92
Introduction This manual provides information needed to operate and understand the vehicle and its components. More detailed information is contained in the Owner’s Warranty Information for North America booklet, and in the vehicle’s workshop and maintenance manuals. Freightliner chassis are equipped with various chas- sis and driver controls. Not all of the information con- tained in this manual applies to every vehicle. If parts on your chassis differ from those shown, they may have been installed by the vehicle final-stage manu- facturer. The safety or performance of your vehicle could be adversely affected by the installation of nonstandard components. Note the limitations and specifications provided in the vehicle and chassis manuals, and consult Freightliner Custom Chassis Corporation be- fore making any alterations to the chassis. For your reference, keep this manual in the vehicle at all times. IMPORTANT: Descriptions and specifications in this manual were in effect at the time of printing. Freight- liner Custom Chassis Corporation reserves the right to discontinue models and to change specifications or design at any time without notice and without in- curring obligation. Descriptions and specifications contained in this publication provide no warranty, ex- pressed or implied, and are subject to revisions and editions without notice. Environmental Concerns and Recommendations Whenever you see instructions in this manual to dis- card materials, you should first attempt to reclaim and recycle them. To preserve our environment, fol- low appropriate environmental rules and regulations when disposing of materials. Event Data Recorder This vehicle is equipped with one or more devices that record specific vehicle data. The type and amount of data recorded varies depending on how the vehicle is equipped (such as the brand of engine, if an air bag is installed, or if the vehicle features a collision avoidance system, etc.). Customer Assistance Center Having trouble finding service? Call the Customer Assistance Center at 1–800–385–4357 or 1–800– FTL–HELP. Call night or day, weekdays or week- ends, for dealer referral, vehicle information, or breakdown coordination. Our people are knowledge- able, professional, and committed to keeping your vehicle moving. Reporting Safety Defects If you believe that your vehicle has a defect that could cause a crash or could cause injury or death, you should immediately inform the National Highway Traffic Safety Administration (NHTSA) in addition to notifying Freightliner Custom Chassis Corporation. If the NHTSA receives similar complaints, it may open an investigation, and if it finds that a safety defect exists in a group of vehicles, it may order a recall and remedy campaign. However, NHTSA cannot become involved in individual problems between you, your dealer, or Freightliner Custom Chassis Corporation. To contact NHTSA, you may call the Vehicle Safety Hotline toll-free at 1-888-327-4236 (TTY: 1-800-424-9153); go to http://www.safercar.gov; or write to: Administrator, NHTSA, 400 Seventh Street, SW, Washington, DC 20590. You can also obtain other information about motor vehicle safety from http://www.safercar.gov. Canadian customers who wish to report a safety- related defect to Transport Canada, Defect Investigations and Recalls, may telephone the toll- free hotline 1-800-333-0510, or contact Transport Canada by mail at: Transport Canada, ASFAD, Place de Ville Tower C, 330 Sparks Street, Ottawa, Ontario, Canada K1A 0N5. For additional road safety information, please visit the Road Safety website at: http://www.tc.gc.ca/ roadsafety/menu.htm Foreword STI-425 (12/05P) Printed in U.S.A.

Foreword - RV Tech Library · lights, taillights, parking lights, license plate lights, and panel lights is located on the instrument panel. See Fig. 2.3. Control knob positions are

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Page 1: Foreword - RV Tech Library · lights, taillights, parking lights, license plate lights, and panel lights is located on the instrument panel. See Fig. 2.3. Control knob positions are

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.

Freightliner chassis are equipped with various chas-sis and driver controls. Not all of the information con-tained in this manual applies to every vehicle. If partson your chassis differ from those shown, they mayhave been installed by the vehicle final-stage manu-facturer.

The safety or performance of your vehicle could beadversely affected by the installation of nonstandardcomponents. Note the limitations and specificationsprovided in the vehicle and chassis manuals, andconsult Freightliner Custom Chassis Corporation be-fore making any alterations to the chassis.

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. Freight-liner Custom Chassis Corporation reserves the rightto discontinue models and to change specificationsor design at any time without notice and without in-curring obligation. Descriptions and specificationscontained in this publication provide no warranty, ex-pressed or implied, and are subject to revisions andeditions without notice.

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 1–800–385–4357 or 1–800–FTL–HELP. Call night or day, weekdays or week-ends, for dealer referral, vehicle information, orbreakdown coordination. Our people are knowledge-able, professional, and committed to keeping yourvehicle moving.

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

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 Freightliner CustomChassis Corporation.

To contact NHTSA, you may call the VehicleSafety Hotline toll-free at 1-888-327-4236 (TTY:1-800-424-9153); go to http://www.safercar.gov; orwrite to: Administrator, NHTSA, 400 SeventhStreet, SW, Washington, DC 20590. You can alsoobtain other information about motor vehicle safetyfrom http://www.safercar.gov.

Canadian customers who wish to report a safety-related defect to Transport Canada, DefectInvestigations and Recalls, may telephone the toll-free hotline 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: http://www.tc.gc.ca/roadsafety/menu.htm

Foreword

STI-425 (12/05P)Printed in U.S.A.

Page 2: Foreword - RV Tech Library · lights, taillights, parking lights, license plate lights, and panel lights is located on the instrument panel. See Fig. 2.3. Control knob positions are

© 1997-2005 Freightliner LLC. All rights reserved.

No part of this publication, in whole or part, may be translated, reproduced, stored in a retrieval system, or transmittedin any form by any means, electronic, mechanical, photocopying, recording, or otherwise, without the prior written per-mission of Freightliner LLC. For additional information, please contact Freightliner LLC, Service Systems and Docu-mentation, P.O. Box 3849, Portland OR 97208–3849 U.S.A. or refer to http://www.Freightliner.com and http://www.FreightlinerChassis.com.

Foreword

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ContentsChapter Page

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

1 Vehicle Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.12 Driver Controls and Instruments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.13 Engines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.14 Transmissions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.15 Steering System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.16 Brake System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.17 Pretrip Inspection and Daily Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.18 In an Emergency . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.19 Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.1

10 Towing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.1Index . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I.1

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1

Vehicle IdentificationVehicle Specification Label . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.1Vehicle Identification Number (VIN) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.1

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Vehicle Specification LabelThe vehicle specification label contains the name ofthe manufacturer, the month and year of manufac-ture, the certification statement, vehicle identificationnumber, gross vehicle weight rating (GVWR), frontand rear gross axle weight ratings (GAWRs), tire andwheel sizes, and the recommended maximum tireinflation pressures. See Fig. 1.1 .

On incomplete vehicles, it is the responsibility of thefinal-stage manufacturer to complete the vehicle andlabel it for compliance with the Federal Motor VehicleSafety Standards.

Vehicle Identification Number(VIN)The chassis vehicle identification number (VIN) ispermanently attached to the chassis. See Fig. 1.2 .On VCL chassis models, the VIN label is mountedabove the upper-left corner of the radiator. On XC

chassis models, the VIN label is mounted above theupper-right corner of the side radiator. On front en-gine models, the VIN label is mounted to the right ofthe radiator on the front of the frontwall. The last sixdigits are the chassis serial number.

NOTE: Always include the chassis serial num-ber (last six digits of the VIN) when communi-cating to Freightliner LLC.

09/11/2002 f080123

Fig. 1.1, Vehicle Specification Label

Vehicle Identification

1.1

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12/04/2001 f080122

Fig. 1.2, Vehicle Identification Number (VIN) Label, Typical

Vehicle Identification

1.2

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2

Driver Controls andInstruments

Instrument Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.1Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.1SmartWheel (optional) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.7Warning and Indicator Lights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.8Instruments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.10Multiple Module Data Computer (MMDC) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.13Instrumentation Control Unit (front-engine diesel chassis) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.18Level One Heading Here . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.22

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Instrument PanelOn XC, XCS, and VCL chassis vehicles equippedwith System III electrical wiring, the warning and indi-cator light module (System III instrumentation) is lo-cated on the instrument panel and contains all of thestandard and optional warning and indicator lights.

System III instrumentation includes a speedometerand a tachometer. A digital odometer display is lo-cated in the speedometer and a digital tripmeter dis-play is located in the tachometer.

The odometer and the tripmeter can both display ei-ther English or metric values (miles or kilometers). Atrip reset switch is located on the dash panel. If theswitch is depressed for more than four seconds, bothdisplays will cycle between English and metric val-ues. At the left sides of the displays, a triangle willpoint to either an "m" or a "k" depending on whichscale is selected.

To reset the tripmeter, depress the switch for lessthan four seconds. The tripmeter resets to either 0miles or 0 kilometers. The display indicates in onetenth (mile or kilometer) increments, depending onthe scale selected.

NOTE: Beginning with 2002 model year ve-hicles, a single odometer/tripmeter display isinstalled. Press the trip reset switch for lessthan four seconds to cycle the display betweenodometer and tripmeter modes. Press theswitch for more than four seconds (in tripmetermode) to reset the tripmeter. Press the switchfor more than four seconds (in odometer mode)to cycle the display between English and metricvalues.

ControlsIgnition Switch and KeyThe ignition switch can be turned to four positions:ACCESSORY, OFF, ON, and START. See Fig. 2.1 .

The key can be inserted and removed only from theOFF position. The headlights (low beams), brakelights, fog lights, dome lights, clearance lights, turnsignals, hazard warning lights, and parking lights op-erate with the ignition switch in the OFF position, re-gardless of whether the key is inserted.

NOTE: In the ACCESSORY position (the key isturned fully counterclockwise) the electricgauges will not operate.

Turn the key fully clockwise to the START positiononly when starting the engine. When the enginestarts, release the key. When released, the key willrotate counterclockwise to the ON position.

In the ON position (key turned 45 degrees clock-wise), all electrical systems are operable. The warn-ing lights and the buzzer for low air pressure and lowoil pressure operate until the engine is started andminimum pressures are built up.

Headlight Switches and Panel Lights(models built from August 2003, on)The control knob for the headlights, side markerlights, taillights, parking lights, license plate lights,and panel lights is located on the instrument panel.See Fig. 2.2 . The headlight control knob used formodels built after August 2003 operates as follows:

• All lights are OFF if the control knob is turnedto the left position.

• If the knob is in the middle position, all lightsare on except the headlights.

• If the knob is in the right position, all lights in-cluding the headlights are on.

• If the knob is pulled out, all lights including thefog lights are on.

07/10/96

1

2

34

f601179

1. Accessory2. Off

3. On4. Start

Fig. 2.1, Ignition Switch

Driver Controls and Instruments

2.1

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A separate dash panel dimmer control adjusts dashpanel brightness. Turn the knob upwards to increasethe panel brightness, and down to dim the light. SeeFig. 2.2 .

Headlight Switches and Panel Lights(models built before August 2003)The control knob for the headlights, side markerlights, taillights, parking lights, license plate lights,and panel lights is located on the instrument panel.See Fig. 2.3 . Control knob positions are as follows:

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

• If pulled out to the first stop, all lights are onexcept the headlights.

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

A separate dash panel dimmer control adjusts dashpanel brightness. See Fig. 2.4 . Turn the knob to theright to brighten the panel lights or to the left to dimthem.

The high-beam headlights are activated by pullingthe turn signal lever toward the driver. See Fig. 2.5 .When the headlights are on high beam, the high-beam indicator light comes on in the instrumentpanel. The ignition switch must be in the ON positionfor the high beams to operate.

10/26/2005

OFFCARGODOME

OFF

PULL

f610781

1 2 3 4

56

1. Lights Off2. Parking Lights On3. All Lights On, Including Headlights4. Increase Cargo Dome/Instrument Panel Brightness5. Decrease Cargo Dome/Instrument Panel Brightness6. Pull Out for Fog Lights

Fig. 2.2, Light Control Knob (RV models built fromAugust 2003, on)

A B C

11/14/2000 f601188b

A. Lights OffB. Parking Lights OnC. All Lights On, Including Headlights

Fig. 2.3, Light Control Knob (RV models built beforeAugust 2003)

A B

11/16/2000 f610455

A. Decrease BrightnessB. Increase Brightness

Fig. 2.4, Panel Light Dimmer Control (RV models builtbefore August 2003)

05/15/97 f601363

Fig. 2.5, Turn Signal Lever, Douglas Steering Column

Driver Controls and Instruments

2.2

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Interrupt Switch (optional)A spring-loaded interrupt switch temporarily deacti-vates the marker lights and taillights. With the vehiclelights on, raise and release the interrupt switch tobriefly turn off the marker lights and taillights.

Parking Brake ControlsAll pneumatic braked vehicles are equipped with adiamond-shaped parking brake control knob. SeeFig. 2.6 . Pull the knob to apply the parking brake. Inair brake systems, before the parking brake can bereleased, the air pressure in either brake systemmust be at least 65 psi (448 kPa). See Chapter 6 fordetailed operating instructions.

WARNINGIf the vehicle is equipped with an air suspensionsystem, do not move the vehicle with the air sus-pension deflated. Doing so could result in a lossof vehicle control, possibly causing personal in-jury and property damage.

NOTE: Chassis built with an air suspensiondump option have an automatic feature that willnot allow the suspension to be deflated unlessthe parking brakes are set. The suspension willautomatically inflate when the parking brakesare released.

Auto-Apply Parking Brake

The auto-apply parking brake is electronically con-trolled and set by pressing "Pb" on the shift selector.To release the parking brake, depress the servicebrake and shift from the "Pb" position to any drivegear. See Chapter 6 for detailed operating instruc-tions. See Fig. 2.13 .

Turn Signal LeverThe turn signal lever is mounted on the steering col-umn. See Fig. 2.5 and Fig. 2.7 . Push the lever coun-terclockwise to turn on the left turn signal; push itclockwise to turn on the right turn signal. When oneof the turn signals is on, a green turn signal indicatorlight flashes at either the far-left or far-right side ofthe warning and indicator light panel. When the turnis completed, the signal will cancel and the lever willreturn to the neutral position.

Hazard Warning Lights (models builtfrom July 2002, on)To activate the hazard warning lights on RV modelsbuilt after July 2002, pull out the hazard warning lightswitch located under the turn signal switch. SeeFig. 2.8 . When the switch is pulled out, all of the turnsignal lights and both of the indicator lights on thecontrol panel will flash. To cancel the hazard warninglights, move the turn signal switch up or down.

Hazard Warning Lights (models builtbefore July 2002)Pull out the hazard warning light switch on the steer-ing column to activate the hazard warning lights. SeeFig. 2.9 . The hazard warning light switch is locatedon the bottom of the steering column. When theswitch is pulled out, all of the turn signal lights andboth of the indicator lights on the control panel willflash. To cancel the warning lights, push the switchin.

f421624

Fig. 2.6, Parking Brake Control Knob

10/26/2005 f544668

1 2

1. Turn Signal Lever2. Hazard Warning Light

Switch

Fig. 2.7, Turn Signal Lever, TRW Steering Column

Driver Controls and Instruments

2.3

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Allison Automatic TransmissionsAllison automatic transmissions are controlled by anelectronic control unit (ECU). The ECU processesinformation from sensors, pressure switches, and theshift selector to automatically control the transmissionaccording to programmed specifications. SeeFig. 2.10 , and Fig. 2.11 . See Chapter 4 for completetransmission operating instructions.

Later vehicles may be equipped with an Arens shift-by-wire (SBW) push-button shift selector. SeeFig. 2.12 .

NOTE: SBW Allison 1000/2400 series automatictransmissions have a Park (P) position andSBW Allison 2000 series transmissions do not.The shift selectors appear the same except thatthere is no Park (P) position button on the se-ries 2000 selector. See Chapter 4 for completetransmission operating instructions.

SBW Allison 2100 series automatic transmis-sions have a park brake (Pb) position button onthe transmission selector. See Fig. 2.13 .

10/26/2005 f462037

1

2

1. Hazard Warning LightSwitch

2. Turn Signal Lever

Fig. 2.8, Hazard Warning Light Switch Location (RVmodels built after July 2002)

1

11/15/2000 f461791a

1. Hazard Warning Light Switch

Fig. 2.9, Hazard Warning Light Switch Location (RVmodels built before July 2002)

R N

D

2

1

11/16/2000 f270073

D

Fig. 2.10, Allison 2000, 2000 MH Shift Selector Lever(six positions)

Driver Controls and Instruments

2.4

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Cruise Control System

WARNINGDo not use the cruise control system when driv-ing conditions do not permit maintaining a con-stant speed, such as in heavy traffic or on roadsthat are winding, icy, snow covered, slippery, orwith a loose driving surface. Failure to follow thisprecaution could cause a collision or loss of ve-hicle control, possibly resulting in personal injuryor property damage.

If the cruise control is column-mounted, it is operatedby two switches on the turn signal lever. See

Fig. 2.14 . A RESUME-ACCEL/ON/OFF switch allowsthe driver to select cruise control, drive with thepedal, accelerate while in cruise control, or resumecruise speed after slowing down. A spring-loadedSET COAST switch allows the driver to select thecruise speed or temporarily disable the cruise controlto reduce speed.

If the cruise control is steering wheel-mounted, it isoperated by two switches on the steering wheel. AResume/Set Accel/Coast switch allows the driver toselect cruise control, accelerate while in cruise con-trol, temporarily disengage cruise control, or resumecruise speed after slowing down. The On/Off switchactivates or turns off the cruise control function.

The system can also be used for throttle controlwhen the vehicle is parked. See Chapter 3 for de-tailed operating instructions.

N

R

D

1

2

3

11/16/2000 f270113a

4

NOTE: The number displayed on the Digital Display but-ton is the highest forward range available in the se-lected position. Visually check to confirm the range se-lected. If the display is flashing, the shift is inhibited.1. Digital Display2. Mode ID3. Mode Indicator (LED)4. Push Simultaneously for Diagnostic Mode and Fluid

Level Check (optional)

Fig. 2.11, Allison WTEC III Shift Selector

MONITOR

SELECT

SERVICE

R

N

P

D

MODE

PARK BRAKE must be set.WARNING: If "P"is not displayed

!

ARENS CONTROLS

04/02/2003 f270122

1

2

3

4

5

8

12

13

6

14

7

1011

9

1. SBW Shift Selector2. Drive (D) Button3. Neutral (N) Button4. Reverse (R) Button5. Park (P) Button6. Select Display7. Select/Monitor Display

Window

8. Monitor Display9. Service Display10. Mode Function Label11. Mode Light12. Mode Button13. Upshift Button14. Downshift Button

Fig. 2.12, SBW Push-Button Shift Selector

Driver Controls and Instruments

2.5

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NOTE: On vehicles equipped with the optionalSmartWheel, the cruise control switches are lo-cated on the left SmartWheel switch panel. SeeChapter 3 for additional information.

Tag Axle Suspension Dump Switch(optional)The tag axle suspension is a non-liftable, full-timesuspension designed to increase the Gross VehicleWeight Rating (GVWR). It is used when the rearsuspension/axle will be loaded to a weight greaterthan 20,000 lb (9072 kg). Under certain conditions,air can be exhausted from the air springs to improvemaneuverability or traction on the rear axle via thetag axle suspension dump switch.

The tag axle suspension dump switch is operated bya three-position, dash-mounted rocker switch. SeeFig. 2.15 . The manual "TAG DUMP" mode is acti-vated by pressing and holding the rocker switch allthe way in. The "AUTO DUMP" mode is activatedautomatically during reverse gear applications whenthe rocker switch is placed in the middle (level) posi-tion. When you depress and hold the bottom of therocker switch, the tag axle suspension dump switchis placed in the "OFF" (down) position, and the "TAGDUMP" mode is inactive.

If the vehicle exceeds a speed of 8 mph (13 km/h)while the operator is holding the switch in the "TAGDUMP" position, the tag axle suspension dumpswitch control system will override the "TAG DUMP"mode and the tag suspension air springs will be re-filled.

IMPORTANT: The tag axle suspension dumpswitch feature must be cycled on and off of the

MONITOR

SELECT

SERVICE

R

N

Pb

D

MODE

PARK BRAKE must be set.WARNING: If "P"is not displayed

!

ARENS CONTROLS

f270122a

1

2

3

4

5

8

12

13

6

14

7

1011

9

10/25/2005

1. Shift Selector2. Drive (D) Button3. Neutral (N) Button4. Reverse (R) Button5. Park Brake (Pb)

Button6. Select Display7. Select/Monitor Display

Window

8. Monitor Display9. Service Display10. Mode Function Label11. Mode Light12. Mode Button13. Upshift Button14. Downshift Button

Fig. 2.13, SBW Push-Button Shift Selector with ParkBrake (Pb) Button (MC chassis)

05/15/97 f601363

Fig. 2.14, Cruise Control, Column-Mounted

f61074708/05/2004

Fig. 2.15, Tag Axle Suspension Dump Switch

Driver Controls and Instruments

2.6

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"TAG DUMP" position if an override event oc-curs while the switch is held in the "TAG DUMP"position.

Tilt/Telescope Steering ColumnIf equipped with a Douglas tilt/telescope steering col-umn, pull the lever upward to change the position ofthe wheel. See Fig. 2.16 . Push the lever downwardto extend or retract the column. Release the lever tolock the position. See Chapter 5 for more informa-tion.

If equipped with a TRW tilt/telescope steering col-umn, depress and hold the foot pedal to unlock thecolumn. Tilt and/or telescope the column to the de-sired position. Release the pedal to lock the columnin place. See Chapter 5 for more information.

WARNINGDo not adjust the steering wheel while the ve-hicle is in motion. This could cause reduced ve-hicle control, resulting in serious personal injury.

Electric HornTo sound the electric horn, push the button in thecenter of the steering wheel.

Backup Alarm (optional)An optional backup alarm, supplied with the chassisand installed by the body builder, sounds when Re-verse (R) gear is engaged. Check the operation ofthe backup alarm daily (if so equipped).

VCL Chassis Dash SwitchesStandard VCL chassis dash switches include tworocker switches, Axle Lift and Pedal Move, and twopaddle switches, Engine Brake On/Off and EngineBrake Lo/Med/Hi. An ATC (automatic traction control)Norm/Spin rocker switch is optional.

SmartWheel (optional)The optional SmartWheel steering wheel control sys-tem allows control of the horn, headlamp and markerlamp interrupt, cruise control functions, and wind-shield wiper functions from steering wheel-mountedswitch panels. See Fig. 2.17 and Fig. 2.18 .

1

11/15/2000 f461176a

1. Tilt/Telescope Lever

Fig. 2.16, Douglas Tilt/Telescope Steering Column(typical)

12/05/2001 f461927

1

2

3

1. Left Switch Panel2. Horn Bar3. Right Switch Panel

Fig. 2.17, SmartWheel

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HornThe horn bar extends across the center of the steer-ing wheel. Press the horn bar to sound the horn.

Headlamp InterruptIf the headlamps are on, press and hold the head-lamp interrupt switch to turn them off. If the head-lamps are off, press and hold the switch to turn themon.

NOTE: The headlamps will remain off or on onlyas long as the switch is being pressed.

Marker Lamp InterruptIf the marker lamps are on, press and hold themarker lamp interrupt switch to turn them off. If themarker lamps are off, press and hold the switch toturn them on.

NOTE: The marker lamps will remain off or ononly as long as the switch is being pressed.

Windshield WipersNOTE: Activating any of the wiper switchescauses the headlamps to come on. To turn theheadlamps off, turn the dashboard headlampswitch on and then off.

Wiper Wash

Press the wiper wash switch to activate the wiperwash pump.

NOTE: The pump will operate only as long asthe switch is pressed. If you selected either theHI/LO or variable switch previously, the wiperswill continue to run in that mode when you re-lease the switch.

Wiper Hi/Lo

Press the wiper HI/LO switch to activate the wipersat low speed. Press the switch again to activate thehigh speed. Pressing the switch once again willcause the wipers to cycle between high and lowspeed with each press of the switch.

Wiper Variable

Press the wiper variable switch to activate the wipersfor one low-speed wipe.

NOTE: Press the switch again within approxi-mately 30 seconds and a second low-speedwipe will occur. The low-speed wipers will con-tinue to activate at the interval determined bythe time between the last two presses of theswitch. Additional presses of the switch willshorten the interval. The variable mode will can-cel if you select any other wiper mode.

Wiper Off

Press the wiper OFF switch to cancel all operationsof the wipers. Turning the ignition switch to the OFFposition has the same effect of cancelling all wiperoperations.

Warning and Indicator LightsAll of the warning and indicator lights are housed inlens and bezel assemblies. See Fig. 2.19 .

The warning and indicator light module may include:

• A low water warning light, that comes on whenthe coolant level is too low.

• Green right and left turn signal indicator lights,that flash on and off when the outside turn sig-nals are flashing.

• A high-beam indicator light, that comes onwhen the headlights are on high beam.

12/05/2001 f461928

1

2

3

4

5

6

7

8

9

10

11

12

1. Left Switch Panel2. Headlamp Interrupt3. Cruise On/Off4. Cruise Cancel5. Cruise Resume6. Cruse Set

7. Right Switch Panel8 Marker Lamp Interrupt9. Wiper Off10. Wiper Hi/Lo11. Wiper Variable12. Wiper Wash

Fig. 2.18, SmartWheel Switch Panels

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• A red parking brake indicator light, that comeson when the parking brakes are activated andthe ignition switch is in the ON position.

On the air brake system, a chime comes onwhen:

– The ignition key is in the OFF positionand the parking brakes are not applied.

– The ignition key is in the ON position,the transmission is in Neutral (N), theservice brake pedal is not depressed,and the parking brakes are not applied.

– The ignition key is in the ON position,the vehicle is not in Neutral (N), and theparking brakes are applied.

• A red warning light for the brake system. Whenconditions cause the brake system warninglight to come on, a warning chime also alertsthe driver.

• On the air brake system, the low air light/chimeactivates when the brake system pressure islow. The light/chime will normally come onwhen you first start the engine, but will go offwhen the air pressure in the air tanks reachesapproximately 65 to 76 psi (448 to 524 kPa).

The parking brakes will not disengage until theair pressure has reached 65 psi (448 kPa).

• A coolant temperature warning light, thatcomes on when the engine coolant tempera-ture exceeds the engine manufacturer’s recom-mendations. See the Caterpillar or the Cum-mins Operation and Maintenance Manual.

• A check transmission warning light that willcome on during vehicle operation (not duringstart-up) if the ECU (electronic control unit) hassignalled a diagnostic code. Diagnostic codesindicate malfunctions in transmission operation.If this light stays on continuously during opera-tion, have the transmission serviced as soonas possible.

• A transmission oil temperature warning light,that comes on when the transmission tempera-ture has exceeded the normal operating tem-perature.

• An oil pressure warning light, that comes onwhen the oil pressure falls below the minimumoil pressure recommended by the enginemanufacturer. See the Caterpillar or the Cum-mins Operation and Maintenance Manual forminimum oil pressure levels.

08/09/2000 f610447

LOWAIR

WATERIN

FUEL

CHECKTRANS

ABS ATC

TRANSTEMP

PARK

BRAKESTOPENG

LOWWATER

CHECKENG

WAITTO

START

ENGPROT

ENGBRAKE

SHIFTINHIBIT

SEATBELT

1

24

2

23

3

22

4

21

5

20

6

19

7

18

8

17

9

16

10

15

11

14

12

13

1. Left-Turn Signal Indicator Light2. Stop Engine Warning Light3. Check Engine Warning Light4. Low Engine Coolant Warning

Light5. ABS Warning Light6. High-Beam Indicator Light7. Automatic Traction Control

Indicator Light8. Seat Belt Warning Light

9. Check Transmission WarningLight

10. Brake Warning Light11. Water in Fuel Indicator Light12. Right-Turn Signal Indicator Light13. Blank Position14. Shift Inhibit Warning Light15. Low Air Warning Light16. Engine Brake Activation Light17. Oil Pressure Warning Light

18. Engine Coolant High TemperatureWarning Light

19. Transmission TemperatureWarning Light

20. Low Fuel Warning Light21. High or Low Voltage Warning

Light22. Engine Protection Warning Light23. Wait to Start Warning Light24. Parking Brake Indicator Light

Fig. 2.19, System III Message Center

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When the ignition switch is in the ON position,oil- and brake-system warnings (as equipped)activate until the engine starts and minimumpressures are exceeded. If the low-oil pressurewarning light or brake system warning light re-mains on after running the engine for 15 sec-onds, shut down the engine and determine thecause.

• A low fuel indicator light, that comes on whenthe vehicle is running low on fuel.

The warning and indicator light module may also in-clude the following lights: wait to start, check engine,water in fuel, stop engine, engine protection, and en-gine brake. See the Caterpillar or the Cummins Op-eration and Maintenance Manual for more informa-tion.

IMPORTANT: If the warning system does notactivate when the ignition switch is in the ONposition, repair the system to provide warningprotection for oil pressure, coolant temperature,and the brake system.

Antilock Braking System (ABS)Vehicles equipped with an antilock braking system(ABS) have an ABS warning light that comes onwhen the vehicle is started. When the vehicle speedexceeds 6 mph (10 km/h), the light will go off if theABS system is functioning normally.

WARNINGIf the ABS warning light does not work as de-scribed above or comes on while driving, repairthe ABS system immediately to ensure full an-tilock braking capability. Operating the vehiclewhen the ABS needs to be serviced could causean accident, possibly resulting in personal injuryor death, or property damage.

See Chapter 6 for more information.

InstrumentsSpeedometerThe speedometer registers vehicle speed in milesper hour (mph). See Fig. 2.20 . Standard speedom-eter gauges are equipped with an odometer thatrecords total distance traveled.

NOTE: The tripmeter will indicate total trip miles.Selecting trip reset will erase the current displayand start counting at 00000.0 miles.

Coolant Temperature GaugeDuring normal engine operation, the coolant tem-perature gauge should read in the normal range. SeeFig. 2.21 or Fig. 2.22 . If the temperature remainsbelow or exceeds the normal range, inspect the cool-ing system to determine the cause.

Engine Oil Pressure GaugeThe oil pressure gauge should read in the normalrange. See Fig. 2.23 and Table 2.1 .

15

5

25

35 4555

65

75

85

MPH

MILES

0000000

08/22/96 f601201

Fig. 2.20, Speedometer

12 o’clock N O R M A L

C H

05/08/2000

1

2

3

4

5

f610416

1. 180°F (82°C)2. 196°F (91°C)3. 210°F (99°C)

4. 216°F (102°C)5. Red Line, 220°F

(104°C)

Fig. 2.21, Engine Temperature (vehicles built beforeMarch 1, 2000)

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Oil Pressure *

Engine ModelOil Pressureat Idle Speed

psi (kPa)

Oil Pressureat Rated RPM

psi (kPa)Caterpillar 6–10 (41–69) 48–52 (331–359)Cummins 10–15 (69–103) 45–55 (310–379)* Oil pressures are given with the engine at operating temperatures. With

the engine cold, oil pressures may be higher.

Table 2.1, Oil Pressure

CAUTIONA sudden decrease or absence of engine oilpressure may indicate mechanical failure. Bringthe vehicle to a safe stop and investigate thecause to prevent further damage. Do not operatethe engine until the cause has been determinedand corrected.

VoltmeterThe voltmeter indicates the vehicle charging systemvoltage when the engine is running, and the batteryvoltage when the engine is stopped. See Fig. 2.24 .By monitoring the voltmeter, the driver can be awareof potential charging system problems and havethem repaired before the batteries discharge enoughto create starting difficulties.

The voltmeter should indicate voltage in the normalrange when the engine is running. The voltage of afully charged battery is 12.7 to 12.8 volts when theengine is stopped. A completely discharged batterywill produce only about 12.0 volts. The voltmeter willindicate lower voltage as the vehicle is being startedor when electrical devices in the vehicle are beingused.

If the voltmeter shows an undercharged or over-charged condition for an extended period, have thecharging system and batteries checked at a repairfacility.

NOTE: Some vehicles may be equipped with abattery isolator system and a gel cell battery bythe body builder. On these vehicles, the voltme-ter measures the average voltage of all of thebatteries when the engine is running. When theengine is stopped, the voltmeter shows only theengine-starting battery voltage and does not in-dicate the voltage of the gel cell batteries.

CAUTIONGel cell batteries can be damaged if the batteryvoltage is allowed to drop below 12.0 volts or if

12 o’clock N O R M A L

C H

05/08/2000

1

2

3

4

5

f610417

1. 140°F (60°C)2. 180°F (82°C)3. 210°F (99°C)

4. 216°F (102°C)5. Red Line, 220°F

(104°C)

Fig. 2.22, Engine Temperature (vehicles built sinceMarch 1, 2000)

12 o’clock N O R M A L

L H

05/08/2000 f610415

1

2

3

4

1. 0 psi2. 30 psi (205 kPa)

3. 45 psi (310 kPa)4. 65 psi (450 kPa)

Fig. 2.23, Oil Pressure

12 o’clock N O R M A L

8 18

05/10/2000

1

2

f610418

3

1. Red Warning, 8 to 11.5 V2. 13.5 V3. Red Warning, 15.5 V

Fig. 2.24, Voltmeter

Driver Controls and Instruments

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the 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.

Fuel GaugeThe fuel gauge indicates the amount of fuel in thefuel tank(s). See Fig. 2.25 .

TachometerThe tachometer indicates the revolutions per minute(rpm) of the engine. See Fig. 2.26 .

Transmission Temperature Gauge(optional)The transmission temperature gauge indicates thetemperature of the transmission oil. See Fig. 2.27 .The temperature gauge reading should not exceed225°F (107°C).

CAUTIONIf the transmission continues to overheat duringnormal operation, have it checked and repaired.Continued operation over 300°F (149°C) maycause damage to the transmission.

Air Pressure GaugesIMPORTANT: Two separate air pressure gaugesindicate air pressure in the front axle and therear axle air brake systems. See Fig. 2.28 .Build air pressure in both systems to 95 to 120psi (620 to 827 kPa) before moving. An alarmwill sound if the pressure drops below a safeoperating range.

Intake-Air Restriction IndicatorAn intake-air restriction indicator measures thevacuum on the engine side of the air cleaner at theair cleaner outlet. See Fig. 2.29 . Replace the aircleaner element every two years, or when filter re-striction reaches 25 inH2O. Reset the indicator bypressing the button on the bottom.

NOTE: A new air cleaner element will normallyread 10 to 12 inH2O. Rain or snow can wet thefilter and cause a higher than normal readingtemporarily.

See Table 2.2 for intake-air restriction levels.

f601200

1/2

FUEL

E F

08/22/96

Fig. 2.25, Fuel Gauge

05/22/97 f601361

X100RPM

Fig. 2.26, Tachometer

12 o’clock N O R M A L

C H

05/08/2000

1

2

f610419

3

4

1. 160°F (71°C)2. 230°F (110°C)3. Red Warning, 275°F

(135°C)

4. 320°F (160°C)

Fig. 2.27, Transmission Temperature

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Intake-Air Restriction

Engine *Maximum

Restriction Witha Clean Air Filter

MaximumRestriction Witha Dirty Air Filter

Caterpillar C7 25 inH2O 12 inH2OCummins ISB,ISC, and ISL 25 inH2O 10 inH2O

* Turbocharged engines must be checked at full load and governed enginespeed.

Table 2.2, Intake-Air Restriction

Multiple Module DataComputer (MMDC)The Multiple Module Data Computer (MMDC) readsand shares vehicle information from the engine,transmission, and brake system computers. Informa-tion is taken from a data bus and sensor signals(analog, digital, or frequency) on the vehicle. It isthen converted to digital information for the gaugesto read.

The instrument system consists of three major com-ponents:

• An annunciator module that concentrates all ofthe warning and indicator lights in one area tofacilitate efficient visual scanning of the panel.

• An assortment of individual analog stylegauges that display the value of specific perfor-mance parameters.

• An interactive graphical information center dis-play that is capable of communicating moredetailed information about the status and per-formance of the vehicle as needed.

The location of these components in the dash mayvary from one vehicle to another.

Annunciator ModuleThe annunciator module contains the following warn-ing and indicator lights. See Fig. 2.30 .

• Green right and left turn signal indicator lights,that flash on and off when the outside turn sig-nals are flashing.

• A check transmission warning light that willcome on during vehicle operation if the trans-mission electronic control unit (ECU) has sig-nalled a diagnostic fault code. Diagnostic

11/16/2000

R

1300

f610456

psi100

65

F

1300psi

100651

2

1. Front Axle Air Brake Pressure2. Rear Axle Air Brake Pressure

Fig. 2.28, Air Pressure Gauges

PUSH TO RESET

H 0 VACUUM225201510

7

IN H 0 VACUUM2

f09017605/22/97

Fig. 2.29, Intake-Air Restriction Indicator

Driver Controls and Instruments

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codes indicate malfunctions in the transmissionoperation. If this light stays on continuouslyduring operation, have the transmission ser-viced as soon as possible.

• A blue high-beam indicator light that comes onwhen the headlights are on high beam.

• On the air brake system, the low air light acti-vates when the brake system pressure is low.The light will normally come on when the en-gine is first started, but will go off when the airpressure in the air tanks reach approximately65 to 76 psi (448 to 524 kPa).

• A red parking brake indicator light that comeson when the parking brake is activated and theignition switch is in the ON position.

• An amber wait to start indicator light thatcomes on when the intake-air pre-heater is ac-tivated.

• An amber check info center indicator light thatcomes on when the info center is displaying analarm condition or warning message.

• A cruise on indicator light that comes on whenthe cruise control is on.

• A shift inhibit warning light that comes on whenthe transmission ECU is prohibiting shifting.

• Vehicles equipped with an antilock braking sys-tem (ABS) have an ABS warning light thatcomes on when the vehicle is started. If anABS fault has been cleared, the vehicle speedmust exceed 7 mph (10km/h), for the light togo off if the ABS system is functioning nor-mally.

WARNINGIf the ABS warning light does not work as de-scribed above or comes on while driving, repairthe ABS system immediately to ensure full an-tilock braking capability. Operating the vehiclewhen the ABS needs to be serviced could causean accident, possibly resulting in personal injuryor death, or property damage.

The annunciator module may also include the follow-ing lights: check engine, stop engine, and engineprotection. See the Caterpillar or the Cummins Op-eration and Maintenance Manual for more informa-tion.

10/07/2003 f610671

LOWAIR

CHECKTRANS

ABS

CRUISEON

PARKBRAKE

STOPENGINE

CHECKENGINE

WAITTO

START

ENGPROT

CHECKINFO

SHIFTINHIBIT

1

24

2

23

3

22

4

21

5

20

6

19

7

18

8

17

9

16

10

15

11

14

12

13

CENTER

1. Left-Turn Signal Indicator2. Stop Engine Warning Light3. Check Engine Warning Light4. Check Transmission Warning

Light5. ABS Warning Light6. High-Beam Indicator Light7. Blank Position8. Low Air Warning Light

9. Engine Protection Warning Light10. Parking Brake Indicator Light11. Blank Position12. Right-Turn Signal Indicator Light13. Blank Position14. Shift Inhibit Warning Light15. Cruise Control Indicator Light16. Blank Position

17. Check Info Center Indicator Light18. Blank Position19. Blank Position20. Wait to Start Warning Light21. Blank Position22. Blank Position23. Blank Position24. Blank Position

Fig. 2.30, Annunciator Module

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IMPORTANT: If the warning system does notactivate when the ignition switch is in the ONposition, repair the system to provide properwarning protection.

GaugesSee Fig. 2.31 for an example of a typical instrumentpanel. The following is a description of the instrumentpanel gauges.

Speedometer/Odometer

The speedometer registers vehicle speed in milesper hour or kilometers per hour (mph/kph). Standardspeedometers are equipped with a combinationodometer/tripmeter that records total distance trav-eled and trip distance. Resetting the trip odometerwill erase the current display and start counting at0000.0 miles. A short press (less than three seconds)of the trip reset will toggle the display between tripmode and odometer mode. A long press (greaterthan three seconds) of the trip reset while in tripmode will reset the tripmeter. The tripmeter can alsobe reset using the information center. The odometerwill be displayed with six numbers and no decimal(000000), while the tripmeter will be displayed withfour numbers and one decimal (0000.0).

Tachometer

The tachometer indicates the revolutions per minute(rpm) of the engine.

Coolant Temperature Gauge

During normal engine operation, the coolant tem-perature gauge should read in the normal range. Ifthe temperature remains below or exceeds the nor-mal range, inspect the cooling system to determinethe cause.

Fuel Gauge

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

Turbo Boost Gauge (optional)

The turbo boost gauge indicates the boost pressureat the turbo. See the Caterpillar or the Cummins Op-eration and Maintenance Manual for more informa-tion.

Engine Oil Pressure Gauge

The oil pressure gauges should read in the normalrange.

CAUTIONA sudden decrease or absence of engine oilpressure may indicate mechanical failure. Bringthe vehicle to a safe stop and investigate thecause to prevent further damage. Do not operatethe engine until the cause has been determinedand corrected.

Voltmeter

The voltmeter indicates the vehicle charging systemvoltage when the engine is running, and battery volt-age when the engine is stopped. By monitoring thevoltmeter, the driver can be aware of potential charg-ing system problems and have them repaired beforethe batteries discharge enough to create starting diffi-culties.

The voltmeter should indicate voltage in the normalrange when the engine is running. The voltage of afully charged battery is 12.7 to 12.8 volts when theengine is stopped. A completely discharged batterywill produce only about 12.0 volts. The voltmeter willindicate lower voltage as the vehicle is being startedor when electrical devices in the vehicle are beingused.

If the voltmeter shows an undercharged or over-charged condition for an extended period, have thecharging system and batteries checked at a repairfacility.

Some vehicles may be equipped (by the bodybuilder) with a battery isolator system and a gelcell battery. On these vehicles, the voltmetermeasures the average voltage of all the batter-ies when the engine is running. When the en-gine is stopped, the voltmeter shows only thegel cell battery voltage and does not indicatethe voltage of the engine-starting batteries.

Air Pressure Gauges

IMPORTANT: Two separate air pressure gaugesindicate air pressure in the primary and second-ary air systems. Build up air pressure in bothsystems to 95 to 120 psi (620 to 827 kPa) be-fore moving. It is normal to observe fluctuation

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in these gauges during operation of the vehicle.An alarm will sound if the pressure drops belowa safe operating range.

Transmission Temperature Gauge (optional)

The transmission temperature gauge indicates thetemperature of the transmission oil.

CAUTIONIf the transmission continues to overheat duringnormal operation, have it checked and repaired.Continued operation may cause damage to thetransmission.

Audible AlarmsThe instrumentation system provides for the followingaudible alarms:

• A rapidly pulsating buzzer sounds anytime thestop engine warning light is activated.

• A rapidly pulsating buzzer sounds anytime thelow air warning light is activated. On the airsystem, the low air light/buzzer will normallycome on when the engine is first started, butwill go off when the air pressure in the airtanks reaches approximately 65 to 76 psi (448to 524 kPa). The parking brake will not disen-gage until the air pressure has reached 65 psi(448 kPa).

8 18

VOLT

OIL

ENG TEMP TRANS TEMP FUEL

REAR AIR

FRONT AIR

L H

C H C H E F

0 150

0 150

15

2535

4555

65

755

10

1520

2530

350 85

03/02/2004 f610697

LOWAIR

CHECKTRANS

ABS

CRUISEON

PARKBRAKE

STOPENGINE

CHECKENGINE

WAITTO

START

ENGPROT

CHECKINFO

SHIFTINHIBITCENTER

12

3

4

5

6

78

9

10

11

1. Transmission Temperature Gauge2. Engine Temperature Gauge3. Oil Pressure Gauge4. Tachometer5. Voltmeter6. Annunciator Module

7. Speedometer8. Front Air Pressure Gauge9. Rear Air Pressure Gauge10. Trip Meter Rest11. Fuel Gauge

Fig. 2.31, Typical Instrument Panel

Driver Controls and Instruments

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• A chirping buzzer sounds under the followingconditions:

– The ignition key is in the ON position,the transmission is not in neutral (N),and the parking brake is applied.

– The ignition key is in the ON position,the transmission is in neutral (N), theservice brake is not depressed, and theparking brake is not applied.

– The ignition key is switched to the OFFposition and the parking brake is not ap-plied.

– The buzzer will sound continuously any-time the ignition is turned off when thepanel lamps are still illuminated.

• The buzzer will sound for three seconds to in-dicate that the system is operating correctly.

Information CenterThe information center is an interactive graphical dis-play that is capable of displaying text messages andgraphics to communicate real-time information aboutthe status and performance of the vehicle to the op-erator. This information is organized in a menu struc-tured format.

Power on Initialization

When the ignition is turned on, the information centerwill illuminate with the Freightliner Custom Chassislogo, and then display the home screen. The favoritescreen will be displayed if a favorite screen is set up.

Navigating the Menu Screens

The menu structure is navigated using six buttonslocated on the face of the information center. SeeFig. 2.32 for the symbol, name, and function of thenavigation buttons.

Menu Structure

The menu structure is organized around three menuscreens: the home screen, the setup screen, and thealarm screen. Each of these screens contains lists ofthe sub-menu screens that may be accessed byhighlighting the desired sub-menu and pushing theenter button.

Home Screen Features

The following real time trip computer data is found inthe trip computer and trip meter sub-menus of thehome screen.

• Instantaneous Fuel Economy

• Average Fuel Economy

• Fuel Remaining

• Odometer

• Multiple Trip Odometers

The following vehicle performance data is found inthe engine sub-menu of the home screen.

• (E–information) A screen that simultaneouslydisplays speed, RPM, and gear information.

• RPM

• Speed

• Engine Temperature

• Oil Pressure

• Battery Voltage

Service and diagnostic screens are found under theservice sub-menu of the home screen. These arepassword protected sub-menus and are for Freight-liner Custom Chassis dealer use only.

Setup Screen Features

The following can be done from the setup screen.

• Adjust the contrast of the display

• Switch between English and metric mode

• Designate a favorite screen that the display willmove to when the ignition is turned on or whenthe red button is pushed. The clock display isthe default.

Alarm Screen Features

The following alarm screen features are available.

• Alarm sub-menu—Alarm messages have prior-ity over other display screens. Pushing the "E"button temporarily clears the alarms. But if thealarm is still active after five minutes, the infor-mation center will display the alarm screenagain.

• Time/Date sub-menu—the clock can be setusing this sub-menu.

Driver Controls and Instruments

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Menu Structure Road MapThe menu structure road map is provided to illustratethe screens that are available in the information cen-ter, the path to specific screens, and the details ofeach individual screen. See Fig. 2.33 , Fig. 2.34 ,Fig. 2.35 , Fig. 2.36 , Fig. 2.37 , and Fig. 2.38 .

Instrumentation Control Unit(front-engine diesel chassis)Figure 2.39 shows a typical set of instruments forvehicles equipped with the MC Recreational Vehicleinstrument cluster (ICU3-M2).

Figure 2.40 shows a more basic instrument cluster.The tachometer and the transmission temperaturegauge are not shown.

The Recreational Vehicle instrument cluster (ICU3-M2) is an an updated version of the basic electronicdashboard (ICU3). It can accept information from thedatalink and from various sensors installed on thevehicle, and deliver that information to electronicgauges.

There are six gauges on the driver’s instrumentpanel.

The instrument cluster has the capability to drive in-dependent stand-alone gauges such as those in-stalled on the auxiliary dash panel. Figure 2.41shows a typical dash.

Dash Message CenterThe dash message center is the heart of the instru-ment cluster. It has two parts, a set of 26 warningand indicator lights similar to those found on a con-ventional lightbar, and a dash driver display screen.The driver display screen is a one-line by seven-character liquid crystal display (LCD) that normallyshows odometer readings. Below this display is asmaller one-line by three-character LCD that showsvoltmeter readings.

The dash message center houses all of the standardand optional warning and indicator lights. Warningmessages and diagnostic fault codes will appear inthe driver display screen. For more information onthis system, see under the heading "Ignition Se-quence" in this chapter.

Ignition SequenceThe dash message center goes through a prescribedignition sequence each time the ignition switch isturned on. See Fig. 2.42 for the ignition sequence.

When the ignition is turned on, all the electronicgauges complete a full sweep of their dials, thewarning and indicator lights light up, and the buzzersounds for 3 seconds.

The following lights illuminate during the ignition se-quence:

• Fasten Seat Belt Warning

• Low Battery Voltage Warning

Scroll Up Highlights the line above

Highlights the line below

Selects highlighted line

Cycles through screens within a menu

Jumps to Favorite Screen

Returns to the previous menu

Scroll Down

Enter

Toggle

Red Button

Home

Symbol Name Purpose

03/01/2004 f060185

E

T

H

Fig. 2.32, Information Center Menu Options

Driver Controls and Instruments

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• High Coolant Temperature Warning

• Low Engine Oil Pressure Warning

• Parking Brake On Indicator

• All engine indicator/warning lights, includingCheck Engine and Engine Protection

• All ABS indicator/warning lights, includingWheel Spin, Tractor ABS, and Trailer ABS (ifinstalled)

NOTE: While the engine and ABS warning lightsilluminate during the ignition sequence, they arenot controlled by the instrument cluster but bytheir own system ECU (electronic control unit).On Caterpillar engines, the engine protectionlight illuminates when the engine starts, andstays on for about 5 seconds.

When the ignition switch has been turned on, theICU performs a self-test, looking for active faults.

During the first half of the self-test, all segments ofthe display illuminate as follows:

• First line (odometer): "888888.8"

• Second line (units): "TRIP MI KM HOURS"

• Third line (voltmeter): "38.8 VOLTS SERVICE"

• Fourth line: "ENGINE"

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

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

If the instrument cluster 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. Once the parking brakeis released, the dash message center displays theodometer again.

Trip MetersEngineService

Trip Center

02/27/2004

Setup

E

Trip CenterTrip Meters

E

AlarmTime/Date

E

TT T

Next Drop Down Menu

HOMESCREEN

TOGGLE

FAVORITE

HOME

UP

ENTER

DOWN

Use the "UP" or " Down" arrows tohighlight the desired menu option.To enter the selected menu option press "E".To return to the previous menu, press "H".

EngineService

f544414

E

T

H

Fig. 2.33, Home Screen

Driver Controls and Instruments

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NOTE: If active faults are present, take the ve-hicle as soon as possible to an authorizedFreightliner service facility.

If the fault is mission critical, that is, if it is a seriousproblem that requires immediate attention, the engineprotection system will activate. In most cases, thecheck engine light will illuminate also.

Some examples of mission critical faults include:

• High coolant temperature

• Low coolant level

• Low engine oil pressure

NOTE: The check engine light does not illumi-nate for a low air pressure fault.

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

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

02/27/2004

Trip CenterSubmenu

AverageEconomy

8.0

InstantEconomy

12.3

FuelF

Normal

Trip MetersSubmenu

Tripmeter 1

378.0

E

Fuel

MI

Tripmeter 2

123.0MI

Odometer

4265.8MI

Reset Tripmeter 1

Reset Tripmeter 1

Back to AverageEconomy

"E" must be held until the Trip Odometer resets

Tripmeter 1 is the same asTrip odometer in the GaugeLCD display. They can bothbe reset by remote trip resetswitch and info Center.

Tripmeter is onlydisplayed and resetin the Info Center.

Trip CenterTrip Meter

Screen Detail

E

T

T

E

T

T

T T

E

E

Back to Tripmeter 1

f544413

RESET

RESET

Fig. 2.34, Trip Center/Trip Meter Detail

Driver Controls and Instruments

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operating the vehicle, bring the vehicle to anauthorized Freightliner service facility whenconvenient.

OdometerThe odometer is set to display in either miles or kilo-meters, depending on the primary scale of thespeedometer. The legend, either "MI" or "KM," illumi-nates between the odometer and the volts displaywhen the engine is running or the headlights areturned on.

The odometer is a seven-digit display with a decimalpoint, until the vehicle has traveled 999,999.9 miles

or kilometers (km). At one million miles (km), theodometer resets itself to "1000000," without the deci-mal point, and can continue up to 9,999,999. Theodometer only displays significant figures (no leadingzeros).

Mode/Reset SwitchThe mode/reset switch is located on the right side ofthe instrument cluster. See Fig. 2.43 . The mode/reset switch is used to scroll through the displays onthe message display screen, and to reset the trip dis-tance and trip hours values to zero.

02/27/2004

Setup

E

Engine RPM

2300 rpm

40000

T

Road Speed

55 mph

850

E

Battery

Normal

T

Oil Pressure

800

14.4 v8 13 18. . . . . .

Normal14.4 v

T

E − INFO

55 mph

T

Engine Temp

24080

Normal180 F

2300 rpm

4th Gear

Back to EngineRPM

Service Submenu

Diagnostics

ENTERPASSWORD

TT

T

E

f544415

Engineand

ServiceScreenDetail

Authorized Serviceuse only

Fig. 2.35, Engine and Service Screen Detail

Driver Controls and Instruments

2.21

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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.

Level One Heading HereThis text is considered fill material to overcome anunresolved problem. Please delete this text but notthe tags! and go ahead as per normal.

Setup Submenu

Contrast

Units

Favorite

ENTERPASSWORD

XXXX

(FACTORY USE ONLY)

Contrast

Clock

Example Screen Setup screen:

E

T

f544416

Vehicle

Units10

ENG

FACTORY CALIBRATION

Vehicle

Pressing "E" causes highlight to flash.

Pressing arrows will change values from 3 to 10

for contrast level.

Pressing "E" causes highlight to flash then the arrows allow change from

English to Metric.

Pressing "E" allows user to select which screen the system will start on every time the system powers

up or when the red button is pushed.

E

E

E

3 5

4 6

7

8

9

10

ENGMET

CLOCK Engine

Trip Meters Favorite

E

E

E

From this screen you can: 1. Adjust the contrast level. 2. Change between English/Metric mode. 3. Select which screen you would like the system to power up with. 4. Access the factory screens.

03/10/2004

Fig. 2.36, Setup Screen

Driver Controls and Instruments

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03/01/2004

Time/Date

E

01:42:12/18/2002

AM/PM

E

Hours

E

Minutes

E

Seconds

E

Month

E

Day

E

Year

"E" selects category to the left. When "SET" appears arrows will

adjust value. "E" to accept.

"E" selects category to the left. When "SET" appears arrows will

adjust value. "E" to accept.

"E" selects category to the left. When "SET" appears arrows will

adjust value. "E" to accept.

"E" selects category to the left. When "SET" appears arrows will

adjust value. "E" to accept.

PM

1 − 12 or 0 − 23

0 − 60

0 − 60

1 − 12

1 − 31

0 − 65535

AM

24

AM43

Example Screen

E

E

E

E

E

E

E

Clock set screen

f544419

Fig. 2.37, Clock Set Screen

Driver Controls and Instruments

2.23

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Batt LOW10.0 volts

Threshold

TranT Norm285 deg F

275ENG BRAKE

TRANS ECUNO DATAOver 25

AirP4 Low0 psi

Threshold

Fuel LOW10.0 gallonsThreshold

AUTO IDLE10.0 volts

ThresholdPARK SETIN GEAR

AirP3 Low0 psi

Threshold

Temp HIGH240 deg FThreshold

HeadlightsAreOn

NEUTRALNO BRAKE

Seconds

ENG ECUNO DATAOver 25

OIL LOW4 psi

Threshold

Brake Fuse0.0 volts

Threshold

WAITTO

START

22.565

Seconds

65

5 psi

220° F

7.0

13.4v

03/01/2004 f544418

Alarm

E

11.5 15.5

The alarm screens indicate: 1st The item in alarm state 2nd Current value 3rd The threshold that needs to be met to eliminate the alarm.

Fig. 2.38, Alarm Screen

Driver Controls and Instruments

2.24

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0

5

10

1520

30

RPM5

15

2535

4555

65

75

85

MPHkm/h

25

X100

30

5070

90

130

110

10

E F

1/2

0 100

50

PSI

WATER

OIL

TRANS

FUEL

100

150 200

250

100

225

350

f610782

PUSH−MODEHOLD−RESET

1

2 3 4 5

6

10

9 8 711/07/2005

1. Engine Oil Pressure Gauge2. Dash Message Center3. Dash Driver Display Screen4. Headlight High-Beam Indicator

5. Fuel Level Gauge6. Mode/Reset Switch7. Speedometer (U.S. version)8. Tachometer (optional)

9. Transmission Temperature Gauge(optional)

10. Coolant Temperature Gauge

Fig. 2.39, Gauge Layout (typical, U.S.)

Driver Controls and Instruments

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8 f610785

2 3 5 6

WATER

100

150 200

250

0 100

50

PSI

OIL

E F

1/2

FUEL

0

20

40

60 80100

120

140km/hMPH

20

40

80

60

0

PUSH−MODEHOLD−RESET

11/08/2005

71

4

TRANSTEMP

ABS TRAILERABS

AIRFILTERBRAKE

CHECKENGINE

ENGINEPROTECT

NOCHARGE

1. Coolant Temperature Gauge2. Engine Oil Pressure Gauge3. Dash Message Center

4. Headlight High-Beam Indicator5. Dash Driver Display Screen6. Fuel Level Gauge

7. Mode/Reset Switch8. Speedometer (NAFTA version)

Fig. 2.40, Gauge Layout (basic)

Driver Controls and Instruments

2.26

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5

4

f610578

1

23

10/11/2001

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

1. L/H Control Panel2. Instrumentation Control Unit (ICU3-M2)3. R/H Control Panel

4. Auxiliary Dash Panel5. Climate Control Panel

Fig. 2.41, Dash Panel Layout (typical)

Driver Controls and Instruments

2.27

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POWER ON

PARK BRAKE

IGNITION ON

HEADLIGHTS ON

RELEASE PARK BRAKE

f040420b10/24/2001

RELEASED − MOVING

FAULT CODESCREEN

IF NO FAULTSWERE DETECTED

ELECTRONIC GAUGE NEEDLESSWEEP, WARNING/INDICATORLIGHTS COME ON, BUZZER SOUNDS

IF FAULT DETECTED

ICU PERFORMS SELF−TEST:

888888.8

ABS 136

ODOMETERSCREEN

123456.7

12.3 VOLTS

123456.7

12.3 VOLTS

MI

MI

TRIP MI KM HOURS38.8 VOLTS SERVICE

ENGINE

Fig. 2.42, Ignition Sequence

09/25/99

PUSH− MODE HOLD− RESET

f610340

Fig. 2.43, Mode/Reset Switch

Driver Controls and Instruments

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3

EnginesEngine Starting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.1Cold Weather Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.2Engine Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.2Cruise Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.4Engine Shutdown . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.6High Altitude Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.7Engine Braking (optional) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.7

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Engine Starting

WARNINGDo not use any starting aid, such as ether, in en-gines with an air intake heater. This could causean explosion and serious personal injury ordeath.

NOTE: For cold weather starting, see "ColdWeather Operation" in this chapter.

IMPORTANT: Before starting the engine, readChapter 2 in this manual for detailed informa-tion on how to read the instruments and operatethe controls. Also, before engine start-up, per-form the engine pretrip inspection and dailymaintenance checks in Chapter 7 .

CAUTIONIf 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.

1. Set the parking brake.

2. Place the transmission in Neutral (N).

CAUTIONDon’t crank the engine for more than 30 secondsat a time during any of the following procedures.Wait two minutes after each try to allow thestarter to cool. Failure to do so could causestarter damage.

CaterpillarNOTE: See the Caterpillar Operation and Main-tenance Manual for detailed information onstarting procedures.

Cummins

CAUTIONIf the engine is equipped with a turbocharger,protect the turbocharger during start-up by notopening the throttle or accelerating the engineabove 1000 rpm until normal engine idle oil pres-sure registers on the gauge.

NOTE: See the Cummins Operation and Main-tenance Manual for detailed information onstarting procedures.

Mercedes-Benz

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 START position.Without touching the accelerator pedal, start theengine.

2. Idle the engine for one to three minutes at 600 to850 rpm before operating the engine under load.

3. 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.

Engines

3.1

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Cold Weather Operation

WARNINGDo not use any starting aid, such as ether, in en-gines with an air intake heater. This could causean explosion and serious personal injury ordeath.

CaterpillarSee the Caterpillar Operation and MaintenanceManual for cold weather procedures.

CumminsSee the Cummins Operation and MaintenanceManual for cold weather procedures.

Mercedes-BenzSee theMercedes-Benz Operation and MaintenanceManual for cold weather procedures.

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

The intake air preheater is activated by turning theignition switch to the ON position. If the engine is atnormal temperature, the INTAKE HEATER indicatorgoes 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 repeatthe starting procedure.

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

Engine OperationOperating vehicles with diesel engines in areaswhere there are concentrated flammable vapors(such as diesel, gasoline, or propane fumes) can cre-ate a hazardous situation. These vapors can be

drawn into the engine through the air intake andcause engine overspeed. Be especially cautious oflow-lying or closed-in areas, and always check forsigns that flammable vapors may be present.

DANGERDon’t 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.

NOTE: Heavy-duty engines are equipped fromthe manufacturer with ethylene glycol coolantonly.

CaterpillarCaterpillar electronic engines can be equipped with avariety of options designed to warn the driver of en-gine malfunctions. The driver of a vehicle equippedwith these engines should know the extent of thewarning system in order to bring the vehicle to a safestop if the engine malfunctions. If the driver doesn’tunderstand how the warning system works, an en-gine shutdown could cause a safety hazard. SeeChapter 2 for information on the control panel forthese engines.

The electronic control system can monitor engine oilpressure, coolant temperature, intake manifold airtemperature, and coolant level.

In the engine monitoring "OFF" mode the ECM (elec-tronic control module) will ignore the oil pressuresensor and coolant level sensor (if installed). Enginemonitoring "WARNING" mode uses oil pressure,coolant temperature, intake manifold temperature,and the coolant level sensor (if so equipped and en-abled). The "CHECK ENGINE" light will flash and thewarning light will come on when the diagnostic codeis active. Engine monitoring "DERATE" and "SHUT-DOWN" modes allow the ECM to alter engine perfor-mance or stop the engine to help the engine avoiddamage and return to normal conditions.

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

Engines

3.2

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that it has thermostatic controls. If the fuelheater has a timer, set the timer to activate onlyfor a limited period of time before the enginestarts. Make sure that the fuel heater is usedonly for starting the engine.

1. On a downhill grade, do not coast or put thetransmission in Neutral (N). Select the correctgear that does not allow the engine to exceed itsmaximum speed. Use the brakes to limit vehiclespeed.

2. As with any engine, prolonged idling of a Cater-pillar engine is not recommended. An idling en-gine wastes fuel and if left unattended is alsounsafe.

CumminsThe driver should be familiar with the vehicle warningsystem in order to bring the vehicle to a safe stop ifthe engine malfunctions. See Chapter 2 for informa-tion on the control panel for these engines.

1. Cummins engines produce high horsepower andpeak torque characteristics at low rpm. Becauseof this, it is not necessary to operate the engineat high rpm to deliver the required horsepower atthe wheels. These characteristics may also resultin less shifting and make shifting at lower rpm (topeak 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 rpm,rather 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 this

flexibility. The driver who stays in top gear anduses the wider speed range will achieve the bestfuel economy.

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

6. The Cummins engine is effective as a brake ondownhill grades, but take care not to overspeedthe engine going downhill.

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.

Mercedes-BenzNote: Mercedes-Benz engines are equippedwith the electronic engine control system, whichmonitors the engine as it is running. If the en-gine control unit (ECU) detects a fault seriousenough to harm normal operation, the electronicengine system switches over to emergency run-ning mode. When in emergency running mode,the engine operates at a maximum 1300 rpm.This allows you to move the vehicle to a servicelocation.

Proper operation and maintenance are key factors inobtaining the maximum life and economy of a vehicleengine. Follow the directions in this manual and theengine manufacturer’s operator’s manual for trouble-free, economical engine operation.

1. 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 rpm,rather than in the next lower gear at the maxi-mum rpm.

2. 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.

3. Never allow the engine to exceed the high-idlegoverned speed (2700 rpm). Use the exhaustbrake and the optional turbo or constant-throttlebrake, if installed, to lower engine rpm below thehigh-idle governed speed.

Engines

3.3

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

Cruise ControlThe cruise control allows you to automatically controlthe speed of the vehicle above 32 mph (50 km/h).The switches that operate the cruise control are lo-cated on the turn signal lever. See Fig. 3.1 .

NOTE: On vehicles equipped with the optionalSmartWheel, the cruise control switches are lo-cated on the left switch panel. See Fig. 3.2 andFig. 3.3 .

WARNINGDo not use the cruise control system when driv-ing conditions do not permit maintaining a con-stant speed, such as in heavy traffic or on roadsthat are winding, icy, snow covered, slippery, orwith a loose driving surface. Failure to follow thisprecaution could cause a collision or loss of ve-hicle control, possibly resulting in personal injuryor property damage.

CAUTIONDo not shift to Neutral (N) when using cruisecontrol. This will cause the engine to overspeed,which can damage the engine.

1. To cruise at a particular speed:1.1 Move the slide switch on the turn signal

lever to the ON position or press the ONbutton on the steering wheel.

08/15/2003 f610668

1 2

1. Cruise SET/COAST Button2. Cruise RESUME/ACCEL Button

Fig. 3.1, Cruise Control Switches (turn signal lever)

12/05/2001 f461927

1

2

3

1. Left Switch Panel2. Horn Bar3. Right Switch Panel

Fig. 3.2, SmartWheel (optional)

12/05/2001 f461928

1

2

3

4

5

6

7

8

9

10

11

12

1. Left Switch Panel2. Headlamp Interrupt3. Cruise On/Off4. Cruise Cancel5. Cruise Resume/Accel6. Cruise Set/Coast

7. Right Switch Panel8. Marker Lamp Interrupt9. Wiper Off10. Wiper Hi/Lo11. Wiper Variable12. Wiper Wash

Fig. 3.3, SmartWheel Switch Panels

Engines

3.4

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1.2 Hold the accelerator pedal down until thevehicle reaches the desired speed. Thespeed must be above 32 mph (50 km/h).

1.3 Press and release the SET/COAST buttonat the end of the turn signal lever or pressthe SET/COAST button on the steeringwheel.

1.4 One second after releasing the SET/COAST (lever) button or the SET/COASTon the steering wheel, take your foot off ofthe accelerator pedal.

You can increase the vehicle speed whilethe cruise control is engaged by pressingon the accelerator pedal, by moving theslide switch on the turn signal lever to theRESUME/ACCEL position, or by pressingthe SET/COAST button on the steeringwheel. When you release the pedal, theslide switch, or the button, the vehicle willreturn to the set speed.

To increase the set speed, accelerate tothe desired speed, then press and releasethe SET/COAST (lever) button or the SET/COAST button on the steering wheel.

To decrease the set speed, press theSET/COAST (lever) button or the SET/COAST button on the steering wheel.When the vehicle slows to the desiredspeed, release the SET/COAST (lever)button or the SET/COAST button on thesteering wheel.

2. To disengage the cruise control:

2.1 Depress the brake pedal, or

2.2 Move the slide switch on the turn signallever to the OFF position or press theOFF button on the steering wheel.

If the brake pedal was used to disengagethe cruise control, you can return the ve-hicle to the set speed with the slide switchor the steering wheel button. Accelerate toa speed above 32 mph (50 km/h), thenmove the slide switch to the RESUME/ACCEL position or press the RESUME/ACCEL button on the steering wheel. Thecruise control will return the vehicle to theset speed.

NOTE: The set speed will be maintained within4 mph (6 km/h) above or below the set speedwhen grades do not exceed 7-percent (mostinterstate highways). At higher altitudes, the setspeed can vary by more than 4 mph (6 km/h).

If actual vehicle speed decreases 5 mph (8km/h) or more below the set speed, the cruisecontrol will automatically disengage.

When pulling a heavy load, climbing a verysteep hill, or driving into a strong wind, bring thevehicle up to speed with the accelerator pedaland then let the cruise control take over.

3. High Idle (With Cruise Control Option)

3.1 Place the shift lever in Neutral (N).

3.2 On the turn signal lever, move the slideswitch to the ON position or press the ONbutton on the steering wheel. Accelerateto the desired rpm. Press and release theSET/COAST or SET/COAST button on thesteering wheel.

3.3 Disengage by stepping on the brakepedal, by moving the ON/OFF switch tothe OFF position, or by pressing the OFFbutton on the steering wheel.

SmartWheel Cruise Control

WARNINGDo not use the cruise control system when driv-ing conditions do not permit maintaining a con-stant speed, such as in heavy traffic or on roadsthat are winding, icy, snow covered, slippery, orwith a loose driving surface. Failure to follow thisprecaution could cause a collision or loss of ve-hicle control, possibly resulting in personal injuryor property damage.

Cruise On/Off

Press the cruise control ON/OFF switch to activatethe cruise control or to turn it off.

Cruise Set

Press the cruise control SET/COAST switch to setthe desired cruising speed.

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Cruise Accel

Press the cruise control RESUME/ACCEL switch toaccel above the current speed setting.

Cruise Resume

Press the cruise control RESUME/ACCEL switch toresume cruise control activation.

Cruise Coast

Press the cruise control SET/COAST switch to coastthe vehicle.

Cruise Cancel

Press the cruise control CANCEL switch to disen-gage cruise control without losing the current speedsetting.

Engine Shutdown

CAUTIONStopping the engine immediately after it has beenworking under load can result in overheating andaccelerated wear of engine and turbochargercomponents and cause oil coking problems. Fol-low the procedures outlined below to allow theengine to cool.

When safe to do, shut down the engine at thefirst sign of malfunction. Almost all malfunctionsgive some warning to the operator before signifi-cant damage occurs. Many engines are savedbecause alert operators heed warning signs (sud-den drop in oil pressure, unusual noises, etc.)and immediately shut down the engine.

Caterpillar1. With the vehicle stopped, apply the parking

brakes. Reduce the engine speed to low idle.

2. Place the transmission in Neutral (N).

3. If the engine has been operating at low loads,run it at low idle for 30 seconds before stopping.If the engine has been operating at highwayspeed or at high loads, run it at low idle for threeminutes to reduce and stabilize internal enginetemperatures before stopping.

4. Turn the ignition key to the OFF position to shutdown the engine.

5. If the engine is equipped with an idle shutdowntimer, it can be set to shut the engine down aftera preset amount of time. Ninety seconds beforethe preset shutdown time, the "CHECK ENGINE"light will begin to flash at a rapid rate. If theclutch pedal or service brake indicates a positionchange during this final 90 seconds, (with thediagnostic lamp flashing) the idle shutdown timerwill be disabled until 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 freezing temperatures are expected, allow theengine water jacket expansion tank to cool. Thencheck the coolant for proper antifreeze protec-tion. 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.

Cummins1. With the vehicle stopped, place the transmission

shift lever in the Neutral (N) position and set theparking brake using the parking brake controlknob.

2. It is important to idle an engine for 3 to 5 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.

3. Do not idle the engine for excessively long peri-ods.

IMPORTANT: Long periods of idling are notgood for an engine because the combustionchamber temperatures drop so low that the fuelmay not burn completely. This will cause carbonto clog the piston rings and may result in stuckvalves.

4. If the engine is not being used, shut it down byturning the ignition key to the OFF position.

Engines

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Mercedes-BenzEmergency Shutdown

If any of the following occur, shut down the engineimmediately:

• the oil pressure swings back and forth or fallssharply

• engine power and rpm fall even though theaccelerator pedal remains steady

• the engine gives off heavy exhaust smoke

• the coolant and/or oil temperature climb abnor-mally

• abnormal sounds suddenly occur in the engineor turbocharger

Normal Engine Shutdown

1. With the vehicle stopped, apply the parkingbrake and place 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 thecombustion 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(46°C).

CAUTIONExcept in emergency, do not shut down the en-gine when the coolant temperature is above194°F (90°C). To do so could damage the engine.

3. Turn off the ignition switch and shut down theengine.

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. Most turbocharged engines are ratedfor higher altitudes than naturally aspirated engines.An engine will have smoky exhaust at high altitudesunless a lower gear is used. Shift gears as neededto avoid excessive exhaust smoke.

Engine Braking (optional)Exhaust BrakeIMPORTANT: The exhaust brake is a vehicleslowing device, not a vehicle stopping device. Itis not a substitute for the vehicle service brakes.Use of the exhaust brake for vehicle downhillcontrol and slowing down on level terrain willallow the service brakes to remain cool andready for an emergency.

WARNINGDo not use the exhaust brake if road surfaces areslippery. Using the exhaust brake on wet, icy, orsnow-covered roads could result in loss of ve-hicle control, possibly causing personal injury ordeath, or property damage.

To get the best result from the exhaust brake, it isnecessary to observe several simple operating prin-ciples.

The exhaust brake is activated when the followingconditions are satisfied.

1. The ON/OFF switch is in the ON position.

2. The engine is not being fueled.

The Allison transmission provides for optimumretarding downshift operation when the exhaustbrake is selected. When the switch is turned ONand your foot is removed from the throttle pedal,the transmission will immediately preselect alower gear. The transmission then starts todownshift through the gears to reach the prese-lected gear. Downshifting occurs at a higherspeed than is usual when the exhaust brake is

Engines

3.7

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not turned on. This allows the exhaust brake toprovide the maximum retarding power.

Compression (Engine) Brake (VCLonly)IMPORTANT: A compression (engine) brake is ahydraulic-electric engine attachment that con-verts a diesel engine into an air compressor.This is done by changing engine exhaust valveoperation. A compression (engine) brake is nota substitute for a service braking system, exceptin emergencies, because it does not provide theprecise control available from the servicebrakes.

WARNINGDo not use the compression brake if road sur-faces are slippery. Using the compression brakeon wet, icy, or snow-covered roads could resultin loss of vehicle control, possibly causing per-sonal injury or death, or property damage.

The compression brake is controlled by a singleswitch with three positions: OFF, LO, and HI.

To engage the compression brake, the switch mustbe in the LO or HI position and the throttle pedalmust be fully released. To disengage the compres-sion brake, depress the throttle pedal, or move thedash switch to OFF.

WARNINGIf the compression brake is engaged when thetransmission is in Neutral (N), the braking powerof the compression brake can stall the engine,which could result in loss of vehicle control, pos-sibly causing personal injury or death, or prop-erty damage.

Since the compression brake is most effective atrated engine speed, gear selection is very important.Gearing down the vehicle within the limits of therated engine speed makes the compression brakemore effective. Maximum braking occurs with the useof the lowest gear that does not exceed the ratedengine speed. A rule of thumb for gear choice is toselect the gear that normally would be used to climban approaching downhill grade. Generally, this same

gear can be used with the compression brake for acontrolled descent of the hill.

"Control speed" is the speed at which the compres-sion brake performs 100 percent of the requireddownhill braking, resulting in a constant speed of de-scent. The control speed varies, depending on ve-hicle weight and the downhill grade.

For faster descent, select a higher gear than thatused for control speed. Service brakes must then beused intermittently to prevent engine overspeed andto maintain desired vehicle speed.

IMPORTANT: When descending a grade, re-member that frequent use of service brakescauses them to become hot, which results in areduction of their stopping ability. Control gradedescent speed so that the service brakes areused infrequently and remain cool, thus retain-ing their effectiveness.

A driver may descend at a rate slower than controlspeed by selecting a lower gear, one that will notoverspeed the engine. The compression brake re-tarding force will then be sufficient to cause vehicledeceleration. Occasional deactivation of the com-pression brake may be necessary to maintain thedesignated road speed under these conditions.

The compression brake can be used to assist instopping a vehicle if the service brakes quit working.By energizing the compression brake as soon as aservice brake problem is apparent, a retarding effectis applied to the vehicle. As grade conditions permit,the driver can progressively downshift, using thecompression brake in each gear. Eventually, thecompression brake will stop the vehicle.

WARNINGUsing the compression brake as a primary brak-ing system when the service brakes are operableis dangerous. This can cause long, unpredictablestopping distances, possibly resulting in per-sonal injury or death, or property damage.

Whenever vehicle braking is required, the compres-sion brake may be used with the service brakes.There is no time limit for operation of the compres-sion brake.

1. After the engine is warmed up and the vehicle isin motion, move the switch to the desired posi-tion, LO or HI. Depending on the engine model,

Engines

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LO will provide 1/3 to 1/2 of the full braking ca-pacity of the engine. HI will provide maximumengine braking.

2. The compression brake activates when theswitch is in either the LO or the HI position andthe driver’s foot is removed from the throttlepedal. If it fails to activate, stop the vehicle in asafe spot and check the adjustment of thethrottle switch. If no cause can be detected in theelectrical system, check the compression brakingsystem.

3. To obtain the maximum retarding effect, maintainthe top governed speed of the engine throughthe appropriate selection of gears when the com-pression brake is in use.

4. When the throttle pedal is depressed, the com-pression brake is deactivated.

CAUTIONIf the compression brake fails to shut off whenthe switch is turned off, shut down the engineand repair the compression brake before continu-ing operation. Failure to do so could result indamage to the engine.

Mercedes-BenzConstant-Throttle Valves

To increase braking performance, Mercedes-Benzengines are equipped with constant-throttle valves(optional) in each combustion chamber. Small valvesbuilt into the cylinder head allow a small amount ofcompressed air to escape through the exhaust portduring the combustion stroke. The constant-throttlevalves are open during the entire time that the en-gine brake is activated. Although some braking abilityis lost because the valves are constantly open,constant-throttle braking is quieter in operation thanother types of engine brakes.

When both the exhaust brake and the constantthrottles are installed, a three-position switch on thedash controls the amount of engine braking deliv-ered. Like the exhaust brake, the constant throttlesare deactivated when the accelerator or clutch pedalis depressed. The ABS system, when active, alsodeactivates constant-throttle braking.

The engine brake will deactivate if the engine speedfalls below a preset level. This level is programmablebut is set at the factory at 1100 rpm.

Exhaust Brake

An exhaust brake is an optional auxiliary braking sys-tem that assists but does not replace the servicebrake system. The exhaust brake can be used aloneor together with the constant-throttle valves for steepor long grades. 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 only active when the enginespeed is between 1100 and 2700 rpm. Depressingthe accelerator or clutch pedal deactivates the ex-haust brake. The ABS system, when active, also de-activates the exhaust brake.

The exhaust brake is a butterfly valve mounted in theexhaust pipe. When the driver’s foot is not on theaccelerator pedal and the upper half of the exhaustbrake switch is pressed in, with the amber light onthe switch illuminated, an air cylinder shuts the but-terfly valve which restricts the flow of exhaust gasesand retards the engine. This retarding action is car-ried through the engine and drivetrain, slowing thevehicle and reducing the need for frequent servicebrake applications.

Exhaust brakes are not intended for use as the pri-mary braking system during vehicle operation.

Engines

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4

TransmissionsAllison Automatic Transmissions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.1

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Allison AutomaticTransmissions

CAUTIONDo not allow the vehicle to coast in neutral. Thiscan result in severe transmission damage. Also,no engine braking is available.

WARNINGNever shift from neutral (N) to drive (D) or re-verse (R) at engine speeds above idle. The ve-hicle will lurch forward or backward, which couldcause property damage and personal injury.

CAUTIONThe engine should never be operated for morethan 30 seconds at full throttle with the transmis-sion in gear and the output stalled. Prolongedoperation of this type will overheat the transmis-sion fluid and will result in severe damage to thetransmission.

1000/2000/2000 MH ModelsOperationIMPORTANT: The Allison 2000 MH 5-speedtransmission requires the use of TranSynd Syn-thetic ATF (automatic transmission fluid). Do notuse Dexron III ATF in this transmission.

1. Select Drive (D) for all normal driving conditions.See Fig. 4.1 . The vehicle will start out in First (1)gear, and as speed increases, the transmissionwill upshift through each gear automatically. Asthe vehicle slows down, the transmission willdownshift to the correct gear automatically.

Occasionally the road, load, or traffic conditionsmake it desirable to restrict the automatic shiftingto a lower range. The lower the gear range, thegreater the engine braking power.

2. Use Second (2) for slow driving in heavy citytraffic, or on mountain roads when more precisespeed control is desirable. Use it also for climb-ing long grades and for engine braking when de-scending moderately steep grades. To prevent

excessive engine speed, do not drive faster than45 miles per hour (72 km/h) in this range.

3. Use First (1) for climbing very steep grades andfor engine braking at low speeds when goingdownhill. To prevent excessive engine speed, donot drive faster than 25 miles per hour (40 km/h)in this range.

NOTE: In the lower gear ranges, the transmis-sion will not upshift above the highest gear se-lected unless the engine governed speed is ex-ceeded.

See the Allison Transmission Operator’s Manualfor more information on 1000, 2000, and 2000MH transmission operation.

3000 MH/4000 MH/4000 MHP ModelsGeneral Information

3000 MH, 4000 MH, and 4000 MHP series automatictransmissions have six forward speeds and one Re-verse (R) speed. These transmissions have elec-tronic shift controls that can be programmed to allowthe use of different numbers of geared speeds. SeeFig. 4.2 . For instance the transmission can be pro-grammed to operate as a 4-speed, 5-speed, or6-speed unit in the "primary" shift mode. If needed, a

R N

D

2

1

11/16/2000 f270073

D

Fig. 4.1, 1000, 2000, 2000 MH Shift Selector Lever(typical)

Transmissions

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"secondary" shift mode can be programmed to pro-vide another shift configuration to optimize vehicleuse under different operating conditions. To activatea secondary shift mode, or other special function pro-grammed into the electronic control unit (ECU), de-press the Mode button. A label just above the Modebutton identifies the special function.

NOTE: Each time that a push button is de-pressed on the shift selector, a short beep willbe heard. This indicates that the ECU has re-ceived input to change operation.

The 3000 MH, 4000 MH, and 4000 MHP seriestransmission systems are designed to warn the

driver of transmission malfunctions. The driverof a vehicle equipped with these transmissionsshould know the extent of the warning system inorder to safely operate the vehicle. See Chap-ter 2 for information on the warning system.

Operation

1. Start the engine.

2. Use Reverse (R) to back the vehicle. Completelystop the vehicle before shifting from a forwardgear to Reverse (R) or from Reverse (R) to aforward gear. There is only one Reverse (R)gear.

3. Select Drive (D) for all normal driving conditions.The vehicle will start out in First (1) gear, and asspeed increases, the transmission will upshiftthrough each gear automatically. As the vehicleslows down, the transmission will downshift tothe correct gear automatically.

The pressure of your foot on the acceleratorpedal influences the automatic shifting. When thepedal is fully depressed, the transmission willautomatically upshift near the governed speed ofthe engine. A partially depressed position of thepedal will cause the upshifts to occur at a lowerengine speed.

4. Occasionally the road, load, or traffic conditionsmake it desirable to restrict the automatic shiftingto a lower range. The lower the gear range, thegreater the engine braking power.

Use the up or down arrow buttons on the shiftselector to reach the desired gear.

5. Use Neutral (N) and apply the parking brakewhen the vehicle is parked with the engine run-ning.

See the Allison Transmission Owner’s Manual formore information on 3000 MH and 4000 MHtransmission operation.

NOTE: In the lower gear ranges, the transmis-sion will not upshift above the highest gear se-lected unless the engine governed speed isexceeded.

N

R

D

1

2

3

11/16/2000 f270113a

4

NOTE: The number displayed on the Digital Display but-ton is the highest forward range available in the se-lected position. Visually check to confirm the range se-lected. If the display is flashing, the shift is inhibited.1. Digital Display2. Mode ID3. Mode Indicator (LED)4. Push Simultaneously for Diagnostic Mode and Fluid

Level Check (optional)

Fig. 4.2, WTEC III Shift Selector

Transmissions

4.2

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1000/2000/2100/2400 Models (ArensSBW)General Information

The Arens shift-by-wire (SBW) push-button shift se-lector is part of an electronic shift control systemused with Allison series 1000/2000/2100/24005-speed automatic transmissions. An electronic ac-tuator is mounted to the transmission.

The 1000/2400 series transmissions have a parkpawl and the SBW selector has a Park (P) position.The 2000 and 2100 series transmissions do not havea park pawl and there is no Park (P) position buttonon the selector. The 2100 series transmission has apark brake (Pb) button. Otherwise, the two selectorsare identical. See Fig. 4.3 , Fig. 4.4 , and Fig. 4.5 .

In case the vehicle needs to be towed and the SBWsystem cannot be activated to move the transmissionout of Park (P), a manual procedure is provided toshift the transmission. At the actuator, on the trans-mission, a port is provided to insert an Allen wrenchto shift the transmission manually. See Chapter 10for more information.

Transmission Operation

1. At the top left side of the selector, is the selectdisplay. On the left side of the display window,an LED character indicates which gear has beenselected.

2. At the top right side of the selector, is the moni-tor display. On the right side of the display win-dow, an LED character indicates which gear isactually engaged.

WARNINGIf the Park (P) position is selected and the letterP does not appear on the monitor side of the dis-play window, you must set the parking brake.Otherwise the vehicle could move unexpectedlyand cause an accident, possibly resulting in per-sonal injury and property damage.

NOTE: Only the 1000/2400 series 5-speedtransmissions have a park pawl and a Park (P)button.

3. The Park (P) button shifts the transmission toNeutral (N) and engages the park pawl. When

Park (P) is selected, the monitor side of the dis-play window will show a letter P.

WARNINGAlways place the transmission in the Park (P) orNeutral (N) position and set the parking brakebefore releasing the service brakes and exitingthe vehicle. Otherwise the vehicle could moveunexpectedly and cause an accident, possiblyresulting in personal injury and property damage.

CAUTIONIf the ignition switch is turned to the OFF posi-tion before selecting Park (P), a buzzer will soundand the monitor display will show the gear that iscurrently engaged. Select Park (P) to turn off thebuzzer and the display. Also, with the engine notrunning (ignition switch in the ON position and

MONITOR

SELECT

SERVICE

R

N

P

D

MODE

PARK BRAKE must be set.WARNING: If "P"is not displayed

!

ARENS CONTROLS

04/02/2003 f270122

1

2

3

4

5

8

12

13

6

14

7

1011

9

1. SBW Shift Selector2. Drive (D) Button3. Neutral (N) Button4. Reverse (R) Button5. Park (P) Button6. Select Display7. Select/Monitor Display

Window

8. Monitor Display9. Service Display10. Mode Function Label11. Mode Light12. Mode Button13. Upshift Button14. Downshift Button

Fig. 4.3, SBW Shift Selector (1000/2400 series)

Transmissions

4.3

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park pawl not engaged), a buzzer will sound andthe monitor display will show an N for Neutral(N). Select Park (P) to turn off the buzzer and thedisplay.

4. Select the R button to place the transmission inReverse (R). An R will appear on both sides ofthe display window.

WARNINGDo not leave the vehicle if the transmission is inNeutral (N) without first setting the parking brake.The vehicle could roll or move unexpectedly andcause an accident, possibly resulting in personalinjury and property damage.

5. Select the N button to place the transmission inNeutral (N). An N will appear on both sides ofthe display window. The vehicle may be startedin Neutral (N).

6. Select the D button to place the transmission inDrive (D). The transmission will automaticallyshift through the full range of First (1) throughFifth (5) gears. When Drive (D) is first selected,the display will show D1, indicating that Drive (D)was selected and that First (1) gear is engaged.As the transmission automatically upshifts anddownshifts, the display will show the gear cur-rently engaged (D1, D2, D3, D4, or D5).

7. With the transmission in Drive (D), select thedownshift (down arrow) button to manually down-shift one gear at a time, from Fifth (5) to First (1).The select display will show the selected gearand the monitor display will show the gear cur-rently engaged. From D5 at the top of the Drive(D) range, the display will show 44, 33, 22, and11 as progressively lower gears are manuallyselected.

MONITOR

SELECT

SERVICE

R

N

D

MODE

ARENS CONTROLS

04/02/2003 f270123

1

2

3

4

7

11

12

5

13

6

910

8

1. SBW Shift Selector2. Drive (D) Button3. Neutral (N) Button4. Reverse (R) Button5. Select Display6. Select/Monitor Display

Window

7. Monitor Display8. Service Display9. Mode Function Label10. Mode Light11. Mode Button12. Upshift Button13. Downshift Button

Fig. 4.4, SBW Shift Selector (2000 series)

MONITOR

SELECT

SERVICE

R

N

Pb

D

MODE

PARK BRAKE must be set.WARNING: If "P"is not displayed

!

ARENS CONTROLS

f270122a

1

2

3

4

5

8

12

13

6

14

7

1011

9

10/25/2005

1. Shift Selector2. Drive (D) Button3. Neutral (N) Button4. Reverse (R) Button5. Park Brake (Pb)

Button6. Select Display7. Select/Monitor Display

Window

8. Monitor Display9. Service Display10. Mode Function Label11. Mode Light12. Mode Button13. Upshift Button14. Downshift Button

Fig. 4.5, SBW Push-Button Shift Selector with ParkBrake (Pb) Button (2100 Series, front-engine diesel

chassis)

Transmissions

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NOTE: The transmission will remain in themanually selected gear until Drive (D) is se-lected. Select Drive (D) at any time during themanual downshifting sequence (or upshift pro-gressively to Drive [D] using the up arrow but-ton) and the transmission will upshift and down-shift automatically.

8. With the transmission in 11, 22, 33, or 44, selectthe upshift (up arrow) button to manually upshiftone gear at a time until Drive (D) is selected.The select display will show the selected gearand the monitor display will show the gear cur-rently engaged. From 11 at the bottom of theDrive (D) range, the display will show 22, 33, 44,and D5 as progressively higher gears are manu-ally selected.

NOTE: The transmission will remain in themanually selected gear until Drive (D) is se-lected. Select Drive (D) at any time during themanual upshifting sequence and the transmis-sion will upshift and downshift automatically.

9. The function of the mode button may vary fromvehicle to vehicle. The label above the buttonidentifies the function.

10. A light in the upper right-hand corner of themode button illuminates when the mode functionis active.

CAUTIONAn illuminated service display may indicate aloss of safety back-up systems. Use extra carewhen shifting to ensure that the transmission isoperating properly.

11. The service display illuminates if a fault is de-tected in the SBW system. Have a qualified tech-nician inspect the SBW system as soon as pos-sible.

12. A flashing select/monitor display indicates thatthe transmission (and not the SBW system) hasinhibited a selected transmission operation. Seethe Allison Transmission Operator’s Manual formore information.

Transmissions

4.5

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5

Steering SystemPower Steering System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.1Tilt/Telescope Steering Column . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.1

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Power Steering SystemNOTE: When there is no load on the vehicleand the front tires are pointed straight ahead,the steering wheel spokes should be at the 9and 3 o’clock positions or within 10 degrees toeither side. See Fig. 5.1 .

Tilt/Telescope Steering Column

WARNINGNever try to tilt or telescope the steering columnwhile driving the vehicle. Doing so could causeloss of vehicle control and result in personal in-jury or death, or property damage.

Douglas ColumnTo change the position of your steering wheel, pullthe tilt/telescope lever upward and move the steeringwheel to the desired position. Release the lever tolock the position. The steering wheel can also betilted up to provide easier exit and reentry. SeeFig. 5.2 .

If the vehicle is equipped with a telescoping steeringcolumn, push the lever downward and extend or re-tract the steering wheel as desired.

TRW ColumnTo tilt the steering column, press down on the footpedal (located below the steering wheel) to releasethe steering column lock. Adjust the column to the

desired position. Release the foot pedal to lock thesteering column in place. To telescope the steeringcolumn, press down on the foot pedal to release thesteering column lock. Pull the steering wheel upwardor push it downward until it is at the desired height.Release the foot pedal to lock the steering column inplace.

NOTE: For safety, the steering column is lockedat all times unless the foot pedal is depressed.

f460307b11/15/2000

1 2

10°

10°

10°

10°

1. 9 o’Clock 2. 3 o’Clock

Fig. 5.1, Steering Wheel Centered

1

11/15/2000 f461176a

1. Tilt/Telescope Lever

Fig. 5.2, Douglas Tilt/Telescope Steering Column(typical)

Steering System

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6

Brake SystemAir Brake System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.1Antilock Braking System (ABS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.3Hydraulic Brake System (front-engine diesel chassis) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.4

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Air Brake SystemGeneral Information

WARNINGFreightliner neither recommends nor approvesconnecting a trailer or other towed vehicle’sbraking system directly to the vehicle brakingsystem. Freightliner also neither recommendsnor approves tapping into the vehicle air brakesystem nor operating a towed vehicle or trailer’sbraking system by means of the vehicle brakingsystem. Failure to observe this warning couldresult in personal injury or death, or substantialproperty damage.

A dual air brake system consists of two independentair brake systems which use a single set of brakecontrols. Each system has its own reservoir, plumb-ing, and brake chambers. The primary system oper-ates the service brakes on the rear axle; the second-ary system operates the service brakes on the frontaxle.

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.

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

The warning light and buzzer come on if air pressuredrops below 65 to 73 psi (448 to 503 kPa) in eithersystem. If this happens, check the air system pres-sure gauges to determine which system has low airpressure. Although the vehicle’s speed can be re-duced using the foot brake control pedal, either thefront or the rear service brakes will not be operating,causing a longer stopping distance. Bring the vehicleto a safe stop and have the air system repaired be-fore continuing.

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

Air Brake System With External Fill (Schrader)Valve

If your engine will not start and it is desirable to re-lease the parking brake, do the following: Block thewheels. Turn the ignition switch to the ON position.Fill the air reservoir for the braking system by exter-nal means. The parking brake will not release untilair pressure reaches 65 psi (448 kPa). The low airbuzzer will sound until air pressure reaches 65 to 73psi (448 to 503 kPa) with the ignition switch in theON position.

CAUTIONIf the air pressure in the braking system dropsback below 38 to 42 psi (262 to 290 kPa) theparking brake will reengage.

OperationBefore driving the vehicle, secure all loose items inthe cab so that they will not fly forward during a fullbrake application. Make sure that all occupants arewearing seat belts.

During normal brake stops, depress the foot brakecontrol pedal until braking action slows the vehicle.Increase or decrease the pressure on the pedal sothat the vehicle comes to a smooth, safe stop. Whenthe forward speed of the vehicle has decreased al-most to the idling speed of the engine, shift thetransmission into Neutral (N). Apply the parkingbrake if the vehicle is to be parked.

IMPORTANT: In the event of a total loss of ser-vice brakes with full system air pressure, usethe parking brake control valve (yellow knob) tobring the vehicle to a complete stop in the saf-est location possible.

The yellow diamond-shaped knob on the controlpanel actuates the parking brake valve. See Fig. 6.1 .Pull out the knob to apply the parking brake.

Brake System

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WARNINGIf the vehicle is equipped with an air suspensionsystem, do not move the vehicle with the air sus-pension deflated. Doing so could result in a lossof vehicle control, possibly causing personal in-jury and property damage.

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 (L) orFirst (1) gear and lightly apply the brakes to heat anddry them.

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

Brake Burnishing (new vehicle)

CAUTIONCheck the brake system and ensure that it is inproper operating condition before attempting thebrake burnishing procedure.

1. In a safe area, make 10 sharp brake applicationsor "snubs," slowing the vehicle from 40 to 20mph (64 to 32 km/h) using light (approximately10 to 20 psi [69 to 138 kPa]) brake pressure.

2. Make 10 stops from 20 mph (32 km/h) usingmoderate (20 to 30 psi [138 to 207 kPa]) brakepressure.

3. Make 2 stops from 20 mph (32 km/h) using hard(full application of air pressure) brake applica-tions.

NOTE: After the hard brake applications, it isnormal to notice a hot brake odor.

4. Next, drive the vehicle approximately 5 to 7 miles(8 to 11 km) allowing the brakes to cool, andthen come to a stop.

NOTE: After performing the burnishing proce-dure, there should be no brake noise and thebrakes should have good stopping ability.

5. Inspect each wheel and ensure that there is noexcessive end-play.

6. Inspect the brake adjusters and air chambersand ensure that the pushrods have proper andequal stroke.

7. If the brakes pull the vehicle to one side or grabafter the burnishing procedure, contact a Freight-liner RV dealer for service.

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 amechanical 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 of

f421624

Fig. 6.1, Parking Brake Control Knob

Brake System

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automatic 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.

Antilock Braking System (ABS)Meritor WABCO® Antilock BrakingSystem (ABS)The 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 is in effect.

IMPORTANT: For proper ABS system operation,do not mismatch tire sizes among any of the sixtires on the vehicle. Mismatching tire sizes couldresult in a reduced braking force, leading tolonger stopping distances and cause an ABSevent to register on the ECU (electronic controlunit).

Meritor WABCO ABS includes signal-generating tonewheels and sensors located in the wheel hubs ofeach sensed axle. The sensors transmit vehiclewheel speed information to an electronic control unit(located behind the passenger seat). The controlunit’s main circuit interprets the wheel speed sensorsignals and calculates wheel speed, wheel retarda-tion, and a vehicle reference speed. If the calcula-tions indicate wheel lockup, the main circuit signalsthe appropriate solenoid control valve to reduce brak-ing pressure. During emergency braking, the sole-noid control valve alternately reduces, increases, ormaintains air pressure supply in the brake chamberto prevent front and rear wheel lockup.

WARNINGAn accumulation of road salt, dirt, and debris onthe antilock braking system (ABS) tone wheelsand sensors can cause the ABS warning light toilluminate. If the ABS light comes on, have theABS serviced. Operating the vehicle when theABS needs to be serviced could cause an acci-

dent, possibly resulting in personal injury ordeath, or property damage.

IMPORTANT: During winter months in areaswhere corrosive materials are used on the high-ways, periodically clean the underside of thevehicle to ensure proper ABS functioning. Therequired frequency of cleaning will vary withconditions. In general, do not allow corrosivematerials to remain on the underside of the ve-hicle for extended periods of time.

The electronic control unit monitors the wheel sen-sors, solenoid control valves, and the electrical cir-cuitry. The ABS warning light comes on after turningthe ignition switch to the ON position. The warninglight goes out only if all of the vehicle’s ABS compo-nents are working properly.

The Meritor WABCO ABS system combines onefront-axle control channel with the rear axle (four-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 sensorand solenoid valve on the right-rear axle. If, duringvehicle operation, the safety circuit senses a failurein any part of the ABS system (a sensor, solenoidcontrol valve, wiring connections, short circuit, etc.),the ABS warning light comes on and the control cir-cuit where the failure occurred is switched to normalbraking action. The remaining control circuit will re-tain the ABS effect. Even if the ABS system is par-tially or completely inoperative, normal braking abilityis maintained. An exception would be if a solenoidcontrol valve (or combination solenoid control valve)is damaged and inoperative. As these componentsare an integral part of the air brake system, normalbraking may be impaired or inoperative.

WARNINGIf any of the ABS warning lights do not work asdescribed above or come on while driving, repairthe ABS system immediately to ensure full an-tilock braking capability. Operating the vehiclewhen the ABS needs to be serviced could causean accident, possibly resulting in personal injuryor death, or property damage.

During emergency or reduced-traction stops, fullydepress the brake pedal until the vehicle comes to asafe stop; do not pump the brake pedal. With thebrake pedal fully depressed, the ABS system will

Brake System

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control all wheels to provide steering control and areduced braking distance.

WARNINGAlthough the ABS system improves vehicle con-trol during emergency braking situations, thedriver still has the responsibility to change driv-ing styles depending on existing traffic and roadconditions. Failure to change driving styles toaccommodate existing traffic and road conditionscould cause an accident, possibly resulting inpersonal injury or death, or property damage.

Hydraulic Brake System (front-engine diesel chassis)General InformationThe hydraulic brake system includes a powerbooster, master cylinder, reservoir, hydraulic lines, abrake rotor on each wheel hub, and a brake caliperand pad assembly at each rotor. See Fig. 6.2 .

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

system. Do not mix types and brands of fluidbecause of possible incompatibility.

The master cylinder controls braking power to thefront and rear brakes. The Bendix Hydro-Max® powerbooster is attached to the rear of the master cylinderand is connected to the power steering system(which provides pressurized power steering fluid). Anelectrically powered "reserve" pump operates if thereis inadequate fluid flow from the power steeringpump to the power booster. The brake system warn-ing light comes on if there is a problem within thesystem. Bring the vehicle to a safe stop and correctthe problem before continuing operation of the ve-hicle.

Meritor WABCO® Antilock BrakingSystem (ABS), Hydraulic BrakeSystemsThe Meritor WABCO Antilock Braking System (ABS)is an electronic wheel speed monitoring and controlsystem that works with the hydraulic brake system.ABS passively monitors vehicle wheel speed at alltimes, but controls wheel speed during an emer-gency or reduced-traction stop. In normal brakingapplications, the standard hydraulic brake system isin effect.

IMPORTANT: For proper ABS system operation,do not change tire sizes. The sizes of the tiresinstalled during production are programmed intothe electronic control unit. Installing differentsized tires could result in inaccurate wheelspeed signals to the ECU resulting in a reducedbraking force, which could lead to longer stop-ping distances.

ABS includes signal-generating tone wheels and sen-sors located in the wheel hubs of each sensed axle.The sensors transmit vehicle wheel speed informa-tion to an electronic control unit (located on the front-wall) which interprets these signals to calculatewheel speed and a vehicle reference speed. If thecalculations indicate wheel lockup, the appropriatecontrol circuit signals the brake pressure modulatorto increase or decrease braking pressure untilwheelslip has been corrected.

The electronic control unit also has a safety circuitthat constantly monitors the wheel sensors, brakepressure modulator, and the electrical circuitry. Thedash warning light (ABS) comes on after the ignition

10/31/94 f460513a

A

B

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

Fig. 6.2, Hydraulic Brake Reservoir

Brake System

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is switched on. Once the vehicle moves faster thanabout 4 mph (6 km/h), the warning light goes outonly if all the vehicle’s ABS components are working.

If, during vehicle operation, the safety circuit sensesa failure in any part of the ABS system (a sensor,brake pressure modulator, wiring connection, shortcircuit, etc.), the warning light (ABS) comes on andthe control circuit where the failure occurred isswitched 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.

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 brake pedal until the vehicle comes to asafe stop; do not pump the brake pedal. With thebrake pedal fully depressed, the ABS system willcontrol all wheels to provide steering control and areduced braking 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.

OperationBefore driving the vehicle, secure all loose items inthe vehicle so that they will not fly forward during afull brake application. Check that the brake systemwarning light is off after releasing the parking brake.If the warning light does not go off, correct the prob-lem before continuing operation of the vehicle.

During normal brake stops, depress the foot brakecontrol pedal until braking action slows down the ve-hicle. Increase or decrease the pressure on thepedal so that the vehicle comes to a smooth, safestop. When the vehicle comes to a complete stop,shift the transmission into park (P) on the shifter andapply the parking brake.

CAUTIONIf the vehicle is equipped with an air suspensionsystem, do not park the vehicle or move the ve-hicle with the air suspension deflated. This maycause suspension component damage.

Auto-Apply Parking Brake OperationUse the following instructions to operate the parkingbrake:

IMPORTANT: The service brake must always bedepressed when shifting from the parking brake(Pb) position.

• Set by pressing (Pb) on the shift selector.

• To release the parking brake, depress the ser-vice brake and shift from the "Pb" position toany drive gear.

• Shifting from "Pb" to a drive gear and then toneutral (N) releases the parking brake andplaces the vehicle in neutral. The "BRAKE"warning light will flash when this procedure isperformed.

• Shifting directly from "Pb" to "N" does not re-lease the parking brake. "Pb" must be de-pressed, then a drive gear must be selected torelease the parking brake. The "BRAKE" warn-ing light will flash and a chime will sound whenthis procedure is performed.

Brake System

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7

Pretrip Inspection and DailyMaintenance

Pretrip Inspection Checklist . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.1Pretrip Inspection and Daily Maintenance Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.1

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Pretrip Inspection ChecklistThe following pretrip inspection checklist helps en-sure that the vehicle components are in good work-ing condition before each trip.

Pretrip inspections cannot be performed in a shortperiod of time. In checklist form, the sequence belowmay seem to be overly time-consuming. However,careful pretrip inspections save time by eliminatingstops later to adjust items overlooked or forgotten.

Each checklist step corresponds with detailed in-structions found under "Pretrip Inspection and DailyMaintenance Procedures." If any system or compo-nent does not pass this inspection, it must be cor-rected before operating the vehicle.

NOTE: Park the vehicle on a level surface. Shutdown the engine, set the parking brake, andchock the tires.

1. Inspect the batteries and battery cables.

2. Check the fluid level in the windshield washerreservoir.

3. Examine the steering components.

4. Check the fluid level in the coolant reservoir.Check the radiator and charge air cooler for clog-ging or damage. Check the radiator for coolantleaks.

5. Check the condition of the coolant hoses andheater hoses.

6. Check the condition of the drive belts.

7. Inspect the engine for fuel, oil, and coolant leaks.

8. Inspect the engine and chassis wiring.

9. Check the fluid level in the steering system hy-draulic fluid reservoir.

10. Check the engine oil level.

11. Check the oil level in the automatic transmission.

12. Check the intake-air restriction indicator.

13. Inspect the fuel tank(s), fuel filters, fuel lines andconnections, and other fuel system components.

14. Check the fuel level in the fuel tank(s) and besure that the fill area is clean.

15. Check the fuel/water separator and drain anywater present.

16. Inspect the front and rear suspension compo-nents, including the springs and air springs,shocks, and suspension brackets.

17. Check the steering wheel for excessive play.

18. Start the engine and make sure that the oil-pressure warning system is operating. Leave theengine running.

19. Make sure that the horn, windshield wipers andwasher, and heater and defroster are operatingproperly.

20. Make sure that all of the lights are working, in-cluding the brake lights, high- and low-beamheadlights, turn signals, and emergency flashers.Turn the lights off. Shut down the engine.

21. Inspect the air brake components including thebrake chamber pushrods, air reservoirs, and airlines.

22. Check the brake lining wear.

23. Make sure that the brakes are adjusted on allaxles.

24. Check the tire inflation pressures, and inspecteach tire for bulges, cracks, cuts, and punctures.

25. Check for indications of loose wheel nuts andexamine each wheel and components.

26. Check the air brake system for proper operation.

27. Test the service brakes before leaving the lot.

28. Test the parking brake on a 20-percent grade.

Pretrip Inspection and DailyMaintenance Procedures

CAUTIONAn accumulation of road salt, dirt, and debris onthe antilock braking system (ABS) tone wheelsand sensors can cause the ABS warning light toilluminate. If the ABS light comes on, have theABS serviced. Operating the vehicle when theABS needs to be serviced could cause an acci-dent, possibly resulting in personal injury ordeath, or property damage.

IMPORTANT: During winter months in areaswhere corrosive materials are used on the high-ways, periodically clean the underside of the

Pretrip Inspection and Daily Maintenance

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vehicle to ensure proper ABS functioning and tohelp protect chassis components against corro-sion. The required frequency of cleaning willvary with conditions. In general, do not allowcorrosive materials to remain on the undersideof the vehicle for extended periods of time.

NOTE: Drain the air tanks at least every sixmonths.

Air reservoirs serve as storage tanks for compressedair. They collect water condensed from the air andsmall amounts of oil that enter the reservoir in theform of vapor, due to the heat generated duringcompression.

After the water and oil condense, they collect nearthe tank drain valves. Drain the resulting emulsion asfollows:

There are three separate pull-cables for draining theair tanks. Pull and hold each of the three cables untilall moisture is gone.

WARNINGWhen draining the air reservoir, do not look intothe air jets or direct them towards anyone. Dirt orsludge particles may be in the airstream andcould cause injury.

Failure to drain the air reservoirs as instructedcould cause sludge formation in the air brakesystem. Sludge could adversely affect braking,causing loss of control, which could cause death,personal injury, or property damage.

1. Inspect the batteries and battery cables.

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.

1.1 Be sure that the battery hold-down is se-cure. If it is loose, tighten the hold-downbolts; if it is broken, replace it.

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 Remove any corrosion from the hold-downand the top of the battery. Use diluted am-monia or a soda solution to neutralize theacid present, then rinse off the ammoniaor soda solution with clean water.

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. Check the fluid level in the windshield washerreservoir.

Add washer fluid as needed.

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. Examine the steering components.

Examine the steering gear mounting bolts, pit-man arm nut, and the drag link nuts for tight-ness. See Fig. 7.1 . Check for leakage at thegear box. Be sure that the steering driveline andthe U-joints are in roadworthy condition, withoutcracks, breaks, looseness, or other damage.Tighten loose nuts and replace damaged partsas needed.

4. Check the fluid level in the coolant reservoir. SeeFig. 7.2 , Fig. 7.3 , or Fig. 7.4 . Check the radiatorand charge air cooler for clogging or damage.Check the radiator for coolant leaks.

Pretrip Inspection and Daily Maintenance

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CAUTIONCoolant must be filled to the full line of the surgetank. Low coolant could result in engine over-heating, which could cause engine damage.

IMPORTANT: Do not confuse coolant withhydraulic fluid. Both are pink in color.

4.1 If the coolant is low, check the amount ofantifreeze protection. If the protection isadequate, add a 50/50 mixture of waterand antifreeze. If additional protection isneeded, add antifreeze only.

NOTE: Good airflow through the radiatorcore and charge air cooler is essential forproper engine cooling. The cores allow airpassage, but form a particle barrier whichtends to collect insects and airborne debris.

4.2 Inspect for clogged fins. Use compressedair or water to backflush any material re-stricting airflow.

4.3 Inspect and clean the charge air cooler.

4.4 Straighten bent or damaged fins to permitairflow across all areas of the cores.

4.5 Repair or replace the radiator if it is leak-ing.

11/15/2000 f461825

1

2

1. Steering Gear Mounting Bolt Location2. Pitman Arm Pinch Bolt Nut

Fig. 7.1, TRW Steering Gear Installation

11/15/2000 f500350

Fig. 7.2, Coolant Reservoir (used with rear radiator)

11/15/2000 f500351

Fig. 7.3, Coolant Reservoir (used with side radiator)

02/07/2002

1

f200464a

1. Coolant Reservoir

Fig. 7.4, Coolant Reservoir (used with side radiator)

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5. Check the condition of the coolant hoses andheater hoses.

Make sure that the radiator inlet and outlet cool-ant hoses and heater hoses are pliable, and arenot cracking or bulging. Replace hoses that showsigns of cracking, weakening, or bulging. Re-place all hoses, including the heater hoses, atthe same time. Service-type knitted or braidedyarn-reinforced neoprene hose is acceptable.

Tighten hose clamps as necessary, but do notovertighten, as hose life can be adversely af-fected.

Be sure that the hose support brackets are se-curely fastened. Make sure that the hoses arenot located near sources of wear, abrasion, orhigh heat.

6. Check the condition of the drive belts.

Check the fan belt(s), alternator belt, and refrig-erant compressor belt for signs of glazing, wear(frayed edges), damage (breaks or cracks), or oilcontamination. If a belt is glazed, worn, dam-aged, or oil soaked, replace the belt.

NOTE: A belt tensioner automatically adjusts thefan and alternator belt to the correct tension. Ifthe belt slips, repair or replace the tensioner.For instructions, see the Caterpillar, Cummins,or the Mercedes-Benz Operation and Mainte-nance Manual.

7. Inspect the engine for fuel, oil, and coolant leaks.

Correct any leaks found.

8. Inspect the engine and chassis wiring.

Inspect the engine and chassis for loose wiring,chafed insulation, and damaged or loose hold-down clamps. Tighten loose wires or hold-downclamps; replace damaged wiring or clamps.

9. Check the fluid level in the steering system hy-draulic fluid reservoir. See Fig. 7.5 .

If needed, fill the reservoir to a level between theMIN and MAX marks. Use only Dexron®III ATF,or an equivalent.

IMPORTANT: Do not confuse coolant with hy-draulic fluid. Both are pink in color.

10. Check the engine oil level.

The oil level should show between the upper andlower marks on the dipstick. Add enough oil tobring the level up to the operating range. See theCaterpillar, Cummins, or the Mercedes-Benz Op-eration and Maintenance Manual for recom-mended lubricants and capacities.

CAUTIONMaintain the correct engine oil level. Operatingthe engine with the oil level below the low markor above the high mark could result in enginedamage.

11. Check the oil level in the automatic transmission.See Fig. 7.6 and Fig. 7.7 .

NOTE: The automatic transmission fluidmust be warm to ensure an accurate check.The fluid level rises as temperature in-creases. Check the oil level with the vehicleon a level surface.

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

11.2 Park the vehicle. Set the parking brake,and place the transmission in the Neutral(N) position. Let the engine run at idle.

11.3 Wipe the dipstick clean and check thefluid level. A safe operating level is anylevel within the HOT run (upper) band onthe dipstick. See Fig. 7.8 .

MAX

Min

04/10/97 f461177

Fig. 7.5, Steering System Hydraulic Fluid Reservoir

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11.4 If the fluid is not within this range, add ordrain fluid as needed to bring the level tothe top of the HOT run band. SeeTable 7.1 for fluid types and capacities.

IMPORTANT: For all transmissions, useTranSynd synthetic automatic transmissionfluid (ATF).

NOTE: A cold check may be made when thesump temperature is 60 to 104°F (15 to40°C). Follow the substeps below.

11.5 Run the engine for at least one minute toclear the fluid system of air.

Transmission Lubricant Capacities

ModelRefill Capacity *†:

quarts (liters)1000, 2000, 2000 MH, and 2100 16.0 (15.1)

3000 MH and 4000 MH 17.5 (16.5)* Quantities listed are approximate. Add the recommended amount of fluid

as listed under refill capacity, then perform a "hot check" and add fluid asneeded. Do not overfill.† NOTE: Some Allison 3000 MH transmissions have a deeper oil sump

than other models. These models require 3 additional quarts (2.8 L) of au-tomatic transmission fluid (ATF).

Table 7.1, Transmission Lubricant Capacities

11.6 With the engine running, wipe the dipstickclean and check the fluid level. Any levelwithin the COLD run (lower) band is satis-factory for operating the vehicle. If the

level is not within the COLD run band, addor drain fluid until it reaches the middle ofthe COLD run band.

11.7 Perform a hot check at the first opportu-nity after normal operating temperature,160 to 200°F (71 to 93°C), is reached.

12. Check the intake-air restriction indicator to deter-mine if the air cleaner filter element needs to bechanged. See Fig. 7.9 .

Replace the air cleaner element when the yellowline reaches 25 inH2O vacuum or every twoyears, regardless of mileage. After the air cleanerelement is replaced, press the button on the bot-tom of the air restriction indicator to reset it.

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.

NOTE: The final manufacturer mounts the airrestriction indicator. It is typically mounted in thesame area as the other routine engine servicecheck items, i.e., dipstick, fluid reservoirs.

13. Inspect the fuel tank(s), fuel filters, fuel lines andconnections, and other fuel system components.

Replace leaking fuel tanks; repair or replace anymechanisms, lines, or connections that are leak-ing.

14. Check the fuel level in the fuel tank(s) and besure that the fill area is clean. To keep conden-sation to a minimum, the fuel tanks should befilled at the end of each day, but not to morethan 95-percent of liquid capacity. Federal regula-tions prohibit filling a fuel tank to more than 95-percent of its liquid capacity. Select the propergrade of fuel, as specified by the engine manufac-turer.

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.

01/28/2002

2

f350162a

1 3

1. Coolant Reservoir2. Transmission Fluid Dipstick3. Hydraulic Reservoir

Fig. 7.6, Transmission Fluid Level Check

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Do not mix gasoline or alcohol with diesel fuel.This mixture could cause an explosion, possibly

resulting 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 only low-sulfur diesel fu-els. Low-sulfur diesel fuels have a maximum0.05 percent sulfur content, compared to a0.26 to 0.30 percent sulfur content for someother fuels. Failure to use low-sulfur dieselfuels may void the warranty on emissionscomponents.

f544667

1 23

4

5

10/31/2005

1. Coolant Reservoir2. Engine Oil Fill3. Engine Oil Dipstick

4. Transmission Fluid Dipstick5. Hydraulic Fluid Reservoir

Fig. 7.7, Transmission Fluid Level Check (front-engine diesel chassis)

12/01/97

A

B

f270002a

A. Cold Run Band B. Hot Run Band

Fig. 7.8, Automatic Transmission Dipstick Markings

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14.1 Fuel should always be strained or filteredbefore it is put into the tanks. This willlengthen the life of the engine fuel filter,and reduce the chances of dirt getting intothe engine.

14.2 Before installing the fuel cap, check thefiller area. Clean the filler area with a rag,or if necessary, clean the cap with solvent.

CAUTIONWater in the fuel/water separator will appear asbeads. Drain the separator only enough to re-move the water. Do not drain the separator com-pletely or it will be necessary to prime the fuelsystem before the vehicle may be started again.

IMPORTANT: On all types of separators, stopdraining fluid when you see clear fuel (and nomore water) come out of the separator drainvalve. Drain the fluid into an appropriate con-tainer and dispose of it properly.

15. Check the fuel/water separator and drain anywater present.

NOTE: The fuel/water separator may be re-located by the body manufacturer and thelocations may vary.

15.1 Shut off the engine.

15.2 Remove the fuel cap.

15.3 Open the valve until draining occurs. Drainthe filter sump of water until clear fuel isvisible.

15.4 Close the drain and install the fuel cap.

15.5 Run the engine and check for leaks.

16. Inspect the front and rear suspension compo-nents, including the springs and air springs,shocks, and suspension brackets.

Check for broken spring leaves, loose U-bolts,cut or ruptured air springs (bags), cracks in thesuspension brackets, and loose fasteners in thespring hangers and shackles. Inspect the shockabsorbers for loose fasteners and leaks.

Tighten all loose fasteners. Replace any compo-nent that is worn, cracked, or otherwise dam-aged.

WARNINGDo not replace individual leaves of a damagedfront or rear suspension leaf spring assembly;replace the complete spring assembly. Visibledamage, such as cracks or breaks, to one leafcauses hidden damage to other leaves. Replace-ment of only the visibly damaged part(s) is noassurance that the spring is safe. If cracks orbreaks exist on front spring assemblies in eitherof the two top leaves, a loss of vehicle controlcould occur. Failure to replace a damaged springassembly could cause an accident resulting inserious personal injury or property damage.

17. Check the steering wheel for excessive play.

With the front tires pointing straight ahead, turnthe steering wheel until motion is observed at thefront wheels. Align a reference mark on a rulerSee Fig. 7.10 , then slowly turn the steeringwheel in the opposite direction until motion isagain detected at the wheels. Measure the lash(free play) at the rim of the steering wheel.

Excessive lash exists if steering wheel move-ment exceeds 4-3/4 inches (121 mm) with an18-inch (470-mm) steering wheel. If there is ex-cessive lash, check the steering system for wearor incorrect adjustment of the linkage and steer-ing gear before operating the vehicle.

18. Start the engine and make sure that the oil-pressure warning system is operating.

PUSH TO RESET

H 0 VACUUM225201510

7

IN H 0 VACUUM2

f09017605/22/97

Fig. 7.9, Air Restriction Indicator

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When the engine is started, the oil-pressurewarning light will come on until the oil pressurerises above a preset minimum.

If the warning light does not come on when theignition switch is turned to the ON position, repairthe system.

19. Make sure that the horn, windshield wipers andwasher, and heater and defroster are operatingproperly.

20. Make sure that all of the lights are working.

Turn on the headlights, dash lights, and emer-gency flashers.

Turn all of the lights off. Shut down the engine.

DANGERDo not loosen or remove the parking brake clampring for any purpose. See Fig. 7.11. The parking/emergency brake section of the brake chamber isnot intended to be serviced. Serious injury ordeath may result from sudden release of thepower spring.

Before doing any repairs or adjustments on aservice/parking brake chamber, read the appli-cable warnings and instructions in Group 42 ofthe Recreational Vehicle Chassis WorkshopManual.

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.

CAUTIONIf the brake chamber external breather tube orbreather cap is missing or incorrectly installed,road dirt and debris can adversely affect the op-eration of the brake chamber. Once inside thechamber, dirt and debris cause the internal partsto deteriorate and shorten their lives.

21. Inspect the air brake components including thebrake chamber pushrods, air reservoirs, and airlines.

Inspect the front air brake lines for leaks at thefitting where they enter the air chamber.

With an assistant at the front wheels to inspectthe brake lines, turn the wheels to full lock in onedirection. While holding the service brake pedaldown, inspect the front brake air lines closelywhere they enter the air chambers.

Turn the wheels to full lock in the other direction,hold the service brake pedal down, and repeatthe inspection.

If there is a leak, the hose should be replaced.See Group 42 of the Recreational Vehicle Chas-sis Workshop Manual for the hose replacementprocedure.

Look for worn clevis pins on brake chamberpushrods and missing or damaged cotter keyson the brake chamber pushrod clevis keys. Re-place worn clevis pins and install new cotter pinsif necessary.

Visually inspect the piston rod engagement withthe clevis. At least 7 threads of engagement arerequired; there should be 1 inch (25 mm) ofclearance from the centerline of the clevis pinhole to the end of the piston rod. See Fig. 7.12 .See Group 42 of the Recreational Vehicle Chas-sis Workshop Manual for adjustment procedures.

See if the chamber piston rod is in line with theslack adjuster. Misalignment can cause the pis-ton rod to rub on the nonpressure chamber andcause a dragging brake. See Group 42 of theRecreational Vehicle Chassis Workshop Manualif the chamber piston rod is improperly aligned.

f460158c11/15/2000

A

Fig. 7.10, Measuring Lash at the Steering Wheel

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Visually inspect the exterior surfaces of thechamber for damage. Make sure that breatherholes in the nonpressure section(s) are open andfree of debris. See Group 42 of the RecreationalVehicle Chassis Workshop Manual to replaceany damaged parts.

On all parking brake installations, check for thepresence of an end cover cap or dust plug andmake sure that the cap or plug is securelysnapped into place. On most MGM parking brakechambers equipped with an integral release bolt,an end cover cap is installed over the releasebolt. Be sure that the end cover cap is snappedtightly into place.

Check for rusted connections, missing snaprings, and damaged camshaft grease seals. Re-pair or replace damaged or missing parts.

Check the air reservoir band fasteners. Makesure that the outside surfaces of the reservoirsare painted to prevent corrosion damage. Inspectthe reservoir surfaces for damage, such ascracks and dents. Replace corroded or damagedreservoirs with new ones. Do not repair damagedreservoirs. Old or used reservoirs are not accept-able as replacements. If a reservoir requires re-placement, see Group 42 of the RecreationalVehicle Chassis Workshop Manual for instruc-tions.

Inspect the air lines as follows:

21.1 Check the clearance between the hoses,exhaust manifold, and turbocharger, orother hot spots. Excessive heat will causethe material in the hoses to deterioraterapidly or become brittle. Provide at least6 inches (150 mm) of clearance. Moreclearance is recommended if the hose islocated above the heat source.

21.2 Check for kinks, dents, or swelling of thehoses. If a hose is damaged, replace itwith the same size and type.

Do not route the hose on top of anythinglikely to be stepped on or walked on.

21.3 Check for damage to hoses located nearmoving parts, such as drivelines, suspen-sions, and axles. If the moving parts arecatching or pinching the lines, correct asneeded.

1

A

02/22/2000 f421352

A. Do not remove this clamp ring.1. MGM TR–T (TR Series) Brake Chamber shown

Fig. 7.11, Parking Brake Chamber Clamp

f420225a

1

2

3

B

A

08/20/93

4

5

A. Minimum of 1-inch (25-mm) clearance betweencenterline of clevis pin hole and piston rod end.

B. Minimum of 7 threads engagement.1. Piston Rod2. Piston Rod Nut3. Clevis

4. Cotter Pin5. Clevis Pin

Fig. 7.12, Piston Rod Engagement With the Clevis

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21.4 Check for hose damage caused by abra-sion. If a hose is abraded, replace it.Check for the cause of abrasion, such asloose or damaged hose clamps. Repair orreplace the clamps as needed.

21.5 Observe the hose cover condition, espe-cially hoses exposed to water splash andice. If any hose is dried out or ragged (thewire or liner is showing through the cover),replace the hose.

21.6 Inspect air tubing, especially tubing madeof nylon. In cold weather, nylon tubing issensitive to damage, such as nicks orcuts. Replace nicked or cut tubing, even ifit is not leaking.

21.7 Check the bend radii of all hoses. SeeFig. 7.13 . The minimum bend radius of ahose is that bend which the hose will with-stand without experiencing damagingstresses or kinking. For minimum bendradius values, see Group 42 of the Recre-ational Vehicle Chassis Workshop Manual.

When a rubber hose bend does not meetminimum radius requirements, the outsidemay appear smooth even if the inner tubeis kinked. Reroute the hose or replace itwith one of adequate length if the bendradius is not within minimumspecifications.

21.8 Check straight hose installations (thosehoses that do not bend along their rout-ings). Pressure changes can cause ahose to lengthen up to 2-percent, orshorten up to 4-percent. A 100-inch (2540-

mm) length of hose, for example, can con-tract to 96 inches (2440 mm). If the hosehas no slack when it is exhausted of air,replace it with one of adequate length toavoid a possible blow-off from the fittingduring vehicle operation.

21.9 Check for kinked or twisted hoses. A7-percent twist in the hose can reduce itslife by up to 90-percent. Also, a twistedhose under pressure tends to untwist. Thiscould cause it to loosen the fitting. Recon-nect hoses that are twisted.

22. Check the brake lining wear on vehiclesequipped with air brakes. Proper brake operationis dependant on periodic maintenance and in-spection of the brake linings.

22.1 If the axle assembly is not equipped witha dust shield or backing plate, measurethe axle brake lining thickness. If any ofthe brake linings are worn to less than 1/4inch (6.5 mm) at the thinnest point, re-place the linings on all brake assemblieson that axle. See Group 42 of the Recre-ational Vehicle Chassis Workshop Manualfor lining replacement instructions andcamshaft endplay inspection.

22.2 If the axle assembly is equipped with adust shield or backing plate, remove theinspection plugs to inspect the brake liningthickness. If any of the brake linings areworn to less than approximately 1/4 inchat the thinnest point, replace the linings onall brake assemblies on that axle. SeeGroup 42 of the Recreational VehicleChassis Workshop Manual for lining re-placement instructions and camshaft end-play inspection.

22.3 Install the inspection plugs in the dustshields or backing plates if equipped.

23. Make sure that the brakes are adjusted on allaxles.

Adjust the brakes if necessary. See Group 42 ofthe Recreational Vehicle Chassis MaintenanceManual for checking and adjusting procedures.

IMPORTANT: Brake checking and adjusting isnecessary for all vehicles, including thoseequipped with automatic slack adjusters.

11/03/94 f420329aA

NOTE: Center of the hose bend radius should be wellaway from the fitting.A. Bend Radius

Fig. 7.13, Bend Radius

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24. Check the tire inflation pressures, and inspecteach tire for bulges, cracks, cuts, and punctures.

IMPORTANT: The load and cold inflationpressure must not exceed the wheel manu-facturer’s recommendations, even thoughthe tire may be approved for a higher loador inflation. Some wheels are stamped witha maximum load and maximum cold inflationrating. If the load exceeds the maximumwheel capacity, the load must be adjusted orreduced. See and adhere to the tire loadand cold inflation pressure specificationsstated on the vehicle specification label.

NOTE: Tire load limits refer only to individualtires and do not indicate the weights for theentire axle.

24.1 Check the inflation pressures of the tiresbefore each trip, using an accurate tirepressure gauge. See Fig. 7.14 . Check tirepressures when the tires are cool. Themaximum inflation pressure for each tire isprovided on the outer wall of the tire. In-flate the tires to the applicable pressures,if needed. Be sure that valve stem capsare used on every tire, and that they arescrewed on finger-tight.

When traveling at unusual speeds, useTable 7.2 to adjust tire pressure.

For later vehicles with Michelin tires, seethe Michelin Recreational Vehicle TireGuide for correct tire inflation pressuresfor the vehicle load.

Overinflation gives the treaded surface ofthe tire a convex shape. See Fig. 7.15 .This causes premature tire wear in themiddle part of the tire since this section isprimarily in contact with the road.

Underinflation gives the tread surface aconcave shape. See Fig. 7.15 . Thiscauses excessive tire wear on the outeredges of the tire since those edges areprimarily in contact with the road.

Variations in Load and Inflation Limits According toSpeed

Speed Rangemph (km/h)

InflationPressure

Increase inpsi (kPa)

PercentIncrease/

Decrease inLoad

70 to 75 (113 to 121) 10 (69) (–10)61 to 70 (98 to 113) 10 (69) 051 to 60 (82 to 97) 0 041 to 50 (66 to 80) 0 +931 to 40 (50 to 64) 0 +1621 to 30 (34 to 48) 10 (69) +2411 to 20 (18 to 32) 15 (103) +32

Table 7.2, Variations in Load and Inflation LimitsAccording to Speed

f40006111/03/94

Fig. 7.14, Check Tire Pressures

A B C11/03/94 f400062a

A. Tire correctly inflatedB. Tire overinflatedC. Tire underinflated

Fig. 7.15, Check Tire Inflation

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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.

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

IMPORTANT: Moisture inside a tire can re-sult in body ply separation or a sidewall rup-ture. During tire inflation, compressed airreservoirs and lines must be kept dry. Ser-vice inline moisture traps regularly.

24.3 Inspect the tires for bulges, cracks, cuts,or penetrations. A tire pressure check willassist in uncovering hidden damage; aweekly pressure loss of 4 psi (28 kPa) ormore in a tire may indicate damage, andthe tire should be inspected and repairedor replaced.

24.4 If the tires are wearing irregularly, see thetire manufacturer’s recommendations.Have the front axle alignment checked todetermine the cause of irregular tire wear.

Government regulations require the re-moval of front axle tires at 4/32-inch (3-mm) remaining tread depth and rear axletires at 2/32-inch (1.5-mm) remainingtread depth.

24.5 Inspect the tires for oil contamination. Fueloil, gasoline, and other petroleum deriva-tives, if allowed to contact the tires, willsoften the rubber and destroy the tire.

IMPORTANT: Do not use tire dressings.These will cause premature wear and dete-rioration of the tire material. Use only soapand water to clean tires.

WARNINGOn vehicles equipped with ZF independent frontsuspension (IFS) and ZF SB 7000 front air diskbrakes, the only approved front wheels and valvestems are those that come on the chassis as de-

livered from the FCCC manufacturing plant.These wheels have a special bolt pattern. Valvestems other than those delivered with the chas-sis may interfere with the brake calipers. The useof unapproved front wheels and/or front wheelvalve stems could cause component damage andresult in personal injury or death, or propertydamage.

IMPORTANT: Rinse the Accuride® Accu-Shield™

wheels with high-pressure water to remove anydebris. Use a cotton cloth dipped in a mild soapsolution to help remove stuck on dirt andgrease. Rinse the remaining soap residue fromthe wheels. Dry the wheels thoroughly with acotton cloth.

25. Check for indications of loose wheel nuts andexamine each wheel and components.

Check the wheel nuts for indications of loose-ness. Remove all dirt and foreign material fromthe assembly. Dirt or rust streaks from the studholes, metal buildup around stud holes, or out-of-round or worn stud holes may be caused byloose wheel nuts. Tighten the wheel nuts to thecorrect torque specifications in the proper tight-ening sequences. See Group 40 of the Recre-ational Vehicle Chassis Maintenance Manual forinstructions.

Examine the wheel assembly components (in-cluding rings, flanges, studs, and nuts) for cracksor other damage.

Replace broken, cracked, badly worn, bent,rusty, or sprung rings. Be sure that the lockringand side ring are matched according to size andtype.

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.

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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.

26. Check the air brake system for proper operation.

26.1 Release the parking brake by pushing inthe parking brake control valve knob.Check the air governor cut-in and cut-outpressures. Run the engine at fast idle.The air governor should cut out the aircompressor at approximately 125 psi (862kPa). With the engine idling, make a se-ries of foot valve applications. The air gov-ernor should cut in the air compressor atapproximately 95 psi (655 kPa). If the airgovernor does not cut in and out as de-scribed above, it must be adjusted tothese specifications. If the air governorcannot be adjusted or repaired, replace itbefore operating the vehicle.

26.2 Check air pressure buildup time as fol-lows:

Release the parking brake by pushing inthe parking brake control valve knob.

With the air system fully charged to 125psi (862 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 to125 psi (862 kPa) is more than 30 sec-onds, eliminate any leaks or replace theair compressor before operating the ve-hicle.

26.3 Check the air pressure reserve. With theair system fully charged to 125 psi (862kPa), stop the engine and note the airpressure. Then make one full brake appli-cation and observe the pressure drop. If it

drops more than 25 psi (172 kPa), all ar-eas of leakage must be eliminated beforeoperating the vehicle.

WARNINGBefore operating the vehicle, be sure that theparking brake passes the following tests. Other-wise an unexpected parking brake applicationcould occur, causing some loss of vehicle con-trol and possibly resulting in serious personalinjury.

26.4 Check the air leakage in the system.

With the parking brake applied, the trans-mission out of gear, and the tires chocked,charge the air system until cutoff pressureof 125 psi (862 kPa) is reached.

With the service brakes released, shutdown the engine, wait one minute andnote the air pressure gauge reading. Ob-serve the air pressure drop in psi (kPa)per minute.

Charge the air system until cutoff pressureof 125 psi (862 kPa) is reached. With theparking brake released and the servicebrake applied, shut down the engine, waitone minute and note the air pressuregauge reading. Observe the air pressuredrop in psi (kPa) per minute.

If leakage exceeds the limits shown inTable 7.3 , repair all areas of leakage be-fore driving the vehicle.

Maximum Allowable Service Brakes Air LeakageBrakes Released Brakes Applied

2 psi (14 kPa) 3 psi (21 kPa)

Table 7.3, Maximum Allowable Service Brakes AirLeakage

27. Test the service brakes before leaving the lot.

Depress the brake pedal, release the parkingbrake, and check that the brake system warninglight goes off. If the warning light remains on af-ter releasing the parking brake, correct the prob-lem before driving the vehicle.

28. Test the parking brake on a 20-percent grade.

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Apply the parking brake with the vehicle on a20-percent grade (or as steep a grade as the ve-hicle may normally be parked on). The ramp sur-face should be made of Portland cement or theequivalent. If the parking brake does not hold thevehicle, repair the parking brake system.

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8

In an EmergencyFreightliner Help . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.1Hazard Warning Lights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.1Towing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.1Emergency Starting With Jumper Cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.1Changing a Flat Tire . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.2Running Out of Fuel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.3

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Freightliner HelpIn the event of a vehicle emergency, call the Cus-tomer Assistance Center at 1–800–385–4357 or1–800–FTL–HELP. Call night or day, weekdays orweekends, for dealer referral, vehicle information, orbreakdown coordination.

Hazard Warning LightsPull out the hazard warning light switch on the steer-ing column to activate the hazard warning lights.When the hazard warning light switch is pulled out,all of the turn signal lights and both of the turn signalindicator lights on the control panel will flash. To can-cel the warning lights, push the switch in.

TowingSee Chapter 10 for towing information.

Emergency Starting WithJumper CablesWhen using jumper cables, follow the instructionsbelow.

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 that both starting systems have thesame voltage outputs and avoid making sparks.Otherwise the vehicle charging systems could beseverely damaged. Also, do not attempt tocharge isolated, deep-cycle batteries with jumpercables; follow the manufacturer’s instructionswhen charging deep-cycle batteries.

1. Apply the parking brakes and turn off the lightsand all other electrical loads.

2. Connect one end of a jumper cable to the posi-tive terminal of the booster battery and connectthe other end of the cable to the positive terminalof the discharged battery. See Fig. 8.1 .

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 of the cable to a ground atleast 12 inches (300 mm) away from the batter-ies of the vehicle needing the start. The vehicleframe is usually a good ground. Do notconnectthe cable to or near the discharged batteries.

4. Start the engine of the vehicle with the boosterbatteries and let the engine run for a few minutesto charge the batteries of the other vehicle.

f54128608/21/96

C

1 2AB

D

A. 1stB. 2nd

C. 3rdD. To Frame (ground)

1. Booster Battery 2. Discharged Battery

Fig. 8.1, Jumper Connections

In an Emergency

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CAUTIONDon’t crank the engine for more than 30 secondsat a time during any of the following procedures.Wait two minutes after each try to allow thestarter to cool. Failure to do so could causestarter damage.

5. Attempt to start the engine of the vehicle with thebatteries receiving the charge.

6. When the engine starts, let it idle for a few min-utes.

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.

7. Disconnect the grounded (negative) cable fromthe frame or other non-battery location; then dis-connect the other (negative) end of the cable.

8. Disconnect the remaining (positive) cable fromthe newly charged battery first; then disconnectthe other (positive) end.

Changing a Flat Tire

WARNINGThis vehicle is very heavy. Jacking this vehicleshould be done with extreme caution. The vehiclecould slip, causing personal injury or death.

WARNINGWheel lug nut torque is very high and thewheel/tire assemblies are very heavy. Changing atire could result in back injury. If possible, call aqualified service facility to change a flat tire.

IMPORTANT: If a flat tire occurs while driving,gradually decrease vehicle speed. Holding thesteering wheel firmly, move to a safe place onthe side of the road.

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

2. Set the parking brake and turn the ignition switchto the OFF position.

3. Turn on the emergency flashers.

4. Remove the spare wheel, jack, jack handle, andlug wrench from storage, if so equipped.

5. Use a block to chock the wheel diagonally oppo-site the wheel being changed.

NOTE: The jacking point for the front and rearwheels is directly under the axle.

6. Place the jack on a solid surface. Insert the jackhandle and pump the handle to slightly raise thevehicle. Do not raise the wheel off of the ground.Loosen the wheel lug nuts, but do not removethem.

NOTE: On VCL chassis vehicles only, the dualrear wheels are attached using two-element lugnuts. The larger nut retains the outer dual. Theinner square stud retains the inner dual. Re-move and install these nuts separately. The reardual outer lug nut must be loosened to checkand retighten the inner nut.

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

8. Install the spare wheel and the lug nuts. Makesure that the beveled sides of the nuts face in-ward.

9. In a star pattern, tighten the nuts evenly untilsnug.

10. Lower the vehicle until the wheel touches theground. Tighten the wheel nuts to the correcttorque specifications in the proper tightening se-quences. See Group 40 of the Recreational Ve-hicle Chassis Maintenance Manual for instruc-tions.

11. Finish lowering the vehicle to the ground, thenremove the jack.

12. Remove the wheel chock (the block), then stowthe jack, jack handle, and lug wrench.

13. After operating the vehicle for 50 to 100 miles(80 to 160 km), retighten the nuts. Tighten thewheel nuts to the correct torque specifications inthe proper tightening sequences. See Group 40 ofthe Recreational Vehicle Chassis MaintenanceManual for instructions.

In an Emergency

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Running Out of Fuel

WARNINGDiesel fuel is highly flammable. When you ap-proach a vehicle and the smell of diesel fuel ispresent, immediately shut off all engines and ig-nition sources. Avoid causing sparks and stayaway from arcing switches and equipment. Extin-guish cigarettes, pilot lights, flames, or othersources of ignition in the area and adjacent ar-eas. Immediately provide extra ventilation to thearea. Do not start the vehicle or any other type ofequipment until the fuel leak is corrected and thearea cleared of fuel. Failure to perform these ac-tions could lead to the ignition of the fuel, whichcould cause personal injury or death, or severeproperty damage.

If your vehicle runs out of fuel, stop the vehicle on alevel location away from traffic. The engine may berestarted by adding at least two gallons (eight liters)of fuel to the fuel tank. If the vehicle is not level, upto six gallons (22 liters) of fuel may be required. Pro-longed engine cranking may be required to pumpfuel from the fuel tank to the engine before the en-gine will start.

CAUTIONDon’t crank the engine for more than 30 secondsat a time during any of the following procedures.Wait two minutes after each try to allow thestarter to cool. Failure to do so could causestarter damage.

If your vehicle will not start by cranking the engine,the fuel system may need to be primed. See the Cat-erpillar, Cummins, or the Mercedes-Benz Operationand Maintenance Manual.

In an Emergency

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9

SpecificationsFluids and Lubricants . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.1Fuse/Relay/Circuit Breaker Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.1Electric Service Center . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.1

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Fluids and LubricantsSee Table 9.1 for fluid and lubricant specifications.

Fluid and Lubricant SpecificationsComponent Recommended Fluid or Lubricant

Front Axle Spindle Pins, Tie Rods, Drag Link, IntermediateSteering Shaft, Front Brake Pedal Shafts, Slip Spline andUniversal Joints

Multipurpose Grease Lithium 12 Hydroxy Stearate NLGI No.2; for temperatures below 0°F (–18°C), use MIL-G-10924B

Hydraulic Steering System Reservoir Dexron® III ATFEngine Oil * See BelowAllison Transmission Fluid. TranSynd Synthetic ATFFuel Grade No. 2-0 or 2-DFront Axle Wheel Bearings

Rear Axle DifferentialHypoid Gear Oil SAE 80-90

Engine Coolant 50% Water/50% Ethylene Glycol Antifreeze (with approvedSCAs)

Hydraulic Brake Reservoir Heavy-Duty DOT 3 Brake FluidAuto-Apply Park Brake Reservoir Dexron® III ATF* See the Caterpillar or the Cummins Operation and Maintenance Manual for engine oil specifications.

Table 9.1, Fluid and Lubricant Specifications

Fuse/Relay/Circuit BreakerIdentificationCircuit breakers protect against circuit overload. If acircuit becomes overloaded (usually caused by ashort to ground), the circuit breaker opens, stoppingcurrent flow. The vehicle may be equipped with auto-reset breakers.

Fuse/Relay/Circuit BreakerIdentification (front-engine dieselchassis)The electrical system has four separate power distri-bution modules (PDMs) containing both fuses andrelays. An optional tow power PDM is also available.The PDMs are mounted in two places:

• Two in the cab area left of the steering wheel

• Two (or three including the optional tow powerPDM) on the exterior side of the operator’s sta-tion

See Fig. 9.1 and Fig. 9.2 .

Fuse/Relay/Circuit BreakerIdentificationThe electrical system has two separate boxes con-taining both fuses and relays. The boxes aremounted in one of three locations:

• on the exterior frontwall of the driver’s area

• on the interior frontwall under the dash

• on a side panel in the driver’s area

Box 1 and box 2 are mounted approximately 6inches (15 cm) apart. See Fig. 9.3 and Fig. 9.4 .

Electric Service CenterOn "new VCL" (tag axle) chassis models, severalelectrical components (and fuel and hydraulic filters)are consolidated in one area in an electric servicecenter. The service center is located at the rear ofthe vehicle on the right side. See Fig. 9.5 .

Specifications

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f54467711/11/2005

Fig. 9.1, Cab PDMs

Specifications

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f54467811/11/2005

Fig. 9.2, Chassis and Optional Tow Power PDMs

Specifications

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12/04/2001 f543996

Fig. 9.3, Fuse/Relay Box 1

Specifications

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12/04/2001 f543997

Fig. 9.4, Fuse/Relay Box 2

Specifications

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09/30/2002

1

2

3

4

5 6 7 8 9 10

11

12

13 f602103

1. Fuel Filter (primary)2. Low Coolant Module3. Starter Relay4. Diagnostic Connector5. Battery Disconnect

Switch6. ABS ECU (electronic

control unit)7. Cab Power Circuit

Breaker

8. Cab Power CircuitBreaker (optional)

9. Transmission ControlModule (TCM)

10. TCM Fuses/Relays11. Trailer Fuses/Relays12. Fuel Filter (secondary)13. Hydraulic Filter

Fig. 9.5, Electric Service Center

Specifications

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10

TowingTowing the Vehicle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.1Towing With the Vehicle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.2

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Towing the VehicleIMPORTANT: When it is necessary to tow thevehicle, follow the instructions below closely toprevent damage to the vehicle.

On vehicles equipped with an independent frontsuspension, do not tow the vehicle by the sus-pension assembly. Components of the suspen-sion can be damaged.

When towing or pushing any vehicle equippedwith an Allison transmission, disconnect thedriveshaft at the rear axle and support it as nec-essary, regardless of the distance or speedtraveled.

Removing the Transmission from thePark (P) PositionIf a vehicle with a shift-by-wire (SBW) system needsto be towed and the system cannot be activated totake the transmission out of Park (P), follow thesteps in the procedure below.

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

1. Set the parking brake on the tow vehicle.

2. Chock the tires of the tow vehicle.

3. Set the parking brake on the disabled vehicle.

4. Chock the tires of the disabled vehicle.

5. Underneath the disabled vehicle, at the transmis-sion, remove the access hole plug at the rear ofthe SBW actuator. See Fig. 10.1 .

6. Insert a 3/16-inch allen wrench or hex keythrough the access hole into the rear of the ac-tuator. Turn the allen wrench in a clockwise di-rection until the transmission comes out of thePark (P) position.

7. Replace the access hole plug.

8. Remove the chocks from the tires of both ve-hicles.

NOTE: The transmission may also be placed inthe Park (P) position using this procedure.

Front Towing Hookup1. Disconnect the battery ground cable.

2. If the vehicle is to be lifted and towed, removethe driveshaft.

CAUTIONFailure to remove the driveshaft when towing thevehicle with the rear wheels on the ground couldresult in damage to the transmission and otherparts.

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

3. Attach the towing device.

f270124

12

3

05/16/2003

1. SBW Actuator2. Access Hole Plug3. Shift Selector Shaft (part of Allison transmission)

Fig. 10.1, SBW Actuator (at transmission)

Towing

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4. Lift the vehicle and secure the safety towingchains. If additional clearance is needed, removethe front wheels.

5. Connect the clearance lights, taillights, and sig-nal lights. Connect any special towing lights re-quired by local regulations.

WARNINGBefore releasing the parking brakes, make theconnection to the towing vehicle or chock thetires on the disabled vehicle. Failure to do socould result in hazardous conditions because thevehicle could suddenly roll and injury could oc-cur.

6. Release the parking brake.

CAUTIONBefore attempting to tow a vehicle with air sus-pension (and during the towing operation), en-sure that the air suspension is properly aired. Airthe suspension through the Schrader valve onthe air dryer. Attempting to tow a vehicle with animproperly aired suspension may result in dam-age to the chassis and body.

Rear Towing Hookup1. Position the front tires so that they point straight

ahead and secure the steering wheel in this posi-tion.

2. Disconnect the battery ground cable.

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

3. Attach the towing device.

4. Lift the vehicle and secure the safety towingchains. If additional clearance is needed, removethe bumper extension, if so equipped.

5. Connect the clearance lights, taillights, and sig-nal lights. Also connect any special towing lightsrequired by local regulations.

CAUTIONBefore attempting to tow a vehicle with air sus-pension (and during the towing operation), en-sure that the air suspension is properly aired. Airthe suspension through the Schrader valve onthe air dryer. Attempting to tow a vehicle with animproperly aired suspension may result in dam-age to the chassis and body.

Towing With the Vehicle

WARNINGFreightliner neither recommends nor approvesconnecting a trailer or other towed vehicle’sbraking system directly to the vehicle brakingsystem. Freightliner LLC also neither recom-mends nor approves tapping into the vehicle airbrake system, nor operating a towed vehicle ortrailer’s braking system by means of the vehiclebraking system. Failure to observe this warningcould result in severe injury or death, or substan-tial property damage.

Do not tow unbraked vehicles 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.

General InformationIMPORTANT: An auxiliary braking system isstrongly recommended when towing. Followyour state’s motor vehicle regulations and thebody builder’s recommendations to determine ifan auxiliary system is required for towing.

Towing a load puts an additional strain on yourvehicle’s engine, drivetrain, brakes, tires, andsuspension. For your safety and the care ofyour vehicle, properly match the towed load tothe vehicle as follows:

1. Never load the vehicle over the Gross VehicleWeight Rating (GVWR). Considerable damage to

Towing

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the drivetrain may result if the vehicle is over itsGVWR. Check the GVWR safety compliance cer-tification label (provided by the final manufac-turer) to find the GVWR.

2. Use the Gross Combined Weight Rating (GCWR)and Gross Vehicle Weight (GVW) to determinethe towing capacity. Refer to the final manufac-turer for GCWR. If the GCWR is exceeded, seri-ous damage to the drivetrain and brake systemmay result. Loading past the GCWR may lead tounsafe operating and braking conditions.

3. Subtract the GVW (which is the actual weight ofthe vehicle alone) from the GCWR (which is thetotal weight this vehicle can safely pull) to deter-mine the acceptable weight this vehicle can tow.

4. Make sure that the towing equipment is properlyand safely attached to your vehicle.

5. When descending a steep grade, shift the trans-mission into the next lower gear or use the ex-haust brake to provide additional engine braking.

NOTE: In a high-altitude operating environment,your engine will lose power at the rate of 1 per-cent per 1000 feet (305 meters) of elevation.For these high-altitude operating conditions, areduction in gross vehicle weights and grosscombination weights is recommended and willresult in improved vehicle performance.

6. To avoid vehicle damage and handling difficulty,evenly distribute the trailer load. Always tie theload down securely.

7-Pin ConnectorThe following information lists the amperage (amp)load limits for each of the connections in the 7-pinconnector. See Fig. 10.2 for an example of the 7-pinconnector.

• Electric Brakes (to brake the system) — A 12gauge wire interfaces with the 7-pin connectortrailer tow plug. See the brake manual for ex-act specifications.

• RH Stop/Turn — 20 amp

• Back Up Lamps — 10 amp

• LH Stop/Turn — 20 amp

• Running Lamps — 20 amp

• Ignition [+] (to charge the tow vehicle batteries)— 40 amp

• Ground [–] — for all

HitchesUse a hitch and ball recommended by your vehiclemanufacturer or your dealer and make sure that itslocation is compatible with that of the trailer. Use agood weight-carrying hitch that uniformly distributesthe trailer tongue loads through the bumper and theframe. Do not exceed the recommended towing ca-pacity of the vehicle.

CAUTIONAlways disconnect the battery and the engineECM (electronic control module) before weldinganything to the chassis frame.

Do not use single-clamp bumper hitches orhitches that attach to the vehicle axle. However,multi-clamp bumper hitches for occasional use ofa rental trailer are acceptable if properly at-tached. Follow the towing instructions of a repu-table rental agency. Never attach safety chains tothe bumper.

Whenever a trailer hitch is removed, be sure to haveall mounting holes in the underbody properly sealedto prevent possible entry of exhaust fumes, dirt, orwater.

02/02/2005 f544573

ELECTRIC BRAKESRH STOP/TURN

BACKUP LAMPSLH STOP/TURN

RUNNING LAMPS

Fig. 10.2, 7-Pin Connector

Towing

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Trailers

WARNINGAlways use safety chains between the vehicleand the trailer. Failure to do so could cause per-sonal injury or death if the hitch fails.

IMPORTANT: Before connecting a trailer lightingsystem directly to the lighting system of the ve-hicle, see your dealer or rental trailer agency forthe correct type of wiring and relays for yourtrailer and for heavy-duty flashers.

Parking With A Trailer

Park the vehicle on a flat surface. Chock the tires asfollows:

1. Select Neutral (N) on the gear shift selector whiledepressing the service brake.

2. Continue depressing the service brake and haveanother person place wheel chocks under thetrailer wheels.

3. Once the wheel chocks are in place, release theservice brake, making sure that the chocks areholding the vehicle and trailer.

Trailer Towing Tips

Towing a trailer significantly alters the manner inwhich the towing vehicle performs.

• Before starting on a trip, practice turning, stop-ping, and backing in an area away from heavytraffic to gain experience in handling the extraweight and length of the trailer. Take enoughtime to learn the "feel" of the vehicle/trailercombination before starting out on a trip.

• Skillful backing requires practice. Back veryslowly, with someone outside at the rear of thetrailer to guide your efforts. Place your hand atthe bottom of the steering wheel and move it inthe direction you want the rear of the trailer toswing. Make small corrections instead of exag-gerated ones. A slight movement of the steer-ing wheel will result in a much larger move-ment of the rear of the trailer.

• Allow considerably more room for stoppingwhen the trailer is attached. If you have amanual brake controller, "lead" with the trailer

brakes (if so equipped) when approaching astop, if possible. Trailer brakes are also handyfor correcting trailer side-sway. Just touch themfor a moment without using your vehicle brakesand the trailer should settle down and tracksteadily again.

• To assist in attaining good handling of the ve-hicle trailer combination, it is important that thetrailer tongue load be maintained at approxi-mately 10 to 15 percent of the loaded trailerweight.

• Check everything before starting out on theroad. After you have traveled about 50 miles(80 km), stop in a protected location anddouble-check your trailer hitch and electricalconnections for security. Also, examine thetrailer wheel lug nuts for tightness.

• Because trailer wheels will be closer than thetowing vehicle wheels to the inside of the turn,drive slightly beyond the normal turning point.

• Allow extra distance for passing other vehicles.Downshift to a lower gear for better accelera-tion, if necessary.

• Ahead of the vehicle, allow at least the equiva-lent of one vehicle and trailer length combinedfor each 10 mph (16 km/h) of speed.

• If your vehicle begins to lose speed as youclimb a hill, downshift to a lower gear for morepower at the rear wheels.

• Before descending a steep grade, slow downand shift to a lower gear. Driving with thetransmission in a lower gear will assist in re-ducing downhill speed. If the trailer should be-gin to sway, touch the trailer brakes (if soequipped), not the vehicle brakes, and thetrailer should settle down.

Towing

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Subject Page

AAir Brake System . . . . . . . . . . . . . . . . . . . . . . . . . 6.1

Automatic Slack Adjusters . . . . . . . . . . . . . . . . . 6.2Brake Burnishing (new

vehicle) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.2General Information . . . . . . . . . . . . . . . . . . . . . 6.1Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.1

Allison Automatic Transmissions . . . . . . . . . . . . . . . 4.11000/2000/2000 MH Models . . . . . . . . . . . . . . . 4.11000/2000/2100/2400

Models (Arens SBW) . . . . . . . . . . . . . . . . . . . 4.33000 MH/4000 MH/4000

MHP Models . . . . . . . . . . . . . . . . . . . . . . . . . 4.1Antilock Braking System (ABS) . . . . . . . . . . . . . . . . 6.3

Meritor WABCO® AntilockBraking System (ABS) . . . . . . . . . . . . . . . . . . 6.3

CChanging a Flat Tire . . . . . . . . . . . . . . . . . . . . . . . 8.2Cold Weather Operation . . . . . . . . . . . . . . . . . . . . 3.2

Caterpillar . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.2Cummins . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.2Mercedes-Benz . . . . . . . . . . . . . . . . . . . . . . . . 3.2

Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.1Allison Automatic

Transmissions . . . . . . . . . . . . . . . . . . . . . . . . 2.4Backup Alarm (optional) . . . . . . . . . . . . . . . . . . 2.7Cruise Control System . . . . . . . . . . . . . . . . . . . 2.5Electric Horn . . . . . . . . . . . . . . . . . . . . . . . . . . 2.7Hazard Warning Lights

(models built before July2002) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.3

Hazard Warning Lights(models built from July2002, on) . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.3

Headlight Switches andPanel Lights (models builtbefore August 2003) . . . . . . . . . . . . . . . . . . . 2.2

Headlight Switches andPanel Lights (models builtfrom August 2003, on) . . . . . . . . . . . . . . . . . . 2.1

Ignition Switch and Key . . . . . . . . . . . . . . . . . . 2.1Interrupt Switch (optional) . . . . . . . . . . . . . . . . . 2.3Parking Brake Controls . . . . . . . . . . . . . . . . . . . 2.3Tag Axle Suspension Dump

Switch (optional) . . . . . . . . . . . . . . . . . . . . . . 2.6Tilt/Telescope Steering

Column . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.7Turn Signal Lever . . . . . . . . . . . . . . . . . . . . . . 2.3VCL Chassis Dash Switches . . . . . . . . . . . . . . . 2.7

Cruise Control . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.4SmartWheel Cruise Control . . . . . . . . . . . . . . . . 3.5

Subject Page

EElectric Service Center . . . . . . . . . . . . . . . . . . . . . 9.1Emergency Starting With

Jumper Cables . . . . . . . . . . . . . . . . . . . . . . . . . 8.1Engine Braking (optional) . . . . . . . . . . . . . . . . . . . 3.7

Compression (Engine) Brake(VCL only) . . . . . . . . . . . . . . . . . . . . . . . . . . 3.8

Exhaust Brake . . . . . . . . . . . . . . . . . . . . . . . . 3.7Mercedes-Benz . . . . . . . . . . . . . . . . . . . . . . . . 3.9

Engine Operation . . . . . . . . . . . . . . . . . . . . . . . . . 3.2Caterpillar . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.2Cummins . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.3Mercedes-Benz . . . . . . . . . . . . . . . . . . . . . . . . 3.3

Engine Shutdown . . . . . . . . . . . . . . . . . . . . . . . . 3.6Caterpillar . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.6Cummins . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.6Mercedes-Benz . . . . . . . . . . . . . . . . . . . . . . . . 3.7

Engine Starting . . . . . . . . . . . . . . . . . . . . . . . . . . 3.1Caterpillar . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.1Cummins . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.1Mercedes-Benz . . . . . . . . . . . . . . . . . . . . . . . . 3.1

FFluids and Lubricants . . . . . . . . . . . . . . . . . . . . . . 9.1Freightliner Help . . . . . . . . . . . . . . . . . . . . . . . . . 8.1Fuse/Relay/Circuit Breaker

Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.1Fuse/Relay/Circuit Breaker

Identification (front-enginediesel chassis) . . . . . . . . . . . . . . . . . . . . . . . 9.1

Fuse/Relay/Circuit BreakerIdentification . . . . . . . . . . . . . . . . . . . . . . . . . 9.1

HHazard Warning Lights . . . . . . . . . . . . . . . . . . . . . 8.1High Altitude Operation . . . . . . . . . . . . . . . . . . . . . 3.7Hydraulic Brake System (front-

engine diesel chassis) . . . . . . . . . . . . . . . . . . . . 6.4Auto-Apply Parking Brake

Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.5General Information . . . . . . . . . . . . . . . . . . . . . 6.4Meritor WABCO® Antilock

Braking System (ABS),Hydraulic Brake Systems . . . . . . . . . . . . . . . . 6.4

Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.5

IInstrument Panel . . . . . . . . . . . . . . . . . . . . . . . . . 2.1Instrumentation Control Unit

(front-engine diesel chassis) . . . . . . . . . . . . . . . 2.18

Index

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Page 92: Foreword - RV Tech Library · lights, taillights, parking lights, license plate lights, and panel lights is located on the instrument panel. See Fig. 2.3. Control knob positions are

Subject Page

Dash Message Center . . . . . . . . . . . . . . . . . . 2.18Ignition Sequence . . . . . . . . . . . . . . . . . . . . . 2.18Mode/Reset Switch . . . . . . . . . . . . . . . . . . . . 2.21Odometer . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.21

Instruments . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.10Air Pressure Gauges . . . . . . . . . . . . . . . . . . . 2.12Coolant Temperature Gauge . . . . . . . . . . . . . . 2.10Engine Oil Pressure Gauge . . . . . . . . . . . . . . . 2.10Fuel Gauge . . . . . . . . . . . . . . . . . . . . . . . . . . 2.12Intake-Air Restriction

Indicator . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.12Speedometer . . . . . . . . . . . . . . . . . . . . . . . . 2.10Tachometer . . . . . . . . . . . . . . . . . . . . . . . . . . 2.12Transmission Temperature

Gauge (optional) . . . . . . . . . . . . . . . . . . . . . 2.12Voltmeter . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.11

LLevel One Heading Here . . . . . . . . . . . . . . . . . . . 2.22

MMultiple Module Data Computer

(MMDC) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.13Annunciator Module . . . . . . . . . . . . . . . . . . . . 2.13Audible Alarms . . . . . . . . . . . . . . . . . . . . . . . 2.16Gauges . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.15Information Center . . . . . . . . . . . . . . . . . . . . . 2.17Menu Structure Road Map . . . . . . . . . . . . . . . . 2.18

PPower Steering System . . . . . . . . . . . . . . . . . . . . 5.1Pretrip Inspection and Daily

Maintenance Procedures . . . . . . . . . . . . . . . . . . 7.1Pretrip Inspection Checklist . . . . . . . . . . . . . . . . . . 7.1

RRunning Out of Fuel . . . . . . . . . . . . . . . . . . . . . . . 8.3

SSmartWheel (optional) . . . . . . . . . . . . . . . . . . . . . 2.7

Headlamp Interrupt . . . . . . . . . . . . . . . . . . . . . 2.8Horn . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.8Marker Lamp Interrupt . . . . . . . . . . . . . . . . . . . 2.8Windshield Wipers . . . . . . . . . . . . . . . . . . . . . . 2.8

TTilt/Telescope Steering Column . . . . . . . . . . . . . . . 5.1

Subject Page

Douglas Column . . . . . . . . . . . . . . . . . . . . . . . 5.1TRW Column . . . . . . . . . . . . . . . . . . . . . . . . . 5.1

Towing the Vehicle . . . . . . . . . . . . . . . . . . . . . . . 10.1Front Towing Hookup . . . . . . . . . . . . . . . . . . . 10.1Rear Towing Hookup . . . . . . . . . . . . . . . . . . . 10.2Removing the Transmission

from the Park (P) Position . . . . . . . . . . . . . . . 10.1Towing With the Vehicle . . . . . . . . . . . . . . . . . . . 10.2

7-Pin Connector . . . . . . . . . . . . . . . . . . . . . . . 10.3General Information . . . . . . . . . . . . . . . . . . . . 10.2Hitches . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.3Trailers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.4

Towing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.1

VVehicle Identification Number

(VIN) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.1Vehicle Specification Label . . . . . . . . . . . . . . . . . . 1.1

WWarning and Indicator Lights . . . . . . . . . . . . . . . . . 2.8

Antilock Braking System(ABS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.10

Index

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