vehicle control, possibly resulting in seriouspersonal injury or death.

3. Make sure the locks are open. If the locks areclosed, pull the release handle all the way out.

4. Position the tractor so that the fifth wheel lockopening is in line with the trailer kingpin.

5. Back the tractor close to the trailer and stop.

6. Chock the trailer wheels.

7. Apply the trailer brakes.

8. Adjust the trailer height so that the fifth wheel willlift the trailer. The trailer should contact the fifthwheel four to six inches (10 cm to 15 cm) behindthe fifth wheel bracket pin.

9. Slowly back the tractor in to the trailer.

10. Test for kingpin lockup by pulling on the traileragainst the chocks. Check for correct maximumclearance between the lock halves. If more than1/8-inch (3.2-mm) clearance exists between thelock halves, the lock must be adjusted. SeeGroup 31 of the Acterra® Workshop Manual foradjustment procedures.

WARNINGAdjust the locks correctly to a maximum clear-ance of 1/8 inch (3 mm). Incorrect adjustment ofthe lock could cause the trailer to disconnect,possibly resulting in serious personal injury ordeath.

11. Make a visual inspection for proper kingpinlockup. Make sure the lock is closed and that theadjustment nut is snug against the fifth wheel.

WARNINGThe coupling procedure is not complete withoutan inspection. You must get out of the tractorand verify that the fifth wheel is properly coupledto the kingpin. Failure to verify that the fifthwheel is properly coupled to the kingpin couldcause the trailer to detach from the tractor, possi-bly resulting in serious personal injury or death.

NOTICEAlways make sure the connect-hanger/supportkeeps the trailer air hoses and electrical cablespositioned so that they do not rub on anything.Rubbing may wear through hoses or cables, re-sulting in air leaks, or exposed or broken wires,potentially affecting trailer brake or electrical sys-tems.

12. After lockup is completed, connect the tractor-to-trailer air system lines and electrical cable to thetrailer. Take care to prevent dirt or foreign mate-rial from entering the air lines.

13. Charge the air brake system with air. Make surethat the air connections do not leak.

14. Retract the trailer landing gear and secure theratchet handle.

15. Remove the chocks from the trailer tires.

Fifth Wheels

10.1

16. The load distribution on the front steering axleand rear drive axle(s) will have a direct effect onthe steering control of the vehicle.

Determine the front and rear axle weights byweighing the vehicle on scales designed for thispurpose.

The maximum axle weight ratings are shown onthe Federal Motor Vehicle Safety Standard(FMVSS) label or Canadian Motor Vehicle SafetyStandard (CMVSS) label attached to the left reardoor post of the tractor. The desired load on theaxle is no less than 80 percent of the maximumaxle weight rating, but in no instances should the

axle load exceed the maximum axle weight rat-ing given on the FMVSS or CMVSS label.

WARNINGDo not overload any tractor axle by improperlyloading the trailer. This could cause erratic steer-ing and loss of vehicle control, possibly resultingin serious personal injury or death.

Unlocking the Fifth Wheel LockMechanism1. Apply the tractor parking brakes.

1

1

2 2 3 3

4 4

11/10/1999 f310823 A B

A. Plate Mount B. Angle Mount1. Release Handle2. Lock Adjustment Nut

3. Top Plate4. Lock Mechanism

Fig. 10.1, Holland 3500 Series Fifth Wheels

07/11/2000 f310841

2 2

1 1

4

33

5

A B

A. Closed Position, Locked B. Open Position, Unlocked1. Release Handle and Spring2. Adjustment Nut

3. Lock Halves4. Lock Pivot

5. Sliding Yoke

Fig. 10.2, Type B Kingpin Lock Mechanism (bottom view)

Fifth Wheels

10.2

2. Pull the trailer air supply valve to cut off the airsupply to the trailer.

3. Chock the front and rear of the trailer tires toprevent the trailer from moving.

WARNINGDo not use the trailer service brakes for parking;they are not designed for this purpose. If airbleeds out of the trailer air tank during parking,the vehicle could roll causing serious personalinjury or property damage.

4. Lower the trailer landing gear until the weight isremoved from the fifth wheel.

5. Disconnect the tractor-to-trailer air system linesand electrical cable. Plug the air lines to preventdirt or foreign material from entering the lines.

6. Release the kingpin locking mechanism by pull-ing the release handle (Fig. 10.1 ) all the wayout.

7. Slowly drive the tractor away from the trailer.

Fontaine ® Fifth Wheels6000/7000 Series No-Slack® IIStationary ModelsOn Fontaine fifth wheels, kingpin release is accom-plished by pulling the release handle located on theside of the fifth wheel. Kingpin lockup occurs whenthe kingpin is forced into the jaws and the releasehandle moves to the locked position.

The fifth wheel top plate is mounted to the tractorframe using a mounting angle. The fifth wheel shouldbe mounted in a position that best distributes thetrailer load over the tractor axles.

Fifth Wheel Lock Mechanism forTrailer KingpinThe Fontaine fifth wheel lock mechanism (Fig. 10.3 )for the trailer kingpin consists of a spring-loaded jawand a sliding wedge. The jaw and wedge each havea pin permanently attached. The pin on the jaw andthe pin on the wedge fit into elongated notches in therelease handle. The notches in the handle control thelimit of movement for both the jaw and wedge. Thenotches are arranged so that the wedge is actuatedfirst during release of the kingpin.

During lockup, the jaw is moved first with the spring-loaded wedge being allowed to slip into place againstthe jaw. A timing bracket ensures that the wedge andjaw are moved at the correct time.

Placing the release handle in the unlocked positionmoves the wedge away from the jaw. This action un-locks the jaw so that it can be moved by the trailerkingpin. When the tractor is moved out from underthe trailer, the kingpin moves the jaw until the kingpinis out of the mechanism. With the jaw in the un-locked position, the release handle will remain in theunlocked position until manually moved by the opera-tor.

During coupling, the motion of the kingpin enteringthe jaw will move the jaw and wedge. The jaw willmove behind the kingpin, followed by the wedge. Thepurpose of the wedge is to reinforce the jaw and takeup slack around the pin. Any wear on the jaw is im-mediately taken up by the wedge so there is no slackin the connection.

1

2 A

3

B C

01/04/95 f310184c

NOTE: Kingpin correctly entering the lock. Note how thesteel tongue allows lock halves to close completelyaround the neck and shoulder of the kingpin.

A. Unlocked PositionB. Locking

C. Locked

1. Wedge2. Jaw

3. Trailer Kingpin

Fig. 10.3, Fontaine Kingpin Lock Mechanism

Fifth Wheels

10.3

Correct adjustment of the wedge stop rod is impor-tant to the proper functioning of the locking mecha-nism. For adjustment instructions, see Group 31 ofthe Acterra® Maintenance Manual.

Special precautions must be taken during coldweather to ensure that the Fontaine® No-Slack® lock-ing mechanism operates freely. Ice and sludge canbuild up and lubricants become thick and binding atlow temperatures. When the temperature dropsbelow freezing, Fontaine recommends the use of acleaner or degreaser on the latching mechanism,making sure that the moving parts operate freely.This should be followed by an application of 90-weight oil to all moving parts.

Fifth Wheel Locking OperationLocking the Fifth Wheel Lock Mechanism1. Chock the front and rear of the trailer tires to

prevent the trailer from moving.

2. The kingpin lock mechanism must be fully open,the release handle should be in the extendedposition, and the fifth wheel plate must be com-pletely lubricated with chassis grease. If the fifthwheel is equipped with a retractable handle, thehandle will not be fully extended. For lubricationinstructions, see Group 31 of the Acterra® Main-tenance Manual.

WARNINGKeep the fifth wheel plate lubricated to preventbinding between the tractor and trailer. A bindingfifth wheel could cause erratic steering and lossof vehicle control, possibly resulting in seriouspersonal injury or death.

3. Position the tractor so that the fifth wheel lockopening is in line (both vertically and horizontally)with the trailer kingpin. The kingpin should be ina position to enter the throat of the lockingmechanism, as shown in Fig. 10.3 . Adjust thetrailer landing gear to give enough alignmentheight for positive kingpin lockup.

4. With the fifth wheel lock opening aligned with thetrailer kingpin, back the tractor slowly toward thetrailer, making sure that the kingpin enters thethroat of the locking mechanism. Continue back-ward motion until positive lockup occurs.

5. Apply the tractor parking brakes.

6. Make a visual and physical check for positivekingpin lockup. When lockup has occurred, thefifth wheel release handle will have moved to thelocked position. See Fig. 10.4 .

7. Release the tractor parking brakes. Test for king-pin lockup by pulling on the trailer against thechocks.

NOTICEAlways make sure the connect-hanger/supportkeeps the trailer air hoses and electrical cablespositioned so that they do not rub on anything.Rubbing may wear through hoses or cables, re-sulting in air leaks, or exposed or broken wires,potentially affecting trailer brake or electrical sys-tems.

8. After lockup is completed, connect the tractor-to-trailer air system lines and the electrical cable tothe trailer. Take care to prevent dirt or foreignmaterial from entering the air system lines.

9. Charge the air brake system with air. Make surethat the air connections do not leak.

10. With the trailer wheels chocked and the brakesset, check for clearance between the kingpin andthe fifth wheel jaws by moving the tractor forwardand backward against the locked kingpin. Thereshould be no slack between the tractor and thetrailer. If slack is present, uncouple the trailer.

For adjustment instructions, refer to the manufac-turer’s service information.

WARNINGEliminate slack between the trailer and the trac-tor. Incorrect fifth wheel adjustment could causethe trailer to disconnect, possibly resulting in se-rious personal injury or death.

11. Retract the trailer landing gear, and secure theratchet handle.

12. Remove the chocks from the trailer tires.

13. The load distribution on the front steering axleand rear drive axle(s) will have a direct effect onthe steering control of the vehicle.

Determine the front and rear axle weights byweighing the vehicle on scales designed for thispurpose.

Fifth Wheels

10.4

The maximum axle weight ratings are given onthe Federal Motor Vehicle Safety Standard(FMVSS) label or Canadian Motor Vehicle SafetyStandard (CMVSS) label attached to the left reardoor post of the tractor. The desired load on theaxle is no less than 80 percent of the maximumaxle weight rating, but in no case should the axleload exceed the maximum axle weight ratinggiven on the FMVSS or CMVSS label.

WARNINGDo not overload any tractor axle by improperlyloading the trailer. This could cause erratic steer-ing and loss of vehicle control, possibly resultingin serious personal injury or death.

Unlocking the Fifth Wheel LockMechanism1. Apply the tractor parking brakes.

2. Pull the trailer air supply valve to cut off the airsupply to the trailer.

3. Chock the front and rear of the trailer tires toprevent the trailer from moving.

WARNINGDo not use the trailer service brakes for parking;they are not designed for this purpose. If air

bleeds out of the trailer air tank during parking,the vehicle could roll causing serious personalinjury or property damage.

4. Lower the trailer landing gear until the weight isremoved from the fifth wheel.

5. Disconnect the tractor-to-trailer air system linesand electrical cable. Plug the air lines to preventdirt or foreign material from entering the lines.

6. Release the kingpin locking mechanism by pull-ing the release handle to the unlocked position.See Fig. 10.4 .

7. Slowly drive the tractor away from the trailer.

11/12/99

1

2 3

1

f310825

A B

NOTE: Make sure the safety latch is down when the control handle is locked.

A. Locked B. Unlocked1. Release Handle 2. Jaw 3. Wedge

Fig. 10.4, Fontaine 6000/7000 Series Fifth Wheel, Locked and Unlocked (bottom view)

Fifth Wheels

10.5

11

Pretrip and Post-TripInspections and

MaintenancePretrip and Post-Trip Inspection Checklists . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11.1Pretrip and Post-Trip Maintenance Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11.3

Pretrip and Post-TripInspection ChecklistsRegulations in both Canada and the United Statesclearly indicate that it is the driver’s responsibility toperform an inspection and ensure the complete road-worthiness of a vehicle before placing it into servicefor the day. Commercial vehicles may be subject toinspection by authorized inspectors, and an unsafevehicle can be put "out of service" until the driver orowner repairs it.

IMPORTANT: The pre- and post-trip checklists,and inspections and maintenance proceduresdetailed in this chapter, are not all-inclusive .Also refer to other component and body manu-facturers’ instructions for specific inspection andmaintenance instructions.

Use the inspection checklists to ensure that vehiclecomponents are in good working condition beforeeach trip. A driver that is familiar with the vehicle,and drives it regularly, can perform the daily inspec-tions, then add the weekly and monthly post-trip in-spections as scheduled. If the driver does not oper-ate the vehicle on a consistant basis, all three of theinspection procedures should be performed beforethe trip.

NOTE: Procedure reference numbers in the thechecklists reference the corresponding detailedinstructions found under the pretrip and post-tripmaintenance procedures.

Pre- and post-trip inspections cannot be donequickly. However, careful inspections save time byeliminating stops later to adjust items overlooked orforgotten.

If any system or component does not pass this in-spection, it must be corrected before operating thevehicle. Whenever equipment requires adjustment,replacement, repair, addition of lubricants, or achange of lubricants, see the Acterra® WorkshopManual for procedures and specifications, and seethe Acterra® Maintenance Manual for lubricant rec-ommendations, specifications, and maintenanceintervals.

See Table 11.1 for a list of procedures that shouldbe perfomed daily, before the first trip.

See Table 11.2 for a list of procedures that shouldbe performed weekly, post-trip.

See Table 11.3 for a list of procedures that shouldbe performed monthly, post-trip.

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

Pretrip and Post-Trip Inspections and Maintenance

11.1

Procedure Performed(check off)

Daily Pretrip Inspections/ChecksProcedureReference

_______ Drain manually drained air reservoirs (that are not equipped with automatic drainvalves) D1

Check _______ windshield washer reservoir fluid D2Inspect _______ wheel seal and hub cap (for leakage) —Check _______ surge tank coolant level D3Inspect _______ radiator and charge air cooler D4Check _______ engine for fuel, oil, or coolant leaks —Inspect _______ engine and chassis wiring D5Inspect _______ air intake system D6Check _______ intake-air restriction indicator mounted on air intake D6Check _______ engine oil level D7Check _______ power steering fluid level —Inspect _______ fuel tank(s), fuel lines, and connections D8Check _______ fuel level D9Check _______ fuel/water separator D10Inspect _______ front and rear suspension components D11Inspect _______ headlights, mirrors, and window glass, and windshield wipers D12Check _______ doors (open without difficulty and close securely) —

_______ Adjust driver’s seat, then align rearview and downview mirrors —Check _______ dash-mounted intake-air restriction indicator D6Check _______ oil- and air-pressure warning systems D13Check _______ ICU fault codes D14Check _______ horn, windshield wipers, and windshield washer D15Check _______ heater, defroster, and optional mirror heat controls D16Check _______ backup alarm —Check _______ panel lights and interior lights D17Check _______ exterior lights and reflectors D18Check _______ tire pressure D19Inspect _______ tire condition D20Inspect _______ rims and wheels D21Check _______ automatic transmission fluid level —Inspect _______ air brake chambers and pushrods D22Inspect _______ air brake lines D23Inspect _______ slack adjusters D24Check _______ air brake system operation D25Inspect _______ frame rails (missing bolts), crossmembers (bent or loose) —

Check _______ mud flaps (aren’t damaged, at least 10 inches above the ground, and bracketsare secure) —

Check _______ exhaust system (mounted securely, connected tightly, no signs of leaks such assoot trails) —

_______ Remove chocks and test service brakes D26

Inspector___________________________________________________ Date ________________

Table 11.1, Daily Pretrip Inspection and Maintenance Checklist


11.2


Weekly Post-Trip Inspections/ChecksProcedureReference

_______ Manually drain air reservoirs that are equipped with automatic drain valves —Inspect _______ batteries and battery cables W1Check _______ wheel bearing lubricant level W2Inspect _______ steering components W3Check _______ serpentine drive belt condition W4Check _______ V-belt tension W5Inspect _______ seat belts and tether belts W6

Inspector___________________________________________________ Date ________________

Table 11.2, Weekly Post-Trip Inspection and Maintenance Checklist


Monthly Post-Trip Inspections/ChecksProcedureReference

_______ Clean the battery terminals M1Inspect _______ radiator hoses and heater hoses M2

Check _______ fluid level in the hydraulic clutch reservoir (if applicable, and if necessary, fill withDOT 4 brake fluid) —

Check _______ steering wheel play M3Check _______ outer surfaces of the hood and body (for visible surface breaks and damage) —Check _______ hood tilt damper (attached at both ends) —Inspect _______ brake lining wear M4Inspect _______ driveshaft —

Inspector___________________________________________________ Date ________________

Table 11.3, Monthly Post-Trip Inspection and Maintenance Checklist

Pretrip and Post-TripMaintenance ProceduresDaily Pretrip Inspection andMaintenanceWhenever equipment requires adjustment, replace-ment, and/or repair, see the Acterra® WorkshopManual for procedures and specifications. Specificreferences to the manual will be found where appro-priate.

1. Drain manually drained air reservoirs.

Water and oil normally enter the air reservoir inthe form of vapor because of the heat generatedduring compression. After the water and oil con-dense, drain the resulting emulsion as follows:

1.1 Open the wet tank valve. The drain cockor pull chain drain is located on the for-ward end of the supply air reservoir, whichis connected directly to the air compres-sor. Block the valve open.

WARNINGWhen draining the air reservoir, do not look intothe air jets or direct them toward anyone. Dirt orsludge particles may be in the airstream andcould cause injury.

1.2 Exhaust the remaining air and moisturefrom the system by opening the draincocks on the bottoms of the remaining airreservoirs. Block the valves open.


11.3

1.3 Water and oil emulsion often form pocketsthat will not drain while compressed air isin the reservoirs. Because of these pock-ets, leave the valves blocked open duringthe first part of the pretrip inspection.

1.4 If the drained water is cloudy or oily, itmay indicate a problem with the compres-sor. If oil is allowed to contaminate the airdryer, it will not remove the water from theair brake system, which could adverselyaffect braking.

2. Check the fluid level in the windshield washerreservoir.

Add washer fluid as needed. Unscrew the cap toadd fluid.

WARNINGWasher fluids may be flammable and poisonous.Do not expose washer fluid to an open flame orany burning material, such as a cigarette. Alwayscomply with the washer fluid manufacturer’s rec-ommended safety precautions.

3. Check the coolant level in the surge tank.

See Fig. 11.1 . If the coolant is low, add a 50/50mixture of water and the type of antifreeze cur-rently installed in your vehicle. Fill the surge tankwith coolant to the MAX line when the tank iscool. If the surge tank was empty, start the en-gine after refilling and check the level againwhen the engine is at operating temperature.

CAUTIONCoolant must be filled to the full line of the surgetank. Low coolant could result in engine over-heating, which could cause engine damage.

4. Inspect the radiator and charge air cooler.

4.1 Inspect the radiator and charge air coolerfor clogged fins. Use compressed air orwater directed from the fan side of thecore to backflush any material restrictingairflow.

4.2 Inspect the radiator and charge air coolerfor damage and accumulated debris.Straighten bent or damaged fins to permitairflow across all areas of the cores.

NOTE: When traveling through areas of highinsect concentration, it may be necessary toclean the exterior of the radiator or thecharge air cooler core as often as every 200miles (320 km).

4.3 On vehicles equipped with air condition-ing, also inspect and clean the condenser.If clogged, the condenser can restrict air-flow through the radiator.

4.4 Check the radiator for leaks. If leaks arefound, have the radiator repaired or re-placed. See Group 20 of the Acterra®

Workshop Manual for instructions, or takethe vehicle to an authorized Sterlingdealer.

5. Inspect the engine and chassis wiring.

Check for loose wiring, chafed insulation, anddamaged or loose hold-down clamps. Tightenloose wires or hold-down clamps; replace dam-aged wiring or clamps.

6. Inspect the air intake system for leaks or dam-age.

CAUTIONFailure to maintain a sealed air intake systemcould allow the entry of dirt and contaminantsinto the engine. This could adversely affect en-gine performance and result in engine damage.

6.1 Check the intake-air restriction indicator.

f500270

1

2

11/14/95

1. Low Coolant Level Sensor2. Fill Cap

Fig. 11.1, Coolant Level Checking


11.4

6.2 Replace the filter element if the yellow sig-nal stays locked at 25 inH2O for Cumminsor Caterpillar engines or 22 inH2O forMercedes-Benz engines. See Group 09 ofthe Acterra® Workshop Manual for filterelement replacement instructions.

NOTE: After replacing the filter element,reset the restriction indicator by pressing therubber reset button.

6.3 Inspect the secondary or safety filter ele-ment in the air cleaner when replacing theprimary element, and replace it whenclogged or dirty. This element should bereplaced with every third primary elementreplacement.

6.4 Check the engine air intake piping fromthe air cleaner to the engine intake. In-spect the piping for loose connections,cracks, torn or collapsed hoses, punc-tures, and other damage. Tighten looseconnections, and have damaged compo-nents replaced. Make sure the piping sys-tem is airtight so that all intake air passesthrough the air cleaner.

7. Check the engine oil level.

If the oil level is at or below the minimum fill (or"add") mark on the dipstick, add enough oil tomaintain the level between the minimum fill (or"add") and the maximum fill (or "full") marks onthe dipstick. See Fig. 11.2 . Engine lube oil musthave a sulfated ash level less than 1.0 wt %;currently referred to as CJ-4 oil. Use the properSAE viscosity rating for the temperature and timeof year.

CAUTIONOperating the engine with the oil level below theminimum fill (or "add") mark or above the maxi-mum fill (or "full") mark could result in enginedamage.

8. Inspect the fuel tanks, fuel lines, and connectionsfor leaks.

8.1 Check that the fuel tanks are secured totheir mounting brackets and that themounting brackets are secured to theframe.

8.2 Replace leaking fuel tanks.

8.3 If lines or connections are leaking, havethem repaired or replaced.

For repair and/or replacement procedures,see Group 47 of the Acterra® WorkshopManual, or take the vehicle in to an autho-rized Sterling dealer.

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

WARNINGNever operate the engine with the fuel tank shut-off valves partly closed. This could damage thefuel pump, causing sudden loss of engine power,possibly resulting in serious personal injury dueto reduced vehicle control.

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

To keep condensation to a minimum, fuel tanksshould be filled at the end of each day. Federalregulations prohibit filling a fuel tank to morethan 95 percent of its liquid capacity.

WARNINGNever fill fuel tanks to more than 95 percent oftheir liquid capacity. This could make them morelikely to rupture from impact, possibly causingfire and resulting in serious personal injury ordeath by burning.

02/09/96 f180038

1

1. Dipstick

Fig. 11.2, Oil Level Checking


11.5

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

IMPORTANT: Use ultralow-sulfur diesel(ULSD) with 15 ppm sulfur content or less,based on ASTM D2622 test procedure. Fail-ure to use ultralow-sulfur diesel fuels mayvoid the warranty on emission components.

9.1 Fuel should always be strained or filteredbefore being put into the tanks. This willlengthen the life of the engine fuel filterand reduce the chances of dirt getting intothe engine.

9.2 Before installing the fuel cap, clean thearea with a rag, or if necessary, clean thecap with solvent.

9.3 If needed, prime the fuel system. Forpriming procedures, see the applicableengine manufacturer’s manual.

10. If equipped with a fuel/water separator, check itfor contaminants.

10.1 With the engine shut down, partially openthe drain valve under the collection bowland drain water and contaminants asneeded.

10.2 Check the fuel/water separator for leaks.

IMPORTANT: When draining fluid from a fuel/water separator, drain the fluid into an appropri-ate container and dispose of it properly. Manystates now issue fines for draining fuel/waterseparators onto the ground. On all types ofseparators, stop draining fluid when you seefuel come out of the separator drain valve.

11. Inspect the front and rear suspension compo-nents, including springs, spring hangers, shocks,and suspension brackets.

11.1 Check for broken spring leaves, looseU-bolts, cracks in the suspensionbrackets, and loose fasteners in the springhangers and shackles.

11.2 Inspect the shock absorbers for loose fas-teners and leaks.

11.3 Tighten all loose fasteners and have anycomponent(s) replaced that are worn,cracked, or otherwise damaged.

11.4 On vehicles with air suspensions, checkfor leaks. Check air suspension compo-nents for cuts and bulges.

12. Clean the windshield, side, and rear windows,then check the condition of the windshield wiperarms and blades.

12.1 Replace the wiper arms if the wiperblades are not tensioned against the wind-shield.

12.2 Replace damaged or deteriorated wiperblades.

WARNINGWhen cleaning windshields and windows, alwaysstand on the ground or on a secure ladder orplatform. Use a long-handled window cleaner. Donot use the cab steps, tires, fenders, fuel tanks,engine, or under-hood components to access thewindshield or windows. Doing so could cause afall and result in an injury.

13. Check the oil- and air-pressure warning systems.

13.1 Check if the warning systems come onwhen the ignition is turned on, and if not,have the systems repaired.

13.2 Start the engine, then check that the oil-and air-pressure warning systems are op-erating. The buzzer should stop soundingwhen the preset minimum is reached. Ifthe air pressure in both systems is abovethe preset minimum when the engine isstarted, test the low air pressure warningsystem by lowering the pressure to belowthis range, or until the warning systemcomes on.

The air pressure in both the primary andsecondary air reservoir systems must beabove 65 psi (448 kPa) on most vehicles.For vehicles with an optional Bendix dryerreservoir module (DRM), the cut-out pres-sure is 130 psi (896 kPa).

14. Check the instrumentation control unit (ICU) forfault codes.


11.6

During the ignition sequence, if an active fault isdetected in any device that is connected to theECU, the message display screen will show theactive fault codes, one after the other, until theparking brake is released or the ignition switch isturned off. See Chapter 2 for detailed operatinginstructions for the ICU.

15. Make sure that the horn, windshield wipers, andwindshield washers are operating properly.These devices must be in good working order forsafe vehicle operation.

15.1 Make sure that the horn works. If a horn isnot working, have it repaired before tripdeparture.

15.2 Check the wiper and washer control onthe multifunction turn signal switch. If thewipers and/or washers are not working,have them repaired before trip departure.

16. During cold weather, make sure the heater, de-froster, and optional mirror heat controls are op-erating properly. If so equipped, turn on the mir-ror heat switch and make sure the system isworking.

17. Check the operation of all the panel lights andinterior lights.

Turn on the headlights, dash lights, and four-wayflashers and leave them on. If any of the gaugebulbs, the dome light bulbs, or the right- and left-turn indicator bulbs are not working, replacethem.

18. Make sure all the exterior lights are workingproperly.

Check that all the lights and reflectors are clean.See Fig. 11.3 .

18.1 Check that the brake lights, taillights,headlights, parking lights, turn signals,marker lights, identification lights, roadlights (if so equipped), and front clearancelights are working properly and are clean.

18.2 Test the high and low beams of the head-lights.

18.3 Replace light bulbs or sealed beam unitsthat are not working.

18.4 Be sure all reflectors and lenses are ingood condition and are clean. Replaceany broken reflectors or lenses.

19. Check tire inflation pressures using an accuratetire pressure gauge.

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

19.1 Be sure valve stem caps are on every tireand that they are screwed on finger-tight.

19.2 Inflate the tires to the applicable pressuresif needed. A weekly pressure loss of 4 psi(28 kPa) or more in a tire may indicatedamage. The tire should be inspectedand, if necessary, repaired or replaced.

19.3 If a tire has been run flat or underinflated,check the wheel for proper lockring andside-ring seating, and possible wheel, rim,or tire damage before adding air.

Moisture inside a tire can result in bodyply separation or a sidewall rupture. Dur-ing tire inflation, compressed air reservoirsand lines must be kept dry. Use well-maintained inline moisture traps and ser-vice them regularly.

11/17/99 f601856

1

1

2

3

4 5 4

1. Headlight2. Turn Signal Light3. Side Marker Light

4. Clearance Light5. Identification Lights

Fig. 11.3, Exterior Light Locations


11.7

WARNINGDo not operate the vehicle with underinflated oroverinflated tires. Incorrect inflation can stressthe tires and make the tires and rims more sus-ceptible to damage, possibly leading to rim ortire failure and loss of vehicle control, resultingin serious personal injury or death.

IMPORTANT: The load and cold inflation pres-sure must not exceed the rim or wheel manu-facturer’s recommendations, even though thetire may be approved for a higher load inflation.Some rims and wheels are stamped with amaximum load and maximum cold inflation rat-ing. If they are not stamped, consult the rim orwheel manufacturer for the correct tire inflationpressure for the vehicle load. If the load ex-ceeds the maximum rim or wheel capacity, theload must be adjusted or reduced.

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

20.1 Check the tire tread depth. If tread is lessthan 4/32 inch (3 mm) on any front tire, orless than 2/32 inch (1.5 mm) on any reartire, replace the tire.

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

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

21. Check the wheel nuts or rim nuts for indicationsof looseness. Examine each rim and wheel com-ponent.

21.1 Remove all dirt and foreign material fromthe assembly. Dirt or rust streaks from thestud holes, metal buildup around studholes, or out-of-round or worn stud holesmay be caused by loose wheel nuts. SeeFig. 11.4 and Fig. 11.5 .

21.2 Examine the rim and wheel assemblycomponents (including rims, rings, flanges,studs, and nuts) for cracks, or other dam-age.

See Group 33 or Group 35 of theActerra® Workshop Manual for serviceprocedures on the studs and hubs, andsee Group 40 in the same manual forwheel and tire servicing, or take the ve-hicle to an authorized Sterling dealer.

WARNINGHave any worn or damaged wheel componentsreplaced by a qualified person using the wheelmanufacturer’s instructions and the wheel indus-try’s standard safety precautions and equipment.Otherwise a vehicle or workshop accident couldoccur, possibly resulting in serious personal in-jury or death.

21.3 Have broken, cracked, badly worn, bent,rusty, or sprung rings and rims replaced.Be sure that the rim base, lockring, andside ring are matched according to sizeand type.

21.4 Make sure all wheel nuts are tightened450 to 500 lbf·ft (610 to 678 N·m) for Ac-curide wheels with unlubricated threads.Use the tightening pattern in Fig. 11.6 for10-hole wheels and the tightening patternin Fig. 11.7 for 8-hole wheels. See Group40 of the Acterra® Workshop Manual formore information.

02/09/95 f400058

Fig. 11.4, Dirt and Rust Streaks from the Stud Holes


11.8

CAUTIONInsufficient wheel nut torque can cause wheelshimmy, resulting in wheel damage, stud break-age, and extreme tire tread wear. Excessivewheel nut torque can break studs, damagethreads, and crack discs in the stud hole area.Use the recommended torque values and followthe proper tightening sequence.

NOTE: Vehicles operating under severe or ad-verse conditions should be checked more fre-quently.

22. Inspect the air brake chamber and the air brakechamber pushrods.

WARNINGDo not operate the vehicle with the front brakesbacked off or disconnected. Backing off or dis-connecting the front brakes will not improve ve-hicle handling and may lead to loss of vehiclecontrol resulting in property damage or personalinjury.

22.1 Check that the air brake chamber ismounted securely on its mounting bracket,and that there are no loose or missingbolts.

02/09/95 f400001

Fig. 11.5, Worn Stud Holes

1

2

3

45

6

7

8

9

10

f400081a08/23/93

Fig. 11.6, Tightening Pattern, 10-Hole Wheels

f400052a

1 2

3

4

5 6

7

8

A

08/20/93

Fig. 11.7, Tightening Pattern, 8-Hole Wheels


11.9

22.2 Look for worn clevis pins on brake cham-ber pushrods and missing or damagedcotter pins on brake chamber pushrod cle-vis pins. Replace worn clevis pins and in-stall new cotter pins if necessary.

22.3 See if the chamber piston rod is in linewith the slack adjuster. Misalignment cancause the piston rod to rub on the non-pressure chamber and cause a draggingbrake. See Group 42 of the Acterra®

Workshop Manual.

CAUTIONIf the external breather tube or breather cap ismissing or incorrectly installed, road dirt and de-bris can adversely affect the operation of thebrake chamber. Once inside of the chamber, dirtand debris can cause the internal parts of thechamber to deteriorate faster.

22.4 Inspect the exterior surfaces of the cham-ber for damage. Make sure that breatherholes in the non-pressure section(s) areopen and free of debris. See Group 42 ofthe Acterra® Workshop Manual to replaceany damaged parts.

DANGERDo not loosen or remove the parking brake clampring for any purpose. The parking/emergencybrake section of the brake chamber is not in-tended to be serviced. Serious injury or deathmay result from sudden release of the powerspring.

22.5 On all parking brake installations, makesure the end cover cap or dust plug is se-curely snapped into place. See Fig. 11.8 .

NOTE: On most MGM parking brake cham-bers equipped with an integral release bolt,an end cover cap is installed over the re-lease bolt.

22.6 Check for rusted connections, missingsnap rings, and damaged camshaftgrease seals. Have damaged or missingparts repaired or replaced.

23. Inspect the air brake lines.

23.1 Check the clearance between the hosesand the exhaust manifold or other hotspots. Excessive heat will cause materialin the hoses to deteriorate rapidly or be-come brittle. Provide at least 6 inches(150 mm) of clearance. More clearance isrecommended if the hose is located abovethe heat source.

23.2 Check for kinks, dents, or swelling of thehoses. If damaged, have the hose re-placed with the same size and type.

NOTE: Do not route the hose on top of any-thing likely to be stepped on.

23.3 Check for damage to hoses located nearmoving parts, such as drivelines, kingpins,suspensions, and axles. If moving partsare catching or pinching the lines, correctas needed.

23.4 Check for hose damage caused by abra-sion. If abraded, have the hose replaced.Check for the cause of abrasion, such asloose or damaged hose clamps. Have theclamps repaired or replaced as needed.

1

A

02/22/2000 f421352

A. Do not remove this clamp ring.1. MGM TR–T (TR Series) Brake Chamber shown

Fig. 11.8, Parking Brake Chamber Clamp


11.10

23.5 Observe the hose cover condition, espe-cially hoses exposed to water splash andice. If dried out or ragged (the wire or lineris showing through the cover), have thehose(s) replaced.

23.6 Inspect the air tubing, especially tubingmade of nylon. In cold weather, nylon tub-ing is sensitive to damage, such as nicksor cuts. Have nicked or cut tubing re-placed, even if it is not leaking.

23.7 Check for kinked or twisted hoses. Aseven-percent twist in the hose can re-duce its life by up to 90 percent. A twistedhose under pressure tends to untwist,which may loosen the fitting. Reconnecthoses that are twisted.

NOTE: The front brake lines flex continu-ously in vehicle operation, so they requirespecial examination. Give particular attentionto the areas near where they connect to thefront air brake chambers. This inspectionrequires two people, one in the driver seatand another to inspect the brake line con-nections at the wheels.

23.8 Both wheel air lines must be inspectedwith the emergency brake set, engineidling, air pressure at 80 to 90 psi (550 to620 kPa), and the brake pedal held down.

23.9 Turn the wheels to full lock in one direc-tion and inspect both air lines where theyconnect to the air chambers, then turn thewheels to full lock in the other directionand inspect both lines. If a hose is leak-ing, have it replaced.

IMPORTANT: ABS-equipped vehicles operat-ing in regions where especially corrosive iceremoval chemicals are used may experiencehigher than normal rotor corrosion. Tonerings should be routinely inspected for corro-sion. Severe corrosion of the integral ABStone ring may cause the ABS warning lampin the dash to illuminate due to false wheelspeed readings. If the ABS warning lampilluminates at any time other than at vehiclestart-up, have the problem repaired immedi-ately.

24. Inspect the slack adjusters.

24.1 Meritor Slack Adjusters: Check the bootfor cuts, tears, or other damage. Have itreplaced if necessary.

24.2 Gunite Slack Adjusters: Inspect the slackadjuster for any signs of damage. If dam-aged, have the slack adjuster replaced.

Inspect the slack adjuster boot for cuts ortears. If the boot is damaged, have it re-placed. See Fig. 11.9 .

24.3 Haldex Slack Adjusters: Inspect eachslack adjuster and anchor strap for dam-age. See Fig. 11.10 . Have any damagedcomponents replaced.

25. Check the air brake system for proper operation.

25.1 Check the air governor cut-in and cut-outpressures as follows.

Run the engine at fast idle. The air gover-nor should cut out the air compressor atapproximately 120 psi (827 kPa). With theengine idling, apply the brake pedal sev-eral times. The air governor should cut inthe air compressor at approximately 100psi (689 kPa). If the air governor does not

f42139806/17/2003

1

2

3

4 5

6

78

10

9

1. 7/16-inch AdjustingNut

2. Grease Fitting3. Boot4. Link5. Brake Chamber Piston

Rod

6. Clevis7. 1/2-inch Clevis Pin8. 1/4-inch Clevis Pin9. Grease Relief

Opening10. Slack Adjuster Spline

Fig. 11.9, Gunite Automatic Slack Adjuster


11.11

cut in and out as described above, it mustbe adjusted to these specifications. If theair governor cannot be adjusted or re-paired, replace it before operating the ve-hicle.

25.2 Check the air pressure buildup time asfollows.

With the air system fully charged to 120psi (827 kPa), make one full brake appli-cation and note the air pressure readingon the gauge. Continue to reduce the airpressure by moderate brake applicationsto a maximum of 90 psi (620 kPa), thenrun the engine at governed rpm. If thetime required to raise the air pressure to120 psi (827 kPa) (from the pressurenoted after one brake application) is morethan 30 seconds, eliminate any leaks orreplace the air compressor before operat-ing the vehicle.

25.3 Check the air pressure reserve as follows.

With the air system fully charged to 120psi (827 kPa), stop the engine and notethe air pressure. Then make one full brakeapplication and observe the pressuredrop. If it drops more than 25 psi (172kPa), all areas of leakage must be elimi-nated before operating the vehicle.

25.4 Check the air leakage in the system asfollows.

With the parking brake (spring brake) ap-plied, the transmission out of gear, andthe tires chocked, charge the air systemuntil cut-out pressure of 120 psi (827 kPa)is reached.

With the service brakes released, shutdown the engine, wait 1 minute and notethe air pressure gauge reading. Observethe air pressure drop in psi (kPa) perminute.

Charge the air system until cut-out pres-sure of 120 psi (827 kPa) is reached. Withthe parking brakes released and the ser-vice brake applied, shut down the engine,wait 1 minute and note the air pressuregauge reading. Observe the air pressuredrop in psi (kPa) per minute.

If leakage exceeds the limits shown inTable 11.4 , repair all areas of leakage be-fore driving the vehicle.

Maximum Allowable Service Brake Air Leakage

DescriptionAir Leakage in psi(kPa) Per Minute

Released AppliedTruck or Tractor Only 2 (14) 3 (21)Truck or Tractor w/Single Trailer 3 (21) 4 (28)Truck or Tractor w/Two Trailers 5 (35) 6 (42)

Table 11.4, Maximum Allowable Service Brake AirLeakage

26. Test the service brakes.

When starting to move the vehicle and beforepicking up speed, test the brakes with the footpedal and parking brake control valve (yellowknob) to be sure they will bring the vehicle to asafe stop.

10/11/2005 f421397

1

2

3

4

5

6

7

8 9

A

A. Rotate the control arm toward the brake chamberuntil you can feel it contacting the internal stop.

1. Clevis2. Slack Adjuster3. Clevis Pin4. Manual Adjusting Nut5. Control Arm

6. Control-Arm Washersand Nut

7. Anchor Strap Slot8. Anchor Strap9. Brake Chamber

Fig. 11.10, Haldex Automatic Slack Adjuster


11.12

Weekly Post-Trip Inspection andMaintenance

WARNINGBattery posts, terminals, and related accessoriescontain lead and lead compounds, chemicalsknown to the State of California to cause cancerand reproductive harm. To prevent possible per-sonal injury, always wash your hands after han-dling battery parts and related accessories.

1. Inspect the batteries and battery cables.

1.1 Access the batteries. Be sure the batteryhold-down is secure. If it is loose, tightenthe hold-down bolts; if it is broken, replaceit.

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

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

If the sight glass is clear, the battery has alow level of electrolyte and must be re-placed.

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

If needed, fill the hubs to the level indicated onthe hub cap. See Group 35 of the Acterra® Main-tenance Manual, for recommended lubricants.

IMPORTANT: Before removing the fill plug, al-ways clean the hub cap and plug.

3. Examine the steering components.

See Fig. 11.11 . If repairs are needed, see Group46 of the Acterra® Workshop Manual for instruc-tions, or take the vehicle to an authorized Ster-ling dealer.

3.1 Check the mounting bolts and pitman armnut for tightness.

3.2 Check the drag link nuts for missing cotterpins.

3.3 Inspect the steering drive shaft and steer-ing linkage for excessive looseness, orother damage.

3.4 Tighten loose nuts and have damagedparts replaced as needed.

4. Check the condition of the serpentine drive belt.

Look for signs of glazing, wear (frayed edges),damage (breaks or cracks), or oil contamination.If a belt is glazed, worn, damaged, or oil soaked,have the belt replaced, following the instructionsin Group 01 of the Acterra® Workshop Manual.

5. Check the drive belt for proper tension.

Use your index finger to apply force at the centerof the belt free-span. See Fig. 11.12 . There is noadjustment for belt tension on engines with auto-matic belt tensioners. If there is not proper ten-sion, have the belt tensioner replaced. SeeGroup 01 of the Acterra® Workshop Manual forinstructions, or take the vehicle to an authorizedSterling dealer.

6. Inspect the seat belts and tether belts.

WARNINGInspect and maintain seat belts as instructedbelow. Worn or damaged seat belts could fail

10/11/2001 f461916

1

1

1

2

3

3

1. Steering Gear Mounting Bolt2. Pitman Arm Pinch Bolt Nut3. Drag Link Nut

Fig. 11.11, Steering Gear Fasteners


11.13

during a sudden stop or crash, possibly resultingin serious injury or death.

IMPORTANT: Seat belts have a finite lifewhich may be much shorter than the life ofthe vehicle. Regular inspections and re-placement as needed are the only assur-ance of adequate seat belt security over thelife of the vehicle.

NOTE: When any part of a seat belt needsreplacement, the entire seat belt must bereplaced, both retractor and buckle side.

6.1 Check the web for fraying, cuts, or ex-treme wear, especially near the bucklelatch plate and in the D-loop guide area.

6.2 Check the web for extreme dirt or dustand for severe fading from exposure tosunlight.

6.3 Check the buckle and latch for operationand for wear or damage.

6.4 Check the Komfort Latch for function andcracks or other damage.

6.5 Check the web retractor for function anddamage.

6.6 Check the mounting bolts for tightnessand tighten any that are loose.

Monthly Post-Trip Inspection andMaintenance

WARNINGBattery posts, terminals, and related accessoriescontain lead and lead compounds, chemicalsknown to the State of California to cause cancerand reproductive harm. To prevent possible per-sonal injury, always wash your hands after han-dling battery parts and related accessories.

1. Clean the batteries.

1.1 Remove any corrosion from the hold-downand the top of the battery.

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

1.2 Use a soda solution to neutralize the acidpresent, then rinse off the soda solutionwith clean water.

1.3 If the battery posts or cable terminals arecorroded, disconnect the terminals fromthe posts. Clean them with a soda solutionand a wire brush. After cleaning, connectthe terminals to the battery posts, thenapply a thin coat of petroleum jelly to theposts and terminals to help retard corro-sion.

2. Inspect the radiator and heater hoses, includingthe clamps and support brackets.

2.1 Make sure the radiator inlet and outlethoses are pliable and are not cracking orballooning. Replace hoses that show signsof cracking, weakening, or ballooning.

2.2 Make sure the heater hoses are pliableand are not cracking or ballooning. Re-place hoses that show signs of cracking,weakening, or ballooning.

2.3 Tighten hose clamps as necessary, but donot overtighten, as hose life can be ad-versely affected.

10/31/94 f200036a

A

B

A. Deflection B. Belt Free-Span

Fig. 11.12, Checking Belt Tension


11.14

2.4 Be sure the hose support brackets aresecurely fastened. Make sure the hosesare not located near sources of wear,abrasion, or high heat.

IMPORTANT: Replace all hoses, includingheater hoses, at the same time. Service-typeknitted or braided yarn-reinforced neoprenehose is acceptable. Silicone hoses having anextended service life can be substituted for thereinforced neoprene type. See the FreightlinerService Parts Catalog or contact your SterlingDealer.

3. Check the steering wheel for excessive play.

3.1 Start the engine. With the front tiresstraight ahead, turn the steering wheeluntil motion is observed at the frontwheels.

3.2 Align a reference mark on a ruler, thenslowly turn the steering wheel in the oppo-site direction until motion is again detectedat the wheels.

3.3 Check the lash (free play) at the rim of thesteering wheel. See local/federal regula-tions for acceptable ranges of lash.

If there is excessive lash, check the steer-ing system for wear or incorrect adjust-ment of the linkage and steering gear be-fore operating the vehicle.

4. Check the brake lining wear on all vehicles, in-cluding those with automatic slack adjusters.Proper brake operation is dependent on periodicmaintenance and inspection of the brake linings.

4.1 Check that brake linings are free of oil andgrease.

4.2 Inspect the thickness of the brake linings.If the axle assembly is equipped with adust shield or backing plate, remove theinspection plugs. If any brake linings areworn to less than approximately 1/4 inch(6.4 mm) at the thinnest point, have thelinings replaced on all brake assemblieson that axle. See Group 42 of theActerra® Workshop Manual for lining re-placement instructions and camshaft end-play inspection.

4.3 Check the brake drums for wear andcracks.

4.4 Check that the inspection plugs in the dustshields or backing plates, if so equipped,are installed.


11.15

12

Cab AppearanceCab Washing and Polishing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12.1Care of Fiberglass Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12.1Care of Chrome Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12.1Dashboard Care . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12.1Vinyl Upholstery Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12.1Velour Upholstery Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12.2

Cab Washing and PolishingTo protect the finish of your new vehicle, follow theseguidelines carefully:

• During the first 30 days, rinse your vehicle fre-quently with water. If the vehicle is dirty, use amild liquid soap. Do not use detergent.

• During the first 30 days, do not use anythingabrasive on your vehicle. Brushes, chemicals,and cleaners may scratch the finish.

• During the first 120 days, do not wax yourvehicle.

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

• Avoid washing your vehicle in the hot sun. Al-ways use water. After the cab is completelywashed, dry it with a towel or chamois.

• Do not dust painted surfaces with a dry cloth,as this will scratch the paint.

• Do not remove ice or snow from a painted sur-face with a scraper of any sort.

• To prevent damage to the finish, wax it regu-larly. If the finish has become dull, before wax-ing, remove oxidized paint using a cleaner spe-cifically designed for this purpose. Remove allroad tar and tree sap before waxing. Sterlingrecommends that a quality brand of cleaner orcleaner-polish and polishing wax be used.

• Do not let diesel fuel or antifreeze stand on apainted surface. If either should occur, rinsethe surface off with water.

• To prevent rust, have any nicks or other dam-age on the finish touched up as soon as pos-sible.

• Park your vehicle in a sheltered area wheneverpossible.

Care of Fiberglass PartsWash unpainted fiberglass air fairings and shieldsmonthly with a mild detergent, such as dishwashingliquid. Avoid strong alkaline cleansers.

Apply a wax specifically designed for fiberglass.

Care of Chrome PartsTo prevent rust, keep chrome parts clean and pro-tected at all times. This is especially important duringwinter driving and in coastal areas where there isexposure to salt air.

When cleaning chrome parts, use clean water and asoft cloth or sponge. A mild detergent may also beused.

Sponge gently, then rinse. If necessary, use a non-abrasive chrome cleaner to remove stubborn rust orother material. Do not use steel wool.

To help protect the chrome after cleaning, apply acoat of polishing wax to the surface. Never use waxon parts that are exposed to high heat, such as ex-haust pipes.

Dashboard CarePeriodically wipe the dashboard with a water-dampened cloth. A mild detergent can be used, butavoid using strong detergents.

CAUTIONDo not use Armor-All Protectant ®, STP Son-of-a-Gun®, or other equivalent treatments. Thesecleaners contain vinyl plasticizers that can causestress crazing in the interior plastic panels,which can result in cracking of the panels.

Vinyl Upholstery CleaningTo prevent soiling, frequent vacuuming or light brush-ing to remove dust and dirt is recommended. Harshcleaning agents can cause permanent damage tovinyl upholstery. To preserve the upholstery and pre-vent damage, carefully review the following sectionsfor recommended cleaning procedures. Waxing orrefinishing improves soil resistance and cleanabilityfor all vinyls. Any hard wax, such as that used onautomobiles, may be used.

Ordinary DirtWash the upholstery with warm water and mild soap,such as saddle or oil soap. Apply soapy water to alarge area and allow to soak for a few minutes, thenrub briskly with a cloth to remove the dirt. This canbe repeated several times as necessary.

Cab Appearance

12.1

If dirt is deeply imbedded, use a soft bristle brushafter applying the soap.

If dirt is extremely difficult to remove, wall-washingpreparations normally found around the home can beused. Powdered cleaners, such as those used forsinks and tiles, are abrasive and must be used withcaution as they can scratch the vinyl or give it a per-manent dull appearance.

Chewing GumHarden the gum with an ice cube wrapped in a plas-tic bag, then scrape it off with a dull knife. Any re-maining traces of gum can be removed with an all-purpose light oil (peanut butter will also work) andwiped off.

Tars, Asphalts, and CreosoteTars, asphalts, and creosote stain vinyl after pro-longed contact. They should be wiped off immedi-ately and the area carefully cleaned, using a clothdampened with naphtha.

Paint, Shoe Heel MarksPaint should be removed immediately. Do not usepaint remover or liquid-type brush cleaner on vinyl.An unprinted cloth, dampened with naphtha or tur-pentine may be used. Use care to prevent contactwith parts of the upholstery that are not vinyl.

Sulfide StainsSulfide compounds, such as those found in eggs andsome canned goods, can stain after prolonged con-tact with vinyl. These stains can be removed by plac-ing a clean, unprinted piece of cloth over the spottedarea and pouring a liberal amount of 6 percent hy-drogen peroxide onto the cloth. Allow the saturatedcloth to remain on the spot for 30 to 60 minutes. Forstubborn spots, allow the hydrogen-peroxide satu-rated cloth to remain on the area overnight. Use cau-tion to prevent the solution from seeping into theseams or it will weaken the cotton thread.

Nail Polish and Nail Polish RemoverProlonged contact with these substances causes per-manent damage to vinyl. Careful blotting immediatelyafter contact minimizes damage. Do not spread theliquid during removal.

Shoe PolishMost shoe polishes contain dyes which penetratevinyl and stain it permanently. Shoe polish should bewiped off as quickly as possible using naphtha orlighter fluid. If staining occurs, try the procedure usedfor sulfide stains.

Ball Point InkBall point ink can sometimes be removed if rubbedimmediately with a damp cloth, using water or rub-bing alcohol. If this does not work, try the procedureused for sulfide stains.

MiscellaneousIf stains do not respond to any of the treatments de-scribed above, it is sometimes helpful to expose thevinyl to direct sunlight for up to 30 hours. Mustard,ball point ink, certain shoe polishes, and dyes oftenbleach out in direct sunlight leaving the vinyl undam-aged.

Velour Upholstery CleaningTo prevent soiling, frequent vacuuming or light brush-ing to remove dust and dirt is recommended. Spotclean with a mild solvent or an upholstery shampoo,or the foam from a mild detergent. When using a sol-vent or a dry-cleaning product, follow the instructionscarefully and clean only in a well-ventilated area.Avoid any product that contains carbon tetrachlorideor other toxic materials. With either method, pretest asmall area before proceeding. Use a professionalupholstery cleaning service when extensive cleaningis needed.

Grease and Oil-Based StainsDampen a small absorbent cloth with dry-cleaningsolvent or spot remover. Apply the cloth carefully tothe spot from the outer edge to the center. Pat andblot the spot with a clean, dry cloth. Repeat severaltimes, as necessary, turning the cloths so that thestain does not redeposit on the fabric.

Sugar and Water-Based StainsApply water-based detergent or cleaner, working incircular motions. Pat and blot as dry as possible. Re-peat if necessary before drying thoroughly.

Cab Appearance

12.2

Chewing Gum or WaxHarden the gum or wax with an ice cube wrapped ina plastic bag, then scrape it off with a dull knife. Ex-cess wax can be absorbed by placing a thick whiteblotter over the wax and heating with a warm (nothot) iron. Remove the remainder by using the proce-dure for grease and oil-based stains.

MildewBrush the dry fabric with a soft brush. Sponge withdetergent, and blot. If the fabric is colorfast, dilute ateaspoon of bleach in one quart (one liter) of coolwater. Apply with a swab, directly on the mildewstain. Dab repeatedly with clear, cool water, and blotdry.

Cab Appearance

12.3

13

In an EmergencyHazard Warning Lights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13.1Fire Extinguisher . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13.1Emergency Kit, Optional . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13.1Emergency Starting With Jumper Cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13.1Towing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13.2Fire in the Cab . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13.4

Hazard Warning LightsThe hazard warning lights switch is located either onthe turn signal lever or on top of the steering column.Press the switch to turn on the hazard warning lights.Press the switch again to turn off the hazard warninglights.

Fire ExtinguisherA fire extinguisher is located in the cab by the driv-er’s door.

Emergency Kit, OptionalAn optional emergency kit is located in the cab. Thekit includes one or more of the following: a first aidkit, a reflective vest, a triangular reflector, and a flarekit.

If there is an emergency while driving, cautiously pulloff the road. Turn on the hazard warning lights. Placethe flares and reflector along the side of the road toalert other drivers that an emergency situation exists.

WARNINGUse extreme care when placing flares in emer-gency situations that involve exposure to flam-mable substances such as fuel. An explosion orfire could occur causing serious personal injury.

Emergency Starting WithJumper CablesWhen using jumper cables, use the following instruc-tions.

WARNINGBatteries release explosive gas. Do not smokewhen working around batteries. Put out all flamesand remove all sources of sparks or intense heatin the vicinity of the battery. Do not allow the ve-hicles to touch each other. Do not lean over thebatteries when making connections, and keep allother persons away from the batteries. Failure tofollow these precautions could lead to severepersonal injury as a result of an explosion oracid burns.

CAUTIONMake sure both starting systems have the samevoltage outputs, and avoid making sparks. Other-wise the vehicle charging systems could be se-verely damaged. Also, do not attempt to chargeisolated, deep-cycle batteries with jumper cables.Follow the battery manufacturer’s instructionswhen charging deep-cycle batteries.

On vehicles equipped with optional jump-start posts,attach the positive cable clamp to the positive postinstead of to the battery, and attach the negativecable clamp to the negative post.

CAUTIONConnecting the jumper cables to the vehicleframe rail or to the engine block can cause se-vere damage to the engine wiring.

On vehicles without jump-start posts, the positivecable clamp can be attached to the starter positivelug terminal.

1. Apply the parking brakes and turn off the lightsand all other electrical loads.

2. Connect an end of one jumper cable to the posi-tive terminal of the booster battery (or jump-startpost if equipped) and connect the other end ofthe cable to the positive terminal of the dis-charged battery (or jump-start post if equipped).

WARNINGDo the next step exactly as instructed and do notallow the clamps of one cable to touch theclamps of the other cable. Otherwise, a sparkcould occur near a battery, possibly resulting insevere personal injury from explosion and acidburns.

3. Connect one end of the second jumper cable tothe negative terminal of the booster battery andconnect the other end to the negative jump-startpost or the starter ground lug. The starter groundlug (Fig. 13.1 ) is the best location. Do not usethe frame rail or the engine block as a ground.

NOTE: It may be easier to access the starterground lug by routing the jumper cable under-neath the vehicle. If the starter ground lug is not

In an Emergency

13.1

accessible, connect to the negative battery postof the discharged battery.

WARNINGOn vehicles with Mercedes-Benz AGS transmis-sions, make sure the current gear indicator dis-plays "N" before starting the vehicle. If the trans-mision starts in gear, it could cause an accidentresulting in death, serious personal injury, orproperty damage.

4. Start the engine of the vehicle with the boosterbatteries and let the engine run a few minutes tocharge the batteries of the other vehicle.

5. Attempt to start the engine of the vehicle with thebatteries receiving the charge. Do not operatethe starter longer than 30 seconds, and wait atleast two minutes between starting attempts toallow the starter to cool.

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

WARNINGDo the next step exactly as instructed and do notallow the clamps of one cable to touch theclamps of the other cable. Otherwise, a sparkcould occur near a battery, possibly resulting in

severe personal injury from explosion and acidburns.

7. Disconnect the grounded cable from the vehicle,then disconnect the other end of the cable fromthe negative terminal of the booster battery.

8. Disconnect the remaining cable from the newlycharged battery or jump-start post first, then dis-connect the other end.

TowingWhen it is necessary to tow the vehicle, make surethe instructions below are closely followed to preventdamage to the vehicle.

WARNINGDo not tow an unbraked vehicle if the combinedweight of both vehicles is more than the sum ofthe gross axle weight ratings (GAWR) of the tow-ing vehicle. Otherwise brake capacity will be in-adequate, which could result in personal injury ordeath.

Front Towing Hookup1. Disconnect the battery ground cables.

CAUTIONFailure to remove the axle shafts when towingthe vehicle with the rear wheels on the groundcould result in damage to the transmission andother parts.

2. Remove both drive axle shafts. On dual driveaxles, if the vehicle is to be lifted and towed, re-move only the rearmost drive axle shafts.

On vehicles equipped with an air fairing, removeboth the forward and rearmost drive axle shafts ifthere is insufficient towing clearance.

3. Cover the ends of the hubs with metal plates orplywood cut to fit the axle opening, and drilled tofit the axle shaft studs. This prevents lubricantfrom leaking out and will keep contaminants fromgetting into and damaging the wheel bearingsand axle lubricant.

1

2

3

01/06/99 f150965

4

1. Starter Motor2. Solenoid3. Solenoid Positive Lug Terminal4. Ground Lug

Fig. 13.1, Delco Remy 42-MT Starter

In an Emergency

13.2

CAUTIONFailure to protect the frame rails from the chainscould cause damage, leading to eventual framefailure.

4. On dual drive axles, if the vehicle is to be liftedand towed, chain the forward rear-axle assemblyto the vehicle frame. Use protection to keep thechains from damaging the frame.

5. Remove the bumper extension and chromebumper if equipped. Remove the bumper fairingif equipped.

6. On vehicles equipped with an air fairing, adjustthe trim tab to the lowest position.

CAUTIONDo not pass a sling (for example, a rope or chain)from one tow hook to another to fasten for tow-ing (see Fig. 13.2). Known as reeving, this prac-tice is not permissible in most industrial applica-tions of towing and hoisting. Reeving canoverload the hooks and result in damage to thevehicle.

7. Attach the towing device. Due to the many vari-ables that exist in towing, positioning the liftingand towing device is the sole responsibility of thetowing-vehicle operator.

8. On vehicles equipped with an air fairing, mea-sure the distance from the ground to the bumper,or from the ground to a frame bracket.

9. Lift the vehicle and secure the safety chains. Ifextra towing clearance is needed, remove thefront wheels.

WARNINGFailure to lower the vehicle could result in the airfairing striking an overhead obstruction, such asa bridge or overpass, and causing vehicle dam-age or personal injury.

10. On vehicles equipped with an air fairing, repeatthe measurement taken in step 8. The differencebetween the two measurements must not exceed14 inches (36 cm). If necessary, lower the ve-hicle.

11. Connect the clearance lights, taillights, and sig-nal lights. Connect any special towing lights re-quired by local regulations.

WARNINGFailure to chock the tires or connect the towtruck’s air brake system before releasing thespring parking brakes could allow the disabledvehicle to suddenly roll. This could cause prop-erty damage or personal injury.

12. Chock the tires on the disabled vehicle and con-nect the towing vehicle’s air brake system to thevehicle being towed. Then, release the springparking brakes and remove the chocks.

Rear Towing Hookup

CAUTIONUsing a rear towing hookup on a vehicleequipped with a roof fairing could cause damageto the cab structure.

1. Place the front tires straight forward and securethe steering wheel in this position.

2. Disconnect the battery ground cables.

CAUTIONFailure to protect the frame rails from the chainscould cause damage, leading to eventual framefailure.

3. On dual drive axles, using protection to keep thechains from damaging the vehicle frame, chainthe forward-rear drive axle to the frame.

4. Attach the towing device. Due to the many vari-ables that exist in towing, positioning the liftingand towing device is the sole responsibility of thetowing-vehicle operator.

5. Lift the vehicle and secure the safety chains. Ifextra clearance is needed, remove the bumperextension if equipped.

6. Connect the clearance lights, taillights, and sig-nal lights. Also connect any special towing lightsrequired by local regulations.

In an Emergency

13.3

Fire in the CabThe incidence of fire in medium-duty trucks is rare,according to data from the National Highway TrafficSafety Administration. Federal Motor Vehicle SafetyStandard #302 limits the flammability of specifiedmaterials used inside the cab, but despite this, mostmaterials will burn. The cab of this vehicle containsurethane foam, which is of concern in this respect.

WARNINGUrethane foam is flammable! Do not allow anyflames, sparks, or other heat sources such ascigarettes or light bulbs to contact urethanefoam. Urethane foam in contact with such heatsources could cause a serious, rapid fire, whichcould result in death, severe burns, or gas poi-soning, as well as damage to the vehicle.

In Case of a Cab FireAs quickly as possible, bring the vehicle to a safestop, apply the parking brake, turn off the ignition,and get out of the vehicle.

f88069401/11/2006

OK

OK

1

12

IMPORTANT: Do not reeve when towing.

1. Tow Hook 2. Chain

Fig. 13.2, Reeving

In an Emergency

13.4

Subject Page

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

Automatic Slack Adjusters . . . . . . . . . . . . . . . . . 6.5General Information . . . . . . . . . . . . . . . . . . . . . 6.1Meritor™ WABCO® Antilock

Braking System (ABS), AirBrake Systems . . . . . . . . . . . . . . . . . . . . . . . 6.3

Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.2Air Conditioning, Optional . . . . . . . . . . . . . . . . . . . 4.2Allison AT/MT Series

Transmissions . . . . . . . . . . . . . . . . . . . . . . . . . 8.22Allison AT 500 Series . . . . . . . . . . . . . . . . . . . 8.22Allison MT 600 Models . . . . . . . . . . . . . . . . . . 8.23

Allison MD SeriesTransmissions . . . . . . . . . . . . . . . . . . . . . . . . . 8.19Operating Instructions, MD

Series . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.19Safety Precautions . . . . . . . . . . . . . . . . . . . . . 8.19

Allison On-HighwayTransmissions . . . . . . . . . . . . . . . . . . . . . . . . . 8.16Operating Instructions, On-

Highway Transmissions . . . . . . . . . . . . . . . . 8.17Range Inhibit Indicator, 2000

and 2400 Series . . . . . . . . . . . . . . . . . . . . . 8.17Safety Precautions, On-

Highway Transmissions . . . . . . . . . . . . . . . . 8.16

BBack-of-Cab Grab Handles,

Steps, and Deck Plate . . . . . . . . . . . . . . . . . . . . 3.4Accessing Back-of-Cab Area . . . . . . . . . . . . . . . 3.5Exiting the Back-of-Cab Area . . . . . . . . . . . . . . . 3.5

CCab Door Locks and Handles . . . . . . . . . . . . . . . . 3.1Cab Entry and Exit . . . . . . . . . . . . . . . . . . . . . . . . 3.2

Entering the Driver’s SideWhen There are Two CabAccess Steps . . . . . . . . . . . . . . . . . . . . . . . . 3.2

Entering the Driver’s SideWhen There is One CabAccess Step . . . . . . . . . . . . . . . . . . . . . . . . . 3.3

Entering the Passenger’sSide When There are TwoCab Access Steps . . . . . . . . . . . . . . . . . . . . . 3.3

Entering the Passenger’sSide When There is OneCab Access Step . . . . . . . . . . . . . . . . . . . . . . 3.3

Exiting the Driver’s SideWhen There are Two CabAccess Steps . . . . . . . . . . . . . . . . . . . . . . . . 3.2

Subject Page

Exiting the Driver’s SideWhen There is One CabAccess Step . . . . . . . . . . . . . . . . . . . . . . . . . 3.3

Exiting the Passenger’s SideWhen There are Two CabAccess Steps . . . . . . . . . . . . . . . . . . . . . . . . 3.3

Exiting the Passenger’s SideWhen There is One CabAccess Step . . . . . . . . . . . . . . . . . . . . . . . . . 3.4

Cab Washing and Polishing . . . . . . . . . . . . . . . . . 12.1Canadian Motor Vehicle Safety

Standard (CMVSS) Labels . . . . . . . . . . . . . . . . . 1.2Care of Chrome Parts . . . . . . . . . . . . . . . . . . . . . 12.1Care of Fiberglass Parts . . . . . . . . . . . . . . . . . . . 12.1Clutches . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.15

Clutch Adjustments . . . . . . . . . . . . . . . . . . . . . 7.17Clutch Operation . . . . . . . . . . . . . . . . . . . . . . 7.16General Information . . . . . . . . . . . . . . . . . . . . 7.15Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . 7.17

Cold-Weather Operation . . . . . . . . . . . . . . . . . . . . 7.9Caterpillar . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.10Cummins . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.10Mercedes-Benz . . . . . . . . . . . . . . . . . . . . . . . . 7.9

Cold-Weather Starting . . . . . . . . . . . . . . . . . . . . . 7.5Caterpillar . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.5Cummins . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.6Mercedes-Benz . . . . . . . . . . . . . . . . . . . . . . . . 7.5

DDashboard Care . . . . . . . . . . . . . . . . . . . . . . . . 12.1Defogging and Defrosting Using

Fresh Air . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.1Door Windows . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.1

EEaton Fuller AutoShift

Automated Transmissions . . . . . . . . . . . . . . . . . . 8.1General Information,

AutoShift . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.1Operation, SmartShift With

Eaton Fuller AutoShift . . . . . . . . . . . . . . . . . . 8.3Eaton Fuller Deep-Reduction

Transmissions . . . . . . . . . . . . . . . . . . . . . . . . . 8.13General Information, Deep

Reduction . . . . . . . . . . . . . . . . . . . . . . . . . . 8.13Operation, Deep Reduction . . . . . . . . . . . . . . . 8.13

Eaton Fuller Range-ShiftTransmissions . . . . . . . . . . . . . . . . . . . . . . . . . 8.11General Information, Range-

Shift . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.11Operation, Range-Shift . . . . . . . . . . . . . . . . . . 8.12

Index

I-1

Subject PageEaton Fuller Straight-Shift

Transmissions . . . . . . . . . . . . . . . . . . . . . . . . . 8.10General Information,

Straight-Shift . . . . . . . . . . . . . . . . . . . . . . . . 8.10Operation, Straight-Shift . . . . . . . . . . . . . . . . . 8.10

Eaton Fuller UltraShift™ . . . . . . . . . . . . . . . . . . . . 8.5General Information,

UltraShift ASW . . . . . . . . . . . . . . . . . . . . . . . 8.5Operation, UltraShift ASW . . . . . . . . . . . . . . . . . 8.5Ultrashift Diagnostics . . . . . . . . . . . . . . . . . . . . 8.9

Emergency Kit, Optional . . . . . . . . . . . . . . . . . . . 13.1Emergency Starting With

Jumper Cables . . . . . . . . . . . . . . . . . . . . . . . . 13.1Engine Braking System,

Optional . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.15Mercedes-Benz Engine

Brake/Constant-ThrottleValves . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.15

Engine Break-In . . . . . . . . . . . . . . . . . . . . . . . . . 7.6Engine Operation . . . . . . . . . . . . . . . . . . . . . . . . . 7.6

Caterpillar . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.8Cummins . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.9Engine Protection . . . . . . . . . . . . . . . . . . . . . . 7.6Mercedes-Benz . . . . . . . . . . . . . . . . . . . . . . . . 7.7

Engine Shutdown . . . . . . . . . . . . . . . . . . . . . . . . 7.11Caterpillar . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.12Cummins . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.12Mercedes-Benz . . . . . . . . . . . . . . . . . . . . . . . 7.11

Engine Starting . . . . . . . . . . . . . . . . . . . . . . . . . . 7.2Caterpillar . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.4Cummins . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.5Mercedes-Benz . . . . . . . . . . . . . . . . . . . . . . . . 7.4Pre-Start . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.3Starting Precautions, All

Engines . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.3EPA Emission Control . . . . . . . . . . . . . . . . . . . . . . 1.2

EPA07 Exhaust Emissions . . . . . . . . . . . . . . . . . 1.2Vehicle Noise Emission

Control Label . . . . . . . . . . . . . . . . . . . . . . . . 1.2EPA07 Aftertreatment System

(ATS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.1Exhaust Braking System,

Optional . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.13General Information . . . . . . . . . . . . . . . . . . . . 7.13Pacbrake® Exhaust Brake . . . . . . . . . . . . . . . . 7.14

FFederal Motor Vehicle Safety

Standard (FMVSS) Labels . . . . . . . . . . . . . . . . . 1.1Fire Extinguisher . . . . . . . . . . . . . . . . . . . . . . . . 13.1Fire in the Cab . . . . . . . . . . . . . . . . . . . . . . . . . 13.4

In Case of a Cab Fire . . . . . . . . . . . . . . . . . . . 13.4

Subject PageFontaine® Fifth Wheels . . . . . . . . . . . . . . . . . . . . 10.3

6000/7000 Series No-Slack®

II Stationary Models . . . . . . . . . . . . . . . . . . . 10.3Fifth Wheel Lock Mechanism

for Trailer Kingpin . . . . . . . . . . . . . . . . . . . . 10.3Fifth Wheel Locking

Operation . . . . . . . . . . . . . . . . . . . . . . . . . . 10.4Freightliner SmartShift Shift

Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.1Fresh Air . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.2Fuse, Relay, and Circuit

Breaker Identification . . . . . . . . . . . . . . . . . . . . . 3.5

HHazard Warning Lights . . . . . . . . . . . . . . . . . . . . 13.1Heating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.2High-Altitude Operation . . . . . . . . . . . . . . . . . . . . 7.13Holland Fifth Wheels . . . . . . . . . . . . . . . . . . . . . 10.1

3500 Series StationaryModels . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.1

Fifth Wheel LockingOperation . . . . . . . . . . . . . . . . . . . . . . . . . . 10.1

Hood Tilting . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.4To Return the Hood . . . . . . . . . . . . . . . . . . . . . 3.4To Tilt the Hood . . . . . . . . . . . . . . . . . . . . . . . . 3.4

HVAC General Information . . . . . . . . . . . . . . . . . . 4.1Hydraulic Brake System . . . . . . . . . . . . . . . . . . . . 6.5

General Information . . . . . . . . . . . . . . . . . . . . . 6.5Meritor™ WABCO® Antilock

Braking System (ABS),Hydraulic Brake Systems . . . . . . . . . . . . . . . . 6.6

Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.6

IInstrument and Control Panel . . . . . . . . . . . . . . . . . 2.1

ABS Diagnostic Switch,Optional . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.8

Aftertreatment System (ATS)Request/Inhibit RegenSwitch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.8

Axle Controls . . . . . . . . . . . . . . . . . . . . . . . . . 2.6Battery-Isolation Switch . . . . . . . . . . . . . . . . . . 2.10Cruise Control . . . . . . . . . . . . . . . . . . . . . . . . . 2.9Daytime Running Lights,

Optional . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.3Engine Brake Controls . . . . . . . . . . . . . . . . . . . 2.8Headlight and Parking Light

Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.3Heater and Air-Conditioner

Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.5Horn . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.5Hot Posts . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.6

Index

I-2

Subject Page

Ignition Switch and Key . . . . . . . . . . . . . . . . . . 2.1Instrument and Control

Panel Dimmer Switch . . . . . . . . . . . . . . . . . . . 2.3Marker Blink Switch . . . . . . . . . . . . . . . . . . . . . 2.3Mirror Controls . . . . . . . . . . . . . . . . . . . . . . . . 2.2Mode/Reset Switch, Optional . . . . . . . . . . . . . . . 2.6Parking-Brake-Control Valve . . . . . . . . . . . . . . . 2.5Power Lock Switch, Optional . . . . . . . . . . . . . . . 2.2Power Window Switch,

Optional . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.1Tilt, or Tilt and Telescoping

Steering Wheel, Optional . . . . . . . . . . . . . . . . 2.5Trailer-Air-Supply Valve . . . . . . . . . . . . . . . . . . . 2.5Trailer-Brake Hand-Control-

Valve Lever . . . . . . . . . . . . . . . . . . . . . . . . . 2.5Transmission Controls . . . . . . . . . . . . . . . . . . . 2.10Turn Signal Lever, Signal-

Stat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.4Turn Signal Lever, United

Technologies . . . . . . . . . . . . . . . . . . . . . . . . 2.3Instrumentation Control Unit 3

(ICU3 and ICU3 ’07) . . . . . . . . . . . . . . . . . . . . . 2.21ICU3 Ignition Sequence . . . . . . . . . . . . . . . . . 2.21Mode/Reset Switch . . . . . . . . . . . . . . . . . . . . 2.23

Instrumentation Control Unit 4(ICU4) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.16Buzzer and Chime . . . . . . . . . . . . . . . . . . . . . 2.17Ignition Sequence . . . . . . . . . . . . . . . . . . . . . 2.17Mode/Reset Switch . . . . . . . . . . . . . . . . . . . . 2.17

Instruments . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.13Application Air Pressure

Gauge, Optional . . . . . . . . . . . . . . . . . . . . . 2.16Coolant Temperature Gauge . . . . . . . . . . . . . . 2.14Engine Oil Pressure Gauge . . . . . . . . . . . . . . . 2.13Forward and Rear Axle Oil

Temperature Gauges,Optional . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.15

Fuel Gauge . . . . . . . . . . . . . . . . . . . . . . . . . . 2.14Intake Air Restriction

Indicator, Dash-Mounted,Optional . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.16

Intake Air RestrictionIndicator . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.16

Primary and Secondary AirPressure Gauges . . . . . . . . . . . . . . . . . . . . . 2.14

Speedometer . . . . . . . . . . . . . . . . . . . . . . . . 2.13Tachometer, Optional . . . . . . . . . . . . . . . . . . . 2.13Transmission Oil

Temperature Gauge,Optional . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.15

Voltage Reading . . . . . . . . . . . . . . . . . . . . . . 2.14

Subject Page

MMercedes-Benz Automated

Transmissions . . . . . . . . . . . . . . . . . . . . . . . . . 8.24AGS Diagnostics . . . . . . . . . . . . . . . . . . . . . . 8.29General Information, AGS . . . . . . . . . . . . . . . . 8.24Operation, AGS . . . . . . . . . . . . . . . . . . . . . . . 8.25

Mercedes-Benz ManualTransmissions . . . . . . . . . . . . . . . . . . . . . . . . . 8.15

Meritor™ Axle Lock Operation . . . . . . . . . . . . . . . . . 9.2Meritor™ Drive Axles With

Wheel Lock . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.1Meritor™ Tandem Drive Axles

With Axle Lock . . . . . . . . . . . . . . . . . . . . . . . . . 9.2Meritor™ Wheel Lock Operation . . . . . . . . . . . . . . . 9.1

NNGI Instrument Cluster,

Optional . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.23Instruments . . . . . . . . . . . . . . . . . . . . . . . . . . 2.23Lightbar . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.23Message Center . . . . . . . . . . . . . . . . . . . . . . 2.24Mode and Set Buttons . . . . . . . . . . . . . . . . . . 2.25

PPretrip and Post-Trip Inspection

Checklists . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11.1Pretrip and Post-Trip

Maintenance Procedures . . . . . . . . . . . . . . . . . . 11.3Daily Pretrip Inspection and

Maintenance . . . . . . . . . . . . . . . . . . . . . . . . 11.3Monthly Post-Trip Inspection

and Maintenance . . . . . . . . . . . . . . . . . . . . 11.14Weekly Post-Trip Inspection

and Maintenance . . . . . . . . . . . . . . . . . . . . 11.13

SSeat Belts and Tether Belts . . . . . . . . . . . . . . . . . . 5.5

General Information . . . . . . . . . . . . . . . . . . . . . 5.5Seat Belt Operation . . . . . . . . . . . . . . . . . . . . . 5.5

Seats . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.1Bostrom Talladega™ 915

Seat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.4EzyRider® Seat . . . . . . . . . . . . . . . . . . . . . . . . 5.2General Information . . . . . . . . . . . . . . . . . . . . . 5.1National 2000 Series Seat . . . . . . . . . . . . . . . . . 5.3National Nonsuspended

Seat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.3Two-Passenger Bench Seat . . . . . . . . . . . . . . . . 5.5

Starting After an ExtendedShutdown or Oil Change . . . . . . . . . . . . . . . . . . . 7.6

Index

I-3

Subject PageSteering System . . . . . . . . . . . . . . . . . . . . . . . . . 6.1

General Information . . . . . . . . . . . . . . . . . . . . . 6.1Power Steering System . . . . . . . . . . . . . . . . . . 6.1

TTire and Rim Labels . . . . . . . . . . . . . . . . . . . . . . . 1.2Towing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13.2

Front Towing Hookup . . . . . . . . . . . . . . . . . . . 13.2Rear Towing Hookup . . . . . . . . . . . . . . . . . . . 13.3

TTC Manual Transmissions . . . . . . . . . . . . . . . . . 8.16General Information, TTC . . . . . . . . . . . . . . . . 8.16Operation, TTC . . . . . . . . . . . . . . . . . . . . . . . 8.16

VVehicle Specification Decal . . . . . . . . . . . . . . . . . . 1.1Velour Upholstery Cleaning . . . . . . . . . . . . . . . . . 12.2

Chewing Gum or Wax . . . . . . . . . . . . . . . . . . . 12.3Grease and Oil-Based Stains . . . . . . . . . . . . . . 12.2Mildew . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12.3Sugar and Water-Based

Stains . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12.2Vinyl Upholstery Cleaning . . . . . . . . . . . . . . . . . . 12.1

Ball Point Ink . . . . . . . . . . . . . . . . . . . . . . . . . 12.2Chewing Gum . . . . . . . . . . . . . . . . . . . . . . . . 12.2Miscellaneous . . . . . . . . . . . . . . . . . . . . . . . . 12.2Nail Polish and Nail Polish

Remover . . . . . . . . . . . . . . . . . . . . . . . . . . 12.2Ordinary Dirt . . . . . . . . . . . . . . . . . . . . . . . . . 12.1Paint, Shoe Heel Marks . . . . . . . . . . . . . . . . . 12.2Shoe Polish . . . . . . . . . . . . . . . . . . . . . . . . . 12.2Sulfide Stains . . . . . . . . . . . . . . . . . . . . . . . . 12.2Tars, Asphalts, and Creosote . . . . . . . . . . . . . . 12.2

WWarning and Indicator Lights . . . . . . . . . . . . . . . . 2.10

Engine Protection WarningLights . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.12

Index

I-4

Documents

Foreword - sd95d2cbd361a0b8d.jimcontent.com · Foreword. Contents Chapter Page Introduction, Environmental Concerns and Recommendations, Event Data Recorder, Customer Assistance Center,