Cascadia Driver's Manual

®
CASCADIA
Driver’s Manual
Part Number STI 478
Publication Number STI-478-6
Foreword
Introduction performed. The EDR is designed to record data re-

lated to vehicle dynamics and safety systems for ap-
This manual provides information needed to operate proximately 60 seconds. This data can help provide
and understand the vehicle and its components. a better understanding of the circumstances in which
More detailed information is contained in the Owner’s crashes and injuries occur. Data recorded includes
Warranty Information for North America booklet, and the following items:
in the vehicle’s workshop and maintenance manuals. • how various systems in the vehicle were oper-
Custom-built Freightliner vehicles are equipped with ating
various chassis and cab components. Not all of the • engine system information
information contained in this manual applies to every
vehicle. For details about components in your ve- • how far (if at all) the driver was depressing the
hicle, refer to the chassis specification pages in- accelerator
cluded in all new vehicles and to the vehicle specifi-
• if the driver was depressing the brake pedal
cation decal, located inside the vehicle.
• how fast the vehicle was traveling
For your reference, keep this manual in the vehicle
at all times. NOTE: Data is not recorded by the EDR under
IMPORTANT: Descriptions and specifications in normal driving conditions. Personal data such
this manual were in effect at the time of printing. as name, gender, age, and crash location are
Freightliner Trucks reserves the right to discon- not recorded. However, other parties such as
tinue models and to change specifications or law enforcement could combine the EDR data
design at any time without notice and without with the type of personally identifying data rou-
incurring obligation. Descriptions and specifica- tinely acquired during a crash investigation.
tions contained in this publication provide no To read data recorded by an EDR, special equipment
warranty, expressed or implied, and are subject is required, and access to the vehicle or the EDR is
to revisions and editions without notice. needed. In addition to the vehicle manufacturer, other
parties that have the special equipment, such as law
Environmental Concerns and enforcement, can read the information if they have
access to the vehicle or the EDR.
Recommendations
Whenever you see instructions in this manual to dis- Emissions and Fuel Efficiency
card materials, you should first attempt to reclaim Compliance
and recycle them. To preserve our environment, fol-
low appropriate environmental rules and regulations This vehicle must be regularly inspected and main-
when disposing of materials. tained as indicated in the Cascadia Maintenance
Manual, and in the Pre- and Post-Trip Inspections
Event Data Recorder and Maintenance chapter in this manual, in order to
continue satisfactory performance and ensure cover-
This vehicle is equipped with one or more devices age of the vehicle under the manufacturer’s warranty.
that record specific vehicle data. The type and Many maintenance procedures ensure that the ve-
amount of data recorded varies depending on how hicle and engine continue to comply with applicable
the vehicle is equipped (such as the brand of engine, emissions standards. Maintenance procedures, using
if an air bag is installed, or if the vehicle features a components engineered to comply with greenhouse
collision avoidance system, etc.). gas emissions and fuel efficiency regulations, may be
performed by an authorized Daimler Trucks North
This vehicle is equipped with an event data recorder America dealer, an independent outlet, or the vehicle
(EDR). The main purpose of an EDR is to record owner or operator.
data in certain crash or near-crash situations, such
as air bag deployment or hitting a road obstacle, that The vehicle owner is responsible for determining the
will assist in understanding how a vehicle’s systems suitability of replacement components to maintain
STI-478-6 (11/14)
Part Number STI 478
Printed in U.S.A.
Foreword
compliance with federal and local jurisdictional regu- hotline 1-800-333-0510, or contact Transport
lations. Components including, but not limited to, Canada by mail at: Transport Canada, ASFAD,
tires, cab/sleeper side extenders, chassis fairings, Place de Ville Tower C, 330 Sparks Street, Ot-
bumper, hood, vehicle speed limiters, and idle reduc- tawa, Ontario, Canada K1A 0N5.
tion timers are specifically designed and manufac-
tured to exacting standards for regulatory fuel effi- For additional road safety information, please visit
ciency and greenhouse gas emissions compliance. It the Road Safety website at: www.tc.gc.ca/
is important that these components are always re- roadsafety.
placed with components that meet or exceed the per-
formance of the originally installed components.
Customer Assistance Center

Having trouble finding service? Call the Customer
Assistance Center at 1-800-385-4357 or 1-800-FTL-
HELP. Call night or day, weekdays or weekends, for
dealer referral, vehicle information, breakdown coor-
dination, or Fleetpack assistance. Our people are
knowledgeable, professional, and committed to fol-
lowing through to help you keep your truck moving.
Reporting Safety Defects

If you believe that your vehicle has a defect which
could cause a crash or could cause injury or
death, you should immediately inform the National
Highway Traffic Safety Administration (NHTSA) in
addition to notifying Daimler Trucks North America
LLC.
If the NHTSA receives similar complaints, it may
open an investigation, and if it finds that a safety
defect exists in a group of vehicles, it may order a
recall and remedy campaign. However, NHTSA
cannot become involved in individual problems
between you, your dealer, or Daimler Trucks North
America LLC.
To contact NHTSA, you may call the Vehicle
Safety Hotline toll-free at 1-888-327-4236 (TTY:
1-800-424-9153); go to www.safercar.gov; or
write to: Administrator, NHTSA, 1200 New Jersey
Avenue, SE, Washington, DC 20590. You can also
obtain other information about motor vehicle safety
from www.safercar.gov.
Canadian customers who wish to report a safety-
related defect to Transport Canada, Defect Investi-
gations and Recalls, may telephone the toll-free
© 2007–2015 Daimler Trucks North America LLC. All rights reserved. Daimler Trucks North America LLC is a Daimler
company.
No part of this publication, in whole or part, may be translated, reproduced, stored in a retrieval system, or transmitted
in any form by any means, electronic, mechanical, photocopying, recording, or otherwise, without the prior written per-
mission of Daimler Trucks North America LLC. For additional information, please contact Daimler Trucks North
America LLC, Service Systems and Documentation, P.O. Box 3849, Portland OR 97208–3849 U.S.A. or refer to
www.Daimler-TrucksNorthAmerica.comand www.FreightlinerTrucks.com.
Contents
Chapter Page
Introduction, Environmental Concerns and Recommendations,
Event Data Recorder, Emissions and Fuel Efficiency Compliance,
Customer Assistance Center, Reporting Safety Defects . . . . . . . . . . . . . . . . . . . . Foreword
1 Vehicle Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.1
2 Vehicle Access . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.1
3 Electrical System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.1
4 Instruments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.1
5 Driver Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.1
6 Driver Assistance Features . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.1
7 Seats and Restraints . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.1
8 Climate Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.1
9 Cab Features . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.1
10 Engine Starting, Operation, and Shutdown . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.1
11 Optional Engine Systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11.1
12 Emissions and Fuel Efficient Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12.1
13 Brake Systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13.1
14 Manual Transmissions and Hydraulic Clutch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14.1
15 Automated Transmissions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15.1
16 Drive Axles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16.1
17 Steering System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17.1
18 Fifth Wheels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18.1
19 Trailer Couplings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19.1
20 Pre- and Post-Trip Checklists . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20.1
21 Pre- and Post-Trip Inspections and Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21.1
22 Cab Appearance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22.1
23 Headlight Aiming . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23.1
24 In an Emergency . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24.1
25 Natural Gas Vehicles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25.1
26 Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26.1
Index . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I.1
1
Vehicle Identification
Component Information Label . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.1
Component GWR Label . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.1
Federal Motor Vehicle Safety Standard Labels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.1
Canadian Motor Vehicle Safety Standard Labels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.1
Emissions Labels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.1
Component Information Label The tire and rim portion of the FMVSS certification
label certifies suitable tire and rim combinations that
NOTE: Labels shown in this chapter are ex- can be installed on the vehicle, for the given gross
amples only. Actual specifications may vary from axle weight rating. Tires and rims installed on the
vehicle to vehicle. vehicle at the time of manufacture may have a higher
load capacity than that certified by the tire and rim
The component information label lists the vehicle label. If the tires and rims currently on the vehicle
model, identification number, and major component have a lower load capacity than that shown on the
models. It also lists the major assemblies and instal- tire and rim label, then the tires and rims determine
lations shown on the chassis specification sheet. the load limitations on each of the axles.
One copy of the component information label is at-
tached to the inside of the glove box; another copy is Trucks built without a cargo body that are intended
inside the rear cover of the Owner’s Warranty Infor- for service in the U.S. have an incomplete vehicle
mation for North America booklet. An illustration of certification label attached by the final-stage manu-
the label is shown in Fig. 1.1. facturer. See Fig. 1.5. This label will be attached to
the incomplete vehicle document included with the
vehicle, and certifies that the vehicle conforms to all
applicable FMVSS regulations in effect on the date of
completion.
Canadian Motor Vehicle Safety

Standard Labels
In Canada, tractors with fifth wheels are marked as
certified by means of a statement of compliance label
with the Canadian National Safety Mark attached to
the driver-side door frame B-pillar. See Fig. 1.6.
02/20/2012 f080176
Trucks built without a cargo body and tractors built
Fig. 1.1, Component Information Label without a fifth wheel that are intended for service in
Canada have an incomplete vehicle certification label
Component GWR Label attached to the driver-side B-pillar. After completion
of the vehicle, a complete certification label must be
The component GWR label is located on the attached by the final-stage manufacturer to certify
passenger-side B-pillar. The label provides maximum that the vehicle conforms to all applicable Canada
GWR ratings for each component. Motor Vehicle Safety Standard (CMVSS) regulations
in effect on the date of completion.
See Fig. 1.2 for a typical component GWR label.
Federal Motor Vehicle Safety Emissions Labels

Standard Labels Aftertreatment System Indicators
Label
NOTE: Due to the variety of Federal Motor Ve-
hicle Safety Standard (FMVSS) certification re- Engines and vehicles manufactured after December
quirements, not all of the labels shown will apply 31, 2006 and domiciled in the U.S. or Canada are
to your vehicle. required to meet all EPA regulations effective as of
the vehicle build date, and are equipped with an
Tractors with or without fifth wheels purchased in the emission aftertreatment system (ATS). Vehicles do-
U.S. are marked as certified by means of an FMVSS miciled outside of the U.S. and Canada may not
certification label. See Fig. 1.3. This label is attached have aftertreatment equipment, depending upon local
to the driver-side B-pillar, as shown in Fig. 1.4. statutory emissions guidelines. See Table 1.1.
1.1
02/20/2012 f080178
Fig. 1.2, Component GWR Label
02/20/2012 f080177
Fig. 1.3, Vehicle Certification Label
02/28/2012 f080180
Fig. 1.5, Incomplete Vehicle Certification Label
10/10/2006 f080024
Fig. 1.6, Canadian National Safety Mark
A warning label on the driver-side visor contains im-

portant warning indicators in the instrument cluster
that pertain to the ATS. See Fig. 1.7 or Fig. 1.8.
2
It is a violation of U.S. federal law to alter exhaust
plumbing, ATS, or other components in any way that
would bring the engine/vehicle out of compliance with
certification requirements [Ref: 42 U.S.C. S7522(a)
(3)]. It is the owner’s responsibility to maintain the
02/28/2012 f080182 vehicle so that it conforms to EPA regulations.
1. EPA Noise Emission Control Label
2. FMVSS Certification Label
Fig. 1.4, Label Locations
1.2
EXHAUST AFTERTREATMENT SYSTEM INFORMATION

INDICATOR WARNING
CHECK STOP
LAMP(S)
(Solid) (Flashing) (Flashing)
Level 1 Level 2 Level 3 Level 4
Indicator Lamp Filter Regeneration Filter Parked Regeneration Service Regeneration Required. HEST (High Exhaust
Message(s) Recommended. Regeneration Required − Engine Engine Derate To Idle Only. System Temperature)
Necessary Derate
Diesel Particulate Filter is reaching Filter is now Filter has reached Filter has exceeded maximum Flashing
Filter Condition capacity. reaching maximum maximum capacity. capacity. A regeneration is in
Switch.
capacity. progress.
Required Action Bring vehicle to To avoid engine Vehicle must be Vehicle must be parked, and a
highway speeds to derate, bring vehicle parked, and a Parked Service Regeneration must be Solid
allow for an to highway speeds Regeneration must performed. Check engine Exhaust components
Automatic to allow for an be performed. operator’s manual for details. and exhaust gas are at
Regeneration or Automatic Engine will begin Engine will shut down. high temperature. When
perform a Parked Regeneration, or derate. stationary, keep away
Regeneration. perform a Parked from people and
Regeneration as flammable materials or
soon as possible. vapors.
For a driver performed Parked Regeneration, vehicle must be equipped with a dash mounted Regeneration Switch.
02/20/2009 f080156
Fig. 1.7, ATS Indicators, EPA07
Applicable Emissions System Based on Build Date and EPA Regulations

Build Date Regulation: Emissions Components
EPA07 (reduce nitrogen oxides (NOx) emissions to 1.1 g/bhp-hr, and reduce
January 1, 2007–December 31,
particulate matter emissions to 0.01 g/bhp-hr): Aftertreatment device (ATD) containing
2009
a diesel particulate filter that traps soot and ash.*
EPA10 (reduce NOx emissions to 0.2 g/bhp-hr): EPA07-type ATD, with additional
January 1, 2010–December 31,
selective catalyst reduction (SCR) technology that utilizes diesel exhaust fluid (DEF)
2012
to convert NOx to nitrogen and water vapor.
GHG14: Aerodynamic and fuel efficiency components including, but not limited to,
tires, cab/sleeper side extenders, chassis fairings, bumper, hood, vehicle speed
From March 5, 2012
limiters, and idle reduction timers specifically designed to meet regulatory fuel
efficiency and greenhouse gas emissions standards.
* Cummins, Detroit, and Mercedes-Benz ATD’s are also equipped with a diesel oxidation catalyst to break down pollutants.
Table 1.1, Applicable Emissions System Based on Build Date and EPA Regulations
IMPORTANT: Certain Freightliner incomplete

EPA Noise Emission Control Label vehicles may be produced with incomplete noise
control hardware. Such vehicles will not have a
A vehicle noise emission control label (Fig. 1.9) is vehicle noise emission control information label.
located on the driver-side B-pillar as shown in For such vehicles, it is the final-stage manufac-
Fig. 1.4. It is the owner’s responsibility to maintain turer’s responsibility to complete the vehicle in
the vehicle so that it conforms to EPA regulations.
conformity to U.S. EPA regulations (40 CFR Part
205) and label it for compliance.
1.3
IMPORTANT
DPF Regen Needed Diesel Particulate Filter (DPF)
regeneration is needed.
If flashing, regenerate as soon as
possible. Engine derate possible.
Hot Exhaust Hot exhaust can cause fire.
Keep flammables and people away
from exhaust.
DEF Refill Needed Diesel Exhaust Fluid (DEF) level is

low. Engine derate likely.
DEF
Refill tank with certified DEF.
See operator’s manual for complete instructions. 24−01656−000
11/30/2010 f080162
Fig. 1.8, ATS Indicators, EPA10 and Newer
VEHICLE NOISE EMISSION CONTROL INFORMATION A Vehicle Emission Control Information Label is lo-
DATE OF MANUFACTURE 01/96
FREIGHTLINER CORPORATION
THIS VEHICLE CONFORMS TO U.S. EPA REGULATIONS FOR NOISE EMISSION
APPLICABLE TO MEDIUM AND HEAVY TRUCKS.
cated on the driver-side door. See Fig. 1.10. It is the
THE FOLLOWING ACTS OR THE CAUSING THEREOF BY ANY PERSON ARE PROHIBITED BY
THE NOISE CONTROL ACT OF 1972: owner’s responsibility to maintain the vehicle so that
A. THE REMOVAL OR RENDERING INOPERATIVE, OTHER THAN FOR PURPOSES OF
MAINTENANCE, REPAIR, OR REPLACEMENT, OF ANY NOISE CONTROL DEVICE OR
ELEMENT OF DESIGN (LISTED IN THE OWNER’S MANUAL) INCORPORATED INTO THIS
it conforms to EPA and NHTSA regulations.
VEHICLE IN COMPLIANCE WITH THE NOISE CONTROL ACT.
B. THE USE THIS VEHICLE AFTER SUCH DEVICE OR ELEMENT OF DESIGN HAS
BEEN REMOVED OR RENDERED INOPERATIVE. 24−00273−020
VEHICLE EMISSION CONTROL INFORMATION
10/06/98 f080026 MANUFACTURED BY:
VIN: REGULATORY CLASS:
DATE OF MANUFACTURE:
VEH FAMILY CD:
GVWR−KG
GVWR−LBS EMISSION CONTROL IDENTIFIERS:
Fig. 1.9, Vehicle Noise Emission Control Label THIS VEHICLE COMPLIES WITH U. S. EPA REGULATIONS FOR XXXX HEAVY DUTY VEHICLES.
SEE OWNER’S MANUAL FOR PROPER MAINTENANCE OF THIS VEHICLE. U PART NO. 24−01177−060 REV A
Vehicle Emission Control Information 02/29/2012 f080181
Label Fig. 1.10, Vehicle Emission Control Information Label

Model year 2013 and later vehicles meet additional
requirements as specified by federal greenhouse gas
Certified Clean Idle Label
and fuel efficiency regulations (GHG14). These ve- The California Air Resources Board (CARB) requires
hicles are equipped with components that increase model year 2008 and newer heavy-duty diesel en-
fuel efficiency and reduce GHG emissions. Compo- gines to be equipped with a non-programmable en-
nents may include, but are not limited to, low-rolling gine shutdown system that automatically shuts down
resistance tires; aerodynamic devices such as hood, the engine after five minutes of idling in order to limit
cab side extenders, and fuel tank fairings; vehicle emissions of particulate matter and NOx.
speed limiters; and idle shutdown timers.
1.4
Certified vehicles are equipped with a label placed

near the bottom edge of the driver-side door. See
Fig. 1.11.
CERTIFIED
CLEAN IDLE
02/20/2012 f080179
Fig. 1.11, CARB Clean Idle Label
1.5
2
Vehicle Access
Cab Door Locks and Handles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.1
Grab Handles and Access Steps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.1
Cab-to-Sleeper Access . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.3
Sleeper Door . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.3
Sleeper Luggage Door . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.4
Back-of-Cab Access . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.4
Hood Opening and Closing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.5
Vehicle Access
Cab Door Locks and Handles

One common key operates the ignition switch and all
of the door locks.
IMPORTANT: Each key is numbered. Record
the number so a duplicate key can be made, if
needed. 1
To unlock the driver’s door from outside the cab, in-
sert the key in the lockset and turn it one-quarter turn
clockwise. See Fig. 2.1. To remove the key, turn it 2
counterclockwise to the original position. Pull out on
the door pull handle to open the door.
06/22/2006 3 f720639
1. Lock Button
2 2. Integral Door Upper Grab Handle
3. Door Lever
1
Fig. 2.2, Door Interior
To unlock the door without unlatching it, pull the lock

button upwards.
3
Grab Handles and Access
Steps
10/22/2001 f720397
1. Key 3. Door Pull Handle WARNING
2. Lockset
Fig. 2.1, Exterior Door Handle
Wet or dirty shoe soles greatly increase the
chance of slipping or falling. If your soles are wet
To unlock the passenger’s door from outside the cab, or dirty, be especially careful when climbing
insert the key in the lockset and turn it one-quarter onto, or down from, the back-of-cab area.
turn counterclockwise. Turn the key clockwise to the Always maintain three-point contact with the
original position to remove it. back-of-cab access supports while entering and
NOTE: The cab door locks can be operated exiting the back-of-cab area. Three-point contact
when the doors are open. means both feet and one hand, or both hands
and one foot, on the grab handles, steps, and
To lock a door from outside the cab, insert the key in deck plates. Other areas are not meant to sup-
the lockset and turn it in the direction opposite to the port back-of-cab access, and grabbing or step-
unlocking direction (counterclockwise for the driver’s ping in the wrong place could lead to a fall, and
door, clockwise for the passenger’s door). Close the personal injury.
door if it is open.
Be careful not to get hands or feet tangled in
To lock either door from inside the cab, push the lock hoses or other back-of-cab equipment. Careless-
button downwards. See Fig. 2.2. ness could cause a person to trip and fall, with
possible injury.
To open the door from the inside, lift up on the door
lever. This will unlatch the door whether or not it is
locked.
2.1
Vehicle Access
Entering the Driver Side 5. Grasp the steering wheel with your left hand, and
step up.
When entering the cab from the driver side, use the
grab handle and access steps as follows: 6. Step into the cab with your right foot first, and
grasp the steering wheel with your right hand.
1. Open the driver side door, and place anything
that you are carrying in the cab. Exiting the Driver Side
2. Using both hands, grasp the grab handle that is Exit the cab from the driver side as follows:
on the B-pillar, or use your left hand on the inte-
gral door lower grab handle. See Fig. 2.3. Reach IMPORTANT: Do not attempt to exit the cab
up as far as is comfortable. while carrying any items in your hands.
1. Grasp the steering wheel with both hands, place
your left foot on the top step, then stand on the
threshold facing into the cab.
2. Using your right hand, grasp the grab handle,
located on the B-pillar.
3. Move your right foot to the bottom step.
4. Move your left hand to the integral door lower
grab handle.
5. Step to the ground with your left foot first.
1
Entering the Passenger Side
2 When entering the cab from the passenger side, use
the grab handles and access steps as follows:
5
1. Open the passenger-side door, and place any-
thing that you are carrying in the cab.
2. Using your left hand, grasp the grab handle
that’s on the rear of the door opening. See
Fig. 2.4.
3. Using your right hand, grasp the integral door
lower grab handle.
4
4. Place your right foot on the bottom step, and
step up to the upper step with your left foot.
5. Place your right foot on the top step, and step
3 up.
11/30/2006 f602271
6. Move your right hand to the upper grab handle
1. Steering Wheel 4. Top Step on the windshield post.
2. B-Pillar Grab Handle 5. Integral Door Lower
3. Bottom Step Grab Handle 7. Step into the cab with your left foot first.
Fig. 2.3, Driver-Side Steps and Grab Handle Exiting the Passenger Side
3. Place your right foot on the bottom step, and pull Exit the cab from the passenger side as follows:
yourself up. Move your left hand to the integral
door upper grab handle. IMPORTANT: Do not attempt to exit the cab
while carrying any items in your hands.
4. Place your left foot on the top step.
2.2
Vehicle Access
Cab-to-Sleeper Access
To open the sleeper access on vehicles with vinyl
sleeper curtains, unzip the sleeper curtains. If de-
sired, unsnap the curtains all the way around the
sides and top, and remove the curtains.
To open the sleeper access on vehicles with velour
sleeper curtains, unfasten the snaps at one side,
then push the curtain to the opposite side.
Sleeper Door
2 The sleeper door (Fig. 2.5, Ref. 1) is not intended for
entry or exit. The door is intended only as a conve-
nient means to stow or remove personal belongings
1 in and from the sleeper area. To open the sleeper
door from the inside, push down on the lever handle
located inside the sleeper compartment aft of the
door, or pull out on the upper lever located inside the
cab door opening; see Fig. 2.6. To open the sleeper
door from outside, open the cab door, then pull out
on the upper lever located inside the cab door open-
ing. To close the door, pull on the strap attached to
the inside of the door, or push it closed from the out-
3
side, until it latches.
IMPORTANT: The sleeper doors are two-stage
latching. When closing the doors, ensure that
01/03/2007 4 f720643
they are completely latched to prevent wind
noise and water intrusion.
1. Lower Grab Handle
2. Upper Grab Handle
3. Integral Door Lower Grab Handle
4. Top Step
Fig. 2.4, Passenger-Side Steps and Grab Handles
1. Using both hands, grasp the grab handle thats

on the windshield post, and place your right foot
on the top step while standing up from the seat 1
facing inward.
2. Place your left foot on the bottom step.
2
3. Move your left hand to the lower grab handle
located at the rear edge of the door opening.
See Fig. 2.4.
4. Move your right hand to the integral door lower
grab handle.
04/20/2007 f602302
5. Step to the ground with your right foot first. 1. Sleeper Door
2. Luggage Compartment Door
Fig. 2.5, Sleeper Doors
2.3
Vehicle Access
1 2
03/22/2007 f720661
1. Sleeper Door Lever
2. Luggage Door Lever 3
Fig. 2.6, Sleeper Door Levers
Sleeper Luggage Door

To open the sleeper luggage door, pull out on the
lower lever located inside the cab door opening. See
1
Fig. 2.6. To close the door, push it closed until it
latches.
Back-of-Cab Access 1
WARNING 09/24/2007 f602335
External surfaces of the exhaust system remain 1. Steps 3. Deck Plate

hot after the engine has been shut down. When 2. Grab Handle
accessing the back of the cab or sleeper, do not
Fig. 2.7, Back-of-Cab Access
touch any part of the exhaust system, or severe
burns could occur.
When trailer air and electrical connections cannot be WARNING
reached conveniently from the ground, Federal Motor
Wet or dirty shoe soles greatly increase the
Carrier Safety Regulations require commercial carri-
chance of slipping or falling. If your soles are wet
ers to provide back-of-cab access.
or dirty, be especially careful when climbing
Optional grab handles are mounted either on both onto, or leaving, the back-of-cab area.
cab sidewalls, or on the left sidewall only. See
Always maintain three-point contact with the
Fig. 2.7. Steps are mounted either on the fuel tank(s)
back-of-cab access supports while entering and
or on metal brackets. When a deck plate is neces-
exiting the back-of-cab area. Three-point contact
sary, it is mounted across the top of the frame rails.
means both feet and one hand, or both hands
IMPORTANT: Climb onto, and down from, back- and one foot, on the grab handles, steps, and
of-cab access facing in toward the vehicle, as deck plates. Other areas are not meant to sup-
you would on a ladder. Do not climb up or down port back-of-cab access, and grabbing or step-
facing out away from the vehicle. ping in the wrong place could lead to a fall, and
personal injury.
2.4
Vehicle Access
Be careful not to get hands or feet tangled in

hoses or other back-of-cab equipment. Careless- CAUTION
ness could cause a person to trip and fall, with
possible injury. Do not let the hood free-fall to the full-open posi-
tion. To do so could cause damage to the hood
Entering Back-of-Cab or hood straps.
3. Using the bumper step and grab handle, slowly
When climbing onto the deck plate, do the following:
tilt the hood until the straps support it. See
1. Grasp the sidewall grab handle with both hands. Fig. 2.8.
Reach up as far as is comfortable.
2. Place one foot on the bottom step and pull your-
self up.
3. Place your other foot on the top step.
4. Move your lower hand to a higher position on the
grab handle.
5. Step onto the deck plate.
Climbing Down from Back-of-Cab

To climb down from the back-of-cab area:
1. Grasp the sidewall grab handle with both hands.
2. Step one foot at a time onto the top step.
3. Move your upper hand to a lower position on the
grab handle.
4. Move one foot to the bottom step.
5. Move your upper hand to a lower position on the
grab handle. 03/22/2007 f880788
6. Step to the ground with your upper foot first. Fig. 2.8, Hood Tilting
Hood Opening and Closing To Return the Hood

A grab handle at the front of the hood provides a 1. Grasp the grab handle, and lift the hood a just-
hand-hold for hood tilting. Two tilt-assist struts help to over-center position.
tilt the hood open, and to return it to the operating 2. As the hood goes over center, the hood damper
position. A damper controls the closing rate of the controls the rate of descent to the operating posi-
hood and hood straps prevent the hood from over- tion.
travel. In the operating position, the hood is secured
by a hold-down latch on each side of the hood. 3. Make sure the hood is flush with the cowl, then
secure the hood by engaging both hood hold-
To Tilt the Hood down latches.
1. Apply the parking brakes. IMPORTANT: Make sure that both hold-down
latches are fully engaged before operating the
2. Release both hood hold-down latches by pulling vehicle.
the ends outward.
2.5
3
Electrical System
Electrical Power Distribution . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.1
Emergency Power Supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.3
Progressive Low Voltage Disconnect . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.4
Electrical System
Electrical Power Distribution Auxiliary PDM

Electrical power distribution provides battery power to The optional auxiliary PDM is used when additional
the electrical and electronic systems. See Fig. 3.1 for circuit protection is needed for optional features. For
power distribution component locations. example, if a beacon light is added to the Cascadia,
it may require an auxiliary PDM. The auxiliary PDM
The following components make up the power distri- may contain fuses and relays for these devices. It is
bution system: mounted in the cab, behind the doghouse cover.
• MEGA Fuse Junction Block (MFJB), EPA07
only
Trailer PDM
• Powertrain Power Distribution Module The optional trailer PDM, mounted on the frame rail,
is used to supply trailer power to the chassis-
(PT-PDM)
mounted trailer receptacles. The SAM chassis sup-
• Powernet Distribution Box (PNDB), EPA10 and plies control signals to the relays in the trailer PDM.
newer
SAM Cab
• Cab Load Disconnect Switch
The SAM cab is located behind the glove box inside
• Auxiliary PDM
the vehicle cab. See Fig. 3.4. The SAM cab contains
fuses and relays in addition to solid state circuit pro-
MEGA Fuse Junction Block, EPA07 tection devices that will trip when a circuit is over-
On EPA07 vehicles, the MFJB distributes battery loaded.
power to the alternator, SAM cab, SAM chassis, and Refer to Chapter 25 for fuse and relay locations.
powertrain PDM. Battery power may also be routed
to an inverter and a trailer PDM. The MFJB houses SAM Chassis
up to five MEGA fuses, and is located on the left
frame rail in front of the batteries. See Fig. 3.2. The SAM Chassis is located in the engine compart-
ment on the driver-side frontwall. See Fig. 3.3. The
Powernet Distribution Box, EPA10 SAM chassis contains fuses and relays in addition to
solid state circuit protection devices that will trip
and Newer when a circuit is overloaded.
The PNDB distributes battery power to the SAM cab, Refer to Chapter 25 for fuse and relay locations.
SAM chassis, powertrain PDM, and other keep-alive
circuits. Circuit Protection Features
The PNDB is mounted in the engine compartment on
The SAM chassis and SAM cab may be equipped
the frontwall near the steering column. The label on
with self-resetting circuit breakers instead of fuses.
the PNDB fuse cover identifies typical circuits. See
Fig. 3.3. Self-resetting circuit breakers are tripped when they
reach 170°F (77°C), then self-reset once the tem-
perature drops sufficiently. When the circuit overload
Power Distribution Modules is removed, this circuit protection will self-reset.
Powertrain PDM Some of these circuits require the ignition switch to
be cycled off then back on again for the self-reset to
The powertrain PDM contains fuses and relays that occur.
provide battery and ignition power to the engine, af-
tertreatment device, transmission, and other Some ECU’s are equipped with a self-resetting circuit
powertrain-related circuits. It is mounted in the en- breaker removal tool.
gine compartment, above the driver-side inner
fender. WARNING
Always wear heat-protective gloves when han-
dling a self-resetting circuit breakers, which can
3.1
Electrical System
8
7
6
5
4
3
2
02/27/2012 f001175a
1. SAM Cab 6. MEGA Fuse Junction Block
2. Powertrain PDM (PT-PDM) 7. Cab Load Disconnect Switch (optional location)
3. Powernet Distribution Box (PNDB) 8. Cab Load Disconnect Switch (optional location)
4. SAM Chassis 9. Trailer PDM
5. Main Ground Junction Block
Fig. 3.1, Component Locations
reach extremely high temperatures. Failure to use • Use a circuit breaker removal tool to remove a
appropriate heat protection can lead to serious self-resetting circuit breaker. See Fig. 3.5. Use
injury. of any other tool, including pliers, may damage
the circuit breaker.
NOTICE • Never attempt to probe a self-resetting circuit
breaker while installed on the SAM Cab or
Self-resetting circuit breakers can be perma- SAM Chassis. Remove the circuit breaker first,
nently damaged if improperly handled. Use the or use a non-contact infrared thermometer to
guidelines below to handle them safely. measure temperature.
• Disconnect the batteries before removing a
self-resetting circuit breaker.
3.2
Electrical System
Cab Load Disconnect Switch
1 WARNING
Turning the cab load disconnect switch (CLDS) to
the off position does not disconnect the connec-
tion between the battery and the starter. To work
on the vehicle safely, the negative leads must be
disconnected from the battery.
2
IMPORTANT: The ignition should be turned off
before turning the CLDS to on or off.
The CLDS is used to avoid excessive draw on the
battery when the vehicle is parked for an extended
period of time by disconnecting (or opening) the con-
06/15/2007 f545073 nection between the battery and the most of the ve-
1. MEGA Fuse Junction Block hicle electrical system.
2. Main Ground Junction Block
The CLDS may be mounted:
Fig. 3.2, EPA07 MEGA Fuse Junction Block • inside the cab on the outboard side of the
driver’s seat;
• at the battery box;
• outboard on the left frame rail.
4
See Fig. 3.6 for an EPA07 CLDS; see Fig. 3.7 for an
EPA10 and newer switch.
If the CLDS is turned to the off position while the ve-
hicle is running, the emergency power system will
activate. The powertrain PDM will receive power from
the emergency power feed, but the batteries will not
be charging. See the Emergency Power Supply
heading below for details.
Emergency Power Supply

The Cascadia electrical system has an emergency
power circuit that supplies battery power for exterior
3 lighting. This assists vehicle visibility in the event a
MEGA fuse is open circuit. The emergency power
circuit is live even when the CLDS is turned off.
2 The emergency power supply feature allows for the
02/27/2012 1 f545682a vehicle to be driven off the highway and for the exte-
1. Powertrain PDM (PT-PDM) rior lighting to remain on in the event of a SAM Cab
2. Inline Fuse, Auxiliary PDM or SAM Chassis failure. The emergency power sup-
3. SAM Chassis ply will cause certain exterior lamps to flash (depend-
4. Powernet Distribution Box (PNDB) ing on if it is the SAM Cab or SAM Chassis that
failed), indicating that the vehicle is disabled.
Fig. 3.3, Engine Compartment Power Distribution
Components
3.3
Electrical System
02/07/2007 f544945
Fig. 3.4, SAM Cab Location
SAM Cab Fault • identification lights
If the emergency power supply system activates, do • front marker lights

not shut down the engine until the vehicle is in a safe • turn-signal indicators in the ICU (alternately)
position to do so. It will not be able to be restarted
until the problem is corrected. If emergency power • side marker lights
mode is due to a SAM Cab fault, the gauges will be- • rear turn-signal lights
come unresponsive but the engine will remain run-
ning until it is turned off. • trailer taillights
When the ignition is in the ON position, the emer- If the ignition switch is turned ON while the load dis-
gency power supply will cause the following lamps to connect switch is in the OFF position, the emergency
flash: power supply feature will activate the following
lamps:
• dash panel lights
• clearance lights (flashing)
• clearance lights
• side marker lamps (flashing)
• front marker lights
• low beam headlights
• side marker lights
• trailer taillights Progressive Low Voltage
• rear stop lights Disconnect
SAM Chassis Fault The progressive low voltage disconnect (PLVD) fea-
ture protects the batteries from excessive discharge
The engine may be able to be restarted when the by disconnecting certain circuits from battery power
SAM Chassis fails. When the ignition is in the ON supply. This allows the batteries to maintain accept-
position, the emergency power supply will cause the able charge to restart the vehicle.
following lamps to flash:
When battery voltage drops below a predetermined
• dash panel lights value, loads designated as comfort loads (priority
3.4
Electrical System
1
06/19/2007 f545071
Fig. 3.6, Cab Load Disconnect Switch, EPA07

2
02/20/2012 f545876
1. Circuit Breaker 2. Self-Resetting Circuit

Removal Tool Breaker 05/13/2009 f545527
Fig. 3.5, Self-Resetting Circuit Breaker Removal Fig. 3.7, Cab Load Disconnect Switch, EPA10 and
Newer
level I) are shut down first. Then loads designated as
house loads (priority level II) are shut down. If neces- beeps. No alarm sounds before basic loads are shut
sary, basic loads (priority level III) are shut down last. down.
PLVD allows the driver to continue using critical If the interior lights have been shut down by PLVD,
loads, while noncritical loads are temporarily unavail- pressing one of the interior light switches (if
able. Calculations for disconnecting loads are based equipped) brings the interior lights back on.
on battery voltage, ignition switch status, and engine
See Table 3.1 for the type of loads shut down under
rpm. Also, a time delay is implemented for the shut- specific conditions.
down and reactivation of loads to avoid unnecessary
cycling of loads when battery voltage is close to See Table 3.2 for the loads that are designated com-
shutdown thresholds. fort, house, and basic load status.
One minute before the comfort loads or house loads
are shut down, the alarm in the instrument cluster
Type of Loads Shut Down Under Specific Conditions

Engine On, Voltage less than Engine Off, Voltage less than Engine Off, Voltage less than
Key Switch Position
12.5 Volts 12.3 Volts 12.1 Volts
Off N/A Priority level I, II loads Priority level I, II, and III loads
Accessory N/A Priority Level I loads Priority level I, II loads
3.5
Electrical System
Type of Loads Shut Down Under Specific Conditions

Engine On, Voltage less than Engine Off, Voltage less than Engine Off, Voltage less than
Key Switch Position
12.5 Volts 12.3 Volts 12.1 Volts
On Priority level I loads Priority Level I loads Priority level I, II loads
Start N/A N/A N/A
Table 3.1, Type of Loads Shut Down Under Specific Conditions
Designated Loads
Type of Load Function
12V power receptacle 6 (sleeper, refrigerator)
Amplifier power, accessory
General sleeper light
Foot well light
Reading light 1 (dimmer/theater)
Priority Level I Reading light 2 (dimmer/theater)
Rear baggage compartment light
12V power receptacle 5 (sleeper, cigar), battery
Auxiliary circulation fan-sleeper, battery
Reading light 4 (switched locally), battery
Heated seats, ignition*

Sleeper HVAC controller, accessory*
Cabin HVAC controller, accessory*
Radio, accessory (clamp 15R)
Power feed spare output I, battery
Power feed spare output III, battery
Mirror heating, passenger*
Mirror heating, driver*
Power feed spare output IV, battery
Power feed spare output II, battery
Fuel/water separator heater element, ignition*
Air dryer (pneumatic, electrically heated), accessory*
Priority Level II Auxiliary circulation fan-windshield, accessory*
Accessory heater power
Utility light
Utility light
Dome light rear
Area lighting (lower bunk and sleeper work surface),
battery
Dome light cab, battery
Overhead compartment lights, battery
Stand-alone HVAC, battery
Advertising light, accessory*
Dome light passenger
Dome light driver/forward overhead
3.6
Electrical System
Designated Loads
Type of Load Function
CB radio, battery†
Fleet management system, battery†
Priority Level III Trailer power, battery or ignition
12V power receptacle 2 (dash, phone), battery
12V power receptacle 1 (dash, cigar), battery
* When the vehicle has Optimized Idle, these functions will not operate with the ignition switch in the accessory
position. Optimized Idle may also turn these functions off to reduce stress on the batteries. Refer to the Opti-
mized Idle section in Chapter 11 for more information.
† May or may not shut down depending on how an additional parameter is set at the factory or dealership.
Table 3.2, Load Designation
3.7
4
Instruments
Instrumentation Control Units . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.1
Warning and Indicator Lights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.3
Instruments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.7
Driver Message Center . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.11
Overhead Instrument Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.24
Instruments
Instrumentation Control Units • "Driver Message Center"
The instrumentation control unit (ICU) provides the Ignition Sequence

driver with engine and vehicle information. It is com-
prised of standard and optional gauges, an audible When the ignition is turned on, the ICU runs a self-
warning, a driver message center, and a lightbar con- check. See Fig. 4.4. Observing the ignition sequence
taining warning and indicator lamps (also known as is a good way to ensure the ICU is functioning prop-
telltales). Warning and indicator lamps illuminate in erly.
red (danger), amber (caution), green (status advi- IMPORTANT: Do not crank the engine until the
sory), or blue (high-beam headlights active). ICU self-check is complete.
Cascadia vehicles are equipped with an ICU3, ICU4, NOTE: Air gauges do not complete a sweep of
ICU4M, or ICU4Me. See Fig. 4.1, Fig. 4.2, and
Fig. 4.3 for typical ICU layouts.
their dials during the ignition sequence.
When the ignition is turned on, the following actions
The following headings in this chapter provide addi-
should occur:
tional information and operating instructions for ICU
components: • electronic gauges complete a full sweep of
their dials
• "Warning and Indicator Lights"
• "Instruments"
11
3 5
4 10
2 6
12
1 7
9 8
13
09/10/2009 f610864a
1. Transmission Temperature Gauge 6. Primary Air Pressure Gauge 10. High Beam Indicator
2. Coolant Temperature Gauge 7. Secondary Air Pressure Gauge 11. Driver Display Screen
3. Engine Oil Pressure Gauge 8. Speedometer 12. Mode/Reset Switch
4. Driver Message Center 9. Tachometer 13. Satellite Gauges
5. Fuel/DEF Level Gauge
Fig. 4.1, ICU3 Instrument Cluster (EPA10 shown)
4.1
Instruments
7
1 2 10
3 4 11 12
8 9
5 6 13 14
09/10/2009 f610865b
NOTE: The ICU4 and ICU4M are nearly identical, with the exception of the driver message center (Item 7).
1. Battery Voltage Gauge 6. Turbo Boost Air Pressure Gauge 11. Fuel/DEF Level Gauge
2. Lightbar 7. Driver Message Center 12. Secondary Air Pressure Gauge
3. Engine Oil Pressure Gauge 8. Tachometer 13. Pyrometer
4. Coolant Temperature Gauge 9. Speedometer 14. Rear Axle Temperature Gauge
5. Engine Oil Temperature Gauge 10. Primary Air Pressure Gauge
Fig. 4.2, ICU4M Instrument Cluster (EPA10 shown)
• warning and indicator lamps illuminate, then NOTE: If active faults are present, take the ve-
are extinguished hicle to an authorized Freightliner service facility
• audible alert sounds for approximately four as soon as possible.
seconds or until sufficient air pressure builds If the ICU receives active fault codes, it displays
up in the primary and secondary air systems them one after the other until the parking brake is
• DEF level indicator illuminates all segments released or the ignition is turned off. Once the park-
green, then turns them off one at a time before ing brake is completely released, the ICU displays
turning the leftmost segment amber and then the odometer. If there are no active faults, the ICU
red displays the odometer after the self-check completes.
• Freightliner logo displays on the ICU4Me driver When the self-check is complete on an ICU4M, the
message center for two seconds. fasten seat belt screen displays if the engine is off. If
the engine is running, the idle hours screen displays.
• software revision level of the ICU is displayed
on the driver message center, followed by any Audible Alerts
active faults
An audible alert sounds during the ignition sequence
IMPORTANT: If any red or amber warning and and whenever one of the following conditions exists:
indicator lamps do not illuminate during the ICU
• Engine oil pressure falls below the minimum
self-check or do not go out after the self-check
preset value.
completes, take the action outlined in Table 4.1,
or take the vehicle to an authorized Freightliner • Coolant temperature rises above the maximum
service facility as soon as possible. preset value.
4.2
Instruments
10
1 7
2 8
4 5 6
3 9
06/27/2012 f611164
1. Engine Oil Temperature Gauge 5. Fuel/DEF Level Gauge 8. Secondary Air Pressure Gauge
2. Front Axle Temperature Gauge 6. Tachometer and Engine Oil 9. Transmission Oil Temperature
3. Rear Axle Temperature Gauge Pressure Gauge Gauge
4. Speedometer and Coolant 7. Primary Air Pressure Gauge 10. Driver Message Center
Temperature Gauge
Fig. 4.3, ICU4Me Instrument Cluster
IGNITION SWITCH
• Air pressure falls below approximately 70 psi
TURNED TO ON (483 kPa).
• Parking brake is set with the vehicle moving
faster than two miles per hour.
• System voltage falls below 11.9 volts.
ICU PERFORMS
SELF−TEST
• Door is open or the headlights are on, with the
parking brake off.
IF NO FAULTS IF FAULT DETECTED • Driver seat belt is not fastened with the parking
WERE DETECTED
brake off (optional).
APU 190 • Outside temperature falls below 35°F (1.7°C)
123456.7 (optional).
MI
12.3 VOLTS
PARKING BRAKE PARKING BRAKE

Warning and Indicator Lights
RELEASED RELEASED
The ICU lightbar has three or four rows of warning
123456.7 and indicator lights with icon symbols, depending on
MI
12.3 VOLTS the ICU. The positions of the lights may vary for the
01/18/2012 f040420c different ICU’s, but the telltales are standard for all
applications. See Table 4.1 for a listing of standard
Fig. 4.4, ICU Ignition Sequence and commonly used warning and indicator lamps.
4.3
Instruments
Warning and indicator lamps illuminate in red (dan- gines that are domiciled outside of the U.S. and
ger), amber (caution), green (status advisory), or Canada may not be compliant with EPA07,
blue (high-beam headlights active). EPA10, or GHG14 regulations. Noncompliant
IMPORTANT: Depending upon local jurisdic- vehicles may not be equipped with all of the
tional emissions guidelines, vehicles and/or en- lamps shown in Table 4.1.
Common Warning and Indicator Lamps

Lamp Description Color
Indicates a serious fault that requires engine shutdown
immediately. The engine protection system will reduce the
maximum engine torque and speed, and, if the condition
does not improve, will shut down the engine within 30 to 60
seconds.
STOP STOP Engine* Safely bring the vehicle to a stop on the side of the road Red
and shut down the engine as soon as the red light is seen.
If the engine shuts down while the vehicle is in a
hazardous location, turn the key to the OFF position for
a few seconds, then restart the engine and move the
vehicle to a safer location.
Indicates the coolant temperature is above the maximum

High Coolant Temperature Red
allowable temperature.
Indicates air pressure in the primary or secondary reservoir

Low Air Pressure (EPA07) Red
has dropped below approximately 70 psi (483 kPa).
Low Air Pressure (EPA10 Indicates air pressure in the primary or secondary reservoir
Red
and Newer) has dropped below approximately 70 psi (483 kPa).
Indicates the engine oil pressure is below the minimum

Low Engine Oil Pressure Red
allowable pressure.
Transmission Overheat Indicates high transmission temperature. Red
Indicates low transmission fluid level. Safely bring the

Transmission Fluid Level Red
vehicle to a stop as soon as possible.
Indicates the parking brake is engaged, or hydraulic brake

fluid pressure is low. An audible alert activates when the
Parking Brake (EPA07) Red
BRAKE vehicle is moving over 2 mph (3 km/h) with the parking
brake set.
Parking Brake (EPA10

Indicates the parking brake is engaged. Red
and Newer)
Low Battery Voltage Indicates that battery voltage is 11.9 volts or less. Red
4.4
Instruments

Activates with an audible alert when the system detects that
the parking brake is off and the driver seat belt is not
Unfastened Seat Belt fastened on some vehicles. On other vehicles, this lamp Red
illuminates for 15 seconds when the ignition is first turned
on.
Indicates Electronically Controlled Air Suspension (ECAS)

Check ECAS Red
active fault.
Indicates an engine condition (low oil pressure, low coolant

level, high coolant temperature, high DPF soot level, or
CHECK CHECK Engine* uncontrolled DPF regeneration) that requires correction. Amber
Correct the condition as soon as possible. If the condition
worsens, the STOP engine lamp will illuminate.
Slow (10-second) flashing indicates a regeneration (regen)
is in progress.
High Exhaust System IMPORTANT: When the HEST lamp is illuminated, do
Amber
Temperature (HEST)* not park the vehicle near flammable material.
Solid illumination indicates high exhaust temperatures at the
outlet of the tail pipe when speed is below 5 mph (8 km/h).
Solid illumination indicates a regen is required. Change to a
more challenging duty cycle (such as highway driving ) to
Diesel Particulate Filter raise exhaust temperatures for at least twenty minutes, or
perform a parked regen. Amber
(DPF) Status
Blinking indicates that a parked regen is required
immediately. An engine derate and shutdown will occur.
Malfunction Indicator Indicates an emissions-related fault. See the engine

Amber
Lamp (MIL) operation manual for details.
Momentary illumination indicates the vehicle ABS is

engaged.
Vehicle ABS Solid illumination indicates a problem with the vehicle ABS. Amber
Repair the ABS immediately to ensure full braking
capability.
Momentary illumination indicates the trailer ABS is engaged.
Trailer ABS Solid illumination indicates a problem with the trailer ABS. Amber
Repair the ABS immediately to ensure full braking
capability.
NO Indicates the alternator is not properly powering the

CHARGE No Charge Amber
electrical system.
Indicates the fuel may contain water. Drain any water

Water in Fuel Amber
collected in the fuel/water separators.
Fuel Filter Restriction Indicates the fuel filter is clogged and requires service. Amber
4.5
Instruments

IDLE
MGMT Optimized Idle Indicates optimized idle is enabled. Amber
Check Transmission Indicates an undesirable transmission condition. Amber
Indicates that the system is preventing the starter from

cranking. This can occur when the ignition switch is turned
WAIT Wait To Start (EPA07/ to START before the gauge sweep has completed, or if the
TO START starter has overheated. Amber
EPA10)
Turn the ignition switch back to ON, wait for the lamp to go
out, then turn the ignition switch to START again.
Indicates that the system is preventing the starter from
cranking. This can occur when the ignition switch is turned
to START before the gauge sweep has completed, or if the
starter has overheated.
START
BLOCKED Start Blocked (GHG14) Amber
NOTE: Illumination of the Start Blocked lamp does not
indicate a problem with the starter.
Turn the ignition switch back to ON, wait for the lamp to go
out, then turn the ignition switch to START again.
Flashing indicates the ATC system is active, or the ATC
button has been pressed to allow wheel slip.
WHEEL
SPIN Wheel Spin Solid illumination indicates a problem with the ATC system. Amber
Repair the ATC system immediately to ensure full braking
capability.
Momentary illumination indicates that a stability event has
occurred.
Roll Stability On vehicles that are also equipped with ATC, flashing Amber
indicates the ATC button has been pressed to allow wheel
slip.
Hill Start Aid (HSA) Indicates the HSA switch has been pressed to override the
Amber
Override hill start assist feature.
Indicates the current rear suspension height is not at the

Outside Normal Ride
normal ride height. This light will turn off once the vehicle Amber
Height
returns to normal ride height.
Engine Brake Indicates the engine brake is enabled. Green
Flashing indicates the outside left-turn signal lights are

Left-Turn Signal Green
activated.
Flashing indicates the outside right-turn signal lights are

Right-Turn Signal Green
activated.
4.6
Instruments

Indicates the cruise control is enabled.
Cruise Control NOTE: The ICU4Me does not have a green cruise control Green
telltale.
High-Beam Headlights Indicates the high-beam headlights are on. Blue
* See Fig. 4.5 for an explanation of the aftertreatment system (ATS) warning indicators, and actions required to avoid further engine protection steps.
Table 4.1, Common Warning and Indicator Lamps
Engine Protection System Some vehicles may have a shutdown-override

switch, which may be used to momentarily override
the shutdown sequence. See Chapter 11 for detailed
WARNING information regarding the shutdown process.
When the red STOP engine lamp illuminates, IMPORTANT: Do not attempt to restart the en-
most engines are programmed to shut down au- gine while the vehicle is moving. Bring the ve-
tomatically within 30 seconds. The driver must hicle to a safe stop, then restart the engine.
immediately move the vehicle to a safe location
at the side of the road to prevent causing a haz- To restart the engine, turn the ignition to OFF, leave
ardous situation that could cause bodily injury, it there a few seconds, then turn the ignition to
property damage, or severe damage to the en- START. The engine will run for a short period and
gine. shut down again if the condition does not improve.
See Fig. 4.5 for an explanation of the aftertreatment

system (ATS) warning indicators, and actions re-
Instruments
quired to avoid further engine protection steps. Standard instruments are present on every vehicle.
The STOP engine lamp illuminates when the engine They are listed here in alphabetical order to make
protection system is activated in one of two ways. On the information easier to find.
some engines, the engine protection system will der- Optional instruments, typically located on the auxil-
ate the engine, allowing it to run at lower rpm and iary dash panel or right-hand control panel, are not
slower vehicle speed. Drive the vehicle to a safe lo- found on every vehicle. They are listed here in alpha-
cation or to a service facility. betical order, to make the information easier to find.
IMPORTANT: Safely bring the vehicle to a stop
on the side of the road and shut down the en- Air Intake Restriction Gauge
gine as soon as the red light is seen. If the en- The air intake restriction gauge indicates the vacuum
gine shuts down while the vehicle is in a haz- on the engine side of the air cleaner. On standard
ardous location, turn the key to the OFF position installations, it is mounted on the air intake duct in
for a few seconds, then restart the engine and the engine compartment. As an option for easier
move the vehicle to a safer location. viewing, the air intake restriction indicator (see
Fig. 4.6) can be mounted on the dash, usually on the
On other engines, the engine protection system will right-hand control panel.
shut down the engine. It will first derate the engine,
then shut it down completely 30 to 60 seconds after NOTE: Rain or snow can wet the filter and
the indicator illuminates (depending on the critical cause a temporary high reading.
fault type) if the condition does not improve. Bring
the vehicle to a stop on the side of the road before Air intake restriction vacuum is measured in inches
the engine shuts down. of water (inH2O). For vehicles equipped with a
graduated indicator or a restriction gauge on the
4.7
Instruments

INDICATOR WARNING
CHECK STOP
LAMP(S)
(Solid) (Flashing) (Flashing)
Indicator Lamp Filter Regeneration Filter Parked Regeneration Service Regeneration Required. HEST (High Exhaust
Message(s) Recommended. Regeneration Required − Engine Engine Derate To Idle Only. System Temperature)
Necessary Derate
Diesel Particulate Filter is reaching Filter is now Filter has reached Filter has exceeded maximum Flashing
Filter Condition capacity. reaching maximum maximum capacity. capacity. A regeneration is in
Switch.
capacity. progress.
Required Action Bring vehicle to To avoid engine Vehicle must be Vehicle must be parked, and a
highway speeds to derate, bring vehicle parked, and a Parked Service Regeneration must be Solid
allow for an to highway speeds Regeneration must performed. Check engine Exhaust components
Automatic to allow for an be performed. operator’s manual for details. and exhaust gas are at
Regeneration or Automatic Engine will begin Engine will shut down. high temperature. When
perform a Parked Regeneration, or derate. stationary, keep away
Regeneration. perform a Parked from people and
Regeneration as flammable materials or
soon as possible. vapors.
02/20/2009 f080156
Fig. 4.5, ATS Warning Lamps
Vehicles may be equipped with a go/no-go restriction

indicator without graduations (see Fig. 4.7) instead of
a graduated indicator.
Air Intake Maximum Restriction Values (inH2O)

Pre-EPA07 EPA07 and
Engine Make
Engines Newer Engines
Cummins 25 25
Detroit 20 22
Mercedes-Benz 22 22
Table 4.2, Air Intake Maximum Restriction Values
Application Air Pressure Gauge

An application air pressure gauge registers the air
pressure being used to apply the brakes, and should
be used for reference only. The gauge will not regis-
10/10/2001 f610568 ter air pressure until the foot brake pedal is de-
pressed or the trailer hand brake is applied.
Fig. 4.6, Air Intake Restriction Indicator
dash, check the gauge with the engine off. If the yel-
low signal stays locked in the red zone once the en-
gine is shut down, or is at or above the values
shown in Table 4.2, the air cleaner element needs to
be replaced.
4.8
Instruments
Drive Axle Oil Temperature Gauges

NOTICE
A sudden increase in oil temperature that is not
caused by a load increase may indicate mechani-
cal failure. Bring the vehicle to a safe stop and
investigate the cause to prevent further damage.
Do not operate the vehicle until the cause has
been determined and corrected.
During normal operation, drive axle oil temperature
04/08/2005 f090431 gauges should read as follows:
Fig. 4.7, Manual-Reset Air Restriction Indicator, Go/ • 160 to 220°F (71 to 104°C) for Detroit™ and
No-Go Meritor™ drive axles
• 180 to 200°F (82 to 93°C) for Dana Spicer®
Coolant Temperature Gauge drive axles
Under heavy loads, such as when climbing steep
NOTICE grades, temperatures that exceed the normal oil tem-
A sudden increase in coolant temperature may perature range for a short period are not unusual. If
indicate engine or cooling system failure. Bring the temperature returns to normal when the load de-
the vehicle to a safe stop and investigate the creases, there is no problem.
cause to prevent further damage. Do not operate
the engine until the cause has been determined Engine Oil Pressure Gauge
and corrected.
During normal engine operation, the coolant tem- NOTICE
perature gauge should read 175 to 195°F (79 to
91°C). If the temperature remains below 160°F A sudden decrease or absence of oil pressure
(71°C), inspect the cooling system to determine the may indicate mechanical failure. Bring the vehicle
cause. to a safe stop and investigate the cause to pre-
vent further damage. Do not operate the engine
If coolant temperature rises above the maximum until the cause has been determined and cor-
temperature listed in Table 4.3, the CHECK engine rected.
lamp will illuminate. If the condition does not im-
prove, the STOP engine lamp will also illuminate and The engine oil pressure gauge displays the current
an audible warning will sound. The engine will then engine oil pressure. If engine oil pressure falls below
derate or shut down, depending on the type of en- the minimum levels shown in Table 4.4, the CHECK
gine protection system installed. engine lamp will illuminate. If the condition does not
improve, the STOP engine lamp will also illuminate
and an audible warning will sound. The engine will
Maximum Coolant Temperature
then derate or shut down, depending on the type of
Engine Make Temperature: °F (°C) engine protection system installed.
Cummins 225 (107)
Detroit 215 (101) Minimum Oil Pressure*
Mercedes-Benz 221 (105) At Idle Speed: At Rated RPM:
Engine Model
Table 4.3, Maximum Coolant Temperature psi (kPa) psi (kPa)
Cummins 15 (103) 35 (241)
Detroit 14 (97) 55 (350)
4.9
Instruments
Minimum Oil Pressure*

At Idle Speed: At Rated RPM: 1
Engine Model
psi (kPa) psi (kPa)
Mercedes-Benz 7 (50) 36 (250) 1/2
ULTRA LOW SULFUR
* Oil pressures are given with the engine at operating temperature. With DIESEL FUEL ONLY
the engine cold, oil pressure may be higher. Individual engines may vary
from the listed pressures; observe and record pressures when the engine
is new to create a guide for checking engine condition.
4 E F
Table 4.4, Minimum Engine Oil Pressure
DEF
Engine Oil Temperature Gauge
E F
3
NOTICE
2
08/21/2009 f611045
A sudden increase in oil temperature that is not
caused by a load increase may indicate mechani- 1. Diesel Fuel Level Indicator
cal failure. Bring the vehicle to a safe stop and 2. DEF Level Indicator
investigate the cause to prevent further damage. 3. Low DEF Warning Lamp (amber below 10% DEF)
4. Low Fuel Warning Lamp (amber at 1/8 tank of fuel)
Do not operate the engine until the cause has
been determined and corrected. Fig. 4.8, Fuel/DEF Gauge, EPA10 and Newer
During normal operation, the optional engine oil tem-
The DEF level is indicated in the lightbar on the
perature gauge should read:
lower portion of the gauge. There is a low DEF level
• 200 to 260°F (93 to 126°C) for Detroit and warning lamp that illuminates amber when the DEF
Cummins engines level reaches 10% of capacity. See Chapter 12 for
details of the DEF gauge functions.
• 177 to 203°F (81 to 95°C) for Mercedes-Benz
engines
Primary and Secondary Air Pressure
Under heavy loads, such as when climbing steep Gauges
grades, temperatures that exceed the normal oil tem-
perature range for a short period are not unusual. If
the temperature returns to normal when the load de- WARNING
creases, there is no problem.
If air pressure falls below minimum pressure, the
Fuel Gauge, Pre-EPA10 braking ability of the vehicle will be limited. Slow
the vehicle down and bring it to a gradual stop.
The fuel gauge indicates the level of fuel in the fuel Do not attempt to move the vehicle until air pres-
tank(s). A single fuel gauge is standard. If equipped sure has risen above the minimum level. Moving
with an optional second fuel tank, each fuel tank a vehicle without adequate braking power could
level is indicated on a separate gauge. cause an accident resulting in property damage,
personal injury, or death.
Fuel/Diesel Exhaust Fluid (DEF) Air pressure gauges register the pressure in the pri-
Gauge, EPA10 and Newer mary and secondary air systems. Normal pressure,
with the engine running, is 100 to 120 psi (689 to
For engines that are EPA10-compliant or newer, the
827 kPa) in both systems.
fuel and DEF levels are measured in a dual purpose
fuel/DEF level gauge. See Fig. 4.8. A low-air-pressure warning light and audible alert,
connected to both the primary and secondary sys-
The diesel fuel level is indicated at the top of the
tems, activate when air pressure in either system
gauge, with a low-fuel warning lamp that illuminates
drops below approximately 70 psi (483 kPa).
amber when the diesel fuel level registers 1/8th of
capacity.
4.10
Instruments
When the engine is started, the warning light and Voltmeter

audible warning remain on until air pressure in both
systems exceeds minimum pressure. The voltmeter indicates the vehicle charging system
voltage when the engine is running and the battery
Speedometer voltage when the engine is off. By monitoring the
voltmeter, the driver can stay aware of potential bat-
Two speedometer options are available. The U.S. tery charging problems and have them fixed before
version of the speedometer registers speed in both the batteries discharge enough to create starting diffi-
miles per hour (mph) and kilometers per hour (km/h), culties. Cascadia vehicles are equipped with either a
with mph in larger numbers. The metric version of voltmeter gauge, or a digital voltmeter readout lo-
the speedometer face reverses this arrangement, cated on the bottom line of the dash message center.
with km/h in larger numbers.
The voltmeter will normally show approximately 13.7
Tachometer to 14.1 volts when the engine is running. The voltage
of a fully charged battery is 12.7 to 12.8 volts when
The tachometer indicates engine speed in revolutions the engine is off. Battery voltage under 12.0 volts is
per minute (rpm) and serves as a guide for shifting considered a low battery, and a completely dis-
the transmission and keeping the engine in the ap- charged battery will produce only about 11.0 volts.
propriate rpm range. For low idle and rated rpm, see If the voltmeter shows an undercharged or over-
the engine identification plate. charged condition for an extended period, have the
charging system and batteries checked at an autho-
Transmission Fluid Temperature rized Freightliner service facility.
Gauge On a vehicle equipped with a battery isolator system,
The transmission fluid temperature gauge indicates the voltmeter measures the average voltage of all the
the transmission lubricant operating temperature. batteries when the engine is running. When the en-
Temperatures vary by application, but the transmis- gine is off, the voltmeter shows only the isolated bat-
sion fluid temperature gauge reading should not ex- tery voltage and does not indicate the voltage of the
ceed 250°F (121°C). engine-starting batteries.
NOTICE Driver Message Center

A sudden increase in transmission fluid tempera- ICU3/ICU4
ture that is not caused by a load increase may The driver message center is controlled using the
indicate mechanical failure. Bring the vehicle to a mode/reset switch, located on the right side of the
safe stop and investigate the cause to prevent ICU, and the + and – buttons mounted in the right-
further damage. Do not operate the vehicle until hand pod of the steering wheel (Fig. 4.9). See
the cause has been determined and corrected. Fig. 4.1 and Fig. 4.9. Tap the mode/reset switch or
Under heavy loads, such as when climbing steep the + switch to advance one screen; press and hold
grades, temperatures that exceed the normal oil tem- either switch to select a menu choice or reset the
perature range for a short period are not unusual. If display. When the display resets, an audible chirp
the temperature returns to normal when the load de- sounds.
creases, there is no problem. Four driving screens are accessible when the parking
brake is off. All screens and menus are accessible
Turbocharger Boost Pressure Gauge when the parking brake is on (parked screens).
A turbocharger boost pressure gauge indicates the
Driving Screens
pressure in the intake manifold, in excess of atmos-
pheric pressure, being created by the turbocharger. The following screens are available when the parking
brake is off (when the vehicle is mobile) and no ac-
tive fault codes are found. Use the + and – switches
on the steering wheel, or the mode/reset switch, to
4.11
Instruments
vii. Clear screen (on vehicles with less than 255

miles on the odometer)
+
MRKR
viii. Engine miles/hours
− INT
ix. Setup
ENG
BRK
Temperature Alert
When the outside temperature drops to 35°F (1.7°C)
or less, the ICU displays a caution text at one-
second intervals for five seconds, and an audible
alert sounds. Tap the + or – switch on the steering
wheel, or the mode/reset switch, to acknowledge the
message. The audible alert will not sound again un-
less the temperature cycles above 37°F (4°C) and
back to 35°F (1.7°C) or less. This warning only oc-
curs while the ignition is on and the parking brake is
02/06/2007 f462061 released.
NOTE: To reset values in the ICU4M and ICU4Me driver The temperature alert message allows the driver to
message centers, press and hold the + switch. enable or disable the ambient temperature warning.
Fig. 4.9, Steering Wheel-Mounted Switches
Press and hold the mode/reset switch to toggle be-
scroll through the screens. To reset any values, tween on and off. Release the mode/reset switch,
press and hold the + switch or the mode/reset then tap it to select the displayed choice.
switch. The driving screens appear in the following
order: Diagnostics
i. Odometer When the DIAG screen is displayed, press and hold
the mode/reset switch to access the various diagnos-
ii. Trip distance tic screens. See Fig. 4.11 for a diagram of the diag-
iii. Trip hours nostic screens.
iv. Outside temperature

The diagnostic screens are used by trained techni-
Parked Screens/Menus cians to retrieve fault codes and other diagnostic in-
The following screens and menus are available when formation pertaining to the vehicle. If active fault
the parking brake is on (when the vehicle is parked) codes display during start-up or at any other time,
and no active fault codes are found. Use the + and – make a note of the fault code and take the vehicle to
switches on the steering wheel, or the mode/reset an authorized Freightliner service facility
switch, to scroll through the driving screens. To reset If fault codes are displayed, press and hold the
any values, press and hold the + switch or the mode/ mode/reset switch to view the next fault code until
reset switch. See Fig. 4.10. The parked screens ap- reaching the DIAG screen.
pear in the following order:
i. Odometer
Engine Miles/Hours
ii. When the engine miles/hours screen is displayed,
Trip distance
press and hold the mode/reset switch to access the
iii. Trip hours engines screen submenu. See Fig. 4.11 for a dia-
gram of the engine screens.
iv. Outside temperature
v. Temperature alert
vi. Diagnostics
4.12
Instruments
Display diagnostics
123456.7 dIAG
MI Odometer MI HOURS Press & Hold
12.3 VOLTS n
n = Number of Active Fault Codes
MI = Miles Interval Mode
Tap Tap HOURS = Hours Interval Mode
123456.7 123456.7 To display total

TRIP MI Press & Hold HOURS engine miles/hours
12.3 VOLTS ENGINE
To reset trip miles
Tap Tap
123456.7 *Lo = Oil Level Low

oiL HI = Oil Level High
TRIP HOURS Press & Hold
*Lo
12.3 VOLTS ENGINE Blank = Oil Level OK
To reset trip hours − − = No Message
Tap Tap
56°F SEtUP Display service

**MI **HOURS Press & Hold interval screens
12.3 VOLTS **no
**MI = Miles Interval Mode
**HOURS = Hours Interval Mode
Tap Tap **no = Service Interval Inactive
°t ALrt
Press & Hold
n
To toggle ON OFF
Tap
01/30/2012 f040754
Note: The engine oil level screen displays for Mercedes-Benz engines only (if equipped and enabled).
Fig. 4.10, ICU3 Parked Screens
Setup • seat belt switch learning
The setup menu allows the driver to manage ICU • engine oil level
parameters. The setup screen submenu allows the • other electronic devices that have been re-
driver to enable and change service intervals. See moved from the vehicle (e.g. Qualcomm)
Fig. 4.12.
If service intervals are enabled and service distance ICU4M
or time has been exceeded, the text SERVICE
HOUR/MI (KM) will display at start-up to indicate ve-
Functions
hicle service is required. ICU4M settings and the driver message center are
controlled with the + and – switches and the MY
For each parameter, press and hold the mode/reset
INFO switch, mounted on the dash. See Fig. 4.13.
switch to navigate to the parameter change screen.
Tap the MY INFO switch to drill down from each
In each change screen, tap the mode/reset switch to
main screen to the submenus contained within it.
toggle between options.
Use the + and – switches to scroll through screens
Use the last screen in the setup menu, RESET EE, and select options. Tap the MY INFO switch again to
to reset the parameters the ICU learns back to the exit each change screen.
default settings. Press and hold the mode/reset
With the parking brake off, only the odometer and
switch to reset the following learned parameters:
alert messages can be displayed. Park the vehicle
• automated transmission display and set the parking brake to access the parked
screens and menus.
4.13
Instruments
From Temp Alert Screen
n = Number of *If fault goes inactive, *If fault goes inactive,

Active Fault Codes display "noFault 1" display "noFault n"
dlAG *FAULT *FAULT

Press & Hold Press & Hold Press & Hold
n 01 nn
Tap Tap Tap
AbS 11 ECU 0
Press & Hold
To Setup Screen (or Oil
Level Screen, if equipped)
Tap Tap
123456 123456
Press & Hold
SPN SPN
Tap Tap
FAIL 03 FAIL 00
Press & Hold
Tap Tap
01/31/2012 f040802
Fig. 4.11, ICU4 Diagnostic Screens
Alert Messages 1. parking brake set (with the vehicle moving)

The driver message center displays alert messages 2. parking brake off (with the door open)
when certain conditions occur. They are warnings, 3. low oil pressure or high coolant temperature
cautions, or other messages that require the driver’s
attention, but not all of them are critical to the opera- 4. hard brake warnings (if equipped with roll stabil-
tion of the vehicle. ity advisor)
NOTE: If there is more than one alert message 5. low battery voltage
to display, tap the + switch or the MY INFO 6. ambient temperature below 35°F (1.7°C)
switch to access the next message, and so on,
until all messages have been viewed. 7. turn signal on
More important messages take priority over less im- 8. incoming instant or Qualcomm messages
portant messages. The order of priority is: 9. service warnings
4.14
Instruments
From Engine
Miles/Hours Screen
SET UP SELECT
Press & Hold *MI Press & Hold To toggle
MI KM
Tap Tap
To toggle
°T WARN ON OFF
Press & Hold To toggle
*on ON OFF
LCD LMP
Tap Press & Hold
*on
Tap
Press & Hold to reset all

Service Interval counters
SET UP RESET SELECT
**MI **HOURS Press & Hold **MI **HOURS Press & Hold *MI *HOURS Press & Hold
**no SERVICE *no SERVICE *no SERVICE
To toggle
Tap Tap Tap MI
HOURS
no
*12345 *12345
Press & Hold MI MI Selection? HRS HOURS Press & Hold
SERVICE SERVICE
Tap Select NO Tap

to disable
no Service Intervals
RESET DONE
Press & Hold
EE
Tap Tap NOTE:
* Flash screen text
To Odometer
**Display active mode
01/30/2012 f040755
Fig. 4.12, ICU4 Setup Screens
10. no datalink activity Incoming Message

On vehicles with a Qualcomm onboard communica-
tions system, a notification appears on the driver
message center whenever a message is received.
4.15
Instruments
High Coolant Temp

This message and an audible warning come on
whenever the engine coolant temperature exceeds
the maximum allowable temperature.
If high coolant temperature is detected during the
ignition sequence, it displays as an active fault in-
stead of an alert message. After 30 seconds, the
MY message displays again.
INFO
Low Voltage
On some vehicles, this optional message and an au-
02/22/2007 f610887a
dible warning come on whenever a low voltage con-
Fig. 4.13, MY INFO Switch dition is detected.
NOTE: The incoming message screen also dis- Turn Signal On

plays during the ignition sequence if a message This warning message and audible warning come on
is available. whenever the turn signal remains on for four minutes
or five miles of travel. To dismiss this message, ei-
This message displays for a preset time period, then
ther turn off the turn signal or tap the + and –
returns after a preset interval until it is dismissed by
switches or the MY INFO switch.
the + and – switches or the MY INFO switch.
Parking Brake On Air Temperature

When the outside air temperature drops below 35°F
This warning message and an audible warning come (1.7°C), a warning text is displayed at one-second
on whenever the parking brake is applied and the intervals for five seconds, and an audible warning will
vehicle is moving faster than 2 mph (3 km/h). See sound. Tap the + and – switches or the MY INFO
Fig. 4.14. The screen and audible warning go away
switch to acknowledge the warning. The alert mes-
only when the parking brake is released, or speed is
sage will not occur again unless the temperature
reduced below 2 mph.
cycles above 37°F (4°C) and back below 35°F
(1.7°C). This warning only occurs while the ignition is
on and the parking brake is off.
WARNING Service Warnings

PARK BRAKE ON Service warning alerts display during the ignition se-
quence and indicate if a service interval has been
06/21/2007 f601414
reached or exceeded and maintenance is required.
The messages may indicate the number of miles
Fig. 4.14, Parking Brake On Alert Message (KM) or hours until the next required service or, once
passed, the number of miles (KM) or hours since
Low Oil Pressure maintenance should have been performed.
This warning message and an audible warning come Automated Transmission Display
on whenever the oil pressure falls below the mini-
mum oil pressure, whether the vehicle is idling or in The ICU4M can display current gear information for
motion. Tap the + and – switches or the MY INFO vehicles with an automated transmission. The last
switch to dismiss the message. three digits at the far right on the lower line of the
driver message center are reserved for this informa-
If low oil pressure is detected during the ignition se-
tion.
quence, it displays as an active fault instead of an
alert message. After 30 seconds, the message dis-
plays again.
4.16
Instruments
When a shift request is made by the driver, an up or iii. Odometer

down arrow is also displayed, depending on the shift
iv. Trip distance/hours
direction.
v. Trip advisory
For more information about specific models of auto-
mated transmissions, see Chapter 15. vi. Leg distance/hours
Driving Screens vii. Leg advisory
The following screens are available when the parking viii. Fuel used/average MPG (KM/L)
brake is off (when the vehicle is mobile). ix. Outside air temperature
Tap the MY INFO switch to drill down from each
main screen to the submenus contained within it. Favorite Screen
Use the + and – switches to scroll through screens The driver can set a favorite driving screen using the
and select options. Tap the MY INFO switch again to MY INFO switch. Press and hold the lower half of the
exit each change screen. See Fig. 4.15. MY INFO switch for just over one second to set the
current screen as the favorite screen. A chirp will
i. Fasten seat belt (rpm<100)
sound to verify the screen has been set.
ii. Fuel economy (rpm>100)
Tap the lower half of the MY INFO switch to access
the favorite screen. Tap the MY INFO switch again to
Odometer leave the favorite screen.
−0%III + NOTE: Only driving screens can be set as the
R = Hold + to reset.
Confirmation screen will display
right after the first hold.
10.5 MPG 23456.7 MI
favorite screen.
−
PUSH + KEY +
TO CONFIRM CLEAR Parked Screens/Menus
TRIP MILES 123456.7 R
My Info
TRIP HR 1234:56 Tap the MY INFO switch to drill down from each
− main screen to the submenus contained within it.
Use the + and – switches to scroll through screens
+
and select options. Tap the MY INFO switch again to
R
TRIP ADVISORIES
123 ROLL 456 BRK
exit each change screen. Press and hold the +
−
switch or the upper half of the MY INFO switch to
reset the counters for trip and fuel information.
+
The following screens are available when the parking
LEG MILES 123456.7 R
LEG HR 1234:56
brake is on (when the vehicle is parked). See
Fig. 4.16.
−
i. Odometer
+
LEG ADVISORIES R ii. Trip information including trip miles/hours, idle
123 ROLL 456 BRK
hours, average speed, leg miles/hours
−
iii. Fuel information including fuel used, fuel
+ economy, idle/PTO fuel usage
FUEL USED 12345.6 R
AVG MPG 12:34 iv. Engine information including engine miles/hours,
−
engine/PTO gallons, oil level
+
v. Diagnostic information
OUTSIDE AIR vi. Service information including mileage or time to
TEMPERATURE 56F
next service
01/30/2012 f545600a
vii. Setup information
Fig. 4.15, ICU4M Driving Screens
4.17
Instruments
viii. Vehicle information including Datalink status, ICU Diagnostic Information

serial number, software version
R R R
Odometer
TRIP MILES 123456.7 TRIP ADVISORIES IDLE HOURS 1234:56
TRIP HR 1234:56 123 ROLL 456 BRK AVG MPH 12.3
IDLE HOURS 1234:56
12.3 GAL 123456.7 MI
− − −
−
+ R R
TRIP LEG MILES 123456.7 LEG ADVISORIES

INFORMATION LEG HR 1234:56 123 ROLL 456 BRK
− − − R = Hold + to reset.
+ R R
PUSH + KEY
TO CONFIRM CLEAR
FUEL FUEL USED 12345.6 IDLE GALLONS 12345.6
INFORMATION AVG MPG 12:34 PTO GAL 12345.6 My Info
− − −
+
ENGINE ENG MILES 1234567.8 ENG GALLONS 123456.7 OIL LVL
INFORMATION ENG HOUR 1234:56 PTO GAL 123456.7 *Lo ENGINE
− − − −
85 PER
*Lo ENGINE
To Diagnostic Information Screen

01/30/2012 f545600b
Fig. 4.16, ICU4M Idle Hours, Trip Information, Fuel Information, and Engine Information Screens
ix. Outside air temperature If active fault codes are displayed on the diagnostic
information screens, make a note of the fault code
x. Fasten seat belt warning
and text message, then take the vehicle to an autho-
rized Freightliner service facility See Fig. 4.17 for a
Trip Information diagram of the diagnostic information screens.
Trip Information displays the trip miles, trip adviso-
ries, idle hours, leg miles, and leg advisories, in that Service Information
order. The Service Information menu displays the next ser-
vice interval, expressed in either miles or hours. See
Fuel Information Fig. 4.17. Service intervals can also be deactivated.
Fuel information displays total fuel usage since the For programming service intervals, see Setup Infor-
last reset, fuel mileage, and fuel consumed while mation, below.
idling or running the PTO, in that order.
NOTE: If the vehicle has exceeded the service
Engine Information interval, the miles(km)/hours remaining screen
is replaced by the service was due screen, fol-
Engine information displays engine mileage and
hours, and total fuel consumption, in that order. lowed by the number of miles(km)/hours since
the service was due.
4.18
Instruments
From Engine Information Screen

R = Hold + to reset.
PUSH + KEY
DIAGNOSTIC ACTIVE FAULTS SA(text) SA## SPN#### TO CONFIRM CLEAR
INFORMATION 3 SPN(text) FMI##
My Info
− − −
2 HIST DASH FAULTS SA(text) SA# SPN#

LAST CLR 123456.7 + SPN(text) FMI#
− −
+ +
HOLD + TO CLEAR LAST OCCUR 123456.7

DASH FAULTS 1234 TIMES
− R −
+
ALL FAULTS FIRST OCCUR 123456.7
CLEARED 1234 TIMES
− 2 Sec Timeout
−
This will also clear other vehicle ECU’s inactive
faults when odometer is < 254 MI.
+
If overdue:
SERVICE 12345 MILES TO INTERVAL IS SET SERVICE WAS DUE
INFORMATION NEXT SERVICE TO 12345 MILES 12345 MILES AGO
− − −
To Setup Screen
01/30/2012 f545601
Fig. 4.17, ICU4M Diagnostic Information and Service Information Screens
Setup Information Vehicle Information Screens

The Setup Information menu allows the driver to pro- The vehicle information screens display hardware
gram various features of the ICU4M. See Fig. 4.18. and software information, including the Freightliner
part number and switch ID of the ICU. See Fig. 4.19.
The setup features include:
1. Service intervals (OFF/MILES/HOURS) ICU4Me
2. Outside temperature warning (ON/OFF) Functions
3. Target MPG ICU4Me settings and the driver message center are
4. LCD lamp (ON/OFF) controlled using the ICU4Me control switch located
on the dash, and the + and – switches mounted in
5. Driver message center brightness the right-hand pod of the steering wheel. See
Fig. 4.20 and Fig. 4.9.
6. Language (English/French/Spanish)
The driver message center is divided into four sec-
7. Units of measurement (English/Metric) tions. The odometer and cruise control status field
8. Driver select (ON/OFF) are displayed along the bottom of the message cen-
ter. When cruise control is active, the cruise control
9. Reset parameters to original settings
4.19
Instruments
+ Press to toggle between selections

SETUP PUSH KEY TO SERVICE INTERVAL
INFORMATION CHANGE SERVICE OFF/*MILES/HOURS −
PUSH KEY TO
− − Miles or Hours CHANGE SERV MI
Off −
INTERVAL *2000 MILES + Press to set service interval

− LESS MORE +
+ −
PUSH KEY TO TEMPERATURE WARNING + Press to toggle On Off
CHANGE TEMP WARN − OFF * ON +
−
−
+
PUSH KEY TO TARGET MPG *8.5 + Press to increase target MPG
CHANGE TARGET MPG − LESS MORE +
− Press to decrease target MPG
+
PUSH KEY TO LCD LAMP + Press to toggle On Off
CHANGE LCD LAMP − OFF * ON +
−
−
+
PUSH KEY TO DISPLAY BRIGHTNESS + Press to increase brightness
CHANGE BRIGHTNESS − DARK LIGHT +
− Press to decrease brightness
+
PUSH KEY TO LANGUAGE: *ENGLISH + Press to toggle between selections
CHANGE LANGUAGE FRENCH / SPNISH
−
−
+
PUSH KEY TO UNITS + Press to toggle between selections
CHANGE UNITS *ENGLISH / METRIC

−
−
+
PUSH KEY TO DRIVER SELECT + Press to toggle On Off
CHANGE DRIVER SEL − OFF * ON +
−
− * = Indicates flashing text
+ = My Info
+
PUSH KEY TO RESET PARAMETERS + Press to toggle Yes No
Vehicle Information RESET PARAMETERS − *NO YES + Note: If parking brake is released while in stationary screens,
− the display will return to the bar graph screen.
Screen
+
01/30/2012 f544963a
Fig. 4.18, ICU4M Setup Information Screens
status field displays relevant cruise control icons and the set speed. If the vehicle is equipped with a
4.20
Instruments
1 2
Setup Information
Trip MPG: 5.6 1/7
NW
+
77° F 0 5 10 15
VEHICLE DASH# 123−12345−123
INFORMATION SW VER 1.0
5555555 mi 65 mph
− −
06/26/2012 4 3 f611166
1. Temperature and Compass
Outside Air Temp 2. Message Field
03/30/2010 f040803 3. Cruise Control Status Field
4. Odometer
Fig. 4.19, ICU4M Vehicle Information Screens
Fig. 4.21, Driver Message Center Without Gear Display,
ICU4Me
1 2
1/7
10 NW
77 °F
A econ
Menu 5555555 mi 65 mph
Back 4 3
06/26/2012 f611165
04/03/2012 f611173 1. Gear Display
2. Temperature and Compass
Fig. 4.20, ICU4Me Control Switch 3. Cruise Control Status Field
4. Odometer
manual transmission, time and temperature are dis-
played in the top left corner of the driver message Fig. 4.22, Driver Message Center with Gear Display,
center. The message field displays the driving ICU4Me
screens and alert messages. See Fig. 4.21. portant messages take priority over less important
If the vehicle is equipped with an automated trans- messages.
mission, the gear display is located in the top left
NOTE: All alert messages follow the format
corner of the driver message center. Time and tem-
perature are displayed in the message field, unless shown in Fig. 4.23.
an alert message is active or a driving screen has
been selected. The odometer and cruise control sta-
tus field are displayed along the bottom of the mes-
sage center. See Fig. 4.22. For information about
10 Park Brake On!
transmission display options, see Chapter 15.
A econ
5555555 mi
Alert Messages 06/12/2012 f611192
Alert messages are displayed in the message field to

Fig. 4.23, Parking Brake Alert Message
notify the driver when certain conditions occur. They
include warnings, cautions, and other messages that Press the + switch to acknowledge alert messages
require the driver’s attention. Not all alert messages and revert to the previously displayed driving screen.
are critical to the operation of the vehicle. More im-
4.21
Instruments
The following alert messages will repeat intermittently • Gauge display (if selected)
until the condition is eliminated:
• Predictive Cruise Control (optional)
• turn signal on
• Enter parked menus
• low voltage
Parked Screens/Menus
• no datalink
Park the vehicle and set the parking brake to access
• low transmission air pressure (Detroit transmis-
the parked menus and submenus. See Fig. 4.25. To
sions only) reset values in any of the menus, press and hold the
+ switch.
Driving Screens
• Trip information
+ Enter to • Fuel information
Time &
Stationary
Temperature −
Menu • Engine information
+ − • Diagnostics
− • Service information
• Settings
MPG
Information +
+ Predictive
Cruise Trip Info ICU Info
− Control (opt)
− + −
Trip
Information − +
+ Fuel Info Settings

− +
Gauge + −
−
Leg Display
Information + Screens − +
(if selected) − −
06/21/2012 f040823 Engine Info Diagnostics Service
+ +
Use the + and – switches on the steering wheel to
navigate through the driving screens.
06/26/2012 f040824
Fig. 4.24, Driving Screen Navigation, ICU4Me Use the + and – switches on the steering wheel to
navigate through the parked menus.
With the parking brake off, only the driving screens
are available. Use the + and – switches on the steer- Fig. 4.25, Parked Menus, ICU4Me
ing wheel to scroll through the driving screens; see
• ICU Information
Fig. 4.24. To reset any values, press and hold the +
switch. A small numerical fraction is displayed in the upper
• Temperature right-hand corner of each screen to indicate the num-
ber of available screens or options to scroll through.
• MPG information See Fig. 4.26. Press the upper half of the ICU4Me
• Trip information control switch to select a menu choice. Press the
lower half of the control switch to back out of a se-
• Leg information lected menu or submenu. Use the + switch to scroll
up, and the – switch to scroll down.
4.22
Instruments
since the last reset, and the average MPG since the
Menu Trip Info 1/7 last reset.
Fuel Info Engine Information
Engine Info Using this menu, the driver can view engine miles,
engine hours, gallons used, PTO hours, and PTO
gallons. Engine oil level is optional for Detroit en-
gines. The information contained in the Engine Infor-
mation screens cannot be reset.
MENU
BACK
Diagnostics
Menu Trip 1/2 Active and historical faults are displayed in the diag-
nostics menu. See Fig. 4.27. If there are any active
Trip Info Leg faults, the total number of faults is displayed in pa-
renthesis next to the affected controller. To view spe-
cific active faults, press the upper half of the ICU4Me
control switch on the dash. Press the upper half of
the ICU4Me control switch to toggle between the text
description and the failure code for each selected
MENU fault.
BACK
1/3 Service Information

Menu Miles: 123456.7
Using this menu, the driver can enable, disable, and
Trip Info Gallons: 123456.7 set service intervals for engine miles or engine
hours. After enabling service intervals, select interval
Trip Avg. MPG: 123.4 unit (miles or hours), and the interval duration.
Indicates when to press

Settings
the ENTER switch The settings menu contains the controls for the fol-
lowing settings:
MENU Indicates when to press • Display (includes brightness, contrast, display
BACK the MENU BACK switch light, and night mode settings)
06/21/2012 f611193
• Gauge select
Fig. 4.26, Parked Menu Navigation, ICU4Me
• Language
When navigating the parked menus, the left side of • Self-test
the driver message center displays a "breadcrumb
menu" to show the order of menus and submenus • Temperature warning enable/disable
that have been selected during the current naviga- • Units
tion.
The Gauge Select submenu allows the driver to se-
Trip Information lect certain gauge values for display in the message
The ICU can record data for one trip segment and field while driving. See Fig. 4.28. Use the + and –
switches on the steering wheel to scroll through the
one leg segment. When trip information is reset, all
list of available gauges, then press the upper half of
the leg information is reset as well.
the ICU4Me control switch to select a desired gauge.
Fuel Information The ICU4Me control switch can also be used to un-
check boxes if necessary.
Using this menu, the driver can view the total fuel
used since the last reset, the total idle gallons used
4.23
Instruments
1/2
Overhead Instrument Panel
Menu Active (12)
The optional overhead instrument panel may hold a
Diagnostics Historic (0) citizen’s band (C/B) radio and any switches that can
not be accommodated on the driver’s or auxiliary
dash panels.
The underside of the overhead console also holds
the sun visors and the optional dome/reading light
MENU asssembly. See Chapter 5 for more information on
BACK the dome/reading light assembly.
Menu ABS (1) 1/3
Diagnostics Engine (3)

Active MSF (1)
MENU
BACK
Diagnostics Accelerator Pedal 1/3
Active Problem Detected

Engine (3)
MENU Indicates when to press

BACK the MENU BACK switch
Indicates when to press

the ENTER switch
05/30/2012 f611194
Fig. 4.27, Diagnostics Menu Navigation, ICU4Me
Menu Axle Temp 1/6
Settings Air Pressure

Gauge Disp. x Engine Oil Temp
06/26/2012 f611195
Fig. 4.28, Selecting Gauges to Display, ICU4Me
ICU Information
The ICU Information screen displays the part num-
bers for the instrument cluster and software.
4.24
5
Driver Controls
Ignition Switch and Key . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.1
Lighting Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.2
Horn Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.7
Powertrain Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.7
Cruise Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.11
Dash-Mounted Brake Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.14
Windshield Wiper/Washer Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.15
Suspension/Trailer Connection Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.16
Climate Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.17
Seat Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.19
Adjustable Steering Column Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.20
Driver Controls
Ignition Switch and Key The following functions are operable when the igni-
tion switch is in the OFF position (regardless of
The ignition switch is located on the left-hand dash, whether the key is inserted):
below the headlight switch. See Fig. 5.1. • low-beam headlights
• taillights
• brake lights
• road lights
• dome lights
• clearance lights
• hazard warning lights
2
• utility lights
• baggage compartment lights
1
• spotlights
• electric horn
• clock
04/30/2007 f610916 • refrigerator

1. Headlight Switch 2. Ignition Switch • CB radio
Fig. 5.1, Left-Hand Dash • power mirrors
The ignition switch has four positions: OFF, ACC (ac- • power receptacle
cessory), ON, and START. See Fig. 5.2. • fuel heater
• electric oil pan heater
• electric or diesel-fired engine coolant pre-
heater
Turn the key counterclockwise to reach the ACC po-
sition. In addition to all the functions that are oper-
able in the OFF position, the following functions are
operable when the switch is in the ACC position:
• radio/stereo system
• heater and A/C fan
• mirror defog
07/19/2006 f610805 • windshield fan
Fig. 5.2, Ignition Switch • ether start system
In the OFF position, the ignition switch is vertical. • air dryer

The key can be inserted and removed only in the • backup lights
OFF position.
Turn the key clockwise past the OFF position to
reach the ON position. With the switch in the ON po-
sition, all electrical systems become operable and
5.1
Driver Controls
the warning and indicator lamps illuminate. Wait for Backup Lights
three seconds before starting the engine.
Backup lights activate only when the vehicle is in re-
The SAM Cab vehicle controller automatically cycles verse, and are designed to be used while backing up
all exterior lights off and then on when the head- at night.
lamps are on and the park brake is released, or set.
This rapid flash of the exterior lights is a self-test to Daytime Running Lights
detect any bulb that is not operational. Drivers may
notice all lights flash simultaneously during this pro- The daytime running lights (DRL), if equipped, are
cess. This is the normal operating sequence. A fault automatically activated when the ignition is switched
code is set for any bulb that is out. on and the parking brake is released. The DRL turn
off when the engine falls below 400 rpm, the parking
IMPORTANT: Do not crank the engine until the brake is applied, or the headlights are turned on.
ICU self-check is complete.
Daytime running lights are mandatory for vehicles
Turn the key clockwise past the ON position to reach domiciled in Canada. Vehicles domiciled in any other
the START position to start the engine. Release the location may have an optional override switch
key the moment the engine starts. Do not operate (Fig. 5.4, ref. 2). This is a momentary switch that en-
the starter longer than thirty seconds, then allow the ables the driver to deactivate the DRL. Press the
starter to cool between attempts. If the starter over- upper half of the switch briefly to activate or deacti-
heats, the starter protection system will prevent op- vate the DRL.
eration of the starter until it has cooled. Release the
key the moment the engine starts. Fog Lights
The ignition key also locks and unlocks the cab Fog lights are designed to reduce glare in foggy con-
doors, the baggage door(s) and if equipped, the bunk ditions. The low-beam headlights must be on in order
door(s). to turn the fog lights on. Pull the headlight switch out-
ward to activate the fog lights.
Lighting Controls Hazard Warning Lights
IMPORTANT: Unless otherwise noted below,
The hazard warning light switch is located on the
press the upper half of the switch to activate the
dash in what is referred to as the master module.
desired light(s). Press the lower half of the See Fig. 5.5. The hazard lights can be activated re-
switch to turn the light(s) off. gardless of the ignition switch position.
Exterior Lighting Controls To activate the hazard lights, press the center of the
switch once. The switch will blink at the same rate
Exterior light controls are listed here in alphabetical that the hazard lights flash. Press the switch again to
order. See Fig. 5.3 for exterior light locations. turn them off. All the turn signals on the vehicle and
trailer, as well as the turn signal indicators in the
Auxiliary High Beam Lights ICU, flash simultaneously when the hazard lights are
Auxiliary high-beam lights may be located in the front activated.
bumper. To activate the auxiliary high beam lights,
press the upper part of the dash switch. The auxiliary
Headlights
high beam lights will illuminate only when the high- The headlight switch is a rotary switch located to the
beam headlights are on. They will switch off tempo- left of the steering column, above the ignition switch.
rarily when the low-beam headlights are on, until the See Fig. 5.6.
high beams are on again. Press the lower half of the
switch to deactivate it. See Fig. 5.4. If the Follow Me Home feature is activated, the low-
beam headlights will remain on for nine seconds
after the vehicle is parked, if the headlights were on
prior to engine shutdown. This feature provides tem-
porary lighting in the path of the headlights while
walking to a building or other destination. If a vehicle
5.2
Driver Controls
8
9
8
7
10
1
5
2
3 4
02/03/2012 f544971
1. High-Beam Headlight 6. Side Turn Signal and Marker Light
2. Fog Light, or Auxiliary High-Beam Light 7. Clearance Light
3. Low-Beam Headlight 8. Stop Light, Taillight, and Turn Signal
4. Marker Light 9. Back-Up Light
5. Turn Signal 10. Identification Light
Fig. 5.3, Exterior Lights
door is opened or closed while this feature is active, low-beam headlights are on. Return the turn-signal
the timer will add an additional 10 seconds of light- lever back to its neutral position to deactivate the
ing. This feature can be temporarily disabled by turn- high beams, and return to low beam headlights.
ing the ignition switch on, or by cycling the headlight
When the high-beam headlights are on, a blue light
switch from the off position to one of the other two
illuminates on the instrument cluster. For vehicles
positions.
with fog lights, switching on the high beams will
High-Beam Headlights switch off the fog lights. The headlight low beams
remain on continuously during high-beam operation.
To activate the high-beam headlights, press the turn
signal lever forward towards the windshield while the
5.3
Driver Controls
1 2 3 4 5 6
AUX DRL UTLY FOOT

DOME
HIGH OVRD LAMP WELL
REAR REAR LWR LWR

DOME
DOME DOME LAMP LAMP
01/05/2012 7 8 9 10 11 f611155
1. Auxiliary High Beam Light Switch 7. Rear Cab Dome Light Switch 10. Sleeper Reading Light Switch,
2. DRL Override Switch (mounted in sleeper) Driver Side
3. Utility Light Switch 8. Sleeper Rear Dome Light Switch, 11. Sleeper Reading Light Switch,
4. Cab Foot Well Light Switch Driver Side Passenger Side
5. Panel Lights Switch 9. Sleeper Rear Dome Light Switch,
6. Rear Cab Dome Light Switch Passenger Side
Fig. 5.4, Dash-Mounted and Sleeper-Control Light Switches
NOTE: The ignition switch must be on for the

high beams to work.
Marker Lights
Turn the headlight switch clockwise to past the off
position. See Fig. 5.6.
Marker Interrupt
The marker interrupt switch, located in the right-hand
switch pod of the steering wheel, temporarily flashes
the marker lights. See Fig. 5.7.
03/20/2007 1 2 f610855
1. Hazard Warning 2. Panel Lights Dimmer
Switch Switch
Fig. 5.5, Master Module
5.4
Driver Controls
3
Turn Signals
2
4 The turn-signal lever is on the left side of the steer-
ing column. See Fig. 5.8.
1 2
01/05/2012 f610806
1. Fog Lights (optional)—Activate by pulling the switch
out when the marker lights or headlights are on.
2. Off
3. Marker Lights
4. Headlights 07/19/2006 f820427
1. Wiper Control Dial 2. High-Beam Icon
Fig. 5.6, Headlight Switch
Fig. 5.8, Multifunction Turn Signal Lever
NOTE: The optional self-canceling turn signal

ON/
OFF lever will automatically return to the neutral posi-
tion when the steering wheel returns to the
ACC
RES
MRKR
INT
straight-ahead position after a turn.
CNCL
Move the turn signal lever downward to turn the left-

DEC/ ENG turn signal on; move it upward to turn the right-turn
SET BRK
signal on. To manually cancel the signal, move the
lever to the neutral position.
When a turn signal is activated, a green indicator
light flashes on the instrument cluster.
Turn-Tip Feature
The turn-tip feature is advantageous in lane change
situations when the steering wheel does not travel far
enough to cancel a conventional turn signal request.
Pushing the turn-signal lever halfway to the normal
turning position to activate the turn-tip feature. The
signal will flash for a few seconds, then cancel. Acti-
05/24/2007 f462049 vation of the turn-tip feature is immediately canceled
when a request for the turn signal in the opposite
Fig. 5.7, Steering Wheel-Mounted Controls
direction is made.
Spotlight Utility Lights
The spotlight switch is located on the pivoting handle Utility lights can be swivel-mounted on upper half of
of the spotlight. There may be a single spotlight as- the cab, mounted on the exhaust support, or flush-
sembly mounted above the driver’s door, or one mounted on the back of the cab or sleeper. Press the
above each door. upper half of the switch to activate it. Press the lower
5.5
Driver Controls
half of the switch to turn it off. When activated, a red

indicator light in the switch is illuminated. See
Fig. 5.4.
1
Interior Lighting Controls 2
Interior light controls are listed here in alphabetical 3
order.
The interior lights include panel lights, dome lights,
red map lights, clear reading lights, and courtesy
lights. Vehicles come pre-set from the factory with
theater lighting, which ramps up lights from low
power to full power when activated.
11/21/2006 f544907
Sleepers have rear dome lights, bunk reading lights,
sleeper floor lights, and baggage compartment lights. 1. Clear Reading Lamp 3. Red Map Lamp
2. Clear Dome Lamp
Baggage Compartment Lights Fig. 5.9, Overhead Console Lights
Baggage compartment lights are located on the un-
derside of the lower bunk, on both sides. Both lights headlights are turned on, the panel lights setting will
turn on when either baggage compartment door is default to the intensity that was last set.
opened to illuminate the baggage compartment. The
lights also come on when the lower bunk is raised. Rear Dome Light
A rear cab dome light is located on the roof, between
Foot Well Lights the bunk and the cab on sleeper vehicles. See
When the driver or passenger doors are opened, red Fig. 5.10. The rear cab dome light will activate with
lights illuminate both foot wells. These lights can also the dome lights when a door is opened, then stay on
be activated with the foot well light switch. See for a short time after both doors are closed.
Fig. 5.4. Press the upper half of the switch to turn Use the dash-mounted switch or the switch in the
the foot well lights on, press the lower half of the sleeper panel to activate the rear cab dome light.
switch to turn them off. See Fig. 5.4.
Overhead Console Lights
The overhead console includes a clear reading light,
a clear dome light, and a red map light. See Fig. 5.9.
The dome lights illuminate when a door opens, then
stay on for a short time after both doors are closed.
Press the lens of the reading light, dome light, or
map light to activate each one independently of the
others.
Panel Lights
The panel lights illuminate when the headlights are
turned on. To adjust the brightness of the panel
lights, use the panel lights switch, usually located in 11/21/2006 f544908
the master module next to the hazard flasher switch.
See Fig. 5.4. The panel lights brighten and dim in Fig. 5.10, Rear Cab Dome Light
5% increments, depending on whether the upper half
or the lower half of the switch is pressed. When the
5.6
Driver Controls
Sleeper Dome Light

Two dome lights are mounted on the sleeper roof,
close to the outside walls.
There are two switches in the sleeper that control the
sleeper dome lights. The passenger-side switch will
activate both dome lights. The driver-side switch op-
erates the driver-side light only. Press the upper half
of the switch to turn the sleeper dome light on, press
the lower half of the switch to turn it off.
Sleeper Foot Well Lights

The sleeper foot well switch is located in the lower 1
switch module in the sleeper. It looks identical to the
cab foot well switch. See Fig. 5.4. When the switch
is activated, two lights illuminate the sleeper floor.
Sleeper Reading Lights

Clear reading lights are mounted above the lower
bunk in the rear corners of the sleeper. There are 06/13/2007 f602322
two switches in the sleeper control panel for the 1. Lanyard
reading lights. To turn a reading light on, press the
upper half of the switch. Press the lower half of the Fig. 5.11, Air Horn Control
switch to turn it off. See Fig. 5.4.
The reading lights can also be activated by pressing 1
the lens.
Horn Controls
Air Horn
Air horn(s) may be mounted on the roof of day cabs,
or under the driver-side floor for sleeper cabs. The
air horn is controlled by a wire lanyard that hangs
down inboard by the driver’s door. See Fig. 5.11.
Pull downward on the lanyard to sound the air horn.
02/05/2007 f544961
Electric Horn 1. Horn Button
The button for the electric horn on a vehicle without Fig. 5.12, Steering Wheel, No Airbag
an airbag is located in the center of the steering
wheel. See Fig. 5.12. To sound the horn, press down Powertrain Controls
on the button.
Aftertreatment System Regen
The electric horn on a vehicle with an airbag is acti-
vated by pressing down on the top of the steering
Switches
wheel center pad. See Fig. 5.13. NOTE: See Chapter 12 for detailed information
The horn will sound for the duration that the button is about the operation of the regeneration (regen)
pressed, up to 60 seconds. The electric horn will op- switches and the aftertreatment system (ATS).
erate regardless of the position of the ignition key.
5.7
Driver Controls
2
1
NO
RGEN
02/08/2012 f611157
1. Regen Request 2. Regen Inhibit Switch
Switch
01/13/2012 f462236
Fig. 5.14, Regen Request and Inhibit Switches
Press down on the top of the steering wheel center pad
to activate the horn.
Fig. 5.13, Steering Wheel With Airbag
IMPORTANT: Depending upon local jurisdic-

tional emissions guidelines, vehicles that are 1
domiciled outside of the U.S. and Canada may
not have engines and/or emissions aftertreat-
ment systems that are compliant with EPA07,
EPA10, or GHG14 regulations.
The regen request switch, located on the dash, is 2
used to initiate a parked regen. See Fig. 5.14. To
access the regen request switch, lift the guard and
press the yellow button.
Some vehicles may be equipped with a regen inhibit
switch. See Fig. 5.14. To stop a regen in progress or 3
prevent the start of a regen, press the lower half of
the switch. Regen will be delayed until the switch is
no longer active.
Axle Switches
Some vehicles are equipped with an interaxle differ- 4
ential lock switch and/or a switch for each driver-
controlled differential lock (DCDL). See Fig. 5.15. For
more information about differential locks and using
them for traction control, see Chapter 16.
Engine Brake Switch 01/05/2012 f611158
The Hi/Med/Lo engine brake 3-position switch con- 1. Interaxle Differential Lock Switch
2. Fifth Wheel Slide Switch
trols the amount of engine braking. See Fig. 5.16.
3. Driver-Controlled Differential Lock (DCDL) Switch
Press the lower third of the switch for low, center for 4. Air Suspension Dump Control Switch
medium, and upper third for high.
Fig. 5.15, Axle and Suspension Switches
5.8
Driver Controls
Hill Start Aid Override Switch

HI
Some vehicles are equipped with a Hill Start Aid
(HSA) feature to prevent the vehicle from rolling
LO while on steep grades and to allow for a controlled
launch. HSA is "on" by default. It can be turned off
by pressing and releasing the HSA override switch
on the dash (see Fig. 5.18).
ENG
BRK
05/02/2007 f610905
Fig. 5.16, Engine Brake Switch
There is also an engine brake switch located in the

right-hand switch pod on the steering wheel. See HSA
Fig. 5.7. Press the ENG BRK switch once to engage OVRD
or disengage the engine brake. Refer to Chapter 13
for instructions on using the engine brake.
04/30/2012 f611186
Engine Fan Switch
Fig. 5.18, Hill Start Aid Override Switch
The engine cooling fan can be turned on by the en-
gine fan switch. PTO Switch
To turn the engine fan on, press the upper half of the To activate the PTO function, press the upper half of
switch. The fan will continue to operate for a set the switch. Press the lower half of the switch to de-
amount of time and then turn off unless the coolant activate the PTO function. See Fig. 5.19.
temperature is high enough to continue fan opera-
tion. To turn the fan off before the set time period
ends, press the lower half of the switch. See WARNING
Fig. 5.17.
To avoid injury, do not install a PTO that is not
Detroit Diesel approved onto a Detroit™ Trans-
mission. Use of a non-Detroit Diesel approved
PTO with a Detroit Transmission could result in
unintended operation which could lead to severe
personal injury.
Transmission Controls
Detroit™ Automated Transmissions
ENG
FAN NOTE: See Chapter 15 for complete Detroit
automated transmission operating instructions.
02/26/2007 f610899 Vehicles with Detroit transmissions use the multifunc-
tion control shown in Fig. 5.20. This control moves in
Fig. 5.17, Engine Fan Switch two directions and has two switches. It is used to
request manual shifts, change shift mode, set engine
brake levels, and control specialty engine brake func-
tions during cruise control operation.
5.9
Driver Controls
PTO
A 1 2
02/23/2007 f610894
Fig. 5.19, PTO Switch
Eaton Automated Transmissions

NOTE: See Chapter 15 for complete automated
transmission operating instructions. (−)
The SmartShift electronic transmission control is in-
stalled with the Eaton® Fuller® UltraShift™ and
Eaton Fuller AutoShift™ transmissions. The Smart- B (+)
Shift control is operated by the fingers of the driver’s
right hand, allowing both hands to remain on the
steering wheel.
A two-position driving mode slide switch is mounted
on the body of the control lever just before the
paddle widens out. The slide switch allows the driver
to choose automatic (AUTO) or manual (MAN) mode.
See Fig. 5.21.
Manual Transmissions
NOTE: See Chapter 14 for complete manual
transmission operating instructions.
If so equipped, the transmission range control and
splitter valves are attached to the gear shift knob.
The range-preselection lever allows the selection of C
the low or high range for each transmission ratio. It is 05/30/2012 f270163a
used once during an upshift sequence and once dur- A. Front View
ing a downshift sequence. B. Shift Requests
C. Four positions for engine brake settings
Dependent on the transmission model, some ratios 1. Engine Brake Symbol
can be split using the splitter-control button. 2. D/N/R Switch
3. Mode Switch
Allison Automatic Transmissions 4. Gear Shift Symbol
Automatic transmissions have up to six forward Fig. 5.20, Detroit Multifunction Control
speeds and one reverse speed. These transmissions
have electronic shift controls that can be programmed to allow the use of different geared
speeds. See Fig. 5.22.
5.10
Driver Controls
5 6 7
Cruise Control
4 8
3 WARNING
Do not use the cruise control system when driv-
ing conditions do not permit maintaining a con-
9 stant speed, such as in heavy traffic or on roads
1
2 that are winding, icy, snow-covered, slippery, or
10 roads with a loose driving surface. Failure to fol-
11 low this precaution could cause a collision or
12
01/24/2003 f270120
loss of vehicle control, possibly resulting in per-
sonal injury or property damage.
To upshift manually, pull the lever back (towards the
driver). To downshift manually, push the lever forward
(away from the driver). NOTICE
1. SmartShift Control Lever
2. Slide Switch (forward driving mode switch) When the cruise control is engaged, do not at-
3. MAN Mode (of slide switch) tempt to shift gears without using the clutch
4. AUTO Mode (of slide switch) pedal. Failure to follow this precaution will result
5. Upshift Direction in a temporarily uncontrolled increase in engine
6. Reverse Position (of selector switch) speed. Transmission damage and gear stripping
7. Selector Switch could result.
8. Neutral Lock Button
9. Neutral Position (of selector switch) IMPORTANT: On vehicles equipped with
10. Drive Position (of selector switch) VORAD Collision Warning System with Smart-
11. Low Position (of selector switch)
12. Downshift Direction
Cruise, see Chapter 6 before operating the
cruise control.
Fig. 5.21, SmartShift Control (Eaton Fuller UltraShift
and AutoShift transmissions) NOTE: If the vehicle is equipped with a Detroit
multifunction control, setting the cruise control
with the engine brake on will activate Descent
Control Mode. Moving the lever to the top posi-
tion will resume the set cruise speed. Moving
the lever down to engage the engine brake after
the cruise control has been set will activate De-
1 celeration Mode. See "Descent Control and De-
celeration Modes, Detroit™ Automated Transmis-
2 sions" in this chapter.
The cruise control is operated by four buttons
mounted in the left-hand button pod of the steering
wheel. See Fig. 5.7.
• ON/OFF Button—Press to turn cruise control
on or off. When cruise control is on, a green
telltale illuminates in the ICU. The speed
memory will be retained until the cruise control
is disabled with the ON/OFF button, or the igni-
tion is turned off.
10/31/94 f600369a
1. Indicator Panel 2. Mode ID
Fig. 5.22, Allison Push-Button Shift Selector
5.11
Driver Controls
• DEC/SET Button—Press to set the cruise 4. To increase cruise speed, press the ACC/RES
speed while the vehicle is traveling at the de- button until the vehicle accelerates to the desired
sired speed. Press and hold to decrease the speed.
set cruise speed.
5. To decrease cruise speed, press the DEC/SET
• CNCL Button—Press to pause the cruise con- button until the vehicle decelerates to the desired
trol, while retaining the speed setting in speed.
memory. The cruise control can also be disen-
gaged, while retaining the speed memory, by Run Smart Predictive Cruise™
depressing the brake or clutch pedals.
Predictive Cruise Control (PCC) is an optional fuel
• ACC/RES Button—Press to resume the set savings application that adjusts vehicle speed predic-
speed. Press and hold to accelerate the set tively, based on the approaching road. Using 3D digi-
cruise speed. tal map technology and GPS, PCC evaluates the up-
1. To cruise at a particular speed: coming road grade about a mile in advance to
determine the most fuel-efficient vehicle speed. Ve-
1.1 Press the ON/OFF button to turn cruise hicles equipped with PCC have a sticker on the
control on. dash. See Fig. 5.23.
1.2 Depress the accelerator pedal until the
speedometer reaches the desired speed.
NOTE: Cruise control is cancelled if the
brake or clutch pedal is depressed, or ve-
hicle speed drops below the minimum cruise
control speed.
1.3 Press the DEC/SET button to set the de- 04/15/2009 f100149
sired speed.
NOTE: The speed memory is lost whenever the Fig. 5.23, Run Smart Predictive Cruise Control Sticker
ignition switch is turned to OFF, or cruise control The 3D digital map database contains profile infor-
is turned off. mation for over 200,000 highway miles (322,000 km)
2. To disengage the cruise control, do one of the in the 48 contiguous United States. PCC will vary the
following: set cruise speed by up to 6% depending on the ap-
proaching road grade. If the engine brake is enabled,
• Press the CNCL button. PCC will automatically engage the engine brake
• Depress the brake pedal. when actual vehicle speed exceeds the cruise set
speed by 6%. This is different from conventional
• Depress the clutch pedal (on a manual cruise control, which maintains the speed set by the
transmission only). driver.
3. To resume a preselected cruise speed:
WARNING
3.1 Ensure cruise control is on.
3.2 Press the ACC/RES button. Cruise will Apply the brakes and downshift as necessary
return to the last set speed. when driving on downhill grades. PCC does not
adequately control vehicle speed on steep down-
NOTE: If vehicle speed drops below the hill grades. Failure to use normal braking tech-
minimum cruise control speed, cruise control niques when PCC is active could result in per-
will disengage. To resume to the preselected sonal injury and vehicle damage.
cruise speed, increase vehicle speed to IMPORTANT: PCC adjusts the vehicle set speed
above minimum cruise control speed and to achieve maximum fuel economy, but it does
press the ACC/RES button.
5.12
Driver Controls
not account for traffic flows or surrounding ve- CC Limiter Switch Settings
hicles. Position Approximate Overrun Setting
Driver interaction with PCC is the same as conven- Top in 3 mph (5 km/h)
tional cruise control, using the standard cruise control Middle 6 mph (9 km/h)
buttons. In the event of a problem with PCC, or when Bottom in Unlimited
driving on a road with no profile information avail-
Table 5.1, CC Limiter Switch Settings
able, the system reverts to conventional cruise
control.
Cruise Control ("CC") Limiter Descent Control and Deceleration

Modes, Detroit™ Automated
On vehicles equipped with a CC Limiter (or CC Transmissions
Band) switch (see Fig. 5.24 or Fig. 5.25), the cruise
control limiter allows the vehicle to exceed the set On vehicles equipped with a Detroit multifunction
cruise control speed before engine braking is ap- control (Fig. 5.26), the functions of the lever posi-
plied. The CC limiter switch provides more flexibility tions for engine brake control change when cruise
to the existing cruise control limit function, allowing control is set. Two distinct modes can be activated:
the driver to tune the cruise function to better suit
driving preferences and conditions. To select a limit, • Descent Control Mode—engine braking keeps
use the three-position CC Limiter switch on the dash. the speed below cruise set speed; throttle is
See Table 5.1 for switch settings. not automatically applied.
• Deceleration Mode—engine braking activates
to reduce vehicle speed (with no lower limit) at
a constant rate.
Descent Control Mode

Descent Control Mode keeps the vehicle speed
below the set cruise speed on a downhill.
To activate Descent Control Mode, set the cruise
CC
control speed with the engine brake on (Fig. 5.26,
LIMIT
positions 1, 2, or 3). In this mode, all three levels of
engine braking will be employed to to keep the
02/19/2013 f611203
speed below the set cruise speed. This mode will not
keep the speed above the lower limit of the set
Fig. 5.24, CC Limiter Switch speed, so it is possible to eventually coast to a stop,
unless the lever is moved to "engine brake off" (posi-
tion 0), or throttle is applied. After throttle application,
the Descent Control Mode is resumed.
Moving the lever to "engine brake off" (position 0)
cancels Descent Control Mode and resumes cruise
speed. To reactivate Descent Control Mode, reset the
cruise control speed with the lever in position 1, 2, or
3.
CC
BAND
Deceleration Mode
Deceleration Mode reduces the vehicle speed at a
constant rate.
05/08/2012 f611191
With the cruise control speed set, activate Decelera-
Fig. 5.25, CC Band Switch tion Mode by moving the lever to engine brake on
5.13
Driver Controls
Dash-Mounted Brake Controls

0 NOTE: See Chapter 13 for detailed information
about brake systems.
1
Parking Brake Control Valve
NOTICE
2
Do not step on the service brake pedal while the
parking brakes are applied. To do so can cause
damage to the brake mechanisms.
3
The yellow diamond-shaped knob operates the park-
ing brake valve. See Fig. 5.28. Pull the knob out to
02/19/2013 f270164a
apply both the tractor and the trailer spring parking
0. Resume cruise control set speed. brakes. Push the knob in to release the tractor spring
1, 2, 3. Descent Control maintains set speed. parking brakes. Before the spring parking brakes can
Fig. 5.26, Descent Control Mode Positions, Detroit be released, the air pressure in either air brake sys-
Multifunction Control tem must be at least 65 psi (447 kPa).
(Fig. 5.27, position 1, 2, or 3). This mode engages If the trailer is not equipped with spring parking
one of the engine brake levels, depending on the brakes, pull the parking brake valve out to apply the
lever position. The vehicle will decelerate at a con- tractor parking brakes and the trailer service brakes.
stant rate until the vehicle comes to a stop, unless
throttle applied to override the deceleration, or the
lever is moved to "engine brake off" (position 0). 1
2
Moving the lever to position 0 resumes the previously
set cruise control speed.
0
03/10/99 f610291
1. Trailer Air Supply Valve (red knob)
1 2. Parking Brake Control Valve (yellow knob)
Fig. 5.28, Brake Valve Control Knobs

2
Trailer Air Supply Valve
The red octagonal-shaped knob operates the trailer
air supply valve, which charges the trailer air supply
3
system and releases the trailer spring parking
brakes. See Fig. 5.28.
02/19/2013 f270164a
0. Resume cruise control 2. Medium After the vehicle and its air hoses are connected to a
set speed. 3. High trailer and the pressure in the air system is at least
1. Low 65 psi (447 kPa), push the trailer air supply valve
knob in (and leave it in) to charge the trailer air sup-
Fig. 5.27, Deceleration Mode Positions, Detroit ply system and release the trailer spring parking
Multifunction Control brakes. Pull the trailer air supply valve out before
5.14
Driver Controls
disconnecting a trailer or when operating a vehicle Vehicles with ABS may have Automatic Traction Con-
without a trailer. trol (ATC). On these vehicles, the ATC system auto-
matically limits wheel spin during reduced-traction
Trailer Brake Lever situations. In normal braking applications, the stan-
dard air brake system is in effect.
The trailer brake lever is used to apply the trailer ser-
vice brakes without applying the truck or tractor ser- ATC includes a deep snow and mud option to in-
vice brakes. It is usually mounted on the right-hand crease available traction on extra-soft surfaces like
control panel. See Fig. 5.29. The valve can be par- snow, mud, or gravel. A switch labeled ATC will be
tially or fully applied, but in any partially on position it located on the dash. See Fig. 5.30. Press the switch
will be overridden by a full application of the service to temporarily allow more drive wheel spin. The acti-
brake pedal. Move the lever down to apply the trailer vation of the deep snow and mud option is indicated
brakes; move the lever up to release the trailer by a flashing WHEEL SPIN lamp. Press the switch
brakes. The lever will automatically return to the up again to cycle the system back to normal operation.
position when it is released.
ATC
06/15/2007 f610907
Fig. 5.30, ATC Switch

10/17/2001 f610591
Fig. 5.29, Trailer Brake Lever NOTICE

Antilock Braking System The deep snow and mud option is intended to be
used under specific slippery conditions that re-
The Meritor™ WABCO® Antilock Braking System
quire momentary increased wheel spin. Using
(ABS) passively monitors vehicle wheel speed at all
this option for an extended period of time may
times, and controls wheel speed during emergency
damage the brake system.
stops or wheel lock situations.
During emergency or reduced-traction stops, fully
depress the brake pedal until the vehicle comes to a
Windshield Wiper/Washer
safe stop. Do not pump the brake pedal. With the Controls
brake pedal fully depressed, the ABS will control all
wheels to provide steering control and a reduced The multifunction turn signal lever is attached to the
braking distance. left-hand side of the steering column, just below the
steering wheel. See Fig. 5.8.
The ABS is designed to communicate with a trailer
ABS, if they are compatible. Compatibility will result
in the illumination of the trailer ABS lamp during ve- NOTICE
hicle start-up and fault detection. The trailer ABS
Do not attempt to manually move the windshield
lamp will not illuminate unless a compatible trailer is
wiper arms. Wiper motor damage will occur if the
connected to the tractor.
arms are forcibly moved.
5.15
Driver Controls
The wipers are operated by a rotary switch in the

wiper control dial, which is on the end of the turn sig- NOTICE
nal lever. There are five intermittent settings, marked
on the dial by lines of increasing length, and two Never exhaust air from the suspension while
steady speed settings: LO and HI. driving. When the air is exhausted, the suspen-
sion will not absorb road shocks, and compo-
Turn the wipers on by rotating the control dial coun- nents may be damaged.
terclockwise. Rotate the control dial further to in-
crease the speed of the wipers through the various A red LED in the switch is illuminated when the sus-
intermittent settings, then to LO and HI. pension is deflated.
Rotate the control dial clockwise to slow the wipers ECAS Remote Control Unit (ECAS
down. Rotate the control dial clockwise as far as it
will go to turn the wipers off.
only)
The windshield washer button is located at the end Some vehicles equipped with Electronically Con-
of the turn signal lever. Momentarily press the wind- trolled Air Suspension (ECAS) have a remote control
shield washer button to initiate a single wipe without unit to lower and raise the rear suspension. See
activating the washer pump. The wipers will swipe Table 5.2 for keys and functions.
one full cycle and return to the inactive position. If the suspension is outside normal ride height
To operate the windshield washers, press and hold (amber lamp on), the ECAS system will automatically
the button in. After a short delay, the washer will return the suspension to normal ride height when
pump windshield washer fluid onto the windshield for vehicle speed reaches or exceeds a set speed (usu-
as long as the washer button is pressed. The wind- ally set to 5 mph).
shield wipers will turn on at low speed while the
washer button is pressed. After the button is re- ECAS Remote Control Keys and Functions
leased, the wipers will continue to operate for one to
several wipe cycles, depending on how long the
wash button was pressed initially.
Suspension/Trailer Connection
Controls
Air Suspension Dump Control Switch
NOTICE
Do not operate the vehicle over uneven ground
such as ramps, speed bumps, curbs, etc. with
the air springs deflated. Doing this may lead to
air bag separation from the piston, preventing the
suspension air springs from re-inflating. 08/16/2013 f611211
The air suspension height control switch may be

used to aid in connecting or disconnecting from a Key Function
trailer. See Fig. 5.15. When the switch is set to Remote Control On/Off. The middle
LOWER, the air-suspension dump valve deflates the light will remain lit while the remote is
air springs to lower the rear of the vehicle. In the active.
AUTO position, the automatic ride-control valves op-
erate for normal driving.
5.16
Driver Controls
ECAS Remote Control Keys and Functions Trailer Auxiliary Switch

Memory keys. Pressing the Stop key
and a memory key simultaneously will Trailers that are equipped with pneumatic brakes and
store the current height. Once stored, used in North America or South America are gener-
pressing the key will adjust the ally equipped with power for the trailer lights. The
vehicle to the stored height. connection is passed from the vehicle to the trailer
via the primary receptacle, controlled by a dash
Normal height key. This key will
return the vehicle to normal ride switch.
height. Press the top of the switch to activate the trailer aux-
iliary function. Press the bottom of the switch to turn
Lift and lower keys. These keys will
raise or lower the rear suspension trailer auxiliary function off. See Fig. 5.31.
height.
The Stop key. Pressing the Stop key
will interrupt and stop all adjustments
being made by the remote control.
When the key is off, holding the Stop
key for 2 seconds will cancel the 1
hour Standby mode.
Table 5.2, ECAS Remote Control Keys and Functions
TRLR
AUX
ECAS Standby Mode
Once the key is turned off, the ECAS will enter
02/23/2007 f610888
Standby Mode, remaining powered and adjusting to
level and load changes for 1 hour. To cancel Standby Fig. 5.31, Trailer Auxiliary Switch
mode, hold the STOP button on the remote for 2
seconds.
Climate Controls
Fifth Wheel Slide Control Switch NOTE: See Chapter 8 for detailed climate con-
trol panel operating instructions.
NOTICE
Cab Climate Control
Do not activate the fifth wheel slide control valve
The climate control panel allows you to control the
while the vehicle is in motion. To do so could
heating, ventilating, defrosting, and air conditioning
cause damage to the fifth wheel member, the
(A/C) functions. The cab climate control panel has
kingpin, the cab or trailer, and ultimately to the
three switches to control the functions of the cab
drivetrain.
temperature system; see Fig. 5.32:
The fifth wheel air slide valve allows repositioning of
the sliding fifth wheel from inside the cab. See • fan switch with recirculation button
Fig. 5.15. Move the air slide control valve switch to • temperature control switch with A/C button
the LOCK position to lock the fifth wheel to the base-
plate. Move the switch to the UNLOCK position to • air selection switch (with bunk-override button
unlock the fifth wheel slide mechanism, allowing on sleeper cab only)
changes to the total length of the tractor-trailer and The fan switch controls the fan speed, and forces
changes to axle loads to comply with state or provin- fresh or recirculated air through the air outlets. To
cial laws. increase airflow, turn the switch clockwise to a higher
For detailed operating instructions for fifth wheel number. To decrease airflow, turn the switch counter-
slide, refer to Chapter 18. A red indicator light illumi- clockwise to a lower number.
nates whenever the fifth wheel slide is unlocked.
5.17
Driver Controls
5
4 6
1 2 3
3
7
4
2 6
0 8
2 8
1 9
07/20/2006 f831701
06/08/2007 10 f610948
1. Fan Switch with Recirculation Button
2. Temperature Control Switch with Air Conditioning 1. Face Mode
Button 2. Selection Between Face Mode and Bi-Level Mode
3. Air Selection Switch with Bunk-Override Button 3. Bi-Level Mode
4. Selection Between Bi-Level Mode and Floor Mode
Fig. 5.32, Cab Climate Control Panel 5. Floor Mode
6. Selection Between Floor Mode and Defog Mode
Recirculation mode limits the amount of outside air 7. Defog Mode
that enters the cab. Press the recirculation button to 8. Selection Between Defog Mode and Defrost Mode
prevent dusty or smoky air from entering the cab. 9. Defrost Mode
10. Bunk-Override Button (on sleeper-cabs only)
NOTE: To prevent the buildup of odors and/or
oxygen depletion inside the cab, the system Fig. 5.33, Air Selection Switch With Bunk-Override
Button
switches from full recirculation mode to partial
recirculation mode after 20 minutes. nated when the bunk-override mode is activated.
The temperature control switch is used to select the When the override switch is not activated, the cab
desired temperature. Turn the switch clockwise to the climate control panel can be adjusted without affect-
red area for warm air. Turn the switch counterclock- ing the sleeper settings.
wise to the blue area for cool air.
Sleeper Climate Control
The A/C cools and dehumidifies the air inside the
cab. Press the A/C button, located in the center of The sleeper temperature can be controlled from the
the temperature control switch, to turn the A/C on sleeper climate control panel or from the cab climate
and off. control panel if the bunk-override button is activated.
The air selection switch allows the control of air flow The fan switch controls the sleeper temperature fan
through the face outlets, the floor outlets, the defrost speed. To increase airflow, turn the switch clockwise
(windshield) outlets, or a combination of these out- to a higher number. To decrease the airflow, turn the
lets. See Fig. 5.33. switch counterclockwise to a lower number. See
Fig. 5.34.
Bunk-Override Button The temperature control switch is used to select the
The bunk-override button is located in the center of desired temperature in the sleeper. Turn the switch
the cab air-selection switch (sleeper-cabs only). See clockwise to the red area for warm air. Turn the
Fig. 5.33. switch counterclockwise to the blue area for cool air.
Press the bunk-override button to make the cab con- Press the button in the center of the temperature
trols override the settings on the sleeper temperature control switch to activate the A/C.
control panel; the sleeper temperature will mimic the
cab settings. An amber LED in the button is illumi-
5.18
Driver Controls
1 2 WARNING
Keep hands, tools, and other objects away from
the scissor points under the seats. Failure to do
so could cause personal injury.
The following is a description of adjustments that can
be made to various seats. Not all seats have all of
the adjustments listed below. See Fig. 5.35.
• Backrest tilt
3
06/08/2007 f610949 • Lumbar support
1. Fan Switch 3. Air Conditioning • Isolator
2. Temperature Control Button
• Height adjustment
Fig. 5.34, Sleeper Climate Control Panel
• Bottom cushion angle (fore-and-aft bottom
Cancel bunk-override mode, if activated, by changing cushion height)
the sleeper fan speed or temperature setting. The
• Fore-and-aft seat slide (seat track adjustment)
system will then operate from the sleeper controls.
• Seat tilt
Seat Controls • Headrest adjustment
NOTE: See Chapter 7 for detailed information
about seat controls and adjustments.
1
3 4
2
8
6 7
5
10/26/2000 f910149a
1. Backrest Tilt 5. Bottom Cushion Angle (fore-and- 7. Seat Tilt
2. Lumbar Support aft cushion height) 8. Upper Backrest Adjustment
3. Isolator Feature 6. Fore-and-Aft Seat Slide (seat
4. Height Adjustment track adjustment)
Fig. 5.35, General Seat Adjustments
5.19
Driver Controls
Adjustable Steering Column

Controls
To adjust the steering column, depress the foot pedal
located below the steering column. See Fig. 5.36. Tilt
the steering column to the desired angle. Telescope
the steering column closer or further away by push-
ing or pulling it. Release the foot pedal to lock the
steering column in place.
5
1
07/19/2006 f610799
1. Multifunction Turn 4. Tilt Steering Column
Signal Switch Lever
2. Headlight Switch 5. Steering Wheel
3. Ignition Switch
Fig. 5.36, Steering Column and Left Panel Controls
5.20
6
Driver Assistance Features
VORAD VS-400 System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.1
OnGuard™ Collision Safety System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.7
Lane Departure Warning Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.10
Roll Stability System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.11
Enhanced Stability Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.13
VORAD VS-400 System the up and down arrow buttons, and the OK button.
See Fig. 6.1.
WARNING 5
The VORAD VS-400 System is intended solely as 4
an aid for an alert and conscientious professional
driver. It is not intended to be relied upon to op-
erate a vehicle. Use the system in conjunction 3
with rearview mirrors and other instruments to OK 6
safely operate the vehicle. Operate a vehicle
equipped with the VS-400 System in the same 2 TM
safe manner as if the CWS were not present.

1
The VS-400 System is not a substitute for safe,
normal driving procedures, nor will it compen- 7
sate for any driver impairment such as drugs, 02/03/2012 f610919a
alcohol, or fatigue. 1. Fault Indicator 4. Ambient Light Sensor
2. Info Indicator 5. Collision Alert Lights
The VS-400 System may provide little or no warn- 3. Following Distance 6. User Interface Keypad
ing of hazards such as pedestrians, animals, on- Lights 7. Graphic Display
coming vehicles, or cross traffic.
Fig. 6.1, Driver Interface Unit (DIU)
Failure to drive safely and use the system prop-
erly could result in personal injury and/or death The following warning and indicator lights illuminate
and severe property damage. on the DIU:
The VORAD VS-400 system is an on-board radar • Red: illuminates with the collision alert
system that monitors traffic conditions, warning the
driver of potentially hazardous driving situations. • Yellow: illuminates with 3-, 2-, and 1-second
following distance alerts
The collision warning system (CWS) tracks objects
ahead of the vehicle, warning the driver with visual • Orange: illuminates when a system failure oc-
and audible indicators whenever following distances curs
become unsafe. • Blue: illuminates when information is available
SmartCruise® adjusts the vehicle’s cruise speed in Immediately after the ignition switch is turned to ON,
order to match the speed of traffic ahead, allowing the DIU initializes a self-test routine. During the ini-
the driver to maintain a safe following distance while tialization, the VORAD screen displays and all lamps
cruise control is engaged. illuminate for approximately three seconds, along
The optional side object detection system warns of with a power-up tone. When the initialization is com-
unsafe lane changes by detecting vehicles that may plete, the DIU displays the VS-400 system configura-
be difficult to see in adjacent lanes. tion screen. See Fig. 6.2.
The VORAD VS-400 system performs in fog, rain, Menu Selections

snow, dust, smoke, and darkness. The VS-400 sys-
tem becomes active whenever the ignition key is IMPORTANT: The display of a menu item is
switched to ON. overridden whenever conditions require an alert
or collision warning to be displayed.
Driver Interface Unit After initialization, the menu screen is displayed.
The driver interface unit (DIU) provides visual and Scroll to the desired menu item by pressing an arrow
audible alerts, along with system status information. button, then press the OK button to select the item.
The DIU also provides an interface for changing sys- See Fig. 6.3. If the driver does not make a selection
tem settings. Menu selections are made by pressing within 30 seconds, or the vehicle begins to move, the
DIU reverts to the system status display.
6.1
screens by pressing the down arrow. Pressing any

other key exits Demo mode.
Volume
VORAD started The minimum adjustable volume is 50% of the maxi-
Collision Warn OK mum volume. If the DIU volume is not adjustable, the
A
display screen shows a grayed bar graph whenever
TM
volume adjustment is selected. See Fig. 6.4. After
each ignition switch cycle, the volume will default
back to 100%.
NOTE: Headway and collision alert tones may
be suppressed when the brake is applied if the
system is configured to do so.
VORAD started
Collision Warn OK
B SmartCruise
TM
Volume
OK
02/03/2012 f610921a A
A. Configured for CWS only
TM
B. Configured for CWS and SmartCruise

Fig. 6.2, System Configuration Screens
Volume
OK
B
System Status
Demo OK TM
Volume
TM
02/03/2012 f610925a
A. Adjustable Volume
B. Non-Adjustable Volume
02/03/2012 f610922a Fig. 6.4, Volume Screen
Fig. 6.3, Menu Screen SmartCruise Headway Range

The display of any menu item is overridden when- Headway range adjustment is only available with
ever conditions require an alert or collision warning SmartCruise. Headway range is adjustable between
to be displayed. 3.25 and 2.25 seconds. The headway range setting
will default to 3.25 seconds after each ignition power
Demo (vehicle must be stationary) cycle.
When the vehicle is stationary and Demo mode is If headway range adjustment is disabled, only the
selected, the DIU will demonstrate the meaning of all 3.25 sec screen is displayed. See Fig. 6.5 for the
LED and screen displays, including alert messages various headway range screens. Press the OK but-
and sound warnings. Scroll through the demo ton to exit the menu.
6.2
NOTE: If the headway range is adjusted to adjusted in all driving conditions. Press the OK but-
three seconds or below and SmartCruise is ac- ton to exit the menu.
tive, the 3-second collision warning headway
alert will not display. All other alerts are not Unit Adjustment Screen
suppressed. The unit adjustment screen allows the driver to select
either km/h or mph units for display of SmartCruise
set speed. Press OK to exit the mph selection
screen.
SmartCruise System Status
A Range OK
System status shows the status of each system, indi-
2.25 sec cating if the system is operating normally. If a system
TM
is not operating normally, the system displays Failed
beside the system name. Failed indicates that a fault
is preventing the system from operating and it cannot
be used until the fault is corrected or acknowledged.
Depending on the VS-400 system installed, one of
SmartCruise the screens shown in Fig. 6.6 will appear unless a
B Range OK system fault is active. Press OK to exit the system
3.25 sec
status menu.
TM
VORAD status
SmartCruise Collision warn OK OK
A SmartCruise OK
C Range OK
fixed Press OK for Menu
3.25 sec TM
TM
02/03/2012 f610927a
A. Minimum headway adjustment
B. Maximum headway adjustment
C. Headway range disabled VORAD status
Collision warn OK OK
Fig. 6.5, Headway Range Screen B
Press OK for Menu
Brightness TM
Use the up and down arrows to change the DIU

backlight and warning LED brightness. Press the OK
02/03/2012 f610923a
button to exit the brightness screen.
A. Status display for CWS and SmartCruise
The ambient light sensor reading determines if the configuration
DIU is in daytime or nighttime mode. Menu-adjusted B. Status display for CWS configuration
brightness is applied only to the mode the DIU is in
at the time of adjustment. The previous brightness Fig. 6.6, System Status Screens
settings are repeated after each ignition cycle. How-
ever, the graphic display and the warning LED bright- Diagnostics
ness range are constrained such that they are al- The DIU displays fault codes currently active when
ways visible regardless of how low the brightness is this screen is selected and the vehicle is stationary.
6.3
See Fig. 6.7. Contact an authorized Freightliner ser- The alerts given by the VS-400 system are based on
vice center if fault codes display. the distance to the object ahead, whenever vehicle
speed is 10 mph (16 km/h) or faster. The VS-400
CWS identifies and tracks the nearest object in the
lane of travel. This object is classified by the range,
and assigned a message described under the follow-
DIU DIAGNOSTICS ing headings.
SPN: 00886 FMI:012 OK Object Detected
OK
When a vehicle is detected in the same lane of travel
TM
within 350 ft (107 m) but farther than a 3-second fol-
lowing distance, the DIU will display OBJECT DE-
TECTED. See Fig. 6.9.
02/03/2012 f610929a
Fig. 6.7, DIU Diagnostic Screen
Collision Warning System

The CWS may require a warm-up period of up to
Object Detected OK
one minute if the outside air temperature is below
32°F (0°C). The DIU will display a warm-up message
until the system reaches operating temperature. See TM
Fig. 6.8.
02/03/2012 f610930a
Fig. 6.9, Object Detected Alert
Radar Warming Up
3-Second Headway Alert
Do not use OK
A SmartCruise
When a vehicle is detected to be within a 3-second
following distance, a single yellow indicator will illumi-
TM
nate and the DIU will display 3 seconds. See
Fig. 6.10.
Radar Warming Up
Please wait OK
B 3 seconds OK
TM
TM
02/03/2012 f610924a
02/03/2012 f610931a
A. CWS with B. CWS Only
SmartCruise Fig. 6.10, 3-Second Alert
Fig. 6.8, CWS Warm-Up Screens
6.4
2-Second Headway Alert

When the following distance to the object ahead in
the same lane of travel decreases to within two sec-
onds, a second yellow indicator will illuminate, the
DIU will display 2 seconds, and a single tone will COLLISION OK
sound. See Fig. 6.11.
ALERT
TM
02/03/2012 f610934a
2
seconds OK Fig. 6.13, Collision Alert
TM
SmartCruise
When approaching slower moving traffic with the ve-
hicle’s cruise control engaged, SmartCruise adapts
02/03/2012 f610932a the engine cruise speed to that of the closest vehicle
ahead, allowing the vehicle to maintain a safe follow-
Fig. 6.11, 2-Second Alert ing distance without disengaging the cruise control.
The DIU will display the SmartCruise status screen
1-Second Headway Alert indicating the vehicle’s current set cruise speed.
When the following distance to the object ahead in Once the speed of traffic ahead increases beyond
the same lane of travel decreases to within one sec- the adapted engine cruise speed, the original cruise
ond, a third yellow indicator will illuminate, the DIU control set speed re-engages.
will display 1 sec, and two tones will sound. See
Fig. 6.12. When SmartCruise is engaged, depressing the accel-
erator pedal will override the SmartCruise and will
cause the vehicle to accelerate. Depressing the
brake or clutch pedals will deactivate SmartCruise.
When approaching a slow moving or stopped vehicle
ahead, SmartCruise will attempt to maintain the mini-
1 mum following distance by reducing the engine
sec OK cruise speed and engaging the engine brake, if nec-
essary. If SmartCruise is unable to maintain the mini-
TM
mum following distance, the driver will be alerted by
the CWS headway alerts until the driver takes control
or conditions clear.
02/03/2012 f610933a
Side Object Detection
Fig. 6.12, 1-Second Alert
The optional side object detection system may be
Collision Alert: ½-Second Headway installed on one or both sides of the vehicle. The
radar sensor(s) are located on the side of the ve-
When the following distance to the object ahead in hicle, while the sensor display unit is mounted on the
the same lane of travel decreases to 0.5 second, the A-pillar. See Fig. 6.14.
red indicators all illuminate across of the DIU, the
DIU will display COLLISION ALERT, and a tone will The side sensor display unit uses two lights to dis-
sound repeatedly. See Fig. 6.13. play the status of the side sensor(s). The yellow light
indicates the system is active, but no objects are de-
tected. The red light indicates that the side sensor
detects an object. If the vehicles turn signal is active
6.5
• On approaching a steep hill, objects above the

beam cannot be detected. Generally, the beam
hitting the road surface does not cause an
1 alarm.
2 • The side sensor only detects objects within its
field of view, next to the tractor. A vehicle be-
hind the field of view will not be detected.
3
• The side sensor range is set to detect
average-sized vehicles 2 to 10 feet (0.5 to 3
4 meters) away in the adjacent lane.
• The radar beam will detect near range cut-ins
of approximately 30 feet (9 meters) or less,
02/06/2012 f610935b
depending on the angle of entrance into the
1. Volume Adjust lane in front of your vehicle.
2. Red LED–Object Detected
3. Ambient Light Sensor • A continuous fixed object on the right side of
4. Yellow–No Object Detected the vehicle such as a guard rail, wall, tunnel, or
bridge may cause the side sensor alert light to
Fig. 6.14, Side Sensor Display Unit stay on.
and the sensor detects an object alongside the ve-
hicle, an audible warning tone will sound. WARNING
Special Road Situations Heavy rain or water spray at the side sensor may
cause both the yellow and red lights on the side
Certain road situations may affect the system’s ability sensor display to illuminate at the same time.
to detect objects. These situations include the effects Under these conditions the system is temporarily
of curves, dips, and hills which can provide an unex- unable to provide adequate warnings.
pected result.
Failure to drive safely and use the system prop-
NOTE: A warning may sound when an object is erly could result in personal injury and/or death
detected in front of the vehicle even though the and severe property damage.
driver intends to turn away or stop before reach-
ing the object. Maintenance
• When an object is detected in a very sharp Keep the antenna and side sensor free of buildup of
right- or left-hand turn, the audible alarm will mud, dirt, ice, or other debris that might reduce the
not sound. system’s range.
• When approaching a curve, alarms may sound
and lights illuminate, because of an object off
Failure Display Mode/Fault Codes
the road directly in line with your vehicle. This The VS-400 performs internal diagnostics at power-
will not occur when the brakes are applied. up, then continuously monitors system components
• When approaching a roadway descending to a thereafter.
lower elevation, elevated obstacles such as If a failure is detected, depending on what features
overpasses and overhead signs may be de- are affected, the DIU displays a screen similar to
tected. Fig. 6.15, blinks the orange fault light, and sounds a
tone. Press the OK button to acknowledge the fault.
• Vehicles cannot be detected on the other side
of a hill. An alarm will not sound until the object After the fault has been acknowledged, the DIU will
is within the antenna assembly’s field of view. attempt to return to normal operations. The orange
LED is continuously illuminated while the fault per-
sists. If the fault disappears, the VS-400 transmits a
6.6
The front-looking antenna assembly transmits radar

signals to, and receives them back from, objects
ahead of the vehicle. This allows the determination of
the distance, speed, and angle of the object ahead.
VORAD fault The system uses this information to warn the driver
Collision warn FAILED OK of potentially dangerous situations.
OK
TM
WARNING
The Meritor WABCO OnGuard™ Collision Safety
02/03/2012 f610936a
System is intended solely as an aid for an alert
and conscientious professional driver. It is not
Fig. 6.15, VORAD Fault Display intended to be relied upon to operate a vehicle.
Use the system in conjunction with rearview mir-
message to indicate that the fault status has rors and other instruments to safely operate the
changed to a previously active fault. vehicle. Operate a vehicle equipped with the On-
In the event the CWS antenna becomes blocked Guard in the same safe manner as if the CWS
while the vehicle is moving (e.g., snow, mud, ice, were not present.
tampering, etc.), the system sounds a tone and dis- The OnGuard Collision Safety System is not a
plays the fault screen shown in Fig. 6.16. substitute for safe, normal driving procedures,
Contact an authorized Freightliner dealer to review nor will it compensate for any driver impairment
and clear previously active fault codes. such as drugs, alcohol, or fatigue.
The OnGuard Collision Safety System may pro-
vide little or no warning of hazards such as pe-
destrians, animals, oncoming vehicles, or cross
traffic.
VORAD fault Failure to drive safely and use the system prop-
Radar Blocked OK erly could result in personal injury and/or death
and severe property damage.
OK
TM
OnGuard Display Unit

The OnGuard system controls are located in the dis-
02/03/2012 f610937a play unit. The display provides visual and audible
warnings and messages, as well as verification of
Fig. 6.16, Antenna Blocked Display correct system operation and faults. Menu selections
are made by pressing the up and down arrows, and
OnGuard™ Collision Safety the MODE button. See Fig. 6.17.
System The display includes:
Meritor WABCO OnGuard is a forward-looking radar- • an internal speaker
based adaptive cruise control and collision safety • a graphic display
system with active braking. The system includes a
collision warning system (CWS), adaptive cruise con- • buttons to scroll and select options
trol (ACC) with active braking, and a collision mitiga-
tion system (CMS). Collision Warning System (CWS)
The system performs in fog, rain, snow, dust, smoke, The CWS generates audible and visual alerts when
and darkness. To be detected, objects must be within the vehicle’s following distance may result in a colli-
the radar field of view and provide a surface area sion. The CWS provides only a warning, and will not
that can reflect the radar. control vehicle speed.
6.7
230FT
CWS 55 MPH
10/31/2014 f611143
Fig. 6.18, CWS Object Detected
15 FT
08/30/2011 f545826
Fig. 6.17, OnGuard Display Unit
The CWS cannot be disengaged or turned off, and is CWS 15 MPH

always active at vehicle speeds above 15 mph (25
km/h). 10/31/2014 f611144
Standby Fig. 6.19, CWS Collision Warning

When no object is detected, the display shows that
the CWS is on and the radar is searching. See Adaptive Cruise Control (ACC)
Fig. 6.17. ACC is a radar-based system that works in conjunc-
tion with conventional cruise control to maintain the
Object Detected set cruise speed when no vehicle is being tracked,
When an object is detected in the lane ahead, the and maintains a minimum following distance when an
display shows that the CWS is on and the radar is object is being tracked. The minimum following dis-
tracking an object at the speed shown. See tance is maintained by automatically decelerating the
Fig. 6.18. vehicle using throttle, engine, and service brakes
without driver intervention. When the object is no lon-
If the following distance between the vehicle and the ger being tracked, the set cruise control speed re-
object is too close, the CWS will emit an audible alert sumes automatically.
and the display background will turn yellow. The alert
will end when vehicle speed drops below the object Standby
speed and the following distance is increased.
When no object is detected, OnGuard ACC operates
Collision Warning similarly to conventional cruise control. The cruise
control set speed is shown on the OnGuard display
If the object is traveling slower than the driver’s ve- unit. See Fig. 6.20.
hicle, the CWS warns of an impending collision by
emitting an urgent audible alert and displaying the Object Detected
collision warning symbol with a red background. See
Fig. 6.19. When an object is detected in the lane ahead, the
display shows that ACC is on and the radar is track-
ing an object at the speed shown. See Fig. 6.21.
6.8
15 FT
15 MPH
Set: 60 MPH Set: 60 MPH
10/31/2014 f611145 10/31/2014 f611147
Fig. 6.20, ACC Standby Fig. 6.22, ACC Collision Warning
collision is developing and the driver does decelerate

the vehicle, OnGuard’s active braking automatically
230 FT applies the engine and service brakes to provide
braking power. The active braking application is in-
tended only to provide early braking as the driver is
recognizing and reacting to the situation.
IMPORTANT: CMS and active braking are not
Set: 60 MPH 55 MPH operational at vehicle speeds below 15 mph (25
km/h).
10/31/2014 f611146
Error Screens
Fig. 6.21, ACC Object Detected
IMPORTANT: The OnGuard collision safety sys-
If the driver uses the accelerator pedal to override tem is not operational when an error screen is
the cruise control and approach a vehicle too closely, displayed.
the ACC will emit an audible alert and the display If a system fault is detected, the OnGuard display
background will turn yellow. The alert will end when unit will immediately display an error screen like the
vehicle speed drops below the object’s speed and one shown in Fig. 6.23. The first error code transmit-
the following distance is increased. ted will be displayed first; additional faults (if any)
NOTE: The following distance alert does not can be viewed using the up or down buttons. The
operate at speeds below 15 mph (25 km/h). display does not show stored fault codes.
Collision Warning
If the object is traveling more slowly than the driver’s DATA ERROR
vehicle, the CWS warns of an impending collision by
emitting an urgent audible alert and displaying the ACC1 Link Error
collision warning symbol with a red background. See
Fig. 6.22.
The braking control will activate and slow the vehicle.
The driver must also initiate braking.
Collision Mitigation System (CMS) 10/31/2014 f611148
The CMS provides the driver with audible and visual Fig. 6.23, OnGuard Error Screen
alerts when the vehicle’s following distance could
result in a rear-end collision. If a potential rear-end
6.9
If a fault occurs or OnGuard fails to properly track a

vehicle, take the vehicle in for service as soon as
possible. Standard cruise control will not function COMPONENT TEST
with an active OnGuard system fault.
Refer to the OnGuard Collision Safety System Main-
Brake Pedal Position 37%
tenance Manual MM-0951 for a full list of faults (ww-
EBS Brake Switch ON
w.Meritor.WABCO.com).
IMPORTANT: If the system fails to track an ob- CCVS Brake Switch ON
ject, look for signs of damage to the radar as-
sembly. 10/31/2014 f611151
Additional Features Fig. 6.25, Component Test Menu
Press the MODE button to access the OnGuard dis- • EBS brake switch
play unit additional features from the CWS or ACC • CCVS brake switch
main operating screen. Press the up and down ar-
rows to scroll through each menu, then press the • clutch switch
MODE button to select the value to be changed. In
• park brake switch
edit mode, press the up or down arrows to change a
value setting, then press the MODE button to save • accelerator pedal position
the setting. Pressing MODE in each feature screen
advances the display to the next feature. • driveline engaged
The Display Control menu allows adjustment of the • cruise control enable
alarm volume, LCD brightness, LCD contrast, and • cruise control set speed switch
U.S./metric unit conversion. See Fig. 6.24.
• cruise control coast switch
• cruise control resume switch
DISPLAY CONTROL • cruise control accelerate switch
Alarm Volume 10 • cruise control pause switch
Alarm Tone 4 Lane Departure Warning

LCD Intensity 9 Controls
The Lane Guidance lane departure warning system
10/31/2014 f611149 monitors the vehicle’s position within the roadway
lane markings and sounds a warning in the cab
Fig. 6.24, Display Control Menu when the vehicle is about to stray outside its lane,
provided the turn signal is not on and the vehicle is
The component test menu provides verification of
traveling at least 37 mph (60 km/h). The system in-
system component operation and acts as a valuable
cludes a digital camera mounted high near the center
OnGuard system diagnostic tool. The header will dis-
of the windshield inside the cab and speakers that
play either COMPONENT TEST or ACC FUNCTION,
emit a sound similar to a rumble strip. The sound is
depending on the software release version of the On-
made on the side of the vehicle it’s straying toward,
Guard system. The component test screen shown in
prompting the driver to respond and steer away from
Fig. 6.25 provides access to the following compo-
the sound and back into the center of the correct
nents (press the up or down arrows to scroll through
lane.
the menu):
• brake pedal position
6.10
When the vehicle approaches the lane markings on

WARNING either side, the system sense the activation of a turn
signal. If a turn signal has not been activated, the
The lane departure warning system is intended system initiates the audible warning to alert the driver
only as an aid for a conscientious and alert that the vehicle is departing its current lane of travel.
driver. The system may not indicate lane depar-
tures under certain conditions. Read carefully the The LANE SRCHNG warning light illuminates to indi-
information in this manual to understand the cir- cate the system is not fully functional. When the
cumstances under which this system may not warning light is on, the system audible alert may not
provide adequate lane departure warnings. Do indicate a lane departure. Conditions that can cause
not rely solely on the system to safely operate the warning light to illuminate include:
the vehicle. The system does not warn of all pos- • The system is unable to detect lane markings.
sible hazards. For example, the system cannot
prevent an accident if the driver is impaired or • Vehicle speed is less than 37 mph (60 km/h).
not driving safely. • A system problem is detected.
The lane departure warning system is not a sub-
stitute for safe driving procedures. Roll Stability System
Failure to drive safely and use the system prop- The roll stability system may include the roll stability
erly could result in personal injury and/or death advisor (RSA) only, or it may also include the roll sta-
and severe property damage. bility control (RSC).
The lane departure warning system powers up each A decal (Fig. 6.27) on the auxiliary dash panel, and
time the ignition is turned to ON. The system con- an amber-colored dash indicator light (Fig. 6.28), in-
ducts a self test, and initiates test tones from the left dicate that the vehicle is equipped with roll stability
speaker and then the right speaker. Once the vehicle system components.
is started and the system is ready, the LED in the
switch illuminates.
Press the LANE ALERT switch to temporarily disable
the lane departure warning system. See Fig. 6.26. SAFETY INSTRUCTIONS
Some vehicles are equipped with a timer that auto- lamp indicates traction
matically re-enables the warning system after 15 OR roll control event.
minutes. On all other vehicles, the warning system
will remain disabled until the driver enables the sys- Follow instructions in
tem by pressing the LANE ALERT switch again, or driver’s manual.
24−01204−000
the ignition is cycled off and then on.
07/11/2003 f080125
Fig. 6.27, Roll Stability Decal
LANE
ALERT
01/05/2012 f611156
06/26/2003 f602128
Fig. 6.26, Lane Departure Warning System Disable
Switch Fig. 6.28, Roll Stability Indicator Lamp
6.11
Roll Stability Advisor MSG Message Message to Display Display Buzzer

No. Time: Time:
IMPORTANT: This is not an advance warning Seconds Seconds
system. The roll stability advisor displays a mes- 1 System Fault

WARNING
4 1
sage only after the driving maneuver is com- RAC SYSTEM FAIL
pleted. 2 RSC
ACTIVE SLOWING
4 None
ROLLOVER RISK
The roll stability system uses a lateral-acceleration
sensor that monitors rollover risk. Shortly after a 3 RSA Level 3 VERY HIGH RISK OF 19.6 10
curve, lane change, or other driving maneuver that ROLLOVER DETECTED
results in a rollover-risk detection, a dash warning REDUCE SPEED
light illuminates, an audible tone sounds, and a driver AT LEAST 7 MPH
advisory message is displayed in the driver message
or in metric
center. The purpose is to advise the driver that the
previous maneuver produced a rollover risk. REDUCE SPEED
AT LEAST 11 KPH
The roll stability advisor displays different text mes-
4 RSA Level 2 14 5
sages depending on the severity of the risk of each HIGH RISK OF
ROLLOVER DETECTED
occurrence of risky driving. From the highest risk
level to the lowest risk level, the system will sound REDUCE SPEED
an audible alert, and display a message, as shown in AT LEAST 7 MPH
Fig. 6.29. or in metric
NOTE: The system will calculate and recom- REDUCE SPEED

AT LEAST 11 KPH
mend a speed reduction value. It may be differ-
ent than the values shown here. 5 RSA Level 1 ROLLOVER RISK 8.4 2
DETECTED
Bring the vehicle to an authorized service facility if a
system failure message is displayed. REDUCE SPEED
AT LEAST 7 MPH
Roll Stability Control or in metric

REDUCE SPEED
WARNING AT LEAST 11 KPH
6 HBED Level 3 HARD BRAKING WITH 14 0.5
The Roll Stability Control system is intended only ABS ACTIVATED

as an aid for a conscientious and alert driver. LOOK AHEAD
Carefully read the information in this manual to BRAKE SOONER
understand this system and its limitations. The 7 HBED Level 2 14 0.5
HARD BRAKING
Roll Stability Control system is not a substitute DETECTED
for safe driving procedures. Failure to drive
safely, and use the system properly, could result LOOK AHEAD
BRAKE SOONER
in personal injury and/or death and property
damage. 8 HBED Level 1 LOSS OF TRACTION 14 0.5
ABS ACTIVATED
The roll stability control system automatically reduces
engine power, applies the engine brake, and/or ap- ROAD SURFACE
MAY BE POOR
plies the tractor and trailer brakes when the accelera-
tion sensor detects that the vehicle is at risk of rolling 07/25/2008 f040769
over. The control can intervene even before an advi-
sory message is displayed. Fig. 6.29, Roll Stability and Hard-Braking Warnings
The dash indicator light illuminates whenever the roll
stability control system intervenes.
6.12
Hard-Braking Advisor
The hard-braking advisor uses the information from TRIP ADVISORIES
the ABS wheel speed sensors to determine when
braking is severe enough to produce lockup at one
237 ROLL 518 BRK
or more wheels on the tractor, and/or very rapid ve-
hicle deceleration. Shortly after a hard-braking event A B C D E F
07/25/2008 f040770
occurs, an advisory message is displayed in the
driver message center, indicating that the braking A. RSA lev. 3 Count (2) D. HBED lev. 3 Count (5)
behavior was too aggressive for the current road sur- B. RSA lev. 2 Count (3) E. HBED lev. 2 Count (1)
face conditions. This system is not a replacement for C. RSA lev. 1 Count (7) F. HBED lev. 1 Count (8)
a driver’s good judgment. Sometimes it is necessary Fig. 6.30, Trip Advisor Message Screen
to brake hard.
From the highest risk level to the lowest risk level, If the count reaches more than 9 occurrences an up-
the system will sound an audible alert, and display a arrow symbol will appear, to indicate to the driver
message, as shown in Fig. 6.29. that the count has exceeded 9 counts. See
Fig. 6.31.
Trip/Leg Totals
The driver message center records the number of TRIP ADVISORIES
messages received, and displays the number of
messages as counts. Roll stability advisor (RSA) and 23 ROLL 518 BRK
hard-braking event data (HBED) counts can be
viewed in the trip advisory screen, and the leg advi-
A
sory screen. 07/25/2008 f040771
Counts can be reset using the + key on the steering A. RSA Lev. 1 has more than 9 counts.
wheel. Clearing RSA and HBED leg counts will also
Fig. 6.31, Trip Advisor Message Screen (more than 9
reset the leg miles and leg hours. Clearing RSA and counts)
HBED trip counts will also reset trip miles, trip hours,
leg miles, leg hours, and leg advisory counts. In ad-
dition, resetting leg miles will clear leg counts. Clear- Enhanced Stability Control
ing trip miles will reset miles, hours, and counts in
both the leg and trip screens. WARNING
The TRIP and LEG advisor screens count both the
roll stability advisories (ROLL) and hard-braking Enhance Stability Control (ESC) is intended only
events (BRK). For example, if during a TRIP, the as an aid for a conscientious and alert driver.
driver message center recorded the events in Carefully read the information in this manual to
Table 6.1, the message center would display as understand this system and its limitations. ESC
shown in Fig. 6.30. is not a substitute for safe driving procedures.
Failure to drive safely, and use the system prop-
RSA/HBED Count erly, could result in personal injury and/or death
and property damage.
Message Received Message Counts
RSA Level 3 2 ESC offers the full capability of RSC (shown above)
RSA Level 2 3 with the added capability of complete directional sta-
RSA Level 1 7 bility (yaw control) in oversteer and understeer condi-
HBED Level 3 5 tions to reduce the likelihood of drift-out or jackknife.
The system determines where the driver is attempt-
HBED Level 2 1
ing to steer the vehicle and how much brake demand
HBED Level 1 8
is required in order to more precisely control the ve-
Table 6.1, RSA/HBED Count hicle in an emergency situation.
6.13
ESC works by constantly comparing the driver’s in-

tention with the vehicle’s actual behavior. The system
does this by monitoring systems such as wheel
speed, steering angle, yaw rate, lateral acceleration,
throttle position, and brake application. A central mi-
crocomputer analyzes the collected data and triggers
a response to keep the vehicle on course when an
unstable condition is detected.
When the system detects that the vehicle is at risk of
oversteering or understeering, it applies individual
tractor wheel end brakes and trailer brakes, activates
the engine retarder (if equipped), and/or cuts engine
power, depending on the severity. As a result, the
driver has full control over the vehicle until the sys-
tem detects a potential risk and intervenes accord-
ingly. ESC operates automatically; the driver does
not monitor or activate the system.
6.14
7
Seats and Restraints
Seats, General Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.1
Cascadia 2.0 High-Back Seat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.2
Cascadia High-Back Seat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.3
Sears Atlas Seat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.4
Seat Belts and Tether Belts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.5
Steering Wheel Air Bag . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.8
RollTek Rollover Protection System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.9
Seats, General Information • Lumbar Support changes the shape of the

backrest to give more or less support to the
Unless otherwise noted, all seat adjustments should occupant’s lumbar (lower back) area. This ad-
be made while seated and before the engine is justment is either mechanical or air controlled,
started. depending on the seat model.
Due to the high degree of adjustability of mid- and • Fore/Aft Isolator feature reduces the amount of
high-back air suspension seats, it is possible to com- road shock by isolating the occupant from the
bine the seat back recline adjustment and the seat motion of the vehicle, and allowing the upper
slide adjustment so that the seat back contacts the seat to move in a simple pendulum motion. A
back wall. Use care when adjusting the seat to pre- lockout feature is used whenever the isolator is
vent damage to the seat and the cab interior. not desired.
• Height Adjustment moves the entire seat up or
WARNING down. The adjustment is either manually- or
air-controlled, depending on the seat model.
Keep hands, tools, and other objects away from
the scissor points under the seats. Failure to do • Bottom Cushion Angle (fore-and-aft bottom
so could cause personal injury. cushion height) enables the occupant to raise
or lower the front or back of the bottom cush-
The following is a description of adjustments that can ion. This adjustment is easier to perform when
be made to various Freightliner-installed seats. Not all weight is removed from the seat.
all seats have all of the adjustments listed below.
See Fig. 7.1. • Fore/Aft Seat Slide (seat track adjustment)
moves the entire seat forward or backward on
• Backrest Tilt enables the backrest to pivot for- its track.
ward or backward.
1
3 4
2
8
6 7
5
10/26/2000 f910149a
1. Backrest Tilt 5. Bottom Cushion Tilt (fore-and-aft 7. Seat Tilt
2. Lumbar Support cushion height) 8. Headrest Adjustment
3. Fore/Aft Isolator 6. Fore/Aft Seat Slide (seat track
4. Height Adjustment adjustment)
Fig. 7.1, General Seat Adjustments
7.1
• Seat Tilt allows the seat assembly (back and

bottom cushions) to tilt forward or backward.
• Headrest Adjustment changes the angle of the
upper part of the backrest to provide head and
upper back support.
Cascadia 2.0 High-Back Seat

See Fig. 7.2 for seat adjustment controls. Not all
models of the Cascadia 2.0 Hi-Back seat have all the
adjustments listed below.
Recline
Pull the recline handle to adjust the backrest tilt.
Seat Heating/Ventilation
Use the forward switch to turn the seat heater and
ventilation ON or OFF. To turn on the heat, push the
top of the switch. To turn on the ventilation, push the
bottom of the switch. To turn off the heat or ventila-
tion, move the switch to the middle position. To ad-
just the heat or ventilation, Use the rear button to
adjust seat heating or ventilation. Three settings are
available: low, medium, and high. See Fig. 7.3.
1
2
NOTICE 10 3
9 4
Do not install seat covers on seats with heating 8 5
and ventilation. Do not cover the seat with blan- 7 6
05/11/2012 f910682
kets, clothing, or pillows. Blocking the air flow
through the cushions can overheat and damage 1. Recline Handle
the seat. 2. Heat/Ventilation Adjustment Switch
3. Heat/Ventilation ON/OFF Switch
IMPORTANT: Turn off seat heating/ventilation 4. Lumbar and Side Support Switches
when the seat is unoccupied. 5. Height Adjustment Lever
6. Shock Absorber Adjustment Lever
7. Fore/Aft Isolator Lever
Lumbar Support 8. Bottom Cushion Extension Lever
Press the forward button to adjust lower lumbar sup- 9. Seat Fore/Aft Slide Lever
port, the middle button to adjust upper lumbar sup- 10. Seat Tilt Lever
port, and the rear button to adjust side support. Fig. 7.2, Cascadia 2.0 Hi-Back Seat
Height Adjustment Fore/Aft Isolator

Pull or push the lever to adjust seat height. Rotate the isolator knob to the left to lock the isola-
tor, or to the right to allow movement.
Shock Absorber Adjustment
Move the lever down to increase damping on rough
roads, or up to decrease damping on flat roads.
7.2
4 5 Lumbar Support
To adjust the lumbar support, use the lumbar support
switches on the side of the seat.
3
Height Adjustment
2
To raise or lower the height of the seat, use the
1 height adjustment switch on the side of the seat.
Bottom Cushion Extension

05/08/2012 f910683
To adjust the fore-and-aft position of the seat cush-
1. Ventilation ON ion, remove your weight from the seat, then lift up
2. Heat/Ventilation OFF and pull forward on the cushion adjustment handle.
3. Heat ON To return the cushion to the aft position, lift up and
4. Heat/Ventilation ON/OFF Switch push rearward.
5. Heat/Ventilation Adjustment Switch
Fig. 7.3, Cascadia 2.0 Hi-Back Seat Heat/Ventilation Fore/Aft Seat Slide
Controls
To adjust the fore-and-aft position of the entire seat,
Bottom Cushion Extension move the fore-and-aft seat adjustment lever to the
left and slide the seat forward or backward to the
Pull the lever to move the seat cushion forwards or desired position. Move the lever back to its original
backwards. The cushion moves 2-3/8 inches (60 position to lock the seat in place.
mm) in 3/8-inch (10-mm) increments.
Fore/Aft Isolator
Seat Fore/Aft Slide To engage the isolator, turn the isolator knob rear-
Lift the lever to slide the seat forward or backward. ward to the unlocked position. Turn the isolator knob
Release the lever to lock the seat in position. forward to the locked position when the isolator fea-
ture is not desired.
Seat Tilt
Shock Absorber
Pull the lever and lean back to tilt the seat back-
wards. Three positions are available. To adjust the amount of damping the shock absorber
provides, move the lever up to increase damping;
Armrest Angle move the lever down to decrease damping.
To adjust the armrest angle, tilt the armrest to the Front Cushion Height
highest position, then down to the lowest position,
then to the desired position. To adjust the height of the front of the cushion, re-
move your weight from the seat, then turn the adjust-
Cascadia High-Back Seat ment knob toward the front of the seat (clockwise) to
increase cushion height. To lower the cushion height,
See Fig. 7.4 for seat adjustment controls. turn the adjustment knob toward the rear of the seat
(counterclockwise).
Backrest Tilt
Rear Cushion Height
To tilt the backrest, lean forward slightly to remove
pressure from the cushion, then turn the knob for- To adjust the height of the rear of the seat cushion,
ward or rearward to achieve the desired position. remove your weight from the seat and turn the rear
cushion adjustment knob to one of three positions.
7.3
1
6
2 4 10
3 9
5 8
7
07/18/2007 f910576
1. Rear Cushion Height Adjustment 4. Bottom Cushion Extension Handle 8. Shock Absorber Lever
Knob 5. Fore/Aft Seat Slide Lever 9. Height Adjustment Switch
2. Fore/Aft Isolator 6. Backrest Tilt Knob 10 Lumbar Support Switches
3. Front Cushion Height Adjustment 7. Heater Button
Knob
Fig. 7.4, Cascadia Hi Back Seat
Heater Backrest Tilt

To turn on the heat option, press the button. To turn Pull upward on the recliner handle, move the back-
off the heat option, press the button again. If the ve- rest to the desired position and release the handle.
hicle has Optimized Idle, seat heating will not oper-
ate with the key in accessory mode. Optimized Idle Lumbar Support
may also turn seat heating off to reduce stress on
the batteries. Refer to Chapter 11 for more informa- Rear rocker switch: Push forward to inflate the lower
tion. lumbar bag; push rearward to deflate the bag. Center
rocker switch: Push forward to inflate the upper lum-
bar bag; push rearward to deflate the bag.
Sears Atlas Seat
See Fig. 7.5 for seat adjustment controls. Fore/Aft Seat Slide
To adjust the fore-and-aft position of the entire seat,
squeeze the fore/aft slide lock against the adjustment
bail, and lift the bail up. See Fig. 7.6. Slide the seat
7.4
10/15/2007 B f910599
A. Squeeze the fore-and-aft slide lock against the
adjustment bail.
B. Lift up the adjustment bail.
Fig. 7.6, Fore/Aft Slide Adjustment, Sears Atlas Seat
Armrest Angle
Rotate the control knob, located on the underside of
the armrest, to set the desired angle of the armrest.
5
Isolator
Position the handle to the left to allow isolation
movement. Position the handle to the right to lock-
4 6 out isolation movement.
3
2
1
Suspension Inflation/Deflation
Push forward on the gray rocker switch to inflate and
raise the suspension; push rearward to deflate and
7
lower the suspension.
10/15/2007 f910597 Seat Extension

1. Isolator Lever 5. Backrest Tilt Lever
2. Fore/Aft Seat Slide 6. Lumbar Support Rotate the handle upward to disengage, then move
Lever Switches the seat cushion to the desired position and release
3. Bottom Cushion Tilt 7. Suspension Inflation/ the lever. Three positions are available.
Handle Deflation Switch
4. Seat Extension Lever
Seat Belts and Tether Belts
Fig. 7.5, Sears Atlas Seat
Seat belt assemblies are designed to secure persons
forward or backward to the desired position. Release in the vehicle to help reduce the chance of injury, or
the bail and fore/aft slide lock, to its original position, the amount of injury, resulting from accidents or sud-
to lock the seat in place. den stops. For this reason, Daimler Trucks North
America LLC (DTNA) urges that the driver and all
Bottom Cushion Tilt passengers, regardless of age or physical condition,
use seat belts when riding in the vehicle.
Lift the handle upward and move the seat cushion to
the desired position. Three positions are available.
7.5
Inspect the seat belts and tether belts (if so

WARNING equipped).
Always use the vehicle’s seat belt system when 1. Check the web for fraying, cuts, extreme dirt and
operating the vehicle. Failure to do so can result dust, or for severe fading from exposure to sun-
in severe personal injury or death. light, especially near the buckle latch plate and in
the D-loop guide area.
Seat belt assemblies in DTNA vehicles meet Federal
Motor Vehicle Safety Standard 209, "Type 1" and 2. Check operation of the buckle, latch, Komfort
"Type 2" requirements. Latch or Sliding Komfort Latch (if equipped), web
retractor, and upper seat belt mount on the door
When transporting a child, always use a child re- pillar. Check all visible components for wear or
straint system or the vehicle seat belts as appropri- damage.
ate. To determine whether a child restraint system is
required, review and comply with applicable state 3. Check the seat belt and tether belt connection
and local laws. Any child restraint used must comply points and tighten any that are loose.
with Federal Motor Vehicle Safety Standard 213,
"Child Restraint Systems." When providing a child Seat Belt Operation
restraint system, always carefully read and follow all
instructions pertaining to installation and usage for WARNING
the child. Make certain the child remains in the re-
straint system at all times when the vehicle is in Wear three-point seat belts only as described
motion. below. Three-point seat belts are designed to be
In addition to seat belt assemblies, tether belts are worn by one person at a time. In case of an acci-
installed on suspension-type seats. Tether belts help dent or sudden stop, personal injury or death
secure the seat to the floor and are intended to re- could result from misuse.
strain the seat and seat belt in case of an accident or Fasten the seat belts before driving. Fastening a
sudden stop. three-point seat belt while driving creates a haz-
IMPORTANT: Seat belts have a finite life which ard.
may be much shorter than the life of the vehicle. When engaged and used properly, the Komfort Latch
Regular inspections and replacement as needed (Fig. 7.7) and the Sliding Komfort Latch (Fig. 7.8)
are the only assurance of adequate seat belt introduce a small amount of slack into the seat belt,
security over the life of the vehicle. resulting in a more comfortable ride.
1. Slowly pull the link end of the seat belt out of the
Seat Belt Inspection retractor and pull it across your lap (from out-
board to inboard) far enough to engage the
WARNING buckle. If the retractor locks too soon, allow the
belt to retract slightly, then slowly pull it out
Inspect and maintain seat belts. When any part of again. See Fig. 7.9.
a seat belt system needs replacement, the entire 2. Fasten the seat belt by pushing the latch into the
seat belt must be replaced, both retractor and buckle. Listen for an audible click.
buckle side. Any time a vehicle is involved in an
accident, and the seat belt system was in use, 3. Tug on the seat belt to make sure it is securely
the entire vehicle seat belt system must be re- fastened. If the buckle unlatches, repeat this
placed before operating the vehicle. Do not at- step. If the problem continues, replace the seat
tempt to modify the seat belt system; doing so belt.
could change the effectiveness of the system. 4. Snug the seat belt to your waist.
Failure to replace worn or damaged seat belts, or
making any modifications to the system, may re-
sult in personal injury or death.
7.6
A B
1
03/11/2010 f910620
A. Disengaged B. Engaged
2
Fig. 7.7, Komfort Latch
07/02/2007 f910578
1. Latch 2. Buckle
Fig. 7.9, Three-Point Seat Belt Operation
slack in the shoulder strap is set as described

below. Excess slack in the shoulder strap re-
duces the effectiveness of the seat belt, and in-
creases the risk of injury or death in an accident.
5. Position the shoulder strap diagonally across
your chest with the adjustable D-loop bracket (if
equipped). The shoulder strap must be centered
on your shoulder and chest, away from your face
and neck. See Fig. 7.10. If desired, engage the
Komfort Latch or Sliding Komfort Latch as fol-
11/18/2010 f910621a lows.
Fig. 7.8, Sliding Komfort Latch If equipped with a Sliding Komfort Latch, make
sure that the shoulder strap is snug against your
chest. Without loosening the shoulder strap,
WARNING push the Sliding Komfort Latch switch to the
"ON" position. See Fig. 7.8. To activate the latch
Before activating the Komfort Latch or the Slid- lean forward until you hear a click. This will allow
ing Komfort Latch, make sure the amount of
7.7
for approximately 1 inch (2.5 cm) of slack be-

tween your chest and the shoulder harness.
Once engaged, the latch will allow you to lean
forward about 5 inches (13 cm) without having to
reset the latch. Leaning forward more than 5
inches (13 cm) will disengage the Sliding Kom- A
fort Latch, requiring it to be reset.
If equipped with a Komfort Latch, pull on the
shoulder strap to lessen the pressure of the strap
on your shoulder and chest. Allow no more than
1 inch (2.5 cm) of slack between your chest and
the shoulder harness. More slack can signifi-
cantly reduce the seat belt effectiveness in an
accident or a sudden stop. While holding the belt
slack, press the Komfort Latch lever up, clamp- 01/06/95 f910048a
ing the seat belt webbing (Fig. 7.11 and A. 1 Inch (2.5 cm) Maximum
Fig. 7.12).
Fig. 7.11, Adjusting Shoulder Harness Clearance,
Komfort Latch
A B C
08/09/2010 f910634
A. Correct—Belt is centered on your shoulder and

chest, away from your face and neck.
B. Wrong—Belt must not rub against face or neck.
C. Wrong—Belt must not hang off shoulder.
Fig. 7.10, Proper Shoulder Strap Fit 11/02/95 f910144
6. Unbuckle the seat belt and release the Komfort Fig. 7.12, Locking the Komfort Latch
Latch or the Sliding Komfort Latch as follows.
If equipped with a Sliding Komfort Latch, un- itself under rough road or other abnormal condi-
buckle the seat belt, then tug on the shoulder tions. Make sure the seat belt is completely re-
belt to release the Sliding Komfort Latch, or tracted when it is not in use.
press the Sliding Komfort latch to the "OFF" po-
sition, then unbuckle the seat belt. Steering Wheel Air Bag
If equipped with a Komfort Latch, unbuckle the
seat belt, then release the Komfort Latch by giv-
Operation
ing the shoulder belt a quick tug. If you lean for- NOTE: Only vehicles with the letters "SRS"
ward against the shoulder belt, the Komfort Latch molded into the steering wheel center pad are
will automatically release, and will need to be equipped with a steering wheel air bag.
reset.
The air bag, when used with seat belts, provides ad-
NOTE: Neither the Komfort Latch nor the Sliding ditional protection to the driver in severe frontal colli-
Komfort Latch need to be manually released in sions. Steering wheel air bags are designed to inflate
an emergency situation. Each will release by only in severe frontal collisions. The driver and the
7.8
passenger should always wear seat belts. The steer- for several seconds when the ignition is turned on,
ing wheel air bag will activate during a collision even and then it goes off. The indicator will remain on if
if the seat belts are not fastened, but the system is there is a problem with the air bag system. The ve-
designed to provide protection to the occupant only hicle should be serviced if the SRS indicator does
when the seat belts are fastened. not illuminate when the ignition is turned on, or if the
SRS indicator remains on.
WARNING The air bag module may contain perchlorate mate-
rial; for information, see www.dtsc.ca.gov/
Keep all heavy objects in the cab secured. Do not hazardouswaste/perchlorate. Special handling may
place objects on the steering wheel or between apply; follow appropriate rules and regulations when
you and the steering wheel. Any such objects disposing of materials.
may cause harm during an accident. Keep your
hands on the sides and lower portion of the For all service and maintenance, contact an autho-
steering wheel. Failure to follow these instruc- rized Freightliner service facility.
tions may result in death or personal injury.
For maximum protection in a collision, always be in a
RollTek Rollover Protection
normal seated position with your back against the System
seat back and your head upright. Fasten your seat
belt and ensure that it is properly positioned on your Identification
body as described under the "Seat Belt Operation"
Only seats with the RollTek module under the seat
heading. Since the air bag inflates with considerable
and the molded side-roll air bag cover on the upper
speed and force, a proper seat position will help
side of the seat back are equipped with the RollTek
keep you a safe distance from the inflating air bag.
rollover protection system; see Fig. 7.13. RollTek
may be installed in one of the following configura-
Inspection and Service tions:
• driver seat only or driver and passenger seats
WARNING
• driver seat only, with an optional steering
Do not attempt to service or modify the air bag wheel frontal air bag
system. Unintentional or improper air bag deploy-
ment could cause severe bodily injury or death. • driver and passenger seats, with an optional
Contact an authorized Freightliner service facility steering wheel frontal air bag
for all service and maintenance.
Operation
The air bag system contains components that
use combustible chemicals. Do not cut, drill, The RollTek system, when used with seat belts, pro-
braze, solder, weld, strike, or probe the air bag vides additional protection to the driver and passen-
components. Keep all liquids and chemicals ger (if equipped with a passenger-side system) in
away from air bag components. rollover accidents. The RollTek system provides a
significant increase in seat stability during a rollover.
The surface of the deployed air bag may contain Vehicles equipped with RollTek rollover protection
small amounts of sodium hydroxide (which is a have a sensor mounted in the seat base that acti-
by-product of the gas generant combustion) and vates the side-roll air bag and seat pull-down device
metallic sodium. Sodium hydroxide may be irri- during a rollover.
tating to the skin and eyes. Immediately wash
your hands and exposed skin areas with a mild When the RollTek module senses a rollover, the
soap and water. Flush your eyes immediately if module triggers gas cylinders mounted in the base of
exposed to sodium hydroxide. the seat. The gas cylinders activate the power
cinches that then tighten the lap and shoulder belts
The operational readiness of the air bag system is against the occupant of the seat and lower the seat
indicated by the supplemental restraint system (SRS) suspension, moving the occupant down and away
indicator on the dash. The SRS indicator illuminates from the steering wheel and ceiling. The side-roll air
7.9
07/03/2007 f910579
1 A. Side-roll air bag contained in seat.
10/15/2007 f910598
B. Side-roll air bag deployed.
1. RollTek Module
2. Side-Roll Air Bag Cover Fig. 7.14, Side-Roll Air Bag
Fig. 7.13, RollTek Protection System Components or block the side-roll air bag. Objects that block
the side-roll air bag may prevent proper inflation
bag deploys from the outboard side of the seat as
and could result in serious injury or death.
the seat is pulled down to its lowest position. See
Fig. 7.14. The RollTek system will activate during a rollover
even if the seat belts are not fastened, but the
WARNING RollTek system is only designed to provide protection
to the occupant when the seat belts are fastened.
Always use the seat belts when operating the ve- For vehicles with the RollTek system(s) only, de-
hicle. Failure to do so can result in severe per- vice(s) deploy as follows:
sonal injury or death. Do not place infants and
children in seats equipped with the RollTek sys- • Rollover Crash—occupant seat belt pretension-
tem. The RollTek system is designed for adults ing, seat pretensioning, and side-roll air bag at
only. Doing so could result in severe bodily in- the proper time
jury or death. Keep all heavy objects in the cab • Frontal Crash—no devices deployed
secured. Do not place objects on the seat back
7.10
For vehicles with the RollTek system(s) and frontal

steering wheel air bag, device(s) deploy as follows:
• Rollover Crash—occupant seat belt pretension-
ing, seat pretensioning, and side-roll air bag at
the proper time
• Frontal Crash—steering wheel air bag, occu-
pant seat belt pretensioning, seat pretension-
ing, and the side-roll air bag at the proper time
Inspection and Service

WARNING
Keep hands and tools away from the scissor
points under the seats.
The RollTek system contains components that
use combustible chemicals. Do not cut, drill,
braze, solder, weld, strike, or probe any part of
the RollTek system. Keep all liquids and chemi-
cals away from the RollTek components.
Do not attempt to service or modify the RollTek
system. Unintentional or improper deployment of
the RollTek system could cause severe bodily
injury or death. Contact an authorized Freight-
liner service facility for all service and mainte-
nance.
IMPORTANT: The RollTek system must be re-
placed after being activated. Damaged seat
belts and tethers, or seat belts and tethers that
were worn in an accident, must be replaced,
and their anchoring points must be checked.
The operational readiness of the RollTek system is
indicated by the supplemental restraint system (SRS)
indicator on the dash. The SRS indicator illuminates
for several seconds when the ignition is turned on,
and then it goes off. The indicator will remain on if
there is a problem with the air bag or RollTek sys-
tem. The vehicle must be serviced if the SRS indica-
tor does not illuminate when the ignition is turned on,
or if the SRS indicator remains on.
The air bag module may contain perchlorate mate-
rial; for information, see www.dtsc.ca.gov/
hazardouswaste/perchlorate. Special handling may
apply; follow appropriate rules and regulations when
disposing of materials.
For all service and maintenance, contact an autho-
rized Freightliner service facility.
7.11
8
Climate Control
Cab Climate Control Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.1
Sleeper Climate Control Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.2
ParkSmart™ HVAC System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.3
Accessory Heaters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.5
Climate Control
Cab Climate Control Panel To operate the fan switch, turn the fan switch clock-
wise to increase airflow; turn the fan switch counter-
The standard cab climate control panel has a fan clockwise to decrease airflow.
switch with a recirculation button, temperature control There is a two-second delay between the time the
switch with an A/C button, and a mode control engine is started and the blower is operational. It can
switch. See Fig. 8.1. Sleeper cabs are also equipped take an additional four seconds for the blower to
with a bunk override button. reach high speed. The blower motor performs a self-
test immediately after the engine is started, which
causes the delay. If the vehicle has Optimized Idle,
the fan will not operate with the key in accessory
1 2 3 mode. Optimized Idle may also turn the fan off to
reduce stress on the batteries. Refer to Chapter 11
4
for more information.
2 6
0 8 Recirculation
Recirculation mode limits the amount of outside air
entering the cab. Press the recirculation button to
prevent dusty or smoky air from entering the cab.
See Fig. 8.2. Recirculation mode can also decrease
the time required to cool or heat the cab interior dur-
07/20/2006 f831701 ing extreme outside temperature conditions. When
1. Fan Switch the recirculation mode is turned on, the amber indi-
2. Temperature Control Switch cator on the recirculation button will illuminate.
3. Mode Control Switch
The recirculation button will not work when the mode
Fig. 8.1, Cab Climate Control Panel control switch is in either defog or defrost modes.
NOTE: To prevent the buildup of odors or oxy-
Fan Switch gen depletion inside the cab, the system
The fan switch activates the fan, which forces fresh switches from full recirculation mode to partial
air or recirculated air through the air outlets. The fan recirculation mode after 20 minutes. In ex-
switch has eight fan speed settings and an OFF po- tremely dusty or smoky conditions, the partial
sition. See Fig. 8.2. recirculation mode can be overridden by press-
ing the recirculation button twice to obtain full
recirculation mode. This resets the 20-minute
timer.
Temperature Control Switch

The temperature control switch is used to select the
desired temperature in the cab. Turn the switch
1 counterclockwise for cool air, or clockwise for hot air.
See Fig. 8.3.
Air Conditioning Button

The air conditioner (A/C) cools and dehumidifies the
06/08/2007 f610946
air inside the cab. Press the A/C button, located in
the center of the temperature control switch, to turn
1. Recirculation Button the air conditioner on and off. See Fig. 8.3.
Fig. 8.2, Fan Switch A/C will be automatically disabled when:
8.1
Climate Control
5
4 6
3
7
1 2 8
1 9
06/08/2007 f610947
06/08/2007 10 f610948
1. Air Conditioning Button
1. Face Mode
Fig. 8.3, Temperature Control Switch 2. Selection Between Face Mode and Bi-Level Mode
3. Bi-Level Mode
• outside air temperature is low enough to make 4. Selection Between Bi-Level Mode and Floor Mode
the A/C ineffective; 5. Floor Mode
6. Selection Between Floor Mode and Defog Mode
• engine is running at extremely low rpm; 7. Defog Mode
8. Selection Between Defog Mode and Defrost Mode
• conditions exist that result in the climate con- 9. Defrost Mode
trol system going into protection mode. 10. Bunk Override Button (on sleeper-cabs only)
Mode Control Switch Fig. 8.4, Mode Control Switch With Bunk Override
Button
The mode control switch allows the driver to control
the flow of air through the face outlets, the floor out- Press the bunk override button again to turn bunk
lets, the defrost (windshield) outlets, or a combination override mode off. Adjusting the sleeper climate con-
of these outlets. See Fig. 8.4. trols at any time will also cause the bunk override
mode to cancel.
• Face Mode: Directs all airflow through the face
or instrument panel outlets.
Sleeper Climate Control Panel
• Bi-Level Mode: Directs the airflow equally to
the face outlets and the floor outlets. The standard sleeper climate control panel has a fan
switch and a temperature control switch with an A/C
• Floor Mode: Directs all airflow through the floor button.
outlets.
If the bunk override button has been activated, the
• Floor/Defrost Mode: Directs the airflow equally override mode can be canceled by changing the
to the floor outlets and the defrost outlets. sleeper fan speed or temperature setting. The cli-
• Defrost Mode: Directs all airflow through the mate control system will then operate from the
defrost outlets. sleeper controls.
Bunk Override Button Fan Switch

The bunk override button, equipped on sleeper cabs The fan switch activates the fan, which forces air
only, allows the driver to control the sleeper heat and through the air outlets. The fan switch has eight fan
A/C settings from the cab. See Fig. 8.4. speeds and an OFF position. See Fig. 8.5.
Press the bunk override button to turn the sleeper To operate the fan switch, turn the switch clockwise
heat or A/C on. An amber indicator will illuminate to increase airflow; turn the fan switch counterclock-
when bunk override mode is activated. wise to decrease airflow. If the vehicle has Optimized
8.2
Climate Control
Idle, the fan will not operate with the key in acces- cludes vehicles equipped with Detroit Diesel Opti-
sory mode. Optimized Idle may also turn the fan off mized Idle (O/I). Both configurations are operated in
to reduce stress on the batteries. Refer to Chap- the same way, the differences are in how the batter-
ter 11 for more information. ies and charging system are configured. Refer to
"Standard Vehicle Configuration" or "Vehicles with
1 2
Detroit Diesel Optimized Idle" below for more infor-
mation on your vehicle.
Standard Vehicle Configuration

The ParkSmart™ climate control panel replaces the
standard sleeper control panel in ParkSmart-
equipped sleeper cabs. The ParkSmart HVAC sys-
tem is designed to maintain a comfortable tempera-
ture inside the sleeper, and can operate in
combination with the cab climate control system
3
06/08/2007 f610949
when the vehicle is running, or independently when
the vehicle is parked. It uses a set of four dedicated
1. Fan Switch batteries mounted aft of the starting batteries, either
2. Temperature Control Switch
3. Air Conditioning Button
between the frame rails behind the cab or outside
the frame rail.
Fig. 8.5, Sleeper Climate Control Panel The ParkSmart climate controls operate similarly to
the standard sleeper climate controls. The tempera-
NOTE: When the cab air conditioner (A/C) is on,
ture settings range from 60°F (15°C) to 85°F (29°C),
the sleeper fan will operate at low speed even if with 74°F (23°C) at the very center of the range. The
the sleeper fan switch is in the off position. This fan switch activates the fan. The fan switch has eight
is necessary to protect the evaporator in the fan speeds. Zero (0) is the OFF position. See
sleeper heater and air conditioner system from Fig. 8.6. To operate the fan switch, turn the switch
freezing. In lower fan speed settings, a slight clockwise to increase airflow; turn the fan switch
increase in airflow levels may appear at times, counterclockwise to decrease airflow.
as the control acts to regulate the evaporator
temperature. 1 2
Temperature Control Switch

ONOMY
EC
The temperature control switch is used to select the
desired temperature in the sleeper. Turn the switch
counterclockwise for cool air, or clockwise for hot air.
Air Conditioning Button

The A/C cools and dehumidifies the air inside the 3
05/24/2011 f610949c
sleeper. Press the air conditioning button, located in 1. Fan Switch 3. PARK Mode Control
the center of the temperature control switch, to turn 2. Temperature Control Button
the A/C on and off. Switch
Fig. 8.6, ParkSmart Climate Control Panel
ParkSmart™ HVAC System
There are two variations of the ParkSmart vehicle The ParkSmart HVAC system operates both when
configuration. The standard configuration is the most the engine is running and when the engine is off.
common, and includes all vehicles without Detroit When the engine is running, the air conditioning
Diesel Optimized Idle (O/I). The second variation in- (A/C) is powered by the vehicle electrical system,
while the auxiliary heater core is supplied with engine
8.3
Climate Control
coolant. While the engine is running, the ParkSmart for comfort while the vehicle is parked. Table 8.2
batteries are also being recharged by the vehicle shows the temperature knob setting for desired tem-
electrical system. peratures.
When the engine is off with the key in the ACC or To use the ParkSmart control panel, select a fan
ON positions, A/C mode is powered by the speed (other than off) and push the PARK button.
ParkSmart batteries. The cab fan will also circulate Adjust the temperature control knob to the desired
air in the cab using power from the main vehicle bat- temperature. Refer to Table 8.1 or Table 8.2, de-
teries. The available power for other vehicle-supplied pending what mode is being used.
accessories (house loads) will be affected when run- Start the fuel-operated heater once per month and
ning in this mode. If there is no Low Voltage Discon- allow it to run for 15 minutes. Periodically running the
nect (LVD) control on the main electrical system, the heater will keep fresh fuel in the lines and ensure the
ability to start the vehicle could also be compromised heater is ready to perform when needed.
if this mode is activated for an extended time period.
When the engine is off with the ignition switch in the IMPORTANT: Wait three minutes after shutting
OFF position, the ParkSmart system runs the down the ParkSmart system before turning the
battery-operated A/C or diesel-operated coolant cab load disconnect switch (CLDS) to OFF.
heater, depending on the temperature requested, NOTE: The Espar Hydronic 5 water heater can
and power is drawn from the batteries. The main bat-
use biodiesel blends up to 10% (B-10). Consult
teries and the ParkSmart batteries will both be used
until the system voltage drops to 12.5 volts, then the the engine manufacturer’s manual to confirm the
system will switch to the ParkSmart batteries only. lowest allowable blend (engine or heater) is not
The ParkSmart system will run until the dedicated being exceeded.
batteries reach 11.3 volts. IMPORTANT: The condition and charge of the
Before operating the ParkSmart system, bring the auxiliary batteries will directly affect run time of
sleeper interior temperature to the desired tempera- the ParkSmart system. If the vehicle run-time
ture with the engine running and the bunk curtain between discharges is less than eight hours, or
open. The ParkSmart system is designed to maintain if additional loads are added to the auxiliary bat-
an established comfortable bunk temperature, in teries, the ParkSmart run-time will be less than
parked mode, for up to 12 hours with the bunk cur-
expected.
tain closed. See Table 8.1 for recommended settings
Parked HVAC Comfort Guide

Weather Setting Guide
Outdoor Temperature Minimum
Rest Hours Desired Sunshine Less Than Maximum Blower
Less Than or Equal Temperature Knob
or Equal to: Speed
to: °F (°C) Setting
4 105 (40) Light Sun 8 Full Cold
95 (35) Full Sun 8 Mid
90 (32) Light Sun 8 Full Cold
6
100 (38) Night Time 8 Full Cold
110 (43) Full Sun 6 3 O’clock
75 (24) Night Time 6-8 Full Cold
8
95 (35) Light Sun 6 10 O’clock
85 (30) Light Sun 6 10 O’clock
100 (38) Light Sun 6 Mid
10
95 (35) Night Time 6 10 O’clock
105 (40) Night Time 6 Mid
8.4
Climate Control
Parked HVAC Comfort Guide

Weather Setting Guide
Outdoor Temperature Minimum
Rest Hours Desired Sunshine Less Than Maximum Blower
Less Than or Equal Temperature Knob
or Equal to: Speed
to: °F (°C) Setting
90 (32) Night Time 6 10 O’clock
12
100 (38) Night Time 6 Mid
Table 8.1, Parked HVAC Comfort Guide
Temperature Control Knob Position to Requested • The ParkSmart runs unless the ParkSmart fan
Output Temperature speed control knob is turned to the "OFF" posi-
tion. See Fig. 8.6. The fan speed control knob
Temperature Control Requested Sleeper
must be set at "1" or higher.
Knob Position (Clicks) Temperature: °F (°C)
1 60 (16) • The engine will periodically start and run for at
2 60 (16) least two hours to maintain battery voltage
3 62 (17) then shut off. The ParkSmart will continue to
4 64 (18) operate during this time.
5 66 (19) • If the O/I shuts down due to a fault in the O/I
6 68 (20) system, the ParkSmart will continue to operate
7 70 (21) until it is shut off by the driver or one of the
8 71 (22) automated failsafes.
9 72 (22) • The ParkSmart ON/OFF button and LED indi-
10 73 (23) cator on the parked HVAC control module do
11 74 (23) not function when the vehicle is in O/I mode.
12 75 (24) When the vehicle is not in O/I mode, the
13 76 (24) ParkSmart ON/OFF button and LED indicator
14 77 (25) operate normally.
15 78 (25) All other functions are the same as the standard sys-
16 79 (26) tem.
17 80 (27)
18 82 (38) Accessory Heaters
19 84 (29)
20 85 (29) Optional accessary heaters are available from the
21 Full Hot factory in several configurations. Familiarize yourself
with the equipment on your specific vehicle, and fol-
Table 8.2, Temperature Control Knob Position to low the manufacturer’s operating and maintenance
Requested Output Temperature
instructions.
Vehicles with Detroit Diesel Optimized WARNING

Idle Do not operate fuel-operated heaters in an area
If a Cascadia vehicle is equipped with Detroit Diesel where flammable vapors, including gasoline or
optimized idle (O/I), it will affect the way the diesel fumes, are present, such as at filling sta-
ParkSmart operates. When the driver initiates the tions and tank farms. Turn off a fuel-operated
O/I, the ParkSmart will operate in O/I mode as fol- heater and allow it shut down completely before
lows. entering an area where flammable gases or liq-
uids are present. Heaters continue to operate for
up to three minutes after being turned off.
8.5
Climate Control
Failure to observe these precautions could cause 6

an explosion or fire, resulting in serious property 5
damage, and personal injury or death.
NOTICE
Always ensure that air inlet and outlet grilles are
not restricted. Restriction of any air inlet or outlet
ports could result in damage to the auxiliary
heater. 4
IMPORTANT: To maintain reliable performance,
run the accessory heater for at least 15 minutes
every month to prevent fuel from degrading.
Accessory heaters function when the ignition switch
is in the off position and the cab load disconnect 3
switch is on, if equipped. 2
02/06/2012 1 f611161
IMPORTANT: Wait three minutes after shutting 1. Temperature Control Knob
down an accessory heater before turning the 2. Fan Button
cab load disconnect switch (CLDS) to OFF. 3. Fan Indicator (blue)
4. Off Button
NOTE: The low voltage disconnect (LVD) control 5. Heat Indicator (red)
prevents a heater from draining the batteries 6 Heat Button
below starting voltage.
Fig. 8.7, Espar Mini-Controller
Espar Heater will display briefly followed by the ambient tempera-
Refer to the Espar website, www.espar.com, for ad- ture, and the green indicator will illuminate. Ambient
ditional information. display temperature range is 41°F to 90°F.
To adjust the desired temperature, press the up or
Espar Mini-Controller down arrow buttons. The desired temperature will
To turn the heat on, press the heat button. See display briefly, followed by the ambient temperature.
Fig. 8.7. The red indicator will illuminate when heat The desired temperature will remain in the modulator
mode is activated. Adjust the desired temperature memory when the heater is not in operation. Tem-
with the control knob; rotate the temperature control perature adjustment range is from 41°F to 90°F.
knob clockwise for warmer air, or counterclockwise To turn heat mode off, press the heat button again.
for cooler air. To turn the heat off, press the off but- The heater will initiate a 3-minute cooling cycle.
ton.
To turn the fan on, press and hold the fan button until
To turn the fan on, press the fan button. The blue the blue indicator illuminates and the display shows
indicator will illuminate when ventilation mode is acti- active rotating digits. To turn the fan off, press the
vated. To turn the fan off, press the off button. fan button again.
Espar Digi-Controller NOTE: The Digi-Controller also has a program-
mable run timer that will automatically shut the
Vehicles built after December 8, 2011 with the Digi- heater off after the set time limit. The default
Controller and D2 air heaters are equipped with an
time limit setting is 10 hours.
internal LVD in the Digi-Controller that prevents the
heater from draining battery voltage below 12.0 volts.
To turn heat mode on, press the heat button and the
heater will begin its start-up cycle. See Fig. 8.8. ON
8.6
Climate Control
4 5 To set the desired temperature, rotate the heater

control knob clockwise for warmer air, or counter-
clockwise for cooler air.
Espar To turn the heater off, rotate the heater control coun-
6
terclockwise until it clicks and the indicator light is
extinguished. The heater will initiate a two-minute
3 cooling cycle.
7 Refer to the Webasto website, techwebasto.com,
for additional information.
2
1
02/06/2012 8 f611160
1. Ambient Temperature Sensor
2. Down Arrow Button
3. Fan Button
4. Fan Indicator (blue)
5. Heat Indicator (green)
6 Heat On/Off Button
7. Up Arrow Button
8. Ambient Temperature Display
Fig. 8.8, Espar Digi-Controller
Webasto Heater
To turn the heater on, rotate the heater control knob
clockwise until the indicator light illuminates. See
Fig. 8.9. The Webasto heater requires one to two
minutes to warm up before warm air is delivered.
1
10/24/2014 f611162
1. Off Position
2. Heater On Indicator Light
Fig. 8.9, Webasto Heater Control Knob
8.7
9
Cab Features
Windows . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.1
Mirrors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.1
Cab Amenities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.1
Sleeper Amenities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.2
Cab Features
Windows The mirror can then be adjusted by pressing the di-

rectional switch arrow for the direction the mirror
Power windows are standard on Cascadia™ vehicles. should be adjusted.
The driver’s door has two switches mounted in the The outside door mirrors can be heated to keep
top of the door, that control the driver and passenger them clear of fog, frost, and ice. To heat the mirrors,
windows separately. See Fig. 9.1. The passenger press the upper part of the mirror heat switch on the
door has a switch mounted in the top of the door that dash. See Fig. 9.2. When the mirror heat switch is
controls the passenger-side power window. on, an amber indicator light illuminates inside the
switch. If the vehicle has Optimized Idle, mirror heat-
ing will not operate with the key in accessory mode,
or if the Optimized Idle feature turns mirror heating
off to reduce stress on the batteries. Refer to Chap-
2 ter 11 for more information.
3 4
1
06/13/2007 f602318
MIRR
1. Passenger-Side Window Switch HEAT
2. Driver-Side Window Switch
3. Mirror Directional Switch
4. Left-Hand or Right-Hand Mirror Selector Switch 02/26/2007 f610904
Fig. 9.1, Door Switches (driver-side shown) Fig. 9.2, Mirror Heat Switch
WARNING Cab Amenities

There is no anti-pinch protection when the win- Cascadia vehicles are available with many optional
dow is almost closed. Be sure to clear all objects features. The following are some of those options.
from the window before closing.
Cup Holders
The window switches have three positions: lower
window, neutral, and raise window. Press forward on Two cup holders and a storage tray are molded into
the switch to lower the window. Hold the switch down the center dash. See Fig. 9.3.
in the forward position for approximately one second
to activate the express function; the window will con- Lighting
tinue to roll down after the switch is released. Press
the switch in the rearward position (bump) to raise See Chapter 5 for detailed information regarding
the window. lighting controls.
Power Outlets
Mirrors
Power outlets that supply 12V power for accessories
The standard outside mirrors are mounted on the are located on either side of the cup holders. An op-
door frame. The power mirrors are controlled with a tional ashtray/coin holder may be located in the cen-
left-hand or right-hand mirror selector switch, and a ter dash. See Fig. 9.3.
directional switch. Select the left (driver) mirror, or
the right (passenger) mirror using the selector switch.
9.1
Cab Features
IS IN MOTIO SUSP
N
AIR
LOWER
AUTO
HI
LO OVRD TC
ENG
BRK ENG
SHDN ATC
2
MIRR 4
2
1
HEAT UTLY
LAMP TRLR
AUX DOME
6
0
8
1 1
POUTL A
O
W ET
12
V−
ER
10
PO
OU WER
TL
12V− ET
1
10A
2
06/14/2007 f610950a 3 3
4
1. Power Outlets 02/25/2014 f602319a
2. Cup Holders and Storage Tray
1. Cargo Storage with Netting
Fig. 9.3, Center Dash 2. Overhead Storage Compartment
3. Storage Pocket
Radio and CB 4. Glove Box
The radio and CB are typically installed in the over- Fig. 9.4, Overhead Storage
head console. An optional hot mount may be in-
stalled on the dash for fleet CB radios. Baggage Compartment Doors
The baggage compartment doors are intended as a
Storage convenient means to stow or remove items under the
Storage compartments/grab handles are molded into bunk. The baggage compartment doors can be
the lower portion of the driver and passenger doors. opened using the pull cable located near the aft edge
of the cab door opening on the sidewall behind the
The glove box is located in front of the passenger seat. Pull the cable handle labeled BAGGAGE for-
seat. To lock the latch, insert the key in the lock, and ward to open the door.
turn it 1/2-turn clockwise. Remove the key. To unlock
the latch, insert the key in the lock, and turn it 1/2- IMPORTANT: The baggage compartment doors
turn counterclockwise. The glove box door is hinged are two-stage latching. When closing the doors,
at the bottom. To open the unlocked door, push the ensure that they are completely latched to pre-
button in with your thumb and pull gently on the vent wind noise and water intrusion.
tang-style latch. The door will swing downwards, then
stop in the open position. To close the door, swing it Lighting
upwards, and put gentle pressure on the latch. The
door will be secured, but not locked. See Chapter 5 for detailed information regarding
lighting controls.
Storage pockets are located in the overhead console,
above the driver and passenger seats. A glove box is
located in the center of the overhead console. See
Power Outlets
Fig. 9.4. Power outlets are located underneath the lower
bunk.
Sleeper Amenities
Sleeper Access Door
Cascadia sleepers are available with many optional
features. The following are some of those options. The sleeper access door is not intended for entry or
exit. The door is intended only as a convenient
NOTE: See Chapter 8 for detailed information means to stow or remove personal belongings in the
regarding sleeper climate controls. sleeper area. The sleeper access door can be
opened using two different methods. The primary
method is the pull cable located near the lower rear
edge of the cab door opening on the sidewall behind
9.2
Cab Features
the seat. Pull the cable handle labeled ACCESS for-

ward to open the sleeper door. The secondary
method is the black knob located at the upper rear
edge of the sleeper door opening. Pull the knob
down to open the sleeper door.
IMPORTANT: The sleeper access doors are
two-stage latching. When closing the doors, en-
sure that they are completely latched to prevent
wind noise and water intrusion.
Sliding Side Window

The lower section of the sliding side window moves
vertically and may be locked in multiple positions to
suit. Two spring-loaded tabs are located at the top of
the sliding section. To adjust the window, pull both
tabs toward the center of the glass and move the
sliding section to the desired height. Release the
tabs to lock the sliding section.
9.3
10
Engine Starting, Operation,
and Shutdown
Engine Starting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.1
Engine Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.2
Engine Shutdown . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.4
Engine Starting, Operation, and Shutdown
Engine Starting NOTE: Depending on local jurisdictional emis-

sions regulations, vehicles and/or engines that
This engine chapter is to serve as a guide for best are domiciled outside of the U.S. and Canada
practices only. Each engine model may have operat- may not be equipped with the WAIT TO START
ing characteristics that are unique to that particular or START BLOCKED lamp.
engine, and will be documented in the engine manu-
facturer’s literature. Always refer to specific instruc- 4. Turn the ignition switch to the ON position and
tions and recommendations from the engine manu- allow the gauge sweep to complete. See
facturer. Fig. 10.1. The audible alert will sound for ap-
proximately four seconds.
NOTE: Before starting the engine, read Chap-
ter 4, Instruments, and Chapter 5, Driver During cold conditions, the WAIT TO START
Controls. Read the engine manufacturer’s oper- lamp may illuminate. Wait until the lamp goes out
before turning the ignition key to START.
ating instructions before starting the engine.
WARNING
Never pour fuel or other flammable liquid into the
air inlet opening in the air intake in an attempt to
start the vehicle. This could result in a flash fire
causing serious personal injury or property
damage.
IMPORTANT: Cascadia vehicles are equipped
with starter interlocks to enhance reliability and
safety. Anti-grinding, starter pinion, and thermal
protection logic limit the amount of time and
conditions for starter engagement. Cranking 07/19/2006 f610805
may be limited from 5 to 15 seconds, with a 30-
Fig. 10.1, Ignition Switch
second cool-down period, as determined by the
protection logic. If the engine is turning, the NOTE: The length of time the WAIT TO START
starter will not engage. Depending on the trans- lamp remains illuminated depends on the ambi-
mission option, the starter will not engage if the ent temperature. The lower the ambient tem-
clutch is not fully depressed, or if the transmis- perature, the longer the lamp will be illuminated.
sion is not in neutral.
NOTE: If the ignition switch is turned to START
IMPORTANT: The starter can not be used for before the gauge sweep has completed or if the
priming the fuel system. If the fuel/water separa- starter has overheated, the START BLOCKED
tor filter is replaced, and the fuel system needs lamp may illuminate. Turn the ignition switch
to be primed, see the engine manufacturer’s back to ON, wait for the lamp to go out, then
operating instructions. turn the ignition switch to START again.
1. Before engine start-up, complete the pre- and 5. Once the gauge sweep has completed, turn the
post-trip inspections and maintenance proce- ignition key to the START position. Release the
dures in Chapter 21. key the moment the engine starts.
2. Set the parking brake.
3. Place the transmission in neutral. On vehicles NOTICE
with manual transmissions, fully depress the
Do not rev the engine if the oil pressure gauge
clutch pedal.
indicates no oil pressure. Shut down the engine
10.1
if oil pressure does not build within approxi-

mately ten seconds. Check to determine the
Engine Operation
cause of the problem. Operating the engine with Safety and Environmental
no oil pressure will damage the engine.
Considerations
6. It is not necessary to idle the engine before en-
gaging or starting the operation, but load should WARNING
be applied gradually during the warm-up period
until the oil temperature reaches 140°F (60°C). Do not operate the engine in an area where flam-
7. Apply load gradually during the warm-up period. mable vapors such as gasoline or diesel fumes
are present. Shut off the engine when in an area
where flammable liquids or gases are being
NOTICE handled. Failure to observe these precautions
If the oil pressure gauge indicates no oil pres- could result in serious injury or death.
sure, shut down the engine within approximately All engines on Freightliner vehicles comply with the
ten seconds to avoid engine damage. requirements of the Federal (U.S.) Clean Air Act.
Once an engine is placed in service, the responsibil-
8. Check the oil pressure gauge for any drop in lu-
ity for meeting both state and local regulations is with
bricating oil pressure or mechanical malfunction
the owner/operator.
in the lubricating oil system. Minimum oil pres-
sure at idle is 7 psi (50 kPa). IMPORTANT: Depending upon local jurisdic-
tional emissions guidelines, vehicles that are
Cold-Weather Starting domiciled outside of the U.S. and Canada may
See the engine manufacturer’s operation manual for not have engines and/or emissions aftertreat-
starting aids that are approved for specific engines. ment systems that are compliant with EPA07,
EPA10, or GHG14 regulations.
Starting After Extended Shutdown
Before engine start-up, complete the engine pretrip
NOTICE
inspections in Chapter 21. It is extremely important that the following guide-
lines be followed for engines that comply with
NOTICE EPA07 or newer regulations, or damage may
occur to the aftertreatment device, and the war-
Failure to eliminate water-diluted lubricating oil ranty may be compromised.
may lead to serious engine damage at startup.
• Use ultralow-sulfur diesel with 15 ppm sul-
An engine in storage for an extended period of time fur content or less.
(over winter, for example) may accumulate water in
the oil pan through normal condensation of moisture • Do not use fuel blended with used engine
on the internal surfaces of the engine. Oil diluted by lube oil or kerosene.
water cannot provide adequate bearing protection at • Use only engine lube oil with a sulfated ash
start-up. For this reason, change the engine oil and level less than 1.0 wt%; currently referred
filters after extended storage. to as CJ-4 oil.
Adequate maintenance of the engine and the diesel
particulate filter (DPF) are the responsibility of the
owner/operator, and are essential to keep the emis-
sion levels low. Good operating practices, regular
maintenance, and correct adjustments are factors
that will help keep emissions within the regulations.
The driver should be familiar with the vehicle warning
system in order to bring the vehicle to a safe stop if
10.2
the engine malfunctions. If the driver doesn’t under- Cold-Weather Operation

stand how the warning system works, an engine
shutdown could occur, causing a safety hazard. See Satisfactory performance of a diesel engine operating
Chapter 11 for more information. in low ambient temperatures requires modification of
the engine, surrounding equipment, operating prac-
Engine Break-In tices, and maintenance procedures. The lower the
temperature, the greater the amount of modification
Each engine must pass a full-load operating test on required. For service products approved for use in
a dynamometer before shipment, thereby eliminating cold weather for your engine, see the engine manu-
the need for a break-in. Before running the engine facturer’s engine operation manual.
for the first time, follow the instructions in the manu-
facturer’s engine operation manual. If satisfactory engine temperature is not maintained,
maintenance costs will increase due to greater en-
Normal Operation gine wear. If the engine coolant gets too cold, raw
fuel will wash the lubricating oil off the cylinder walls
and dilute the crankcase oil, causing all moving parts
WARNING of the engine to suffer from poor lubrication.
Do not operate the engine in an area where flam- If the engine is in good mechanical condition and the
mable vapors such as gasoline or diesel fumes precautions necessary for cold-weather operation are
are present. Shut off the engine when in an area taken, ordinary cold weather will not cause difficulty
where flammable liquids or gases are being in starting or loss of efficiency.
handled. Failure to observe these precautions The following points are important to observe when
could result in serious injury or death. operating in cold weather.
Every engine has an operating range in which it per- • Check for cracks in the battery cases, for cor-
forms most efficiently. The operating range extends rosion of the terminals, and for tightness of the
from maximum torque rpm at the low end, to engine cable clamps at the terminals.
rated speed at the high end. Most engines deliver
best fuel economy when operated in the low- and • Charge the batteries to full capacity. Replace
mid-speed segments of the efficiency range and pro- damaged batteries.
duce maximum horsepower at rated speed, which is • If equipped, turn off the load disconnect switch
also the recommended maximum speed of the en- after the engine is shut down to prevent battery
gine. For further engine-specific information, refer to discharge.
the engine manufacturer’s operation manual.
• Have the alternator output checked at an au-
Prolonged idling of engines is not recommended, and thorized Freightliner service provider.
is illegal in some states. Idling produces sulfuric acid
that is absorbed by the lubricating oil, and eats into • Check the condition and tension of the drive
bearings, rings, valve stems, and engine surfaces. If belts.
you must idle the engine for cab heating or cooling, • Refer to the engine manufacturer’s operation
use the high idle function of the cruise control manual for recommended heaters, low-
switches. An idle speed of 900 rpm should be viscosity lubricating oils, winter-grade fuels,
enough to provide cab heat in ambient temperatures and approved coolants.
that are above freezing.
• Periodically check the coolant mixing ratio
If the engine is programmed with an idle shutdown
(concentration of antifreeze in the coolant). Add
timer, 90 seconds before the preset shutdown time,
more if necessary.
the CHECK engine light will begin to flash at a rapid
rate. If the position of the clutch pedal or service • At outside temperatures below -4°F (-20°C), a
brake changes during this final 90 seconds the idle coolant preheater is recommended.
shutdown timer will be disabled until reset.
10.3
NOTICE Engine Shutdown

1. With the vehicle stopped, set the parking brake
For Detroit engines (EPA07 and newer), use of a and place the transmission in neutral.
winterfront is not recommended, as it can cause
false fault codes with the engine and aftertreat-
ment system, and possible emission component NOTICE
failures.
Idle the engine one to two minutes before shut-
If using a winterfront, leave at least 25% of the grille ting it down. After hard operation, shutting down
opening exposed in sectioned stripes that run per- the engine without idling may cause damage to
pendicular to the charge-air-cooler tube-flow direc- the turbocharger.
tion. This assures even cooling across each tube,
and reduces header-to-tube stress, and possible 2. Allow the engine to idle one to two minutes be-
chance of component failure. For engine-specific fore shutting it down. This allows the lubricating
guidelines, see below: oil and the coolant to carry heat away from the
combustion chambers, bearings, shafts, and
Cummins and Mercedes-Benz engines: A winterfront seals.
may be used to improve cab heating while idling, and
only when the ambient temperature remains below
10°F (-12°C). NOTICE
Detroit engines (EPA07 and newer): Use of a winter- Except in an emergency, do not shut down the
front is not recommended. Using a winterfront can engine when the coolant temperature is above
cause excessive fan run time, increased fuel con- 194°F (90°C). To do so could damage the engine.
sumption, and failure of the DEF system heaters to
operate correctly, resulting in fault codes, poor per- 3. Turn off the ignition switch and shut down the
formance, and power reduction. A winterfront should engine.
only be used temporarily in the following situations:
• To improve cab heating while idling in an ex-
tremely cold ambient temperature;
• When the ambient temperature remains below
-22°F (-30°C) and the engine is unable to
maintain a running coolant temperature of
175°F (80°C) during normal over-the-road
operation.
High-Altitude Operation
Engines lose horsepower when operated at high alti-
tude because the air is too thin to burn as much fuel
as at sea level. This loss equals about three percent
for each 1000 ft (300 m) altitude above sea level for
a naturally aspirated engine.
All engines used on Freightliner vehicles are altitude-
compensated by the use of a turbocharger. This re-
duces smoky exhaust at high altitudes, requires less
downshifting, and allows the engine to make better
use of its fuel. Nevertheless, shift gears as needed to
avoid excessive exhaust smoke.
10.4
11
Optional Engine Systems
Engine Protection—Warning and Shutdown . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11.1
Engine Idle Limiting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11.2
Power Takeoff (PTO) Governor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11.2
Optimized Idle® . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11.2
Engine Protection—Warning onds, then restart the engine. Repeat this action until
the vehicle is safely off the road.
and Shutdown
NOTE: The engine warning and shutdown sys-
tem is present on EPA07-compliant and newer
vehicles. CHECK STOP
The driver should be familiar with the vehicle warning

system in order to bring the vehicle to a safe stop if
necessary. If the driver doesn’t understand how the 1 2 3
07/09/2009 f611036
warning system works, the driver may not be able to
utilize the advantage of the advance warning system 1. Malfunction Indicator Lamp (MIL)
to pull over appropriately. 2. CHECK Engine Lamp
3. STOP Engine Lamp
The engine will begin a warning and derate and/or
shutdown process if the engine coolant temperature, Fig. 11.1, Engine Warning Lamps
coolant level, engine oil pressure, or exhaust after-
treatment system (ATS) reach preset levels. On Do not operate the vehicle further until the problem
some engines, the warning process will begin when causing the shutdown has been corrected.
the engine oil temperature, engine coolant tempera- Some vehicles may have a shutdown override
ture, or the intake air temperature reach preset lev- switch, which can be used to momentarily override
els. Detroit™ engines may also begin the warning the shutdown sequence. This switch resets the shut-
and shutdown process if water is detected in the fuel. down timer, restoring power to the level before the
See the engine manufacturer’s operation manual for derate. The switch must be pressed again after five
specific details for your vehicle. See Chapter 12 for seconds to obtain a subsequent override. See
the warning and shutdown modes associated with Fig. 11.2.
the ATS.
Electronic engine protection can be specified as ei-
ther SHUTDOWN or WARNING and DERATE.
OVRD
WARNING
When the STOP engine or CHECK engine lamp
illuminates, most engines are programmed to
shut down automatically within 30 seconds. The ENG
SHDN
driver must immediately move the vehicle to a
safe location at the side of the road to prevent
causing a hazardous situation that could cause 02/26/2007 f610900
bodily injury, property damage, or severe damage
to the engine. Fig. 11.2, Shutdown Override Switch
In SHUTDOWN mode, the red STOP engine lamp
will illuminate when the problem is serious enough to NOTICE
reduce power or speed. See Fig. 11.1. Engine power
will ramp down, then the engine will shut down if the When the derate process begins, immediately get
problem continues while in derate mode. The driver the vehicle serviced in order to prevent severe
has 30 or 60 seconds (depending on the critical fault damage to the engine.
type) after the STOP engine lamp illuminates to
move the vehicle safely off the road. If the vehicle Detroit engines may begin a warning and derate pro-
cannot be moved to a safe location within that time, cess if water is detected in the fuel, or for high en-
turn the ignition switch to OFF for at least five sec- gine coolant temperature. In WARNING and DER-
ATE mode, the CHECK engine, STOP engine, or MIL
11.1
lamp will illuminate to indicate an engine problem

that requires service and the engine controls will
Power Takeoff (PTO) Governor
begin a derate of engine output. Continuing to run
the engine while it is in derate mode could cause WARNING
severe damage to the engine.
To avoid injury, do not install a PTO that is not
Detroit Diesel approved onto a Detroit™ Trans-
Engine Idle Limiting mission. Use of a non-Detroit Diesel approved
Idle Shutdown Timer PTO with a Detroit Transmission could result in
unintended operation which could lead to severe
This feature is an optional 1- to 100-minute idle shut- personal injury.
down system. Its purpose is to conserve fuel by
eliminating excessive idling, and allowing a turbo- Engine power takeoffs (PTO) tap into engine power
charger cool-down period. Idle shutdown timing and to run auxiliary devices, such as hydraulic pumps
parameters are programmable. See the engine that power additional equipment. The following are
manufacturer’s operation manual for specific details general guidelines for operating a PTO.
for your vehicle. 1. Set the parking brake and put the transmission in
The idle shutdown system requires that the transmis- neutral.
sion be in neutral with the parking brake set. 2. Press the dash PTO switch. Release the switch
when the light begins to blink.
California Engine Idle Limiting When the light illuminates steadily, the PTO is
In order to meet the California Air Resources Board engaged and ready to operate. In stationary
(CARB) engine idle limit, vehicles are equipped with mode, the vehicle must remain in neutral with the
an engine idle shutdown feature. The automatic shut- parking brake set.
down feature is required on all California-certified 3. To activate mobile mode, shift from neutral to
engines (with the exception of engines used in spe-
reverse, 1st, or 2nd gear. The clutch will open
cific vehicle types that are exempt from the require-
and the PTO will disengage for a moment.
ment). Owners that wish to have the shutdown fea-
ture disabled on vehicles operating in California 4. Touch the accelerator pedal to close the clutch
should consult with California authorities to determine and engage the PTO in mobile mode. The PTO
if their vehicle qualifies for the exemption. may be operated with the transmission in neutral
When the CARB engine idle limiting feature is en- or reverse, and 1st and 2nd gears only.
abled, the engine will typically shut down after five NOTE: Do not attempt to change gears while
minutes of continuous idling with the transmission in the vehicle is moving. The transmission will ig-
neutral or park, and the parking brake set. It will also nore the request.
shut down after 15 minutes with the transmission in
neutral or park, and the parking brake off. See the 5. To deactivate mobile mode, bring the vehicle to a
engine manufacturer’s operation manual for specific stop. The clutch will open and shut down power
details for your vehicle. to the PTO.
Changing the position of the brake pedal, clutch 6. To resume stationary mode, shift to neutral. The
pedal, accelerator pedal, shutdown override switch, PTO will engage.
or parking brake during the final 30 seconds will
7. To deactivate PTO, press the PTO switch again.
cause the shutdown timer to reset. After an auto-
matic shutdown, the engine may be restarted and When the light in the switch goes out, power to
operated normally. the PTO is shut off.
Optimized Idle®
Optimized Idle reduces engine idle time by running
the engine only when required. Optimized Idle auto-
matically shuts down and restarts the engine as
11.2
needed to ensure engine oil temperature remains Optimized Idle operates in two modes:
within factory preset limits, the batteries stay
• Engine mode: Keeps the battery charged and
charged, and cab/sleeper temperature remains at the
engine oil temperature between 60 and 104°F
thermostat setting. The benefits of the system in-
(16 to 40°C).
clude reduced engine idle time, fuel savings, reduc-
tion of exhaust emissions and noise, increased • Thermostat mode (activated when the optional
starter and engine life, and reduced chance of dead thermostat is turned on): Keeps the cab and
batteries. sleeper at a constant preset temperature, in
addition to all functions available in engine
Vehicles equipped with Optimized Idle have a label
mode.
on the dash, and a telltale (OPT IDLE) in the ICU.
See Fig. 11.3 for the dash label detail. If equipped, a Thermostat mode controls the set point, which is the
thermostat is located above the sleeper bunk. See desired temperature of the cab and sleeper, and the
Fig. 11.4. comfort zone, which is the allowed temperature de-
viation from the set point before the engine starts.
The thermostat display defaults to show the tempera-
OPTIMIZED IDLE TM ture of the sleeper, but changes accordingly as the
buttons are pressed.
TO USE:
− IDLE ENGINE The button functions are as follows:
− CLOSE HOOD
− ENGAGE PARKING BRAKES TO AVOID • Up arrow: Increases the set point and comfort
− PUT TRANSMISSION IN UNINTENTIONAL
NEUTRAL AND VEHICLE MOVEMENT, zone (allowed temperature variation).
HI RANGE (IF EQUIPPED)
DO NOT MOVE SHIFT
− THEN, MOVE CRUISE SWITCH
FROM OFF TO ON LEVER OR RANGE • Down arrow: Decreases the set point and com-
− IF DESIRED, TURN CAB SELECTOR WHEN fort zone.
THERMOSTAT ON (IF EQUIPPED) OPTIMIZED IDLE IS ON
• Cool/Heat: Sets either cooling or heating op-
11/13/96 f080062
eration.
Fig. 11.3, Optimized Idle Dash Label • MODE: Scrolls through the various functions. It
can also be used to set desired temperature
3 4 5 values.
If a vehicle has Optimized Idle, the following func-
2 6 tions will not operate with the key in accessory
MODE mode. Optimized Idle may also turn these functions
7 off to reduce stress on the batteries.
°F
• Cab climate control fan
°C
8 • Sleeper climate control fan

1 • Mirror heat
• Fuel/water separator heat
11/08/96
10 9 f601250
• Seat heat
1. Down Arrow Button 6. MODE Button
2. Up Arrow Button 7. Cooling Icon • Advertising light
3. Upper/Lower 8. Cool/Heat Selection
Temperature Icon Button • Auxiliary circulation fan (windshield)
4. Temperature Display 9. Heating Icon • Air dryer
5. Degrees Fahrenheit 10. Degrees Celsius
Indicator Indicator 1. To activate Optimized Idle (engine mode):
Fig. 11.4, Optimized Idle Thermostat 1.1 Set the parking brake.
1.2 If it is open, close and secure the hood.
11.3
1.3 Start the engine and let it idle. to scroll up or down rapidly. When the de-
sired set point is displayed, release the
1.4 Put the transmission in neutral. button. The set point is stored in memory.
1.5 Turn on the cruise control. 2.6 Select the temperature comfort zone by
The OPT IDLE lamp will blink, indicating pressing the MODE button until the upper
that Optimized Idle is active. The system and lower temperature limit icon is dis-
is now in engine mode and after an initial played. Then use the up or down arrow to
phase, in which the idle speeds up to select one of the three comfort zones: 4°F
1000 rpm, the engine will stop and start (2°C), 7°F (4°C), or 10°F (6°C).
automatically to keep the battery charged
3. To deactivate thermostat mode and return to just
and the engine oil warm.
engine mode, press and hold the MODE button
IMPORTANT: The cruise control must be for three seconds.
turned on once the engine is idling. If it was 4. To shut down Optimized Idle completely, either
previously turned on, turn the cruise control turn off the ignition or use the drive away feature.
off, then turn it on again.
The drive away feature allows the use of all the
2. Activate thermostat mode, if equipped. engine features. Use the drive away feature as
follows:
NOTE: When the system is in thermostat
mode, it is also in engine mode. It will con- 4.1 If the engine is running: Release the park-
tinue to operate in engine mode even if ther- ing brakes or put the transmission in gear.
mostat mode is turned off. If the engine is not running: Start the en-
2.1 With the system in engine mode, set the gine. Release the parking brakes or put
cab and sleeper heater or air conditioner the transmission into gear.
controls to the highest setting. 4.2 Let the engine return to base idle. The
2.2 Turn on the thermostat by touching any of active light will turn off. Optimized Idle is
the four buttons. See Fig. 11.4. now disabled.
The display will flash the current sleeper
temperature and the previous mode (cool-
ing or heating) selected. If the cab needs
to be cooled or heated, the cool/heat icon
will flash.
2.3 Choose either cool or heat by pressing the
Cool/Heat button. Make sure the selection
matches that of the cab controls.
IMPORTANT: If the heat or cool selection of
the thermostat does not match that of the
cab controls, the system will idle and cycle
excessively.
2.4 Select Fahrenheit or Celsius by pressing
and holding the MODE button until either
the "F" or "C" is displayed.
2.5 Select the temperature set point by press-
ing the up or down arrows, as applicable.
Holding the button will cause the display
11.4
12
Emissions and Fuel Efficient
Components
Greenhouse Gas Emissions and Fuel Consumption Standards . . . . . . . . . . . . . . . . . . . . . . . . . . . 12.1
EPA-Regulated Emissions Aftertreatment Systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12.1
Diesel Exhaust Fluid and Tank, EPA10 and Newer Engines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12.3
Emissions and Fuel Efficient Components
Greenhouse Gas Emissions • Engine lube oil must have a sulfated ash
level less than 1.0 wt %; currently referred
and Fuel Consumption to as CJ-4 oil.
Standards IMPORTANT: Using non-specification fuels or
oils can lead to shortened diesel particulate filter
Vehicles and/or engines manufactured after Decem-
ber 31, 2006 and domiciled in the U.S. or Canada (DPF) cleaning or replacement intervals. For
are required to meet all EPA and NHTSA regulations example, using CJ-4+ oil with 1.3% sulfated ash
effective as of the vehicle build date. Engines manu- (30% more ash content) may result in the need
factured between January 1, 2007 and December 31, for DPF cleaning or replacement 20 to 30%
2009 meet EPA07 requirements. Engines manufac- sooner than would normally be required.
tured between January 1, 2010 and December 31,
2012 meet EPA10 requirements. Engines manufac- IMPORTANT: See the engine manufacturer’s
tured from January 1, 2013 meet NHTSA and EPA operation manual for complete details and op-
2014 fuel efficiency and greenhouse gas emission eration of the ATS.
standards (GHG14) requirements.
EPA07 Engines
Model year 2013 and later vehicles meet additional
requirements as specified by GHG14 requirements. Engines built between January 1, 2007 and Decem-
These vehicles are equipped with components that ber 31, 2009 are required to meet EPA07 guidelines
increase fuel efficiency and reduce GHG emissions. for reduced exhaust emissions of particulate matter
Components may include, but are not limited to, low- and nitrogen oxides (NOx). NOx is limited to just
rolling resistance tires; aerodynamic devices such as over 1 gram per brake horsepower hour (g/bhp-hr),
hood, cab/sleeper extenders, and fuel tank fairings; and particulate matter cannot exceed 0.01 g/bhp-hr.
vehicle speed limiter; and idle shutdown timer. If re- The EPA07 ATS varies according to engine manufac-
placement of any drag-reducing component is re- turer and vehicle configuration, but the exhaust muf-
quired, the replacement component must meet or fler is replaced by an aftertreatment device (ATD).
exceed the drag reduction performance of the origi- Inside the ATD, the exhaust first passes over the die-
nally installed component in order to maintain compli- sel oxidation catalyst (DOC), then passes through
ance with GHG14 requirements. the diesel particulate filter (DPF), which traps soot
particles. The soot is burned to ash during a process
EPA-Regulated Emissions called regeneration (regen).
Aftertreatment Systems EPA10 and Newer Engines
IMPORTANT: Depending on local jurisdictional
guidelines, vehicles that are domiciled outside of The EPA mandates that all engines built after De-
cember 31, 2009 must reduce the level of emissions
the U.S. and Canada may not have emissions
exhausted by the engine to the following levels:
aftertreatment systems (ATS) that are compliant
with EPA regulations. • Nitrogen Oxides (NOx) – 0.2 g/bhp-hr
• Particulate Matter (PM) – .01 g/bhp-hr
NOTICE To meet EPA guidelines, engines that are compliant
with EPA10 and newer regulations use an ATS that
Follow these guidelines for engines that comply
has, in addition to a DOC/DPF device like that used
with EPA07 or newer regulations, or damage may
in an EPA07 ATD, a Selective Catalytic Reduction
occur to the aftertreatment device (ATD) and the
(SCR) device to reduce NOx downstream of the en-
warranty may be compromised.
gine. After exhaust gases leave the DPF, a controlled
• Use ultralow-sulfur diesel with 15 ppm sul- quantity of diesel exhaust fluid (DEF) is injected into
fur content or less. the exhaust stream. In the presence of heat, DEF is
converted to ammonia gas, which reacts with NOx in
• Do not use fuel blended with used engine
the selective catalyst chamber to yield nitrogen and
lube oil or kerosene. water vapor, which exit through the tailpipe.
12.1
Regeneration the switch. Regen is then delayed until the switch is

no longer active.
The harder an engine works, the better it disposes of
soot. If the exhaust temperature is high enough, a NOTE: The regen switch can initiate a parked
process called passive regeneration (regen) occurs regen only when the DPF lamp is illuminated.
as the vehicle is driven normally. However, if the en-
gine isn’t running hot enough, the electronic controls
may initiate an active regen, whereby extra fuel is
injected into the exhaust stream to superheat and
reduce the soot trapped in the DPF to ash. Active
regen happens only when the vehicle is moving
above a certain speed, determined by the engine 2
1
manufacturer. See your engine operation manual for
complete details. Both active and passive regen hap-
pen automatically, without driver input. NO
RGEN
WARNING
02/08/2012 f611157
Active regeneration can occur automatically any- 1. Regen Request 2. Regen Inhibit Switch
time the vehicle is moving. The exhaust gas tem- Switch
perature could reach 1500°F (800°C), which is hot
enough to cause a fire, heat damage to objects Fig. 12.1, Regen Request and Inhibit Switches
or materials, or personal injury to persons near
the exhaust outlet. The exhaust temperature can
remain high even after the vehicle has stopped.
WARNING
When stopping the vehicle shortly after an auto-
During parked regen, exhaust temperatures are
matic regen, ensure the exhaust outlets are di-
very high and could cause a fire, heat damage to
rected away from structures, trees, vegetation,
objects or materials, or personal injury to per-
flammable materials, and anything else that may
sons near the exhaust outlet.
be damaged or injured by exposure to high heat.
Before initiating a parked regeneration, make cer-
See Regen Switches, below, for instructions on
tain the exhaust outlets are directed away from
preventing automatic regen if necessary.
structures, trees, vegetation, flammable materi-
When operating conditions do not allow for ATD filter als, and anything else that may be damaged or
cleaning by active or passive regen, the vehicle may injured by prolonged exposure to high heat.
require a driver-activated parked regen. When this
occurs, the DPF lamp illuminates, indicating that a To initiate a parked regen, perform the following
regen is required. The driver must either bring the steps.
vehicle up to highway speed to increase the load 1. Park the vehicle away from all flammable materi-
(thus starting an active regen), or park the vehicle als, put the transmission in neutral, and set the
and initiate a parked regen. See Regen Switches, parking brake.
below, for instructions on initiating a parked regen.
2. Start and warm the engine until the coolant tem-
Regen Switches perature is at least 150°F (66°C).
The regen request switch, located on the dash, is 3. Lift the regen request switch guard and press
used to initiate a parked regen. See Fig. 12.1. To and hold the yellow button for five seconds. As
access the regen request switch, lift the guard and the regen process is initiated, engine rpm in-
press the yellow button. creases and the HEST lamp illuminates to indi-
cate extremely high exhaust temperatures.
Some vehicles may be equipped with a regen inhibit
switch. See Fig. 12.1. To stop a regen in progress or IMPORTANT: The driver must remain with the
prevent the start of a regen, press the lower half of vehicle during the entire regen cycle.
12.2
4. The regen cycle will finish after 20 to 60 minutes, High Exhaust System Temperature
at which time engine idle speed drops to normal (HEST) Lamp
and the vehicle can be driven normally. The
HEST lamp is extinguished when vehicle speed Slow (10-second) flashing of the high exhaust sys-
exceeds 5 mph (8 km/h) or the system has tem temperature (HEST) lamp indicates that a
cooled to normal operating temperature. parked regen is in progress, and the engine’s high
idle speed is being controlled by the engine software,
5. To stop a parked regen at any time during the not the vehicle driver.
process:
Steady illumination of the HEST lamp alerts the
• depress the clutch pedal, brake pedal, or driver of high exhaust temperature during the regen
accelerator pedal; process if the vehicle speed is below 5 mph (8 km/
• press and hold the regen inhibit switch until h), or during a parked regen. See Fig. 12.6.
idle returns to normal;
• shut down the engine.
Maintenance
Authorized service facilities must perform any DPF
ATS Warning Lamps service. For warranty purposes, maintain a record
that includes:
There are three warning lamps that alert the driver of
high exhaust temperature, the need to perform a • date of cleaning or replacement;
parked regen or service the DPF, or of an engine • vehicle mileage;
fault that affects emissions. A decal attached to the
driver’s sun visor explains the ATS warning lamps. • particulate filter part number and serial number.
Fig. 12.2.
See Fig. 12.3 for an explanation of the ATS warn- Diesel Exhaust Fluid and Tank,
ings, and actions required to avoid engine protection
sequences.
EPA10 and Newer Engines
Diesel Exhaust Fluid
Malfunction Indicator Lamp (MIL)
Diesel exhaust fluid (DEF) is used in the ATS to
A steadily illuminated yellow malfunction indicator lower NOx in the exhaust stream. DEF is colorless
lamp (MIL) indicates an engine fault that affects and close to odorless (it may have a slightly pungent
emissions. See Fig. 12.4. odor similar to ammonia). It is nontoxic, nonflam-
mable, and biodegradable. It is mildly corrosive to
DPF Status Lamp aluminum, but does not affect the strength or struc-
When soot accumulates in the DPF and the DPF sta- ture of the aluminum.
tus lamp illuminates, see Fig. 12.5, perform a parked White crystals may be noticeable around compo-
regen or bring the vehicle up to highway speed to nents that come into contact with DEF. The crystals
increase the load (thus starting an active regen). are easily removed with water.
If the DPF status lamp blinks while the CHECK en- DEF consumption varies depending on ambient con-
gine lamp is illuminated, initiate a parked regen im- ditions and vehicle application.
mediately in order to prevent an engine derate.
If the red STOP engine lamp illuminates with the
Freezing Conditions
blinking DPF lamp and the CHECK engine lamp, DEF freezes to slush at around 12°F (-11°C). It is not
begin a parked regen in order to prevent an engine damaged or destroyed if frozen, and is fully usable
shutdown. Park the vehicle and perform a parked when thawed. The DEF in the tank is allowed to
regen. freeze while a vehicle is non-operational. At start-up,
normal operation of the vehicle is not inhibited if the
DEF is frozen; an immersion heater with engine cool-
ant flowing through it warms the DEF once the en-
gine is running, allowing the SCR system to operate.
12.3
IMPORTANT
DPF Regen Needed Diesel Particulate Filter (DPF)
1
regeneration is needed.
If flashing, regenerate as soon as
possible. Engine derate possible.
2
Hot Exhaust Hot exhaust can cause fire.
Keep flammables and people away
from exhaust.
3
DEF Refill Needed Diesel Exhaust Fluid (DEF) level is
low. Engine derate likely.
DEF
Refill tank with certified DEF.
See operator’s manual for complete instructions. 24−01656−000
11/30/2010 f080161
Fig. 12.2, Warning Lamp Decal, Sun Visor
Pre-2013 DEF supply lines are electrically-heated Fuel/DEF Gauge

and are purged when the engine is shut down; com-
plete purging of the DEF lines requires approximately The diesel fuel and DEF levels are measured in a
five minutes after the engine is shut down. dual-purpose gauge. See Fig. 12.9.
DEF supply lines with engine model year 2013 and Fuel level is indicated at the top of the gauge. Below
newer are designed to survive freezing conditions the fuel level, a low fuel warning lamp illuminates
while containing DEF, so purging is not required. amber when the fuel level drops below 1/8th of the
capacity.
DEF Tank The lower portion of the gauge has a DEF warning
Engines that are compliant with EPA10 and newer lamp that illuminates amber when the DEF tank is
regulations are equipped with a DEF tank located on near empty, and a lightbar that indicates the level of
the driver’s side of the vehicle behind the battery box DEF in the tank. The DEF light bar illuminates as fol-
or forward of the fuel tank. See Fig. 12.7 and lows.
Fig. 12.8. The DEF tank has a 19 mm filler neck inlet • Four bars illuminated green—Between 75%
that prevents the hose from a diesel outlet from and 100% full
being inserted, and has a blue cap for easy
identification. • Three bars illuminated green—Between 50%
and 75% full
• Two bars illuminated green—Between 25%
and 50% full
12.4

INDICATOR WARNING
CHECK CHECK STOP
LAMP(S)
(Solid) (Flashing) (Flashing) (Flashing)
Indicator Lamp Filter Regeneration Filter Regeneration Parked Regeneration Parked Regeneration Required − HEST (High Exhaust
Message(s) Recommended Necessary Required − Engine Engine Shut Down System Temperature)
Derate
Diesel Particulate Filter is reaching Filter is now Filter has reached Filter has exceeded Flashing
Filter Condition capacity. reaching maximum maximum capacity. maximum capacity. A regeneration is in
Switch.
capacity. progress.
Required Action Bring vehicle to To avoid engine Vehicle must be Vehicle must be parked and a
highway speeds to derate bring vehicle parked and a Parked Parked Regeneration or Service Solid
allow for an Automatic to highway speeds Regeneration must Regeneration must be performed. Exhaust Components
Regeneration or to allow for an be performed − Check engine operator’s manual and exhaust gas are
perform a Parked Automatic engine will begin for details −engine will shut down. at high temperature.
Regeneration. Regeneration or derate. When stationary, keep
perform a Parked away from people and
Regeneration as flammable materials
soon as possible. or vapors.
See Engine Operator’s Manual for complete Regeneration Instructions.

24−01583−000B
06/29/2009 f080147
Fig. 12.3, ATS Warning Lamps
09/25/2006 f610814a 09/25/2006 f610815a
Fig. 12.4, Malfunction Indicator Lamp (MIL) Fig. 12.5, DPF Status Lamp
• One bar illuminated green—Between approxi- DEF Level Low—Initial Warning

mately 10% and 25% full
When the DEF level is low, the following lamps notify
• One bar illuminated amber—DEF very low, re- the driver. See Fig. 12.10. Refill the DEF tank in
fill DEF order to cancel the warning sequence.
• One bar flashing red—DEF empty, refill DEF • One bar of the DEF level indicator illuminates
amber—DEF very low, refill DEF.
DEF Warnings and Engine Limits • The DEF warning lamp illuminates solid amber.
IMPORTANT: Ignoring the DEF warning lights
results in limited engine power, with the applica-
tion of a 5 mph (8 km/h) speed limit.
12.5
09/25/2006 f610816a
Fig. 12.6, HEST Lamp

1
2
07/24/2009 f470541
1. DEF Tank 2. Fuel Tank
Fig. 12.8, DEF Tank Located Forward of the Fuel Tank
DEF Tank Empty and Ignored

If the empty warning is ignored and the DEF tank is
not refilled, the red STOP engine lamp illuminates in
addition to the MIL lamp and CHECK engine lamp
(on vehicles with a Cummins ISB or ISC/L engine.)
See Fig. 12.12.
1 If the DEF is not refilled, a 5 mph (8 km/h) speed
limit is applied after the next engine shutdown, while
2 parked and idling, or if a fuel refill is detected.
07/24/2009 f470542
1. Batteries 2. DEF Tank DEF Contamination or SCR Tampering
Fig. 12.7, DEF Tank Located Behind the Battery Box
NOTICE
DEF Empty
Once contaminated DEF or tampering has been
When the DEF level reads empty, the following detected, the vehicle must be taken to an autho-
lamps notify the driver. See Fig. 12.11. rized service facility to check the SCR system for
• One bar of the DEF level indicator flashes damage and to deactivate the warning lights and
red—DEF empty, refill DEF. engine limits.
• The DEF warning lamp flashes amber. If contaminated DEF or tampering with the ATS is
detected, the DEF warning light flashes and the MIL
• The MIL lamp illuminates. lamp illuminates to warn the driver. The CHECK en-
Pre-2013 Detroit engines: Power is limited, with a 55 gine lamp also illuminates on vehicles with a Cum-
mph (90 km/h) speed limit. mins ISB or ISC/L engine. See Fig. 12.12.
Cummins and 2013 Detroit engines: Power is limited • Detroit engines: Engine power is limited with
with progressively harsher engine power limits progressively harsher limits applied. If the fault
applied.
12.6
1/2 1/2 1/2

ULTRA LOW SULFUR ULTRA LOW SULFUR ULTRA LOW SULFUR
DIESEL FUEL ONLY DIESEL FUEL ONLY DIESEL FUEL ONLY
E F E F E F
DEF DEF DEF
1 E F E F E F
2
A B C
11/08/2010 f611037
A. Green bars—DEF level indicators C. One bar flashing red—DEF empty, refill DEF
B. One bar illuminated amber—DEF very low, refill DEF
1. Low Fuel Warning Lamp 2. DEF Warning Lamp
Fig. 12.9, Fuel/DEF Gauge
A A
B B
07/09/2009 f470537 11/08/2010 f470539a

A. DEF Warning Lamp (illuminated) NOTE: MIL illuminates. CHECK engine lamp illuminates
B. DEF Lightbar (one bar amber) if Cummins ISB or ISC/L engine. Engine power is lim-
ited.
Fig. 12.10, DEF Level Low Initial Warning A. DEF Warning Lamp (flashing)
B. DEF Lightbar (one bar flashing red)
is not corrected, the STOP engine light illumi-
nates and a 5 mph (8 km/h) speed limit is ap- Fig. 12.11, DEF Empty Warning
plied after the next engine shutdown, while
parked and idling, or if a fuel refill is detected.
• Cummins engines: Engine power is limited with
progressively harsher limits applied. If the fault
is not corrected, the STOP engine light illumi-
nates and a 5 mph (8 km/h) speed limit is ap-
plied after the next engine shutdown, or while
parked and idling.
12.7
11/08/2010 f470540a
NOTE: STOP engine light and MIL illuminate, engine
power is limited, speed limit of 5 mph (8 km/h)
A. DEF Warning Lamp (flashing)
B. DEF Lightbar (one bar flashing red)
Fig. 12.12, DEF Empty and Ignored Warning
12.8
13
Brake Systems
Air Brake System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13.1
Meritor WABCO® Antilock Braking System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13.3
Engine Brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13.5
Brake Systems
Air Brake System releasing the spring parking brakes, make the
connection to a towing vehicle or chock the tires.
Brake System General Information After correcting the brake system problem, uncage
A dual air brake system consists of two independent the spring parking brakes before resuming normal
air systems that use a single set of brake controls. vehicle operation.
Each system has its own reservoirs, plumbing, and
brake chambers. The primary system operates the Primary Air Brake System
service brakes on the rear axle; the secondary sys- Loss of air pressure in the primary air system causes
tem operates the service brakes on the front axle. the rear service brakes to become inoperative. The
Service brake signals from both systems are sent to secondary air system will continue to operate the
the trailer. front brakes and the trailer brakes (if equipped).
WARNING Secondary Air System

Loss of air pressure in the secondary air system
Do not operate the vehicle with the front brakes causes the front axle brakes to become inoperative.
backed off or disconnected. Backing off or dis- The primary air system will continue to operate the
connecting the front brakes will not improve ve- rear service brakes and the trailer brakes (if
hicle handling and may lead to loss of vehicle equipped).
control, resulting in property damage or personal
injury.
Brake System Operation
Brake System Components Before driving your vehicle, allow time for the air
compressor to build up a minimum of 100 psi (689
The warning light and buzzer come on if air pressure kPa) pressure in both the primary and secondary
drops below approximately 70 psi (483 kPa) in either systems. Monitor the air pressure system by observ-
system. If this happens, check the air pressure ing the air pressure gauges and the low-air-pressure
gauges to determine which system has low air pres- warning light and buzzer. The warning light and
sure. Although the vehicle’s speed can be reduced buzzer shut off when air pressure in both systems
using the foot brake control pedal, either the front or reaches approximately 70 psi (483 kPa).
rear service brakes will not be operating at full ca-
pacity, causing a longer stopping distance. Bring the IMPORTANT: Before driving the vehicle, secure all
vehicle to a safe stop and have the air system re- loose items in the cab so that they will not fly forward
paired before continuing. during a full brake application. Make sure all passen-
gers are wearing seat belts.
IMPORTANT: In the event of a total loss of ser-
vice brakes with full system air pressure, use During normal brake stops, depress the foot brake
the parking brake control valve (yellow knob) to control pedal until braking action slows down the ve-
hicle. Increase or decrease the pressure on the
bring the vehicle to a complete stop in the saf- pedal so that the vehicle comes to a smooth, safe
est location possible. stop. Apply the spring parking brakes if the vehicle is
Before a vehicle with insufficient system air pressure to be parked.
can be moved, the spring parking brakes must be
IMPORTANT: An air brake proportioning system
released by applying an external air source at the
gladhands, or by manually caging the parking brake may be used in tractor air brake systems when
springs. the vehicle is not equipped with antilock braking
system (ABS). When operating in bobtail mode,
the rear brake chambers (on which the axle
WARNING load has been greatly reduced) receive reduced
Do not release the spring parking brakes and (proportional) air pressure, while the front axle
then drive the vehicle. There would be no means brake chambers receive full (normal) air pres-
of stopping the vehicle, which could result in se- sure. This results in a different brake pedal
rious personal injury or vehicle damage. Before "feel," as the pedal seems to require more travel
13.1
Brake Systems
and/or effort to slow or stop the vehicle. How-

ever, the air brake proportioning system actually
improves vehicle control when the tractor is in
bobtail mode. When the tractor is towing a
trailer, the rear brake chambers will receive full
(normal) application air pressure.
When parking a vehicle attached to a trailer that
does not have spring parking brakes, apply the trac-
tor parking brakes. Chock the trailer tires before dis-
connecting the vehicle from the trailer.
WARNING
10/17/2001 f610591
If a trailer or combination vehicle is not equipped
Fig. 13.1, Trailer Brake Lever
with spring parking brakes, do not park it by pull-
ing out only the trailer air supply valve knob. The red octagonal-shaped knob in the control panel
This would apply only the trailer service brakes. actuates the trailer air supply valve. See Fig. 13.2.
If air were to bleed from the trailer brake system, After the vehicle’s air hoses are connected to a
the trailer brakes would release, possibly causing trailer and the pressure in both air systems is at least
an unattended runaway vehicle. 65 psi (448 kPa), the trailer air supply valve must be
pushed in. It should stay in to charge the trailer air
NOTICE supply system and to release the trailer spring park-
ing brakes.
Never apply the service and spring parking
brakes simultaneously. To do so transmits exces- Pull the trailer air supply valve out before disconnect-
sive input force to the brake components, which ing a trailer or when operating a vehicle without a
could damage or cause eventual failure of brake trailer. If pressure in both air systems drops to 35 to
actuating components. 45 psi (242 to 310 kPa), the trailer air supply valve
automatically pops out, exhausting the trailer air sup-
Brake Controls ply, and applying the trailer service or spring parking
brakes.
The trailer brake lever (hand control valve) is used
for applying the trailer brakes without applying the
truck or tractor service brakes. It is usually mounted 1
on the right-hand control panel. See Fig. 13.1. The 2
valve can be partially or fully applied, but in any par-
tially on position it will be overridden by a full applica-
tion of the service brake pedal. Moving the lever
down applies the trailer brakes, while moving it up
releases the trailer brakes. The lever will automati-
cally return to the up position when it is released.
03/10/99 f610291
WARNING 1. Trailer Air-Supply-Valve Knob
2. Parking-Brake-Valve Knob
Do not use the trailer service brakes for parking;
they are not designed for this purpose. If air Fig. 13.2, Brake Valve Knobs
bleeds out of the trailer air tank during parking,
The yellow diamond-shaped knob in the control
the vehicle could roll, causing serious personal
panel actuates the parking brake valve. See
injury or property damage. Fig. 13.2. Pulling out the parking brake valve applies
both the tractor and trailer spring parking brakes and
13.2
Brake Systems
automatically causes the trailer air supply valve to ponents. Improperly maintaining the vehicle brak-
pop out. ing system may lead to brake failure, resulting in
property damage, personal injury, or death.
NOTICE
Meritor WABCO® Antilock
Do not use the spring parking brakes if the ser-
vice brakes are hot, such as after descending a Braking System
steep grade. To do so could damage the brakes. The Meritor WABCO Antilock Braking System (ABS)
Allow hot brakes to cool before using the spring is an electronic wheel speed monitoring and control
parking brakes. system that works with the standard air brake sys-
Do not use the spring parking brakes during tem. ABS passively monitors vehicle wheel speed at
freezing temperatures if the service brakes are all times, and controls wheel speed during emer-
wet. To do so could cause them to freeze. If the gency stops.
brakes are wet, drive the vehicle in low gear and IMPORTANT: For proper ABS system operation,
lightly apply the brakes to heat and dry them.
do not change tire sizes. The sizes of the tires
If the trailer is not equipped with spring parking installed during production are programmed into
brakes, pulling out the parking brake valve applies the electronic control unit. Installing different-
the tractor spring parking brakes and the trailer ser- sized tires could result in a reduced braking
vice brakes. When the tractor and trailer parking force, leading to longer stopping distances.
brakes (or trailer service brakes) are both applied,
the trailer brakes are released by pushing in the ABS includes signal-generating tone wheels and sen-
trailer air supply valve, leaving the tractor parking sors located in the wheel hubs of each sensed
brakes applied. Air pressure in the primary or sec- wheel. The sensors transmit vehicle wheel speed
ondary reservoir must be at least 65 psi (447 kPa) information to an electronic control unit (located be-
before the tractor spring parking brakes, or the trailer hind the center dash). The control unit’s main circuit
service or spring parking brakes, can be released. interprets the speed sensor signals and calculates
wheel speed, wheel retardation, and a vehicle refer-
Automatic Slack Adjusters ence speed. If the calculations indicate wheel lockup,
the main circuit signals the appropriate modulator
Automatic slack adjusters should never be manually valve to reduce braking pressure. During emergency
adjusted except during routine maintenance of the braking, the modulator valve alternately reduces, in-
foundation brakes (e.g., replacing shoes), during creases, or maintains air pressure supply in the
slack adjuster installation, or in an emergency situa- brake chamber to prevent front and rear wheel
tion. lockup.
When the brake pushrod stroke exceeds the legal The electronic control unit (ECU) also has a safety
brake adjustment limit on a vehicle, there is likely a circuit that constantly monitors the wheel sensors,
mechanical problem with the foundation brake com- traction control valve (if equipped), modulator valves,
ponents or the adjuster is improperly installed. and the electrical circuitry.
Visit a repair facility as soon as possible when The Meritor WABCO ABS combines one front-axle
brakes equipped with automatic slack adjusters are control channel with one rear-axle control channel to
determined to be out of adjustment. form one control circuit. For example, the sensor and
modulator valve on the left-front axle form a control
WARNING circuit with the sensor and modulator valve on the
right-rear axle. If, during vehicle operation, the safety
Manually adjusting an automatic slack adjuster to circuit senses a failure in any part of the ABS, the
bring the pushrod stroke within legal limits is tractor warning lamp (TRACTOR ABS) illuminates
likely masking a mechanical problem. Adjustment and the control circuit where the failure occurred is
is not a repair. Before adjusting an automatic switched to normal braking action. The remaining
slack adjuster, troubleshoot the foundation brake control circuit will retain the ABS effect. Even if the
system and inspect it for worn or damaged com- ABS is completely inoperative, normal braking ability
13.3
Brake Systems
is maintained. An exception would be if a modulator ing reduced-traction situations. In normal braking ap-
valve (or combination modulator valve) is damaged plications, the standard air brake system is in effect.
and inoperative. As these components are an integral An additional solenoid valve is installed. During
part of the air brake system, normal braking may be reduced-traction situations, the ATC solenoid valve
impaired or inoperative. controls air pressure to the modulator valves and
During emergency or reduced-traction stops, fully they in turn increase, hold, or reduce pressure to the
depress the brake pedal until the vehicle comes to a appropriate brake chambers to provide better traction
safe stop. Do not pump the brake pedal. With the whenever wheel spin occurs.
brake pedal fully depressed, the ABS will control all When the ATC system is in the NORMAL mode, it
wheels to provide steering control and a reduced will apply gentle braking to the spinning wheel, to
braking distance. feed power to the wheel(s) with better traction. If
Although the ABS improves vehicle control during both wheels are spinning, the system will signal the
emergency braking situations, the driver still has the engine to reduce power.
responsibility to change driving styles depending on ATC includes a deep snow and mud option to in-
existing traffic and road conditions. For example, the crease available traction on extra soft surfaces like
ABS cannot prevent an accident if the driver is snow, mud, or gravel. A rocker switch labeled ATC
speeding or following too closely. will be located on the dash. Pressing the switch will
temporarily allow more drive wheel spin. The activa-
Trailer ABS Compatibility tion of the deep snow and mud option is indicated by
a flashing WHEEL SPIN lamp. Pressing the switch
The Meritor WABCO ABS is designed to communi-
again will cycle the system back to normal operation.
cate with a trailer ABS, if they are compatible. Com-
patibility will result in the illumination of the TRAILER
ABS lamp during vehicle start-up and fault detection. NOTICE
The TRAILER ABS lamp will not illuminate unless a The deep snow and mud option is intended to be
compatible trailer is connected to the tractor. The used under specific slippery conditions that re-
dash-mounted lamp will operate as follows when a quire momentary increased wheel spin. Using
compatible trailer is properly connected to the tractor: this option for an extended period of time may
• When the ignition key is turned to the ON posi- damage the vehicle brake system.
tion, the TRAILER ABS lamp will illuminate mo- After the ignition switch is turned on, the TRACTOR
mentarily, then turn off. ABS lamp and the WHEEL SPIN indicator lamp
• If the lamp illuminates momentarily during ve- come on for about three seconds. After three sec-
hicle operation, then shuts off, a fault was de- onds, the warning lights go out if all of the tractor’s
tected and corrected. ABS components are working.
• If the lamp illuminates and stays on during ve- IMPORTANT: If any of the ABS warning lights
hicle operation, there is a fault with the trailer do not work as described above, or come on
ABS. Repair the trailer ABS system immedi- while driving, repair the ABS immediately to en-
ately to ensure full antilock braking capability. sure full antilock braking capability.
IMPORTANT: If a compatible trailer is con-
nected, and the lamp is not illuminating momen- ECAS Automatic Load Transfer
tarily when the ignition key is turned to the ON (ECAS only)
position, it is possible that the lamp is burnt out. On those vehicles equipped with Electronically Con-
trolled Air Suspension (ECAS), ECAS works in con-
Automatic Traction Control junction with ABS. When wheel slippage is detected
Vehicles with electronic engines and ABS may have by the ABS, the ECAS system transfers weight from
Automatic Traction Control (ATC). On these vehicles, the tag axle to the drive axle by changing air pres-
the ATC system automatically limits wheel spin dur- sures in the suspension air bellows, increasing drive
wheel traction.
13.4
Brake Systems
Engine Brake WARNING

Each engine manufacturer uses a specific engine
brake for their engine. Regardless of the manufac- The engine brake must be disengaged when
turer, the engine brake is operated with the principles shifting gears using the clutch pedal. If the en-
outlined in here. Refer to the engine manufacturer’s gine brake is engaged when the transmission is
operation manual for details of their particular engine in neutral, the braking power of the engine brake
brake product. can stall the engine, which could result in loss of
vehicle control, possibly causing personal injury
and property damage.
WARNING
"Control speed" is the speed at which the engine
To avoid injury from loss of vehicle control, do brake performs 100 percent of the required downhill
not activate the engine brake system under the braking, resulting in a constant speed of descent.
following conditions: The control speed varies, depending on vehicle
weight and the downhill grade.
• on wet or slippery pavement, unless the
vehicle is equipped with antilock braking For faster descent, select a higher gear than that
system (ABS) and you have had prior expe- used for control speed. Service brakes must then be
rience driving under these conditions; used intermittently to prevent engine overspeed and
to maintain desired vehicle speed.
• when driving without a trailer or pulling an
empty trailer; For slower descent, select a lower gear, being care-
ful not to overspeed the engine. Occasional deactiva-
• if the tractor drive wheels begin to lock, or tion of the engine brake may be necessary to main-
there is fishtail motion after the engine tain the designated road speed under these
brake is activated. conditions.
NOTE: When the engine brake is enabled, the If the engine is equipped with both cruise control and
engine brake lamp illuminates in the ICU. See an engine brake, the engine brake can operate auto-
Fig. 13.3, Item 1. matically while cruise control is activated. The maxi-
Whenever vehicle braking is required on good road mum amount of braking is selected with the engine
conditions, the engine brake may be used in con- brake control. When the vehicle returns to the set
junction with the service brakes. There is no time cruise speed, the engine brake will turn off.
limit for operation of the engine brake. However, an The engine brake will only operate when the accel-
engine brake does not provide the precise control of, erator and clutch pedals are fully released.
and is not a substitute for, service brakes.
Vehicles equipped with ABS have the ability to turn
the engine brake off if wheel slip is detected. The
WARNING engine brake will automatically turn back on once
wheel slip is no longer detected.
Usage of the engine brake as the primary braking
system can cause unpredictable stopping dis- Engine Brake Operation
tances, that could result in personal injury or
property damage. Service brakes are the primary
vehicle braking system. NOTICE
Since the engine brake is most effective at rated en- Do not allow the engine to exceed its governed
gine speed, gear selection is very important. Gearing speed, or serious engine damage could result.
down the vehicle within the limits of the rated engine
speed makes the engine brake more effective. Rec- NOTE: Depending on the brake type, the engine
ommended engine braking speed is above 1800 rpm brake may be disabled when engine tempera-
and below the rated speed. ture falls below a set level.
13.5
Brake Systems
1 2 3 4 5
6 7 8 9 10 11
IDLE
OPT 2 OPT 4 OPT 5 OPT 6 MGMT OPT 9
CHECK STOP ABS ABS
BRAKE
12 13 14 15 16 17
18 19 20 21 22 23 24 25
05/07/2012 f611094
1. Engine Brake 11. Trailer ABS 18. Left-Turn Signal
2. Optional 12. Low Engine Oil Pressure 19. Low Battery Voltage
3. Wait To Start 13. High Coolant Temperature 20. Water In Fuel
4. Check Transmission 14. Unfastened Seat Belt 21. Driver Message Center
5. Optimized Idle 15. Park Brake On 22. High Beams On
6. CHECK Engine 16. Diesel Particulate Filter (DPF) 23. Brake Air
7. STOP Engine Status 24. Cruise Control On
8. Malfunction Indicator Lamp (MIL) 17. High Exhaust Temperature 25. Right-Turn Signal
9. Vehicle ABS (HEST)
10. Transmission Overheat
Fig. 13.3, ICU3 Message Center (typical)
The engine brake control depends on vehicle con- Mode. Setting the cruise control while the en-
figuration. On some vehicles, there is an engine gine brake is on activates Descent Control
brake (ENG BRK) switch located in the right-hand Mode. For information on these modes, see
pod on the steering wheel that is used to turn the "Cruise Control" in Chapter 5.
engine brake on and off, and an engine brake level
switch on the dash used to set the intensity—high, On vehicles equipped with an engine brake switch in
medium, or low. See Fig. 13.4 and Fig. 13.5. the right-hand pod on the steering wheel, operate the
engine brake after the engine is warmed up and the
On vehicles equipped with a column-mounted Detroit vehicle is in motion, as follows:
multifunction control, the engine brake is controlled
by the lever position, as shown in Fig. 13.6. At the 1. Remove feet from both the clutch and accelera-
top position, the engine brake is off, and at the three tor pedals.
lower positions, the engine brake is on and the inten- 2. Press the upper half of the on/off switch (see
sity (low, medium, high) increases with each step Fig. 13.4) to turn the engine brake on. The en-
down. gine brake will engage at the rate last set on the
NOTE: On vehicles equipped with a Detroit mul- engine brake intensity switch and the engine
tifunction control, setting the engine brake with brake lamp will illuminate.
the cruise control set activates Deceleration
13.6
Brake Systems
3. Press the upper or lower half of the intensity

switch (see Fig. 13.5) to select the desired brak-
ing intensity. HI
Use the intensity switch set at the LOW position
LO
when driving on flat, open stretches of road. If
the service brakes are still required to slow down
on a grade, switch to a higher setting on the
dash switch to maintain constant speed of de-
scent. Grade descent speed should be such that ENG
the service brakes are used infrequently and re- BRK
main cool, thus retaining their effectiveness.
4. For maximum retarding, maintain the top gov- 05/02/2007 f610905
erned speed of the engine through the appropri-
ate selection of gears. When shifting gears, the Fig. 13.5, Engine Brake Level Switch
engine brake will disengage when the clutch
pedal is depressed, then engage when the clutch
pedal is released.
0
5. To cancel the engine brake application, press the
lower half of the on/off switch.
1
ON/
OFF +
ACC/ MRKR
2
INT
RES
CNCL
−
DEC/ ENG
SET BRK
02/19/2013 f270164a
0. Off 2. Medium
1. Low 3. High
Fig. 13.6, Engine Brake Positions, Detroit Multifunction
Control
06/15/2007 f462049a
Fig. 13.4, Steering Wheel Switches
13.7
14
Manual Transmissions and
Hydraulic Clutch
Eaton Fuller 13-Speed and 18-Speed Splitter and Range-Shift Transmissions . . . . . . . . . . . . . . . 14.1
Eaton Fuller 10-Speed Range-Shift Transmissions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14.4
Clutch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14.5
Manual Transmissions and Hydraulic Clutch
Eaton Fuller 13-Speed and 18- lection lever controls range selection and the splitter
control button (located on the side of the shift knob)
Speed Splitter and Range-Shift controls gear splits.
Transmissions Low gear in the front section is used only as a start-
ing ratio. The remaining four forward positions are
Refer to the Eaton website for additional information, used once in the low range and once in the high
www.roadranger.com. range. However, each of the four high range gear
positions can be split with the underdrive ratio (RT
General Information, Eaton Fuller models), or overdrive ratio (RTO models) of the split-
Splitter and Range-Shift ter gear. Ratios cannot be split while the transmis-
sion is in low range.
Combination splitter and range-shift transmissions
allow the choice of two splitter ratios in each lever 18-Speed RTLO Splitter and Range-Shift
position as well as the additional ratio provided in Models
each lever position after shifting to the other range.
Eaton Fuller 18-speed transmissions have 18 forward
IMPORTANT: Not all lever positions are used in speeds and four reverse speeds. These transmis-
each range and the shift patterns vary between sions consisting of a 5-speed front section and a
transmissions. Be sure to read the shift pattern 3-speed auxiliary section. The auxiliary section con-
decal on the dash for the operating instructions tains low and high range ratios, plus an overdrive
for the specific transmission installed in your ve- splitter gear.
hicle.
One ratio in the front section (low) is used as a start-
ing ratio; it is never used when the transmission is in
13-Speed RTLO Models high range. Low gear can be split to provide both a
Eaton Fuller 13-speed transmissions have thirteen direct and an overdrive ratio.
forward speeds and two reverse speeds. Each trans-
The other four ratios in the front section are used
mission consists of a 5-speed front section, and a
once in low range and once again in high range;
3-speed auxiliary section. The auxiliary section con-
however, each of the five ratios (low–1–2–3–4) in low
tains low- and high-range ratios, plus an overdrive
range and each of the four ratios (5–6–7–8) in high
splitter gear. See Fig. 14.1 for the shift pattern.
range can be split with the overdrive splitter gear.
Hi 5 5 7 7 1 All of the 18 speeds are controlled with one shift

R Dir OD Dir OD lever. A range preselection lever and a splitter control
Lo 1 3 button are built into the shift knob. The range prese-
lection lever controls range selection and the splitter
A control button (located on the side of the shift knob)
N controls gear splits.
6 6 8 8
B Operation, Eaton Fuller Splitter and
LOW Dir OD
2
Dir OD
4
Range-Shift
C D
03/13/96 f260044a
IMPORTANT: The shifter knob has an interlock
A. High Range C. Overdrive (forward) feature that prevents the splitter control button
B. Low Range D. Direct Drive (rearward)
from being moved forward when the range pre-
1. Splitter Control Button
selection lever is down (in low range); when in
Fig. 14.1, Eaton Fuller 13-Speed Transmission Shift high range and the splitter control button is in
Pattern the forward position, the range preselection
lever cannot be moved down.
All of the 13 speeds are controlled with one shift
lever. A range preselection lever and a splitter control
button are built into the shift knob. The range prese-
14.1
1. When operating off-road, or under adverse condi- only when operating conditions permit, depend-
tions, always use low gear when starting to move ing on the load, grade, and road speed.
the vehicle forward.
When operating on-highway, with no load, or
Upshifting
under ideal conditions, use 1st gear when start- 1. Position the gear shift lever in neutral. Start the
ing to move the vehicle forward. engine, and bring the air system pressure up to
For all conditions, use the highest gear that is 100 to 120 psi (689 to 827 kPa).
still low enough to start the vehicle moving with 2. Position the range preselection lever down, into
the engine at or near idle speed, and without low range. See Fig. 14.2.
slipping the clutch excessively.
2. Use the clutch brake to stop gear rotation when 1
5 5 7 7
shifting into low (or 1st) or reverse when the ve- Dir OD Dir OD
hicle is stationary. The clutch brake is actuated R 1 1 3 3
Dir OD Dir OD
by depressing the clutch pedal all the way to the
floor. A
N
For normal upshifts and downshifts, only a partial 6 6 8 8
disengagement of the clutch is necessary to LOW LOW
Dir OD Dir OD B
2 2 4 4
break engine torque. Dir OD
Dir OD Dir OD
3. C D
Use double-clutching between all upshifts and 03/13/96 f260157a
downshifts that require movement of the shift
A. High Range C. Overdrive (forward)
lever. Splitting of the high range gears does not B. Low Range D. Direct Drive (rearward)
require movement of the shift lever.
1. Splitter Control Button
4. Never move the shift lever into low gear while in
high range. Fig. 14.2, Eaton Fuller 18-Speed Transmission Shift
Pattern
5. Never move the splitter control button while in
neutral. 3. Make sure the splitter control button is in the di-
rect (rearward) position. See Fig. 14.2.
6. Do not preselect with the splitter control button;
after moving the control button, complete the 4. For 13-speed transmissions:
shift immediately. Press the clutch to the floor, shift into low or 1st
7. Except when downshifting from 5th direct to 4th gear; then engage the clutch, with the engine at
gear, never push the range preselection lever or near idle speed, to start the vehicle moving.
down into low range while operating in high Accelerate to 80 percent of engine governed
range—the splitter will become inoperative. speed.
8. Do not shift from high range to low range at high For 18-speed transmissions:
vehicle speeds. Press the clutch to the floor, shift into low; then
9. engage the clutch, with the engine at or near idle
Do not make range shifts with the vehicle moving
speed, to start the vehicle moving.
in reverse gear.
To shift from low direct to low overdrive, move
10. Never attempt to move the range preselection
the splitter control button into the overdrive (for-
lever with the gear shift lever in neutral while the ward) position, then immediately release the ac-
vehicle is moving. Preselection with the range celerator. Press and release the clutch pedal.
preselection lever must be made prior to moving After releasing the clutch, accelerate again.
the shift lever out of gear into neutral.
5. For 13-speed transmissions:
11. After your shifting ability improves, you may want
to skip some of the ratios. This may be done Shift upward from low to 1st gear, 2nd, etc. until
4th gear, double-clutching between shifts, and
14.2
accelerating to 80 percent of engine governed 8th); single-clutch during split shifts (6th direct to
speed. See Fig. 14.1. 6th overdrive, etc.).
For 18-speed transmissions: For 18-speed transmissions:
Shift upward from low overdrive to 1st direct by To shift from 5th direct to 5th overdrive, move the
first moving the splitter control button into the splitter control button (Fig. 14.2) into the over-
direct (rearward) position (Fig. 14.2). Move the drive (forward) position, then immediately release
shift lever, double-clutching, to the 1st gear posi- the accelerator. Press and release the clutch
tion. pedal. After releasing the clutch, accelerate
again.
Continue upshifting through the shift pattern.
Double-clutch during lever shifts (1st to 2nd to Continue upshifting through the shift pattern.
3rd to 4th); single-clutch during split shifts (1st Double-clutch during lever shifts (6th to 7th to
direct to 1st overdrive, etc.). 8th); single-clutch during split shifts (6th direct to
6th overdrive, etc.).
6. When in 4th gear (13-speed transmissions) or
4th overdrive (18-speed transmissions) and Downshifting
ready to shift up to 5th gear, use the range shift
lever as follows: 1. Downshift from 8th overdrive to 8th direct without
moving the shift lever. Flip the splitter control but-
For 13-speed transmissions:
ton to the direct (rearward) position, then imme-
While in 4th gear, pull the range shift preselec- diately release the accelerator, and disengage
tion lever up, into high range. The transmission the clutch. Engage the clutch, and accelerate the
will automatically shift from low to high range as engine only after the transmission has shifted.
the shift lever passes through neutral. Then, dis-
engage the clutch; double-clutch through neutral; 2. Start the downshift from 8th direct to 7th over-
move the shift lever to 5th gear; engage the drive by flipping the splitter control button to the
clutch, and accelerate the engine. overdrive (forward) position; then, immediately
double-clutch through neutral, moving the shift
For 18-speed transmissions: lever from 8th to 7th gear.
While in 4th overdrive, pull the range shift prese- 3. Shift downward through each of the high range
lection lever up, into high range. The transmis- gears, alternating the procedures in steps 1 and
sion will automatically shift from low to high 2, above, until reaching 5th direct.
range as the shift lever passes through neutral.
4. While in 5th direct and ready for the downshift to
Move the shift lever, double-clutching, to the 5th 4th (13-speed transmissions) or 4th overdrive
gear position. Just before making final clutch en- (18-speed transmissions), push the range prese-
gagement, move the splitter control button to the lection lever down. Then, double-clutch through
direct (rearward) position; then engage the clutch neutral and move the shift lever to the 4th gear
and accelerate. Do not move the control button position. On 18-speed transmissions, move the
while the shift lever is in neutral. splitter control button to the overdrive (forward)
7. Shift up through the high range gears as follows: position beforeengaging the clutch. Do not move
the control button while the shift lever is in neu-
For 13-speed transmissions: tral.
To shift from 5th direct to 5th overdrive, move the 5. Continue downshifting from 4th to 1st as follows:
splitter control button (Fig. 14.1) into the over-
drive (forward) position, then immediately release For 13-speed transmissions:
the accelerator. Press and release the clutch Downshift through the low range gears as condi-
pedal. After releasing the clutch, accelerate tions require.
again.
For 18-speed transmissions:
Continue upshifting through the shift pattern.
Double-clutch during lever shifts (6th to 7th to
14.3
Continue downshifting from 4th overdrive to 4th

HI 7 9
direct, then 4th direct to 3rd overdrive, 3rd over- R
drive to 3rd direct, etc. Single-clutch when split LO 2 4
shifting (direct to overdrive, overdrive to direct).
Double-clutch when making lever shifts (4th to A
3rd, 3rd to 2nd, etc.).
N
IMPORTANT: Never use the clutch brake when
downshifting, or as a brake to slow the vehicle. B
6 8 10
Eaton Fuller 10-Speed Range- 1 3 5
12/15/1999 f261053
Shift Transmissions A. High Range B. Low Range
Refer to the Eaton website for additional information,
Fig. 14.3, Eaton Fuller 10-Speed Transmission Shift
www.roadranger.com.
Patterns
General Information, Eaton Fuller Operation, Eaton Fuller Range-Shift
Range-Shift
1. When operating off-highway, or under adverse
To operate a range-shift transmission, move the shift conditions, always use low gear (if so equipped)
lever through all the low gear positions and then acti- when starting to move the vehicle.
vate a range switch to provide an additional set of
ratios in the high range. Using the same shift lever When operating on-highway, with no load, or
positions as in low range, move the shift lever under ideal conditions, use 1st gear when start-
through each position as before. On some models, ing to move the vehicle (except when equipped
the initial low gear is often used only in low range. with a 9-speed RTO transmission, then always
start in low gear).
IMPORTANT: Not all lever positions are used in each
range and the shift patterns vary between transmis- For all conditions, use the highest gear that is
sions. Be sure to read the shift pattern decal on the still low enough to start the vehicle moving with
dash for the operating instructions for the specific engine idling, and without slipping the clutch ex-
transmission installed in your vehicle. cessively.
2. Use the clutch brake to stop gear rotation when
10-Speed FR/FRO and RT/RTO/RTX shifting into low (or 1st) or reverse when the ve-
Models hicle is stationary. The clutch brake is actuated
by depressing the clutch pedal all the way to the
Eaton Fuller 10-speed transmissions have 10 selec- floor.
tive, evenly spaced forward ratios. Each transmission
has a 5-speed front section and a 2-speed rear For normal upshifts and downshifts, only a partial
range section. The 10 forward speeds are obtained disengagement of the clutch is necessary to
by twice using a 5-speed shift pattern: the first time break engine torque.
in low range, the second time in high range. See 3. Do not make range shifts with the vehicle moving
Fig. 14.3 for the shift patterns. in reverse gear.
NOTE: The 4th/9th and the 5th/10th shift posi- 4. Never attempt to move the range preselection
tions in the RT (direct ratio) and RTX (overdrive lever with the gear shift lever in neutral while the
ratio) transmissions are directly opposite in the vehicle is moving. Preselection with the range
RTO (overdrive ratio) transmissions preselection lever must be made prior to moving
the shift lever out of gear into neutral.
5. Do not shift from high range to low range at high
vehicle speeds.
14.4
6. Double-clutch between all upshifts and down- Downshifting

shifts.
1. With the transmission in high range, shift pro-
7. After your shifting ability improves, you may want gressively downward to the bottom gear in high
to skip some of the ratios. This may be done range, double-clutching between shifts.
only when operating conditions permit, depend-
ing on the load, grade, and road speed. 2. When in the bottom gear of the high range shift
pattern, and ready for the next downshift, push
Upshifting the range preselection lever down into low range.
Double-clutch through neutral, and shift into the
1. Position the gear shift lever in neutral. Start the top gear of the low range shift pattern. As the
engine, and bring the air system pressure up to shift lever passes through neutral, the transmis-
100 to 120 psi (689 to 827 kPa). sion will automatically shift from high range to
2. Position the range preselection lever down, into low range.
low range. 3. With the transmission in low range, downshift
3. Press the clutch pedal to the floor; shift into low through the low range gears as conditions re-
or 1st gear (Table 14.1), then engage the clutch, quire.
with the engine at or near idle speed, to start the IMPORTANT: Never use the clutch brake when
vehicle moving. Accelerate to 80 percent of en- downshifting, or as a brake to slow the vehicle.
gine governed speed.
Eaton Fuller Shift Progressions Clutch

TRANS. LOW RANGE HIGH General Information
MODEL Off-Highway On-Highway RANGE
10-Speed 7 9
The hydraulic clutch control system consists of a
R 2 4 R 2 4 R pedal unit and a slave cylinder, connected by a hy-
Direct or
Overdrive draulic hose and fastened with quick-disconnect
6 8 10
(RT or 1 3 5 1 3 5 clamps. The components of the system have been
RTX) f260329 f260329 f260330
specially designed to use DOT 4 brake fluid. The
Table 14.1, Eaton Fuller Range-Shift Shift pedal unit includes a hydraulic subassembly, com-
Progressions posed of the master cylinder and reservoir, which
can be removed from the pedal unit for service pur-
poses. When the clutch pedal is depressed, the fluid
4. Shift progressively upward from low or 1st gear, in the master cylinder is forced through a hydraulic
to the top gear in low range (Table 14.1), line to the slave cylinder. The fluid pressure moves
double-clutching between shifts, and accelerating the slave cylinder piston, pushing the plunger rod
to 80 percent of engine governed speed. and clutch release lever, which disengages the
5. While in the top gear of the low range shift pat- clutch. The hydraulic system is self-adjusting.
tern, and ready for the next upshift, flip the range Clutches are designed to absorb and dissipate more
preselection lever up into high range. Double- heat than encountered in typical operation. The tem-
clutch through neutral, and shift into the bottom peratures developed in typical operation will not
gear in high range (Table 14.1). As the shift lever break down the clutch friction surfaces. However, if a
passes through neutral, the transmission will au- clutch is slipped excessively, or asked to do the job
tomatically shift from low range to high range. of a fluid coupling, high temperatures develop quickly
6. With the transmission in high range, shift pro- and destroy the clutch. Temperatures generated be-
gressively upward through each of the high tween the flywheel, driven discs, and pressure plates
range gears (Table 14.1), double-clutching be- can be high enough to cause the metal to flow and
tween shifts. the friction facing material to char and burn.
Heat and wear are practically nonexistent when a
clutch is fully engaged. But during the moment of
engagement, when the clutch is picking up the load,
14.5
it generates considerable heat. An improperly ad- ence between the clutch disc and the flywheel and
justed or slipping clutch will rapidly generate suffi- causes the least heat and wear on the clutch assem-
cient heat to destroy itself. bly. When downshifting, the input shaft speed must
be increased by slightly revving the engine to match
To ensure long service life of the clutch; start in the
the flywheel speed for smooth clutch engagement.
right gear, be alert to clutch malfunctions, and know
For transmission operating instructions, refer to the
when to adjust the clutch.
transmission headings in this manual.
Clutch Operation Vehicle Loading
Clutch Break-In Clutches are designed for specific vehicle applica-
With a new or newly installed clutch, the clutch may tions and loads. These weight limitations should not
slip for a short time while the friction surfaces break- be exceeded.
in. However, allowing the clutch to slip for more than
two seconds can severely damage the clutch disc, CAUTION
pressure plate, and the flywheel.
During initial operation of a new vehicle or a vehicle Exceeding vehicle load limits can not only result
with a new clutch, check for clutch slippage during in damage to the clutch, but can also damage the
acceleration. If the clutch slips, decelerate until the entire powertrain.
clutch does not slip. Allow the clutch to cool 15 to 30
seconds, and then gradually accelerate again. If the
Using the Clutch
clutch continues to slip, repeat the procedure. If nec- The clutch pedal must be used only to start the ve-
essary, repeat the procedure up to five times. If the hicle moving or while shifting. To start the vehicle
clutch slips after five attempts, stop the vehicle. Allow moving, depress the clutch pedal all the way to the
the clutch to cool for at least one hour. Notify your floor plate (see "Using the Clutch Brake") and shift
Freightliner dealer of the problem. from neutral to a low gear. Slowly raise your foot until
the clutch starts to engage. In this position the clutch
CAUTION is starting to connect the transmission input shaft to
the flywheel and is causing the most heat and wear.
Do not allow sustained slippage of the clutch; Slightly increase the engine speed and smoothly
this could severely damage the clutch disc, pres- allow the clutch pedal to return to its at rest position.
sure plate, or flywheel. Damage caused by clutch Do not allow the clutch to remain in the partially en-
slippage due to improper break-in is not warrant- gaged position any longer than necessary to obtain a
able. smooth start.
To shift gears while the vehicle is moving, push the
Moving the Vehicle in the Proper Gear clutch pedal most of the way (but not all of the way)
An empty truck can be started in a higher transmis- to the floor plate. Shift the transmission into neutral
sion gear than can a partially or fully loaded truck. A and fully release the clutch pedal. If upshifting, wait
good rule of thumb for the driver to follow is to select long enough for the engine speed to decrease to the
the gear combination that allows the vehicle to start road speed. If downshifting, increase the engine
moving with an idling engine, or, if necessary, just speed to match the road speed. Again, push down
enough throttle to prevent stalling the engine. After the clutch pedal part way and then move the shift
the clutch is fully engaged, the engine can be accel- lever to the next gear position. Fully release the
erated to the correct rpm for the upshift into the next clutch pedal after completing the shift.
higher gear. Slightly depressing the clutch pedal while driving is
damaging to the clutch, because partial clutch en-
Gear Shifting Techniques gagement causes slippage and heat. Resting your
Shift into the next higher gear when the vehicle foot on the clutch pedal will also put a constant thrust
speed allows the transmission input shaft speed to load on the release bearing, thinning the bearing lu-
match the flywheel speed when engaging the clutch. bricant and increasing the wear on the bearing.
This technique results in the smallest speed differ-
14.6
Using the Clutch Brake High clutch disc speeds while coasting can also
cause the clutch facing to be thrown off the disc.
The clutch brake is applied by depressing the clutch Flying debris from the clutch can cause injury to
pedal past the fully released clutch position, almost persons in the cab.
to the floor plate. The last part of the clutch pedal
travel will compress the clutch brake plates together, Clutch Maintenance
stopping the transmission input shaft. The purpose of
the clutch brake is to stop the transmission gears Clutch Adjustment
from rotating in order to quickly engage a transmis-
Eaton Fuller Solo clutches are adjustment-free. As
sion gear after idling in neutral.
the clutch wears, its wear-adjusting technology moni-
tors clutch components and makes any necessary
CAUTION adjustments. The wear adjusting technology comes
from two sliding cams, which rotate to maintain the
Never apply the clutch brake when the vehicle is proper adjustment. Atop the upper cam, a wear indi-
moving. If the clutch brake is applied when the cating tab mirrors the cam’s movement, letting you
vehicle is moving, the clutch brake will try to know when it’s time to replace the clutch.
stop or decelerate the vehicle, causing rapid
wear of the clutch brake friction discs. Consider-
able heat will be generated, causing damage to CAUTION
the release bearings and the transmission front
Operating the vehicle with incorrect free pedal
bearings.
could result in clutch damage.
Holding the Vehicle on an Incline Hydraulic Clutch Fluid Reservoir
Always use the vehicle service brakes to prevent the Checking
vehicle from rolling backwards while stopped on a
hill. Slipping the clutch on a hill to maintain the ve- Make sure that the clutch fluid reservoir is full. See
hicle position will quickly damage the clutch assem- Fig. 14.4. The reservoir is full when the fluid level is
bly. up to the "max" mark. The fluid level must always be
above the "min" mark. Use only heavy-duty brake
Coasting fluid, DOT 4, in the clutch hydraulic system.
Coasting with the clutch pedal depressed and the
transmission in a low gear can cause high driven
disc speed. The clutch speed can be much higher
under these conditions than when the engine is driv-
ing the clutch. This condition creates a hazardous
situation due to the lack of vehicle control and due to
the high clutch disc speed. Engaging the clutch
under these conditions can cause component dam-
age because of the shock loads to the clutch and
drivetrain.
WARNING
Always shift into the gear that is correct for the
traveling speed of the vehicle and engage the
clutch. Coasting with the clutch disengaged can
prevent engagement of the correct transmission
gear which can cause loss of vehicle control,
possibly resulting in personal injury or property 06/05/2007 f250664
damage.
Fig. 14.4, Clutch Fluid Reservoir
14.7
15
Automated Transmissions
Detroit™ Automated Transmissions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15.1
Freightliner SmartShift Shift Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15.5
Eaton Fuller UltraShift . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15.6
Eaton Fuller AutoShift Automated Transmissions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15.11
Eaton Fuller UltraShift PLUS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15.14
Detroit™ Automated 4
Transmissions
Detroit transmissions have twelve forward gears and 3
up to four reverse gears that can be shifted automati-
cally or manually. Shifting and clutch actuation are
computer controlled, and there is no clutch pedal
needed to operate the vehicle. Automatic shifts are
selected for fuel economy or engine power. Manual
shifts can be requested with the shift control and the A 1 2
transmission ECU grants them when conditions per-
mit. In all cases, shifts depend on the following fac-
tors: engine speed, accelerator pedal position, ser-
vice brake usage, engine brake operation, vehicle
load status, and road conditions.
NOTE: To avoid potential engine stall risk or un-
expected shifting, use the interaxle differential
lock when the vehicle is operated in slippery (−)
conditions. See Chapter 16 for information
about the interaxle differential lock.
B (+)
Detroit™ Multifunction Control
Vehicles with Detroit transmissions use the control
shown in Fig. 15.1. This control can be used to re-
quest manual shifts, change driving mode, and set
engine brake levels. See Table 15.1 for an overview
of control functionality.
D/N/R Switch
Use the "D/N/R Switch" to request drive (D), neutral
(N), or reverse (R).
Mode Switch
The driving mode can be changed using the Mode
switch on the shift control (see Fig. 15.1). To activate
the manual drive mode, press and hold the switch
C
briefly. Press the switch quickly to activate the auto-
matic drive mode or change between Automatic 05/30/2012 f270163a
Economy and Automatic Performance modes. See Table 15.1 for a description of control functionality.
A. Front View
Upshifting and Downshifting B. Shift Requests
C. Four positions for engine brake settings
Gear shifts can be requested manually; push the 1. Engine Brake Symbol
lever away to request a downshift, or pull the lever 2. D/N/R Switch
toward you to request an upshift. See Table 15.1 for 3. Mode Switch
more information about upshift and downshift 4. Gear Shift Symbol
requests.
Fig. 15.1, Detroit Multifunction Control
15.1
Functionality, Detroit Multifunction Control

Function/Switch Action/Position Request
D Forward gears
D/N/R N Neutral
R Reverse gears
Activate the automatic drive mode, or switch between
Depress switch and release it quickly
Mode Automatic Economy and Automatic Performance.
Depress switch and hold it briefly Activate the manual drive mode.
Pull the lever toward you momentarily Upshift, single gear
Upshifting and Pull the lever toward you in quick repetitions Upshift, multiple gears
Downshifting Push the lever away momentarily Downshift, single gear
Push the lever away in quick repetitions Downshift, multiple gears
Lever at position 0 (top) Engine brake off
Lever at position 1 Low intensity
Engine Brake*
Lever at position 2 Medium intensity
Lever at position 3 (bottom) High intensity
* For functions with cruise control active, see Chapter 5.
Table 15.1, Functionality, Detroit Multifunction Control
Engine Brake Gear Display Window

The engine brake is controlled by the lever position The gear display window shows the current transmis-
(as shown in Fig. 15.1, Ref. C). At the top position, sion gear and driving mode. See Fig. 15.2.
the engine brake is off, and at the three lower posi-
tions, the engine brake is on and the intensity (low, 2
medium, high) increases with each step down. For
more information about using the engine brake, see
Chapter 13.
NOTE: Using the engine brake with cruise con-
1
5 N
70 °F
A econ
trol can be used to activate Descent Control
Mode or Deceleration Mode. For more informa-
tion, see "Cruise Control" in Chapter 5. 07/09/2012 f611187
1. Driving Mode
Power Up and Shift into Gear 2. Current Gear
1. With the parking brake set and Neutral (N) se- Fig. 15.2, Gear Display Window
lected on the shift control, turn the ignition switch
to the ON position. Driving Modes
2. Start the engine. There are three driving modes: Manual, Automatic
3. Apply the service brake. Economy, and Automatic Performance.
4. In Automatic Economy mode, gear shifts are de-

Select the desired starting gear.
signed for saving fuel. In Automatic Performance
5. Release the parking brake. mode, gear shifts are designed for higher perfor-
mance and are made at higher engine speeds. In
6. Release the service brake and apply the accel- manual mode, gear shifts are requested manually.
erator. See Chapter 5 for more information about upshifting
and downshifting using the control.
15.2
NOTE: In Automatic Performance mode, the eCoast

transmission will automatically change to Auto-
matic Economy mode if it hasn’t received a re- The eCoast feature can improve driving economy.
quest for more power in several minutes, unless When conditions permit, the transmission control au-
tomatically shifts the transmission to neutral to coast
current road conditions require higher engine
at speeds of approximately 22 mph (35 km/h) and
performance. above. An "E" shows in the gear display window
when eCoast is in effect. See Fig. 15.5.
Selected Gear
The eCoast function is not active when any of the
If the selected gear is different than the current gear following occur:
for longer than a half second, the current gear dis-
play will flash and the selected gear value will be • the accelerator pedal is pressed.
shown. Once the current gear and selected gear • vehicle acceleration rate is exceeded.
match, the selected gear display disappears and the
current gear display stops flashing. See Fig. 15.3. • the service brake pedal is pressed.
• the engine brake is in use.
2
• cruise control brakes or accelerates.
1
• vehicle speed exceeds the cruise control set
7 5 N
70 °F
speed by more than approximately 4 mph (6
km/h).
A econ
• the speed limiter is active and the maximum
speed set is exceeded.
07/09/2012 f611188
• diesel particulate filter (DPF) regeneration oc-
1. Selected Gear
2. Current Gear curs.
The eCoast function cannot be deactivated when the
Fig. 15.3, Selected Gear Display
Automatic Economy mode is active.
Suggested Shift NOTE: To disable eCoast, see an authorized
Freightliner service facility.
In Manual mode only, a suggested shift is displayed
to indicate the most economical gear available. The
suggested shift is the number of up or down arrows
from the current gear with a maximum of three up or
down arrows. See Fig. 15.4.
E N
70 °F
A econ
2
1
07/09/2012 f611190
5 N
70 °F
NOTE: Upshift and downshift arrows are not shown
when "E" is shown in the gear display window.
Manual Fig. 15.5, eCoast Display
07/09/2012 f611189
Creep Mode
1. Suggested Shift Arrows Creep mode allows the vehicle to be maneuvered at
2. Current Gear very slow speeds. To activate Creep mode for the
first time within the current driving cycle, press the
Fig. 15.4, Suggested Shift accelerator pedal to launch the vehicle, thereby fully
15.3
engaging the clutch. Following this and for the dura- There are three clutch abuse protection levels. At
tion of the current driving cycle, Creep mode is ac- each, the driver is alerted and functionality is modi-
tive. fied; see Table 15.2.
Once the vehicle is stopped via the service brakes, To avoid clutch overheating, follow these tips:
the vehicle will begin to creep again, without the ac-
• To hold the vehicle stationary on an uphill
celerator pedal actuation, as soon as the service
slope, use the service brakes, not the accel-
brakes are released.
erator pedal.
To begin using Creep mode (once active) from a
parked position, shift from neutral to either drive or • To start moving on an uphill slope, use the ac-
reverse, release the service brakes, and briefly de- celerator pedal and release the brakes as the
press the accelerator pedal. The vehicle’s urge to vehicle begins to move.
move can then be felt. • When hooking up to a trailer, ensure the trailer
If creep is active and no acceleration is achieved is high enough to back under, and use first
within five seconds, then Creep mode will abort. A gear reverse.
display message notifies the operator when Creep • Avoid starting in higher gears, and start in first
mode is about to be aborted. gear when a trailer is attached.
IMPORTANT: When slowing down from higher • Ensure trailer brakes have had time to com-
speeds in drive or reverse, remember that pletely release prior to starting.
Creep mode will be in effect at lower speeds.
• Do not use Creep mode for an extended pe-
Use the service brakes to stop the vehicle.
riod. Stop or adjust the vehicle speed when
warned to deactivate Creep mode.
Clutch Abuse Protection
A vehicle equipped with a Detroit transmission does Engine Overspeed Alerts
not have a clutch pedal, but still has a clutch that is To help protect the engine, the system has display
operated automatically and can be damaged by abu- messages to notify the operator when the engine has
sive driver actions. To protect the clutch, the vehicle exceeded certain thresholds and needs to be slowed
has a clutch abuse protection system that alerts the down before significant engine damage occurs.
driver and restricts functionality when needed. Ex- There are two warnings, one at about 2400 rpm and
tended periods in Creep Mode, slipping the clutch another at 2500 rpm, indicated with messages and a
(using the accelerator pedal to hold the vehicle on a fault code.
hill, for example), and high clutch temperatures can
activate the clutch abuse protection system. A display
message notifies the operator when the protections
Low Transmission Air Warning
are needed. Pneumatic controls are used to shift the transmis-
sion. If there is inadequate air pressure, a warning is
NOTICE displayed and the quality of gear shifts may be de-
graded. Wait for air pressure to build before operat-
To hold the vehicle stationary on an uphill slope, ing the vehicle.
use the service brakes, not the accelerator pedal.
IMPORTANT: If the low transmission air warning
Using the accelerator pedal can overheat and
damage the clutch. To start moving, use the ac- indicator appears while the vehicle is in opera-
celerator pedal and release the brakes as the ve- tion, safely pull the vehicle off the road, and cor-
hicle begins to move. rect the problem.
Clutch Abuse Alerts and Protections

Protections
Alert Level Alert
Highest Start Gear Creep Mode Clutch Function
1 Heavy clutch load message 1 No restriction Normal function
15.4
Clutch Abuse Alerts and Protections

Protections
Alert Level Alert
Highest Start Gear Creep Mode Clutch Function
2 Heavy clutch load message 1 Disabled Normal function
If the accelerator pedal is
depressed, the clutch closes
Clutch overload message and at fixed rate.
3 1 Disabled
buzzer If the accelerator pedal is
released, the clutch opens at
fixed rate.
Table 15.2, Clutch Abuse Alerts and Protections
Freightliner SmartShift Shift control is spring-loaded and returns to mid-position

when released after an upshift or downshift.
Control For Eaton Fuller UltraShift, UltraShift PLUS, and Au-
General Information, SmartShift toShift transmissions (Fig. 15.6), a four-position (R,
N, D, L) selector switch is located at the end of the
The SmartShift transmission control is an electronic lever.
transmission control device. It is installed with the
following transmissions: 5 6 7
• Eaton Fuller UltraShift™
4 8
3
• Eaton Fuller UltraShift™ PLUS
• Eaton Fuller AutoShift™
It replaces the typical floor-mounted shift lever or
9
dash-mounted push button control. 1
2
SmartShift accepts driver requests for transmission 10
functions and transmits them through hard wiring to 11
the transmission control unit (TCU). SmartShift is a 12
01/24/2003 f270120
true shift-by-wire system.
To upshift manually, pull the lever up (towards you). To
SmartShift offers two main advantages over conven- downshift manually, push the lever down (away from
tional transmission control devices. Without a floor- you).
mounted shift control, usable cab space is increased. 1. SmartShift Control Lever
The SmartShift control mounts to the right-hand side 2. Slide Switch (forward driving mode switch)
of the steering column and is operated by the fingers 3. MAN Mode (of slide switch)
of the driver’s right hand, allowing both hands to re- 4. AUTO Mode (of slide switch)
main on the steering wheel. 5. Upshift Direction
6. Reverse Position (of selector switch)
A two-position slide switch (Fig. 15.6) is mounted on 7. Selector Switch
the body of the control lever just before the paddle 8. Neutral Lock Button
widens out. The slide switch allows the driver to 9. Neutral Position (of selector switch)
choose automatic (AUTO) or manual (MAN) mode. 10. Drive Position (of selector switch)
11. Low Position (of selector switch)
In AUTO mode, gears shift automatically, without 12. Downshift Direction
driver interaction. Manual gearshifts are accom-
plished by a momentary pull or push on the control in Fig. 15.6, SmartShift Control (Eaton Fuller UltraShift,
the plane perpendicular to the steering wheel. Pull UltraShift PLUS, and AutoShift Transmissions)
upward (toward you) on the control to upshift and
push downward (away from you) to downshift. The
15.5
Embedded in the selector switch is a small neutral Operation, UltraShift DM

lock button to prevent accidental shifts into gear from
neutral. Any time you shift through N, press down on Power Up
the neutral lock button to move the switch from neu- 1. With the parking brake set, select neutral (N) by
tral (N) to another gear, such as drive (D), low (L), or moving the selector switch to the N position.
reverse (R). When shifting to N, it is not necessary to
press the neutral lock button. 2. With the transmission in neutral, turn on the igni-
tion switch. The CHECK TRANS and TRANS
Eaton Fuller UltraShift TEMP telltale lights come on and go out again
(bulb check).
General Information, UltraShift DM 3. After the ignition is turned on, the current gear
Eaton® Fuller® UltraShift™DM is a ten-speed heavy- indicator shows the dot display, arranged in a
duty fully automated transmission. No clutch pedal is square pattern. All dots in the pattern should light
required to operate the vehicle. up, without gaps or spaces. See Fig. 15.8.
UltraShift DM uses a dry clutch system which is of-
fered only on this automated transmission system.
The UltraShift transmission uses the four-position
SmartShift lever on the steering column to select
gears. To know what gear the transmission is in, look
at the round current gear indicator on the right-hand
control panel as shown in Fig. 15.7. All forward shifts
can be made either manually or automatically, at the
driver’s choice.
2 10/13/2003 f610678
Fig. 15.8, Power-Up Dot Display
4. Wait for the current gear indicator to show a solid

N. When the N is solid, rather than flashing, the
UltraShift DM TCU is powered up. Apply the ser-
vice brake and start the engine.
5. Select drive (D) by pressing in the neutral lock
button and moving the selector switch downward
to the position below neutral. Release the park-
ing brake. The gear is displayed on the current
12/22/2003 f270079a
gear indicator.
To know what gear the transmission is in, look at the NOTE: When D is selected, the transmission
current gear indicator. controller starts up in second gear. If desired,
1. Current Gear Indicator the driver can select to start up in first. No other
2. SmartShift Control start gear is available.
Fig. 15.7, Shift Controls and Indicators, UltraShift 6. On a level grade, release the service brake and
Transmissions press down on the throttle pedal to allow the ve-
hicle to move forward. The vehicle will not move
until the pedal is depressed.
15.6
WARNING
When starting or stopping on hills and grades,
use extra care to prevent the vehicle from rolling
back. A rollback accident could cause death, seri-
ous personal injury, or property damage.
7. Prevent the vehicle from rolling backwards when
stopped on a hill or grade, or when the vehicle is 1 2
starting from a stop on a hill or grade.
3
7.1 To start from a full stop on a hill or grade,
quickly move your foot from the brake
pedal and press firmly on the throttle
pedal.
On steep hills, set the parking brake, and
release it only when there is enough en- 01/21/2004 f270079c
gine power to prevent rollback. 1. Slide Switch (controls forward driving mode)
2. Selector Switch (controls gear selection)
7.2 To stop on a hill or grade, press and hold 3. Neutral Lock Button (prevents accidental shift into
the brake pedal to keep the vehicle from gear)
moving.
Fig. 15.9, Switches, UltraShift Transmissions
On steep hills, set the parking brake.
When parking, chock the tires, front and/or IMPORTANT: Whatever the mode, it is always
rear. Never hold a hill with the throttle possible to shift manually by moving the lever
pedal. This will cause the clutch to over-
up or down as needed. When the engine speed
heat.
is within 75 revolutions per minute (rpm) of the
Power Down load-based shift point for an automatic shift, the
UltraShift DM TCU will advance the shift.
1. Apply the service brakes.
In either mode, the gear indicator displays the cur-
2. Select neutral (N) by pressing in the neutral lock rent gear. See Fig. 15.10.
button and moving the selector switch to N.
When the N on the current gear indicator is solid,
rather than flashing, the UltraShift DM TCU is
ready to power down.
3. With the transmission in neutral, set the parking
brake.
4. Turn off the ignition key and shut down the en-
gine.
Automatic and Manual Modes

The SmartShift control has a slide switch located on
the body of the control lever just before the paddle
widens out. See Fig. 15.9. The slide switch controls
the forward driving mode, automatic or manual. 10/13/2003 f610680
To change mode at any time, move the slide switch NOTE: The gear indicator displays the current gear. In
in the desired direction. This allows the driver to re- this example, it displays first gear.
spond to a wide range of driving conditions, such as Fig. 15.10, Current Gear Display
blind corners, tight curves, and steep hills.
15.7
At the start of a shift, the current gear continues to use the shift lever as described for MAN mode.
display until the transmission has been pulled into There is no AUTO mode for reverse.
neutral. At this point, as the transmission is synchro-
When reverse low is selected, the letter R displays
nizing for the new (target) gear, the gear indicator
on the current gear indicator. When reverse high is
flashes the number of the new gear.
selected, the letter H displays on the current gear
When the shift is complete, the new gear displays indicator. See Fig. 15.11.
solid, without flashing.
Automatic Mode (AUTO)

In automatic drive mode (AUTO), upshifts and down-
shifts are made by the transmission without driver
intervention. Press in the neutral lock button, move
the selector switch to drive (D), and press down on
the throttle pedal. The transmission will shift auto-
matically.
If driving conditions require, it is still possible to re-
quest a manual shift. The transmission will make the
shift if the engine speed is within 75 rpm of the load-
based shift point for that gear.
If the driver presses down on the throttle pedal after 10/14/2003 f610681
a manual downshift in automatic mode, the transmis-
sion will upshift again if the UltraShift DM TCU re- Fig. 15.11, Reverse Gear Display
quires it.
IMPORTANT: Under normal conditions, do not
Manual Mode (MAN) select reverse with the vehicle moving forward.
In manual drive mode (MAN), upshifts and down- The vehicle must be moving at less than two miles
shifts are made by the driver: per hour (3 km/h) before selecting reverse. If reverse
is selected when the vehicle is moving faster, an au-
• To shift up, pull the lever up (towards you).
dible alert will sound and continue sounding at three-
• To shift down, push the lever down (away from second intervals until the control lever is returned to
you). the D position or the vehicle slows to the proper
speed.
The system will hold the current gear until the driver
requests a shift. In downhill situations in particular, If necessary to rock the vehicle, use the selector
the driver must be alert to vehicle speed by down- switch to shift back and forth at low speed between
shifting and/or using the service brakes as needed. reverse and drive.
A shift request will still be refused if the selected gear Neutral
would cause engine overspeed or excessive lugging.
IMPORTANT: Always start the engine with the
Selecting Gears transmission in neutral, the parking brake set,
Reverse and the service brakes applied.
Reverse (R) is at the upper end of the four-position Neutral (N) is directly below R on the four-position
selector switch located at the end of the SmartShift selector switch located at the end of the SmartShift
control lever. To select R, press in the neutral lock control lever. To select N, press in the neutral lock
button and move the selector switch upward to the button and move the selector switch to the position
position above neutral. below R. When neutral is selected, the letter N dis-
plays on the current gear indicator. See Fig. 15.12.
UltraShift DM has two reverse gears, reverse low
and reverse high. To shift manually between them,
15.8
currently selected forward gear (1 through 10) dis-

plays on the gear indicator. See Fig. 15.10.
When in drive, requests to upshift or downshift are
enabled. Either manual or automatic mode can be
selected on the slide switch.
Two starting gears are available, first and second.
The default starting gear is second, but first can be
selected by the driver, if desired. To change the start-
ing gear, press the brake pedal and select D with the
vehicle stopped. The current gear indicator will dis-
play the starting gear. Move the shift lever up or
down until the desired starting gear is displayed.
10/13/2003 f610679 The UltraShift DM TCU adapts to the working condi-
tions of each vehicle and its driver. After power up or
Fig. 15.12, Neutral Display a load change, it needs to learn the new conditions.
While learning, it may hold a gear too long before
upshifting. Start the upshift manually. It may take
WARNING three or four shifts before UltraShift succeeds in
learning the new load-based shift points, but after
Do not coast in neutral. Coasting in neutral can
that it will handle the shifting automatically.
cause an accident, possibly resulting in severe
personal injury or death. Low
Neutral is always available during operation, what- Low (L) is at the lower end of the four-position selec-
ever the vehicle speed. When in neutral, requests to tor switch located at the end of the SmartShift control
upshift or downshift are ignored. If the selector switch lever. To select L, press in the neutral lock button
is moved from neutral to drive while the vehicle is and move the selector switch to the position below
moving, the transmission will shift into a gear within D.
the engine’s operating speed range.
When in low, the current gear is maintained. Re-
When shifting from neutral, always press on the quests to upshift are not enabled.
brake pedal. If the brake pedal is not pressed, the
transmission will not shift, the current gear display IMPORTANT: If the engine is approaching over-
will flash N, and an audible alert will sound. speed, the UltraShift DM TCU will override the
NOTE: To reset the transmission, return the se- current gear setting and upshift to prevent en-
lector switch on the SmartShift lever to N and gine damage.
attempt the shift again, this time with the brake To enhance engine braking, downshifts are per-
pedal pressed. formed at higher rpm than normal.
Before shutting down the engine, return the selector If L is selected from neutral while stopped, the ve-
switch to N. When the ignition is turned off, the trans- hicle starts up in first gear and stays there until the
mission will reset to neutral in a few minutes regard- engine approaches overspeed.
less of the position of the shift lever.
Upshifting
Drive To request an upshift with the transmission in drive,
Drive (D) is directly below N on the four-position se- pull the control lever up (towards you). If the gear is
lector switch located at the end of the SmartShift available, the transmission upshifts and the new gear
control lever. To select D, press in the neutral lock displays on the gear indicator. No skip shifts are
button and move the selector switch to the position available while upshifting.
below N. When drive is selected, the number of the
No upshifts are available in low, except to prevent
engine overspeed.
15.9
If the transmission does not upshift quickly enough Ultrashift Diagnostics

after power-up or a load change, begin the shift
manually. The UltraShift DM TCU will learn the new Clutch Protection Fault
load-based shift conditions after three or four shifts. Excessive clutch slippage creates heat and reduces
If the gear requested is unavailable, a tone will the life of the clutch. These are some conditions
sound. An unavailable request to upshift is not stored which lead to clutch abuse:
in memory. The upshift must be requested again. • Using the throttle to hold the vehicle on a
grade
Downshifting
• Starting the vehicle in too high a gear
NOTE: The driver can manually downshift at
any time, even when the slide switch is set to • Overloading the vehicle
AUTO mode. • Using high idle with the vehicle in gear
To request a downshift with the transmission in drive The UltraShift DM TCU is programmed to prevent
or low, push the control lever down (away from you). clutch abuse. When the clutch overheats, the follow-
If the gear is available, the transmission downshifts ing alerts take place:
and the new gear displays on the gear indicator. Skip
shifts are available while downshifting. • The TRANS TEMP light comes on
For best engine braking, select low while moving. In • The current gear indicator displays CA
low, downshifts are performed at higher rpm than in • A warning tone sounds at one-second intervals
drive.
The alerts continue until the clutch cools, the throttle
IMPORTANT: If the engine is approaching over- is released, or the clutch is fully engaged.
speed, the UltraShift DM TCU will override the
current gear setting and upshift to prevent en- System Problem
gine damage.
In the event of a problem, do the following steps.
If the gear requested is unavailable, a tone will
1. Note the driving conditions at the time the prob-
sound. An unavailable request to downshift is not
stored in memory. The downshift must be requested lem occurred.
again. 2. Record the status of the transmission at the time
of the problem (AUTO or MAN mode, gear set-
When coasting to a stop, the UltraShift DM TCU may
ting R, N, D, or L, current gear, engine speed,
not finish the downshift until the driver presses down
etc.)
on the throttle pedal again.
3. Reset the system, using the procedure below.
IMPORTANT: A downshift request can never
result in a shift into neutral, even if the vehicle is Reset Procedure
in the drive position in the lowest possible gear.
Transmission operation can sometimes be restored
Before starting down a hill, slow down. Downshift to by doing the following reset procedure:
a speed that you can control without hard pressure
on the service brakes. 1. Stop the vehicle when it is safe to do so. Set the
parking brake.
Before entering a curve, slow down to a safe speed.
Downshift if necessary. This lets you use some 2. Place the selector switch in neutral and turn off
power through the curve to help the vehicle be more the ignition.
stable on the turn. It also allows you to regain speed 3. Check all harness connectors as described in
faster as you come out of the curve. Chapter 21.
4. Wait at least two minutes with the engine shut
down.
5. Restart the engine.
15.10
If the problem continues, contact an authorized transmission consists of a 5-speed front section and
Freightliner or Eaton service facility. a 2-speed rear section. The driver must use the
clutch to start and stop the vehicle.
Locked In Gear
The driver does not need to break torque or increase
If the transmission becomes locked in gear, a dash or decrease engine speed to synchronize the shift.
(–) will appear on the current gear indicator when the The transmission signals the engine controller when
vehicle is restarted during the reset procedure. to break torque and the engine controller automati-
NOTE: If the transmission becomes locked in cally increases or decreases engine speed. When
engine speed is correct, the transmission engages
gear while the vehicle is moving, increased the next gear and signals the engine controller to
braking effort may be required to stop the ve- resume operation.
hicle.
If the current gear indicator displays a dash during WARNING
power-up with the selector switch in neutral, do the
following steps. When starting or stopping on hills and grades,
use extra care to prevent the vehicle from rolling
1. Make sure the parking brake is set.
back. A rollback accident could cause death, seri-
2. Turn off the ignition and wait at least two min- ous personal injury, or property damage.
utes.
The AutoShift system consists of the following com-
3. Apply the service brakes. ponents:
4. With the service brakes applied, release the • The SmartShift control paddle on the steering
parking brake. column. See Fig. 15.6.
5. Make sure the selector switch is in neutral and • The gear display module (Fig. 15.13) mounted
turn on the ignition key. Do not attempt to start on the dashboard indicates the current gear
the engine at this time. position or transmission status. The display
also flashes the next gear to be engaged while
6. If necessary to get the transmission to shift into the transmission is in neutral during a gear
neutral, release the pressure on the brake pedal change.
slightly.
• The shifter mechanism performs shifts at the
7. Once the UltraShift DM TCU reaches neutral, a front portion of the transmission. It preselects
solid N will appear on the current gear indicator the shift to neutral and completes the gear
and the vehicle will start. Make sure the service change after driver input.
brakes are applied and the parking brake is set.
• The Electronic Control Unit (ECU) includes two
If the current gear indicator continues to display a controllers: a transmission ECU and a system
dash, contact an authorized Freightliner or Eaton ser- ECU. The transmission ECU controls all trans-
vice facility. mission shift functions and the system ECU
manages all vehicle interfaces for transmission
Eaton Fuller AutoShift shift functions.
Automated Transmissions • An electronic range valve, controlled by the
transmission ECU, is used to perform range
Refer to the Eaton website for additional information, shifts.
www.roadranger.com.
Operation, AutoShift with SmartShift
General Information, AutoShift
Automatic and Manual Modes
10-Speed RT/RTO Models
A two-position slide switch (forward driving mode
Eaton Fuller 10-speed AutoShift transmissions have switch) is located near the end of the control
10 forward speeds and two reverse speeds. The (Fig. 15.6). The switch positions are labelled MAN
15.11
NOTE: Neutral is always available during opera-

tion. When in neutral, upshift and downshift re-
quests are ignored. If the mode selector switch
is moved from neutral (N) to drive (D) while the
vehicle is moving, the transmission will shift into
a gear causing the engine to go to a high torque
level, under the engine’s rated torque.
WARNING
Do not coast in neutral. Coasting in neutral can
cause an accident, possibly resulting in severe
personal injury or death.
10/13/2003 f610680
NOTE: The gear indicator displays the current gear. In Selecting a Starting Gear
this example it displays first gear.
1. In automatic mode, select drive (D) by sliding the
Fig. 15.13, Gear Display Module selector switch downward to the next position
below the neutral position.
(manual shift mode) and AUTO (automatic drive
mode). 2. Disengage the clutch to engage the gear se-
lected. Engage the clutch and drive the vehicle.
NOTE: In automatic drive mode, upshifts and
downshifts require no driver interaction. Move Changing the Default Starting Gear
the selector switch to the drive (D) position, dis-
To select a starting gear other than the default start-
engage the clutch to engage the gear selected,
ing gear, follow the instructions below.
engage the clutch and drive the vehicle. In
manual shift mode, upshifts and downshifts re- 1. Make sure the vehicle is stopped and in drive.
quire either a pull upward or push downward on 2. In either automatic or manual mode, pull upward
the control. on the control (to increase), or push downward
(to decrease). Each pull upward on the control
Driver Message Center increases the starting gear by one gear, but no
Gear information is presented to the driver on the higher than fourth gear.
dash display. In automatic drive mode, the number of 3. The number of the gear selected will flash on the
the forward gear currently engaged appears continu- message display screen until the driver engages
ally on the message display screen when in drive the clutch. This gear will be stored in memory as
(D). In manual shift mode, the current gear is dis- the default starting gear until either a different
played until a new gear is requested. When neutral starting gear is selected by the driver or the en-
(N) is engaged, "N" will appear on the message dis- gine is shut down.
play screen. When reverse (R) is engaged, either
"RL" or "RH" will appear on the message display NOTE: The transmission may also be pro-
screen. grammed so that it is not possible to select a
starting gear other than the preprogrammed de-
IMPORTANT: The information shown on the fault starting gear.
message display screen indicates the state of
the transmission only, not the state of the Upshifting
SmartShift control.
NOTE: With the transmission in drive (D) in the
Neutral Position automatic mode, upshifts require no driver inter-
action.
Select neutral by sliding the selector switch to the
"N" position.
15.12
1. With the transmission in drive in the manual NOTE: The Eaton Fuller AutoShift 18-speed
mode, request an upshift by pulling upward on transmission is able to perform triple downshifts
the control. If the requested gear is available, the when the next three lower gears are available
transmission will upshift. and conditions are right. To triple shift this trans-
NOTE: A single, momentary pull upward on the mission, move the control three times in less
control selects the next higher gear when it is than 1/2 second.
available. Two consecutive, momentary upward If a requested gear is not available, an audible
pulls will cause a skip shift when the next two warning will sound and the gear display module
higher gears are available and conditions are will indicate that the requested gear is not avail-
right. able. Unlike upshifting, an unavailable requested
2. To skip shift, move the control two times in less downshift is stored in memory and the shift will
than 1/2 second. The number of the gear en- be made when the gear is available. The time
gaged will appear on the message display limit for this memory is a programmable param-
screen. eter.
NOTE: The Eaton Fuller AutoShift 18-speed
Start-Up
transmission is able to perform triple upshifts
when the next three higher gears are available 1. With the parking brake applied, press the clutch
and conditions are right. To triple-shift this trans- all the way down to the floor.
mission, move the control three times in less 2. Start the engine.
than 1/2 second.
3. Check to make sure the transmission is in neu-
If a requested gear is not available, an audible tral.
warning will sound and the gear display module
4. With the transmission in neutral, release the
will indicate that the gear is not available. An
clutch.
unavailable requested upshift is not stored in
memory. The upshift must be requested again. NOTE: This allows the speed sensor on the
input shaft to get a reading.
Downshifting
5. Press down on the clutch again and release the
NOTE: With the transmission in drive (D) in the parking brake.
automatic mode, downshifts require no driver 6. Select the desired starting gear.
interaction.
7. Release the clutch.
1. With the transmission in drive in the manual
mode, request a downshift by pushing downward Reverse
on the control. If the requested gear is available,
the transmission will downshift. 1. To engage reverse (R), slide the selector switch
upward to the next position above the neutral
NOTE: A single, momentary push downward on position and disengage the clutch.
the control selects the next lower gear when it is
available. Two consecutive, momentary down- NOTE: AutoShift 10- and 18-speed transmis-
ward pushes will cause a skip shift, when the sions have a dual-range reverse. Reverse low
next two lower gears are available and condi- (RL) is the default reverse gear.
tions are right. 2. Select reverse high (RH) by pulling upward on
2. the control.
To skip shift, move the control two times in less
than 1/2 second. The number of the gear en- NOTE: Reverse may be engaged below a pro-
gaged will appear on the message display grammable forward speed in order to rock the
screen. vehicle. If reverse is selected above the pro-
grammed forward speed, an audible warning will
15.13
sound and a message indicating that the gear is Power Down

not available will appear on the message dis-
play screen. 1. Select Neutral on the shift control.
NOTE: If the gear display does not show a solid
Low Gear Operation "N", neutral has not yet been obtained. Neutral
Use low (L) when descending steep hills and using should always be reached before powering
compression braking. Engine speed will be increased down an UltraShift PLUS, except in cases of
by 200 rpm and shift points will be offset by 200 rpm. emergency.
The efficiency of the exhaust brake will be maxi-
mized. 2. Set the parking brake.
3. Turn off the ignition, and shut down the engine.
Using the Clutch
Use the clutch to start and stop the vehicle. Reverse (R)
NOTE: If attempting to select a non-Neutral
Eaton Fuller UltraShift PLUS mode without applying the service brakes, the
transmission will not shift into gear. To shift into
Eaton Fuller UltraShift PLUS automated transmis-
sions use shift selection software and electric clutch gear, select Neutral, apply the service brakes,
actuation; a clutch pedal is not needed to operate the and select the desired mode again. Also, the
vehicle. These transmissions use the four-position vehicle will not engage reverse above 2 mph (3
SmartShift control (see Fig. 15.6) on the steering km/h).
column to select mode, direction, neutral, low, and to Reverse (R) is at the upper end of the four-position
make manual shifts. To know what gear the transmis- selector switch located at the end of the SmartShift
sion is in, see the current gear indicator on the dash. control. To select R, press in the neutral lock button
Forward shifts can be made either manually or and move the selector switch to the position above
automatically. neutral. The default Reverse gear is engaged.
Power Up
NOTICE
NOTE: Engine cranking is delayed until the
transmission power-up is complete and the gear Avoid launching the vehicle in high range.
display shows a solid "N". Launching the vehicle in high range increases
the likelihood of clutch abuse and could be detri-
1. With the parking brake set, turn the ignition mental to clutch life.
switch to the ON position.
2. Start the engine. Automatic Mode (AUTO)
3. Apply the service brake. In automatic drive mode (AUTO), upshifts and down-
shifts are made by the UltraShift PLUS without driver
NOTE: If the service brake is not applied while intervention. Press in the neutral lock button, move
selecting a starting gear, the initial start gear will the selector switch to Drive (D), and press down on
not be found and the driver will need to select the throttle pedal. The transmission will shift auto-
Neutral and press the service brake while se- matically.
lecting the desired mode. NOTE: If attempting to select a non-Neutral
4. Select the desired mode and starting gear. (Inap- mode without applying the service brakes, the
propriate start gear selections are ignored to transmission will not shift into gear. To shift into
avoid damaging the transmission.) gear, select Neutral, apply the service brakes,
5. Release the parking brake. and select the desired mode again.
6. Release the service brake and apply the accel- In Drive, the start gear is automatically selected. The
erator. selected start gear can vary depending on several
15.14
vehicle inputs such as load, grade, and axle/ transmission will not shift into gear. To shift into
transmission ratio. The start gear can be changed gear, select Neutral, apply the service brakes,
using the SmartShift control, provided the selected and select the desired mode again.
gear would allow the vehicle to launch without dam-
aging the transmission. If the start gear is changed Manual Mode Override
using the SmartShift control, it will be the default until
the vehicle is powered down or the selection is The system is equipped with a manual mode over-
changed again manually. ride function. If the vehicle is being "back driven" (for
example, descending a grade and vehicle speed ex-
IMPORTANT: Prior to ascending a steep grade, ceeds engine speed) and the engine speed is exces-
either reduce the default start gear by one sively high, the system will upshift automatically.
(using the SmartShift control) or apply full Also, if the start gear is changed and it causes the
throttle for the duration of the grade so the ve- engine to lug at takeoff, the system will override the
hicle maintains the proper engine and vehicle current position and select the best available gear.
speed during the entire grade.
Low (L)
In Drive, the transmission automatically performs up-
shifts and downshifts. However, when the transmis- Low (L) is at the lower end of the four-position selec-
sion is near the shift point, the shift can be forced tor switch located at the end of the SmartShift con-
using the upshift or downshift function of the Smart- trol. Use Low when wanting to maximize engine
Shift control. braking and minimize the use of the brake pedal—for
example, when driving down long grades or when
NOTE: The transmission may deny a shift while coming to a stop. To select Low, press in the neutral
ascending or descending a grade if the load of lock button and move the selector switch to the L
the vehicle and grade of the terrain in combina- position. The lowest available start gear will be se-
tion with the drivetrain ratio and engine torque lected (the starting gear cannot be changed in Low).
fall outside of the acceptable range to perform a
If Low is selected while moving, the transmission will
shift. If the shift is denied, a tone will sound. not upshift (unless the system initiates a Low over-
ride). The system will downshift at the earliest oppor-
Manual Mode (MAN) tunity to provide maximum engine braking.
In manual mode (MAN), the driver selects upshifts NOTE: If attempting to select a non-Neutral
and downshifts instead of letting the UltraShift PLUS mode without applying the service brakes, the
select them automatically. Manual shifting may be transmission will not shift into gear. To shift into
helpful when traversing a work site, railroad tracks,
gear, select Neutral, apply the service brakes,
or steep grades, for example. To drive forward, press
in the neutral lock button, move the selector switch to and select the desired mode again.
Drive (D), and press down on the throttle pedal. To
shift up, pull the lever up (towards you); to shift Low Override
down, push the lever down (away from you). The The system is equipped with a Low override function.
system holds the current gear unless a shift is re- If the vehicle is being "back driven" (for example, de-
quested or if the system initiates a manual mode scending a grade and vehicle speed exceeds engine
override. speed) and the engine speed is excessively high, the
NOTE: The transmission may deny a shift while system will upshift automatically. Also, if the start
gear is changed and it causes the engine to lug at
ascending or descending a grade if the load of
takeoff, the system will override the current position
the vehicle and grade of the terrain in combina- and upshift.
tion with the drivetrain ratio and engine torque
fall outside of the acceptable range to perform a Clutch Abuse Protection
shift. If the shift is denied, a tone will sound.
Although a vehicle equipped with an UltraShift PLUS
NOTE: If attempting to select a non-Neutral uses an automated clutch, the clutch can still over-
mode without applying the service brakes, the heat and slip with improper use. The clutch abuse
15.15
protection feature helps protect the clutch if the auto- Engaging Creep Mode
mated clutch starts to overheat. When the clutch
abuse protection feature initiates and sounds a warn- To engage Creep Mode:
ing tone, full clutch actuation must be completed 1. Select Low or Manual Mode and the desired
quickly. If it is not completed quickly enough, the sys- gear (while stopped or moving).
tem will either open the clutch (if the throttle pedal is
not being pressed) or close the clutch (if the throttle 2. Apply the throttle pedal to accelerate the vehicle
pedal is being pressed). If the abuse continues, the until the clutch is closed (engaged).
system will open the clutch and take away throttle 3. Release the throttle pedal. The vehicle will con-
control briefly to allow the clutch to cool down. tinue moving at governed low engine idle speed.
To protect the clutch:
Exiting Creep Mode
• Select the lowest possible start gear for the
application. To exit Creep Mode, apply the throttle pedal to accel-
erate temporarily, or select a higher gear in Manual
• Use Creep Mode when appropriate. Mode. (Creep Mode can be resumed in the selected
• Use the service brakes and the Hill Start Aid gear by releasing the throttle pedal.)
when launching on a grade. NOTE: The transmission will exit Creep Mode if
• Minimize the time it takes to engage the clutch the engine lugs 150 rpm below the governed
from rest. low engine idle speed. In this case, a lower gear
• Do not use the throttle to hold the vehicle on a should be selected if available.
grade; use the service brakes.
Hill Start Aid
• Do not use the throttle to stop roll back on an
incline after Hill Start Aid disengages; use the UltraShift PLUS transmissions are equipped with a
service brakes, and then relaunch. Hill Start Aid (HSA) feature to prevent the vehicle
from rolling while on grades steeper than 3% and
• Do not continually start and stop, especially allow for a controlled launch. A grade sensor is used
when loaded; use a lower gear or Creep Mode. to determine when to engage the feature.
Creep Mode HSA is "on" by default. It can be turned off by press-
ing and releasing the override switch on the dash
The Creep Mode function allows the vehicle to main- (see Chapter 5). HSA will turn back on after the first
tain a constant speed at engine idle without the successful launch.
driver holding the throttle pedal position. This mode
When the vehicle is stopped on a grade greater than
is useful for very low-speed maneuvering and appli-
3% and in a forward mode or reverse, depress the
cations where steady vehicle speed is required. The service brakes then release them. The vehicle will
vehicle speed is determined by the selected gear
begin to move after 3 seconds, and the clutch will
ratio operating at governed low engine idle speed.
perform partial engagements to slow the vehicle mo-
Any available gear may be selected, though the tion. Either step on the brake or apply the throttle to
transmission will downshift or exit Creep Mode to continue negotiating the grade.
prevent stalling if the engine lugs due to load condi-
tions.
Engine Overspeed Protection
By default, Creep Mode can be activated while in
Manual Mode or Low. Eaton’s ServiceRanger diag- The system will upshift if necessary to prevent en-
nostic software can be used to enable Creep Mode gine overspeed in Drive, Manual, and Low.
in Automatic Mode and/or Reverse.
Shuttle Shifting
Shuttle shifting from reverse to any forward mode is
only allowed if the vehicle speed is approximately
zero.
15.16
Auto Start Gear Selection and • If using Manual mode in soft soil and/or sand,
do not attempt an upshift and try to maintain
Override the current gear.
The UltraShift PLUS system uses various inputs to • If the vehicle comes to a stop in the sand it
automatically select the best start gear in Drive and may be necessary to back up prior to attempt-
Manual. This selection can be changed using the ing forward movement.
SmartShift control; however, if the selection re-
quested could cause damage or engine lugging, the ATC Mud/Snow Mode
request will be denied and a tone will sound.
To select the mud/snow mode, depress the ATC
Skip Shifting switch (see Chapter 5). This mode raises the wheel
slip speed that is allowed before the traction control
When appropriate, the UltraShift PLUS system may activates. The point at which the traction control will
skip shift in Drive. When prevailing conditions like actuate the braking system increases with throttle:
load and grade allow, skip shifts can be performed in low throttle allows the system to brake the wheels
Manual mode using the SmartShift control. earlier; heavy/full throttle raises the point of the ac-
ceptable wheel slip.
Auto Neutral
The UltraShift PLUS system will automatically shift to
Load-Based Shifting
neutral if the vehicle is left in Drive and the parking The UltraShift PLUS system is adaptive and will
brake is set. "AN" will show on the gear display. To change the shift points based on grade, engine RPM,
re-engage the transmission, select Neutral and then throttle position, and vehicle load. After changing
either Drive or Reverse on the shift control (it will re- loads or powering up, the system needs to relearn
engage regardless of whether the parking brake is these inputs for the first few shifts to make the
released). proper adjustments.
Automatic Traction Control Coasting

The UltraShift PLUS system requires the Automatic When coasting to a stop on level terrain, the Ultra-
Traction Control (ATC) option to be enabled when Shift PLUS system may not downshift into the lower
driving in soft soil/sand to prevent wheel slippage gears. It will select a gear after the throttle is applied.
and shifting issues. The ATC system has two modes:
"normal" (for sand and loose road surface) and a
mud/snow setting.
ATC Normal Mode

In normal mode, the system will engage the brakes
on the wheel or side that the wheel slip is occurring
to help the vehicle gain traction. The point at which
the traction control will actuate the braking system
increases with throttle: low throttle allows the system
to brake the wheels earlier; heavy/full throttle raises
the point of the acceptable wheel slip.
Adhere to the following points when driving in ATC
normal mode:
• If using Automatic mode in soft soil and/or
sand, maintain the engine speed between
1000 and 1300 rpm to prevent unnecessary
upshifting.
15.17
16
Drive Axles
Differential Locks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16.1
Two-Speed Drive Axles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16.2
Drive Axles
Differential Locks To unlock the interaxle differential, move the lockout

control valve to UNLOCK while maintaining vehicle
Tandem Drive Axles with Interaxle speed, after leaving the poor road conditions. Let up
momentarily on the accelerator to allow the shift,
Differential Lock then resume driving at normal speed.
An interaxle differential lock is standard on vehicles
equipped with tandem drive axles. It is driver- Driver-Controlled Differential Lock
actuated by means of a LOCK/UNLOCK control (DCDL)
valve switch located on the dash in the cab (see
Chapter 5 for more information about the switch). Some vehicles are equipped with a driver-controlled
Engagement can be at any speed, provided the differential lock (DCDL) that is operated by a dash
wheels are not slipping or spinning. A red indicator switch in the cab (see Chapter 5 for more informa-
illuminates when the interaxle differential lock is en- tion about the switch). The differential lock provides
gaged. maximum traction for slippery conditions by forcing
the wheels on a drive axle to rotate together. The
In the UNLOCK position, there is differential action differential lock should be engaged when the vehicle
between the two axles. The differential compensates is stopped or moving at a low, constant speed and
for different wheel speeds and variations in tire size. the wheels are not spinning, slipping, or losing trac-
Keep the interaxle differential unlocked for normal tion. Do not exceed 25 mph (40 km/h) when the dif-
driving on roads where traction is good. ferential lock is engaged.
In the LOCK position, the interaxle differential is On tandem axles there are three possible DCDL op-
locked out and the driveshaft becomes a solid con- tions:
nection between the two axles. Power entering the
forward axle is also transmitted straight through to • Forward-rear carrier only
the rear axle, so both axles turn together at the same
• Rear-rear carrier only
speed. The LOCK position should be used when the
vehicle encounters poor traction conditions; however, • Both rear carriers.
it also increases drivetrain and tire wear and should
An indicator light comes on when the DCDL is en-
be used only when improved traction is required.
gaged. An optional buzzer can also be used to indi-
Interaxle Differential Lockout Operation cate DCDL engagement.
The DCDL provides maximum traction under slippery
NOTICE conditions. When the DCDL is engaged, the clutch
collar completely locks the differential case, gearing,
Do not actuate the interaxle differential control and axle shafts together, maximizing traction of both
valve while the tires are slipping. Do not operate wheels and protecting against spinout. Under normal
the vehicle continuously with the interaxle differ- traction conditions, do not engage the DCDL; operate
ential locked during extended good road condi- the axle with differential action between both wheels.
tions. Using the IAD lock when wheels have good
traction can harm the axle, wear the tires exces- WARNING
sively, and increases fuel consumption. Release
the IAD lock as soon as road conditions permit it. Be especially careful when driving under slippery
conditions with the differential locked. Though
To lock the interaxle differential and achieve maxi- forward traction is improved, the vehicle can still
mum pulling power when approaching slippery or slip sideways, causing possible loss of vehicle
poor road conditions, move the lockout control valve control, personal injury, and property damage.
to LOCK while maintaining vehicle speed, before en-
countering the poor road conditions. Let up momen-
tarily on the accelerator to engage the differential
lock. Proceed over poor road conditions with caution.
Do not wait until traction is lost and the tires are
spinning before locking the interaxle differential.
16.1
Drive Axles
Main Differential Lock Operation To unlock the main differential, move the control
switch to the unlock position. Briefly let up on the
accelerator to relieve torque on the gearing, allowing
NOTICE the differential to fully unlock.
The differential lock should be engaged when the NOTE: If the differential lock system is con-
vehicle is stopped or moving at a low, constant nected through the low speed range of the
speed and the wheels are not spinning, slipping, transmission, shifting out of low speed range will
or losing traction. Engagement at high speed or also unlock the differential.
power can damage the axle(s).
When the differential lock disengages, the indicator
Do not permit rear wheels to spin freely for more light will go off and the buzzer will stop.
than ten seconds when traction is lost. Shift into
LOCK to prevent damage to interaxle and main
differentials.
Single Drive Axles with Traction
Equalizer
To lock the main differential and obtain maximum
traction under slippery conditions, move the control Some single drive axles are equipped with a traction
switch to the lock position. equalizer that is a load-sensing, self-actuating fea-
ture. A traction equalizer provides normal differential
NOTE: On some vehicles, the differential lock action where traction is good. When one wheel be-
system is connected through the low speed gins to spin faster than the other, clutch plates in the
range of the transmission. If this system is used, differential housing automatically engage, delivering
the transmission must be in the low speed power to both wheels. There is no operator control
range for the differential to fully lock. with this feature.
If the vehicle is moving, maintain a constant vehicle A traction equalizer occasionally tends to slip in a
speed while engaging the differential lock. Briefly let jerking motion, producing irregular intervals of sharp
up on the accelerator to relieve torque on the gear- noises. This generally occurs when the vehicle is op-
ing, allowing the differential to fully lock. The indica- erating at low speeds on fairly sharp turns. This con-
tor light should come on and the buzzer should dition is corrected by adding a friction modifier to the
sound on vehicles so equipped. When the differential axle lubricant. This additive tends to reduce the static
is fully locked, the turning radius will increase be- coefficient of friction to a value equal to, or lower
cause the vehicle understeers. See Fig. 16.1. Drive than, the sliding coefficient.
cautiously and do not exceed 25 mph (40 km/h). See Group 35 of the Cascadia™ Maintenance
Manual for additional information on friction modifiers
A and when to add them to axle lubricants.
CAUTION
Tire sizes on both rear wheels should be the
B same on axles equipped with a traction equalizer.
If not, excessive wear may occur in the traction
equalizer.
02/09/96 f350079a
Two-Speed Drive Axles
A. Turning Radius When Differential is Locked Axle Shift
(engaged)—Understeer Condition
B. Turning Radius When Differential is Unlocked
(disengaged) CAUTION
Fig. 16.1, Turning Radius To prevent transmission and axle damage, make
sure the automatic transmission is in high range
16.2
Drive Axles
when performing an axle shift with the vehicle Normal Response: The LED in the switch blinks until
moving. the axle shifts speed. At this point, the LED comes
on steady and stays illuminated. In normal operation,
Axle shift is a function installed on vehicles with two-
the axle may shift so quickly that the blinking of the
speed axles to allow the use of the low speed range
switch is barely noticeable.
when greater traction and maximum pulling power is
needed at low engine speed (rpm). If operation of the switch is not possible for any rea-
Under normal operating conditions, the vehicle is op- son (interaxle lock is on, ignition is turned off, etc.),
erated using the high-speed gear ratios of the axle. the LED will stop blinking and turn off.
Under extreme weather or off-road conditions, at low Slow Response: If operation of the switch is slowed
speed and rpm and/or to pull heavy loads, the ve- for any reason (by cold weather, low air pressure,
hicle must be operated using the low-speed, or re- etc.), the switch will continue to blink until the axle
duction, gear ratios of the axle. shifts. As in the normal response, the LED comes on
steady and stays illuminated.
Axle Shift Switch
Abnormal Response: If the LED blinks for more than
The axle shift switch is a two-position rocker switch 30 seconds, the axle shift function/mechanism may
(Fig. 16.2) installed on vehicles with two-speed not be operating correctly. Bring the vehicle to an
axles. authorized Freightliner service facility for testing.
Axle Switch Interlock

NOTE: On vehicles with tandem drive axles,
there is an interlock that prevents an axle from
shifting speed whenever the interaxle lock is on.
If the axle shift switch is pressed when the interaxle
lock is on, the axle shift will not be completed. The
AXLE LED does the following:
SHIFT • If the LED is off, the LED comes on briefly and
turns off again.
06/12/2007 f610951 • If the LED is on, it stays on.
Fig. 16.2, Axle Shift Switch To complete the axle shift, turn off the interaxle lock
and press the axle shift switch again. If still needed,
To shift the axle from low speed to high speed, press the interaxle lock can then be reactivated.
the top of the switch. To turn the axle shift off (switch
from high speed back to low speed), press the bot-
tom of the switch. When the axle has shifted speed,
the LED turns off.
When the panel lights are on, the AXLE SHIFT leg-
end is backlit in green.
IMPORTANT: If the LED in the switch begins to
blink during normal operation, when the switch
has not been activated, this indicates an error
condition. Bring the vehicle to an authorized
Freightliner service facility as soon as possible.
When the axle shift switch is pressed, three re-
sponses are possible: a normal response, a slow re-
sponse, and an abnormal response.
16.3
17
Steering System
Power Steering System General Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17.1
Power Steering Systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17.1
Steering System
Power Steering System Power Steering Systems

General Information Steering Gear System
When there is no load on the vehicle, and the front The steering gear system includes the power steer-
tires are pointed straight ahead, the steering wheel ing gear, hydraulic hoses, power steering pump, res-
spokes should be centered, ±10 degrees, as shown ervoir, and other components. Some models are also
in Fig. 17.1. See Group 46 of the Cascadia™ Work- equipped with a separate hydraulic power cylinder on
shop Manual for steering adjustment procedures. the right side of the front axle, or a right-hand slave
gear (such as the TRW RCH-45). The power steering
pump, driven by the engine, provides the power as-
sist for the steering system. If the engine is not run-
ning, there is no power assist. If the power-assist
feature does not work due to hydraulic fluid loss,
steering pump damage, or some other cause, bring
the vehicle to a safe stop. Do not drive the vehicle
10° 10° until the cause of the problem has been corrected.
1 2 Rack and Pinion Steering System

The rack and pinion steering gear is mounted to the
10° 10° front axle with two brackets, and connected by tie-
rod ends to the axle steering arms. When the steer-
ing wheel is turned, the intermediate steering shaft
turns the input shaft, rotating the torsion bar and the
06/13/2007 f462080 valve. When the valve turns, power steering fluid is
1. 9 o’Clock 2. 3 o’Clock redirected and provides power assist to turn the pin-
ion gear meshed with the rack teeth, moving the rack
Fig. 17.1, Proper Steering Wheel Position (with tires left or right. The rack, with a tie-rod at each end,
pointed straight ahead) then moves the steering arms on the axle, and pivots
the wheels.
CAUTION This design provides drivers with more responsive
steering, with increased performance and “road feel.”
Never steam clean or high-pressure wash the It virtually eliminates steering issues when the driver
steering gear. Internal damage to gear seals, and hits a bump (bumpsteer), and significantly reduces
ultimately the steering gear, can result. roll steer when a vehicle goes into a curve. Wander-
ing is significantly reduced as well, so the vehicle
WARNING tends to drive straight on the highway. It has a lower
steering ratio, which means drivers don’t have to turn
Driving the vehicle without the power-assist fea- the steering wheel as much to get the wheels to turn
ture of the steering system requires much greater a given distance. Overall, rack and pinion steering
effort, especially in sharp turns or at low speeds, greatly improves steering response, and reduces
which could result in an accident and possible driver effort and fatigue.
injury.
Drivers should carefully use the power available with
a power steering system. If the front tires become
lodged in a deep chuckhole or rut, drive the vehicle
out, instead of using the steering system to lift the
tires from the hole. Also, avoid turning the tires when
they are against a curb, as this places a heavy load
on steering components and could damage them.
17.1
18
Fifth Wheels
Fifth Wheels, General Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18.1
Fifth Wheel Coupling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18.1
Fifth Wheel Uncoupling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18.4
Fifth Wheel Slide . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18.7
Fifth Wheels
Fifth Wheels, General Fifth Wheel Lubrication

Information
WARNING
WARNING Keep the fifth wheel plate lubricated to prevent
binding between the tractor and trailer. A binding
Do not use any fifth wheel that fails to operate fifth wheel could cause erratic steering and loss
properly. Doing so may cause loss of vehicle of vehicle control, possibly resulting in personal
control, possibly resulting in severe personal in- injury or death.
jury or death.
The standard fifth wheel plate must be kept well lu-
Air-Suspension Dump Valve bricated with chassis grease to prevent friction and
binding between the tractor fifth wheel plate and the
The air-suspension dump valve may be used to ad- trailer.
just the tractor height to aid with coupling to or un-
For a low-lube fifth wheel plate, inspect the condition
coupling from a trailer. See Fig. 18.1. When the
of the low-lube pads. There should be no damaged
switch is set to LOWER, the air-suspension dump
or missing pieces. Slight puckering at the outside
valve deflates the air springs to lower the rear of the
edges is normal.
vehicle. In the AUTO position, the automatic ride-
control valves operate for normal driving. For lubrication instructions, see Group 31 of the
Cascadia® Maintenance Manual.
WARNING
Fifth Wheel Coupling
Never exhaust air from the suspension while
driving. The suspension will not absorb road Fifth wheel coupling is activated with the lock control
shocks, possibly damaging components, and ve- handle located on either the right side or left side of
hicle handling may be compromised. This could the fifth wheel. Coupling has successfully occurred
result in loss of vehicle control, possibly result- when the kingpin has been forced into the jaws and
ing in severe personal injury or death. the lock control handle has moved to the locked
position.
NOTICE
NOTICE
Do not operate the vehicle over uneven ground
such as ramps, speed bumps, curbs, etc. with Some fifth wheels may be mounted on sliding
the air springs deflated. Doing this may lead to rails. Before attempting to couple a trailer to a
air bag separation from the piston, preventing the sliding fifth wheel, the slide feature must be
suspension air springs from inflating. locked to prevent the top plate from sliding rap-
idly forward or rearward, causing damage to the
fifth wheel or kingpin.
Fontaine and Holland Fifth Wheels

DO NOT LOWER Coupling
WHEN VEHICLE SUSP
IS IN MOTION AIR 1. Chock the front and rear of the trailer tires to
prevent the trailer from moving.
LOWER AUTO 2. Ensure the fifth wheel jaw is fully open and the
operating rod is in the unlocked position. See
10/25/2010 f611101 Fig. 18.2 or Fig. 18.3.
3. Make sure the fifth wheel top plate is tilted so the
Fig. 18.1, Air-Suspension Dump Valve
ramps are as low as possible.
18.1
Fifth Wheels
1
1
2
1 1
3
B
2
10/26/2010 f310110a
NOTE: Make sure the safety latch is down when the 11/02/2010 f310447
control handle is locked. 1. Safety Latch
A. Unlocked B. Locked 2. Operating Rod (locked)
3. Operating Rod (unlocked)
1. Safety Latch 2. Lock Control Handle
Fig. 18.3, Holland Simplex SE Locking Mechanism
Fig. 18.2, Fontaine Locking Mechanism
4. Position the tractor so that the center of the fifth D

wheel is in line with the trailer kingpin. The king-
C A
pin should be in a position to enter the throat of
the locking mechanism.
NOTICE
Attempting to couple at the wrong height may B
cause improper coupling, which could result in
damage to the fifth wheel or kingpin.
10/28/2010 f311124
5. Adjust the trailer height if required. A. Fifth wheel must lift C. Ramps tilted down
For a standard fifth wheel plate, the trailer trailer D. 4 to 8 inches
should contact the fifth wheel approximately 4 to B. Adjust trailer height
8 inches (10 to 20 cm) behind the fifth wheel Fig. 18.4, Trailer Connection Point, Standard Fifth
pivot. See Fig. 18.4. Wheel
For a low-lube fifth wheel plate, the fifth wheel
prevent from hitting the kingpin too hard, then
must slide freely under the trailer, and the trailer
resume backing slowly until the fifth wheel locks.
should contact the fifth wheel at the pivot. See
Fig. 18.5. On a standard fifth wheel, the fifth wheel must lift
the trailer.
6. With the fifth wheel lock opening aligned with the
trailer kingpin, back the tractor slowly toward the On a low-lube fifth wheel, do not lift the trailer as
trailer. After sliding under the trailer, STOP to this may damage the fifth wheel plate.
18.2
Fifth Wheels
A B
09/10/2010 f311126
A. No gap between trailer B. Kingpin inside lock
and fifth wheel
A
Fig. 18.6, Coupling Inspection
09/10/2010 f311125
A. Adjust trailer height B. Ramps tilted down
NOTICE
Fig. 18.5, Trailer Connection Point, Low-Lube Fifth Always make sure the connection hanger keeps
Wheel the trailer air hoses and electrical cables posi-
tioned so that they do not rub on anything. Rub-
7. Apply the tractor parking brakes. bing may wear through hoses or cables, resulting
in air leaks, or exposed or broken wires, poten-
WARNING tially affecting trailer brake or electrical systems.
11. Charge the air brake system with air, checking
A visual inspection is required by law. Some im- that the air connections do not leak.
proper couplings can pass a pull test. Sound is
not reliable. Get out of the cab and look. Incor-
rect coupling could cause the trailer to discon- WARNING
nect, possibly resulting in serious personal injury
or death. Incorrect fifth wheel lock adjustment could cause
the trailer to disconnect, possibly resulting in se-
8. Perform a coupling inspection, checking that rious personal injury or death.
there is no gap between the bottom of the trailer
and the fifth wheel, and that the kingpin is se- 12. With the trailer wheels chocked and the brakes
curely locked. See Fig. 18.6 set, check for clearance between the kingpin and
the fifth wheel jaws by moving the tractor forward
When lockup has occurred, the fifth wheel con- and backward against the locked kingpin. If slack
trol handle moves to the locked position. Make is present, uncouple the trailer and have the fifth
sure that the safety latch is down over the lock wheel inspected and adjusted by a certified
control handle to hold the control handle in the technician.
locked position. (The safety latch will only rotate
down if the operating rod is fully retracted in the Jost Fifth Wheel Coupling
locked position.) See Fig. 18.2 for Fontaine fifth
wheels. See Fig. 18.3 for Holland fifth wheels. 1. Tilt the ramp down.
9. Release the tractor parking brakes. Test for king- 2. Open the kingpin locks. See Fig. 18.7.
pin lockup slowly inching the tractor forward, pull- 3. Back the vehicle close to the trailer, centering the
ing on the trailer against the chocks.
kingpin on the fifth wheel.
10. After lockup is completed, connect the tractor-to-
4. Chock the trailer wheels.
trailer air system lines and the electrical cable to
the trailer. Take care to prevent dirt or foreign 5. Connect the air lines and electrical cable.
material from entering the air system lines.
6. Ensure that the red trailer air supply valve (trailer
brake) is pulled out, and that the trailer parking
18.3
Fifth Wheels
nect, possibly resulting in serious personal injury

or death.
A 10. Apply the tractor parking brake, then perform a
physical check for positive kingpin lockup, and
that there is no gap between the trailer and the
fifth wheel. See Fig. 18.6.
11. Ensure that the release handle is in the locked
position adjacent to the casting. See Fig. 18.8.
12. Release the tractor parking brakes and test for
kingpin lockup by slowly moving the tractor for-
09/10/2010 f311128 ward, pulling on the trailer against the chocks.
A. Lock held open by catch mechanism
Fifth Wheel Uncoupling
Fig. 18.7, Jost Release Handle Unlocked
Manual Uncoupling
brakes are set. See Chapter 5 in this manual for
operation of the dash-mounted brake controls. 1. Apply the tractor and trailer parking brakes.
2. Chock the trailer rear wheels.
NOTICE 3. Lower the trailer landing gear until the weight is
Attempting to couple at the wrong height may removed from the fifth wheel.
cause improper coupling, which could result in 4. Disconnect the tractor-to-trailer air system lines
damage to the fifth wheel or kingpin. and electrical cable. Plug the air lines to prevent
7. Adjust the trailer height (if required). dirt or foreign material from entering the lines.
For a standard fifth wheel plate, the trailer 5. Verify that both the yellow parking-brake and red
should contact the fifth wheel approximately 4 to trailer-air-supply knobs are out, the tractor and
8 inches (10 to 20 cm) behind the pivot. See trailer parking brakes are set, and that the trailer
Fig. 18.4. is prepared for uncoupling.
For a low-lube fifth wheel plate, the fifth wheel 6. Release the kingpin locking mechanism following
must slide freely under the trailer, and the trailer the instructions for each manufacturer below.
should contact the fifth wheel at the pivot. See 6.1 Fontaine: Lift the safety latch and pull the
Fig. 18.5. lock control handle to the unlocked posi-
8. Back the tractor under the trailer. tion. See Fig. 18.2.
On a standard fifth wheel, the fifth wheel must lift 6.2 Holland: In the locked position the safety
the trailer. indicator swings freely over the operating
rod. See Fig. 18.9, View A.
On a low-lube fifth wheel, do not lift the trailer as
this may damage the fifth wheel plate. To unlock the mechanism, manually rotate
the safety indicator toward the rear of the
9. After sliding under the trailer, STOP to prevent fifth wheel. See Fig. 18.9, View B.
from hitting the kingpin too hard, then resume
backing slowly until the fifth wheel locks. Pull the operating rod out. When the
upper operating rod shoulder is outside
the slot, raise the handle and place the
WARNING shoulder of the upper rod against the plate
casting, above the slot. See Fig. 18.9,
A visual inspection is required by law. Some im-
View C.
proper couplings can pass a pull test. Sound is
not reliable. Get out of the cab and look. Incor-
rect coupling could cause the trailer to discon-
18.4
Fifth Wheels
OK OK
09/10/2010 f311127
Fig. 18.8, Jost Release Handle Locked
The fifth wheel is now in the lockset posi- been uncoupled and coupled again. Failure to do
tion and is ready for uncoupling. As the so may result in separation of the trailer from the
tractor pulls away from the trailer the king- tractor, possibly causing serious personal injury
pin forces the jaw to rotate, contacting the or death.
lock. Continued rotation of the jaw forces
the lock to move outward, and drops the Preparing the Trailer for Uncoupling
upper rod back into the slot. See Fig. 18.9
View D. The wheel is now ready for Before using the air valve to unlock a fifth wheel
coupling. kingpin, prepare the trailer as follows.
1. Apply the tractor and trailer parking brakes.
6.3 Jost: Pull the retractable handle out, then
secure it in the open position with the 2. Chock the trailer rear wheels.
catch. See Fig. 18.7.
3. Lower the trailer landing gear until the weight is
7. Release the tractor parking brake then drive out removed from the fifth wheel.
slowly, allowing the trailer to slide down the fifth
wheel and pick-up ramps. 4. Disconnect the tractor-to-trailer air lines and elec-
trical cable. Plug the air lines to prevent dirt or
Air-Actuated Uncoupling foreign material from entering the lines.
An air-actuated kingpin release valve is optional with Fontaine and Holland Fifth Wheels Air-
all fifth wheels. See Fig. 18.10. Activated Kingpin Unlock
NOTE: In the event of an air system failure, air- 1. Verify that both the yellow parking-brake and red
actuated kingpins can be manually released fol- trailer-air supply knobs are out, the tractor and
lowing the instructions for manual unlocking. trailer parking brakes are set, and that the trailer
is prepared for uncoupling.
WARNING NOTE: On Fontaine and Holland fifth wheels, if
the tractor parking brake is not set, the air-
Once the kingpin release valve has been pulled actuated kingpin-release valve will not activate.
the kingpin lock is released. The vehicle MUST
NOT be driven with the trailer until the trailer has
18.5
Fifth Wheels
1
4
A 2 C
B D
11/02/2010 f311133
A. Locked Position C. Lockset Position (upper rod resting against casting
B. Unlatched Position (safety indicator rotated towards the above slot)
rear of the fifth wheel) D. Open Position (ready for recoupling)
1. Safety Indicator 3. Upper Rod
2. Operating Rod 4. Plate Casting
Fig. 18.9, Holland Kingpin Locking Mechanism
2. Pull and hold the kingpin release valve Jost Fifth Wheels Air-Activated Kingpin
(Fig. 18.10) until the kingpin lock mechanism Unlock
opens and locks in place.
1. Verify that both the yellow parking-brake and red
3. Release the pull valve. trailer-air-supply knobs are out, the tractor and
4. Release the tractor parking brake. trailer parking brakes are set, and that the trailer
is prepared for uncoupling.
5. Drive out from under the trailer.
18.6
Fifth Wheels
The maximum axle weight ratings are shown on the

Federal Motor Vehicle Safety Standard (FMVSS)
label or Canadian Motor Vehicle Safety Standard
(CMVSS) label attached to the left rear door post of
the tractor. The desired load on the axle is no less
than 80 percent of the maximum axle weight rating,
but in no instances should the axle load exceed the
maximum axle weight rating given on the FMVSS or
CMVSS label.
Manual Slide Operation

The manual slide feature is operated from the fifth
wheel plate with a manual release handle using the
10/26/2010 f611102 following procedure. See Fig. 18.11.
Fig. 18.10, Air-Actuated Kingpin Release Valve 1
NOTE: With Jost fifth wheels, if the trailer park-
ing brake is not set the air-actuated valve will
not activate.
2. Release the tractor parking brake.
3. Pull and hold the kingpin release valve, then
drive forward slowly.
4. After the trailer has slid down the fifth wheel and
pick-up ramps, release the pull valve.
Fifth Wheel Slide

WARNING
2
Adjust the fifth wheel slide correctly, and do not 07/25/95 f310190
overload any tractor axle by incorrectly loading 1. Locking Wedge
the trailer. Incorrect slide adjustment or improper 2. Slide Release Pull Handle
axle loading could cause erratic steering and
loss of vehicle control, possibly resulting in seri- Fig. 18.11, Manual Release Sliding Fifth Wheel
ous personal injury or death. (Fontaine shown)
On sliding fifth wheel assemblies, the fifth-wheel 1. Stop the tractor and trailer in a straight line on
plate is attached to rails that allow forward and rear- level ground. Pull the red trailer air supply knob
ward movement of the fifth wheel to optimally distrib- to apply the trailer parking brakes.
ute the load across the axles. Slots are evenly 2. Apply the tractor parking brake, then release the
spaced along the slide rails, and retractable wedges sliding mechanism using the appropriate method
are positioned through the slots to hold the fifth for the fifth wheel manufacturer.
wheel in the desired position.
2.1 Fontaine: Lift the slide release pull handle
The amount of load distribution on the front steering to disengage it from the guide plate. Then,
axle and rear drive axle(s) will have a direct effect on pull out the handle until it is in the un-
the steering control of the vehicle. Determine the locked position and can be positioned
front and rear axle weights by weighing the vehicle against the guide plate to hold it out. The
on scales designed for this purpose.
18.7
Fifth Wheels
handle will stay in the unlocked position 5. Release the tractor parking brakes, then slowly
until it is manually disengaged from the move the tractor forward or backward until the
guide plate. See Fig. 18.12. fifth wheel is in the desired location.
NOTICE
When moving the fifth wheel to the desired posi-
tion, be sure the trailer landing gear will not at
any time come in contact with the tractor frame
or other components. Make sure that the front of
the trailer will not come in contact with the rear
of the cab or with other components if they ex-
tend beyond the rear of the cab.
WARNING
Check that the locking wedges have seated in the
slots. Failure to achieve complete lockup may
10/26/2010 f310050
allow disengagement of the tractor from the
trailer, possibly resulting in serious personal in-
Fig. 18.12, Releasing the Sliding Fifth Wheel, (Fontaine) jury or death.
2.2 6. Apply the tractor parking brakes, then lock the

Holland: Pull the operating rod out. Make
sure both side plungers have released. sliding member in position using one of the fol-
See Fig. 18.13. lowing methods:
6.1 Fontaine: Disengage the slide release
5 pull handle from the guide plate. The slide
4 release pull handle is spring-loaded in the
locked position and will seek the locked
6
position when disengaged from the guide
3 plate. After the slide release pull handle
returns to the fully locked position, visually
8 and physically check the locking wedges
3 to make sure they are fully inserted into
2 the slots in the slide rails. Make sure the
handle is locked in position against the
1 7
guide plate.
6.2 Holland: Raise the operating rod so that it
10/26/2010 f310445 is free to move inward. Make sure that the
lock pins have seated in the base plate
1. Baseplate 5. Slider Saddle Plate
2. Bolted Stop 6. Safety Latch rail holes and the operating rod moves
3. Baseplate Rail 7. Operating Rod into the locked position.
4. Fifth Wheel Mount 8. Operating Lever NOTE: The fifth wheel may need to be moved
Fig. 18.13, Sliding Fifth Wheel Manual Release, slightly to enable the locking wedges to enter
(Holland Simplex) the fully locked position.
3. Lower the trailer landing gear just enough to re-
move the weight from the tractor.
4. Chock the front and rear of the trailer tires to
prevent the trailer from moving.
18.8
Fifth Wheels
Air Slide Operation

The slide feature may be operated with an air switch
mounted in the dash, that operates an air cylinder
that locks and unlocks the slide. See Fig. 18.14.
MUST BE 1
LOCKED WHEN FIFTH
VEHICLE IS IN WHL
MOTION SLIDE
A
UNLOCK LOCK
10/22/2009 f611074
1. Fifth Wheel Air-Slide Switch

Fig. 18.14, Air-Slide Switch
1. Set the air-slide switch (Fig. 18.14) to UNLOCK.

B
Ensure the locking plungers have released. See
Fig. 18.15. 09/10/2010 f311131
For Jost fifth wheels, the mechanism activates as A. Unlocked B. Locked
shown in Fig. 18.16.
Fig. 18.16, Jost Sliding Fifth Wheel
1
2. Lower the trailer landing gear just enough to re-
move the weight from the tractor.
3. Pull the red trailer-air-supply knob to set the
trailer-parking brakes.
4. Slowly move the tractor forward or backward
until the fifth wheel is in the desired location.
NOTICE
Ensure the trailer landing gear does not come in
contact with the tractor frame or other compo-
nents, and that the front of the trailer will not
come in contact with the rear of the cab or other
components if they extend beyond the rear of the
2
cab.
07/25/95 f310189 5. Apply the tractor parking brakes.
1. Locking Wedge 2. Air Cylinder
Fig. 18.15, Air-Operated Sliding Fifth Wheel (Fontaine WARNING
shown)
Check that the locking wedges have seated in the
slots. Failure to achieve complete lockup may
18.9
Fifth Wheels
allow disengagement of the tractor from the

trailer, possibly resulting in serious personal in-
jury or death.
6. Set the air-slide switch to LOCK. Visually inspect
the locking wedges or plungers to make sure
that they are fully inserted in the slide rail slots.
Verify that the plungers have engaged by tugging
the tractor forward while the trailer brakes are
locked and the wheels are chocked.
NOTE: The fifth wheel may need to be moved
slightly to enable the locking wedges to fully
lock.
18.10
19
Trailer Couplings
Air-Suspension Dump Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19.1
Holland Trailer Coupling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19.1
Trailer Couplings
Air-Suspension Dump Valve Operation

The air-suspension height switch may be used to aid Trailer Hookup
in connecting or disconnecting from a trailer. When 1. Chock the front and rear tires of the trailer.
the switch is set to LOWER, the air-suspension
dump valve deflates the air springs to lower the rear 2. Remove the cotter pin, then lift the lock and raise
of the vehicle. In the AUTO position, the automatic the latch.
ride-control valves operate for normal driving. 3. Back up the vehicle, until the drawbar eye is
over the pintle hook.
NOTICE 4. Lower the trailer, until the drawbar eye rests on
Do not operate the vehicle over uneven ground the pintle hook.
such as ramps, speed bumps, curbs, etc. with 5. Close the latch, then insert the cotter pin.
the air springs deflated. Doing this may lead to
air bag separation from the piston, preventing the 6. Hook up the trailer electrical and air lines.
suspension air springs from reinflating. 7. Remove the chocks from the trailer’s tires.
NOTICE Trailer Release

1. Apply the tractor and trailer parking brakes.
Never exhaust air from the suspension while
driving. When the air is exhausted, the suspen-
sion will not absorb road shocks, and compo- WARNING
nents may be damaged.
Do not use the trailer air supply for parking trail-
ers not equipped with spring parking brakes.
Holland Trailer Coupling This applies the trailer service brakes only. As air
General Information bleeds from the trailer brake system, brake appli-
cation is lost. This could allow the unattended
The Holland PH-T-60-AL trailer coupling is designed vehicle to roll away, possibly resulting in serious
for use with trailers having a maximum gross weight personal injury or death.
of 10,000 lb. See Fig. 19.1. It is a rigid-type pintle
2. Chock the front and rear tires of the trailer.
hook, used only on tractor applications, and is fas-
tened to the rear closing crossmember of the vehicle. 3. Disconnect the trailer air and electrical lines.
It is a non-air-adjusted coupling. Plug the air lines to keep out dirt.
4. Take the weight of the trailer drawbar off the
1 2
pintle hook.
3 5. Open the latch, by first removing the cotter pin,
then lift up the lock and raise the latch.
6. Slowly drive the vehicle away from the trailer.
01/20/95 f310314a
1. Lock 3. Latch
2. Cotter Pin 4. Pintle Hook
Fig. 19.1, Holland PH-T-60-AL Trailer Coupling
19.1
20
Pre- and Post-Trip
Checklists
Periodic Inspections and Maintenance, General Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20.1
Checklists . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20.1
Fluids Added . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20.2
Pre- and Post-Trip Checklists
Periodic Inspections and Wheels and Tires Comp.

5 Wheel bearing oil seals and lubrication levels
Maintenance, General 6 Mud Flaps
Information
Saddle Tank Areas Comp.
Regulations in Canada and the U.S. clearly indicate Drain air reservoirs (without automatic drain
that it is the driver’s responsibility to perform an in- 1
valves)
spection, and ensure the complete road-worthiness 2 Fuel tank(s) secure
of a vehicle, before placing it into service. Commer-
3 Frame rails and crossmembers
cial vehicles may be subject to inspection by autho-
4 Visible exhaust components
rized inspectors, and an unsafe vehicle can be taken
"out of service" until the driver or owner repairs it.
Engine Compartment Comp.
Use the following checklists to ensure that vehicle 1 Leakage under engine
components are in good working condition before 2 Air intake system
each trip. Careful inspections eliminate stops later to 3 Engine oil level
fix overlooked or forgotten items. 4 Power steering reservoir level
The checklists in this chapter can be copied and kept 5 Engine coolant level
as a record that the procedures have been com- 6 Visible engine wiring
pleted. For details on how to inspect each item on 7 Frame rails
the checklists, see the corresponding procedure
(step number) in Chapter 21. Cab Comp.
Reset dash-mounted air intake restriction
1
Checklists indicator
2 Air-pressure warning systems
NOTE: Checklists in this chapter correspond 3 Air governor cut-in and cut-out pressures
with the procedures and steps in Chapter 21, 4 Air pressure build-up time
Pre- and Post-Trip Inspections and Mainte- 5 Air system leakage
nance. Your vehicle may not be equipped with 6 Air pressure reserve
all components listed below. 7 Mirrors, windows, windshield
8 Horn, windshield wipers, windshield washers
Daily Pretrip Inspection Checklists 9 Heater and defroster
See the following tables for a list of procedures that 10 Interior lights
should be performed daily, before the first trip. Place 11 Exterior lights
a check mark in the complete (Comp.) column to 12 Seat belts and tether belts
indicate a procedure has been performed. 13 Fuel level
14 Mirror adjustment
Inspector Date 15 Service brakes
16 Backup alarm
Natural Gas Fuel System Comp.

Suspension and Slack Adjusters Comp.
1 Fuel tanks
1 Suspension components
2 Required decals
2 Slack adjusters
3 Vent caps
Wheels and Tires Comp. Plumbing components, fuel fill fitting, fuel
4
lines
1 Wheel covers
Fuel gauge components, fuel level sender
2 Tire condition 5
cable, LNG fuel tank pressure
3 Tire inflation
6 Coolant hoses
4 Rims and wheel components
7 LNG fuel tank pressure
20.1
Pre- and Post-Trip Checklists
Natural Gas Fuel System Comp. Engine Compartment Comp.

8 LNG vaporizer 1 Hood and bumper
9 Low pressure filter drain 2 Hydraulic clutch reservoir
3 Radiator and heater hoses
Weekly Post-trip Inspection Checklist 4 Steering wheel play
See the following table for procedures that should be
performed weekly, post-trip. Place a check mark in Fluids Added
the complete (Comp.) column to indicate a proce-
Use the following table to note any fluids that were
dure has been performed.
added during the inspection and maintenance proce-
dures.
Inspector Date
Fluids Added During Inspection
Fluid Amount Added
Engine Compartment Comp. Wheel Bearing Lubricant
1 Windshield washer reservoir level Engine Oil
2 Air intake restriction indicator Power Steering Fluid
3 Water evacuation components Engine Coolant
4 Automatic transmission fluid level Windshield Washer Fluid
5 Water in fuel/water separator Automatic Transmission
6 Steering components Fluid
7 Serpentine drive belts Hydraulic Clutch Fluid (DOT
4 brake fluid)
Monthly Post-trip Inspection
Checklists
See the following tables for procedures that should
be performed monthly, post-trip. Place a check mark
in the complete (Comp.) column to indicate a proce-
dure has been performed.
Inspector Date
Brake Components Comp.

1 Brake system components
2 Brake chambers
3 Air brake lines
4 Flex air hoses
5 Brake linings and brake drums
6 Brake lining thickness
Saddle Tank Areas Comp.

Drain air reservoirs (with automatic drain
1
valves)
2 Batteries (location may vary)
3 Aerodynamic components
20.2
21
Pre- and Post-Trip
Inspections and
Maintenance
Daily Pretrip Inspection and Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21.1
Weekly Post-Trip Inspections and Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21.10
Monthly Post-Trip Inspections and Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21.13
Pre- and Post-Trip Inspections and Maintenance
Daily Pretrip Inspection and

Maintenance 4
5
Complete the following inspection and maintenance
6
procedures to ensure that vehicle components are in
good working condition before each trip. A driver who 7
3
is familiar with the vehicle and drives it regularly can 8
perform the daily inspections, then add the weekly
and monthly post-trip inspections as scheduled. 2 9
If the driver does not operate the vehicle on a con-
sistent basis, all daily, weekly, and monthly inspec- 1
tion and maintenance procedures should be per-
formed before the trip. 10
IMPORTANT: The pre- and post-trip checklists,

inspections, and maintenance procedures de- 06/17/2003 f421398
tailed in this chapter are not all-inclusive. 1. 7/16-inch Adjusting 6. Clevis
Refer to other component and body manufactur- Nut 7. ½-inch Clevis Pin
ers’ instructions for specific inspection and 2. Grease Fitting 8. 1/4-inch Clevis Pin
maintenance instructions, as well as local, state, 3. Boot 9. Grease Relief
and federal guidelines. 4. Link Opening
5. Brake Chamber Piston 10. Slack Adjuster Spline
NOTE: If any system or component does not Rod
pass this inspection, it must be corrected before Fig. 21.1, Gunite Automatic Slack Adjuster
operating the vehicle. Whenever equipment re-
quires adjustment, replacement, and/or repair,
see the Cascadia Workshop Manual for proce-
dures and specifications.erticfied 1
2
Suspension and Slack Adjuster
Inspection 3
Walk around the vehicle and visually inspect suspen-

sion and slack adjuster components.
1. Inspect the following suspension components for
signs of structural damage, cracks, or wear. 4 8 9
• springs 7
• spring hangers 6
• shocks
• suspension arms 5
10/11/2005 A f421397
• suspension brackets 1. Clevis 6. Control-Arm Washers
• axle seats 2. Slack Adjuster and Nut
3. Clevis Pin 7. Anchor Strap Slot
• bushings 4. Manual Adjusting Nut 8. Anchor Strap
5. Control Arm 9. Brake Chamber
2. Inspect slack adjusters for signs of damage. See
Fig. 21.1, Fig. 21.2, or Fig. 21.3. Fig. 21.2, Haldex Automatic Slack Adjuster
21.1
IMPORTANT: Wheel covers decrease drag force

as a vehicle moves, thereby improving fuel effi-
ciency. If replacement of a wheel cover is nec-
essary, the replacement cover must meet or ex-
3
4
ceed the drag reduction performance of the
originally installed cover in order to maintain
5
compliance with greenhouse gas and full effi-
ciency regulations (GHG14).
6
1. If the vehicle was originally equipped with wheel
7 covers, ensure all wheel covers are present. In-
8 spect wheel covers for damage or wear. Remove
wheel covers from rear drive wheels, if equipped,
prior to inspecting the tires and wheel compo-
nents.
2 NOTE: During wheel cover installation, ensure
the V-notch in the liner inner retaining ring is
centered on the valve stem. The inner and outer
retaining rings should be uniformly aligned to
each other and to the wheel rim. The outer re-
taining ring of the liner is equipped with two
canvas flaps. When installing the face cover,
make sure the cover retaining ring is inserted
9 between the two canvas flaps on the liner outer
1 10
01/31/2011 f422530 retaining ring so that the Velcro strips line up
1. Grease Fitting (if 5. Clevis Pin (large) between the face cover and the liner. Make cer-
equipped) 6. Clevis Pin (small) tain the detachable view cover is centered on
2. Slack Adjuster 7. Actuator Rod the face cover, and the Velcro strips are
Housing 8. Boot
3. Brake Chamber 9. Manual Adjusting Nut
pressed firmly in place.
Pushrod 10. Camshaft Splines 2. Inspect each tire for the following:
4. Clevis
• valve stem caps on every tire, screwed on
Fig. 21.3, Meritor Automatic Slack Adjuster finger-tight
• Inspect slack adjuster boots, if equipped, • bulges, cracks, cuts, and penetrations
for cuts or tears.
• oil contamination (petroleum derivatives will
• Inspect anchor straps, if equipped, for soften the rubber and destroy the tire)
damage.
• tread depth—if tread is less than 4/32 inch
• Look for worn clevis pins on brake cham- (3 mm) on any front tire, or less than 2/32
ber pushrods. inch (1.5 mm) on any rear tire, replace the
tire
• Look for missing or damaged cotter pins
on the clevis pins. • debris lodged between duel tire sets
• Ensure chamber piston rods are in line IMPORTANT: Low-rolling resistance (LRR) tires
with the slack adjusters. minimize wasted energy as a tire rolls, thereby
decreasing rolling effort and improving fuel effi-
Wheel and Tire Inspection ciency. If tire replacement is necessary, replace-
Walk around the vehicle and visually inspect each ment tires must meet or exceed the rolling resis-
wheel and tire assembly. tance of the originally installed tires in order to
21.2
maintain compliance with greenhouse gas and

full efficiency regulations (GHG14). WARNING
Contact your tire manufacturer/supplier to deter- Have any worn or damaged wheel components
mine the rolling resistance of the originally in- replaced by a qualified person using the wheel
stalled tires. Visit www.epa.gov/smartway for manufacturer’s instructions and the wheel indus-
additional information and resources. try’s standard safety precautions and equipment.
Otherwise a vehicle or workshop accident could
3. Check tire inflation. occur, possibly resulting in serious personal in-
For inflation pressures and maximum loads, see jury or death.
the tire manufacturer’s guidelines. Inflate the tires 4.2 Inspect for broken, cracked, badly worn,
to the applicable pressures if needed. bent, rusty, or sprung rings and rims.
If a tire has been run flat or under-inflated, check
the wheel and tire for damage before adding air. NOTICE
Keep compressed air reservoirs and lines dry
during tire inflation. Use well-maintained inline Use the recommended torque values and follow
moisture traps and service them regularly. the proper tightening sequence. Insufficient
wheel nut torque can cause wheel shimmy, re-
sulting in wheel damage, stud breakage, and ex-
WARNING treme tire tread wear. Excessive wheel nut torque
can break studs, damage threads, and crack
Do not operate the vehicle with underinflated or discs in the stud hole area.
overinflated tires. Incorrect inflation can stress
the tires and make the tires and rims more sus- 4.3 Make sure all wheel nuts are tightened. If
ceptible to damage, possibly leading to rim or tightening is necessary, use the tightening
tire failure and loss of vehicle control, resulting pattern in Fig. 21.4 to initially tighten the
in serious personal injury or death. flange nuts to 50 to 100 lbf·ft (68 to 136
N·m). Then tighten the flange nuts to 450
to 500 lbf·ft (610 to 678 N·m).
NOTICE
A weekly pressure loss of 4 psi (28 kPa) or more 1
in a tire may indicate damage. The tire should be 10 8
inspected and, if necessary, repaired or replaced
by a qualified tire service facility.
IMPORTANT: The load and cold inflation pres- 3 6
sure must not exceed the rim or wheel manu-
facturer’s recommendations, even though the
tire may be approved for a higher load inflation.
Consult the rim or wheel manufacturer for the 4
5
correct tire inflation pressure for the vehicle
load.
4. Examine each rim and wheel component. 9
7
4.1 Remove all dirt and debris from the as- 2
sembly. Rust streaks or metal build-up 04/30/2007 f400268
around stud holes, or out-of-round or worn
stud holes, may be caused by loose wheel Fig. 21.4, Tightening Pattern, 10-Hole Wheels
nuts.
5. Inspect the outboard side of all wheel hubs and
the hub oil seal area on the inboard side of each
wheel for signs of oil leakage. If any oil is found
21.3
on wheel and tire or brake components, remove Inspect upstream of the aftertreatment device
the vehicle from service until the leak has been (ATD), if equipped, for cracking or signs of leaks,
fixed. such as soot trails. Inspect downstream of the
ATD for signs of exhaust leaks, such as blister-
If needed, fill the hubs to the level indicated on
ing or warping of nearby components.
the hub cap. See Group 35 of the Cascadia
Maintenance Manual for recommended lubri-
cants. Engine Compartment Inspection
6. Check that mud flaps are undamaged and hang 1. Check the ground underneath the engine for fuel,
10 inches (25.4 cm) or less from the ground. oil, or coolant leaks.
2. Inspect the air intake system for leaks or dam-
Saddle Tank Areas Inspection age.
WARNING NOTICE
When draining the air reservoir, do not look into Failure to maintain a sealed air intake system
the air jets or direct them toward anyone. Dirt or could allow the entry of dirt and contaminants
sludge particles may be in the airstream and into the engine. This could adversely affect en-
could cause injury. gine performance and result in engine damage.
2.1 Push the reset button on the air intake
NOTICE restriction indicator located on the air
cleaner, if equipped.
If the water drained from the air reservoirs is
cloudy or oily, it may indicate a problem with the 2.2 Check the air intake duct from the air
compressor. If oil is allowed to contaminate the cleaner to the engine intake. Make sure
air dryer, it will not remove the water from the air the duct components are secure and air-
brake system, which could adversely affect brak- tight.
ing. 3. Check the engine oil level.
1. Drain the brake system air reservoirs (reservoirs
without automatic drain valves only). NOTICE
WARNING Operating the engine with the oil level below the
minimum fill (or "add") mark or above the maxi-
Never operate the engine with the fuel tank shut- mum fill (or "full") mark could result in engine
off valves partially closed. This could damage the damage.
fuel pump, causing sudden loss of engine power, 3.1 Check the oil level with the vehicle parked
possibly resulting in serious personal injury due on a level surface. See the engine manu-
to reduced vehicle control. facturer’s guidelines for engine shutdown
2. Ensure fuel tanks are secured to their mounting time requirements prior to checking the oil
brackets and that the mounting brackets are se- level.
cured to the frame.
IMPORTANT: On engines that comply with
If equipped with fuel tank shutoff valves, be sure EPA07 or newer regulations, use CJ-4 en-
the valves are fully open. gine oil with less than 1% sulfated ash. Fail-
3. Inspect visible frame rails for missing bolts, shiny ure to use CJ-4 oil may void the warranty on
areas, or rust streaks. Check all visible cross- emission aftertreatment components.
members for damage or signs of looseness. 3.2 If the oil level is at or below the minimum
4. Inspect visible components of the exhaust sys- fill (or "add") mark on the dipstick, add
tem to ensure connections are tight. enough oil to maintain the level between
21.4
the minimum and maximum fill marks. See

2
the engine operation manual for recom-
mended lubricants.
For natural gas vehicles, use only Exxon
Busgard® Geo 15W-40 natural gas engine
oil. 3
4. Check the power steering reservoir fluid level. 4
The power steering fluid level should be between

the MIN COLD mark and the middle mark just 1 5
above it. See Fig. 21.5. If needed, fill the reser-
voir with automatic transmission fluid that meets 4
Dexron III or TES-389 specifications.
02/05/2013 f500390
1. Pressure Relief Cap 4. COLD MIN Fill Line
2. Filler Cap 5. Coolant Level Sensor
3. COLD MAX Fill Line
1 Fig. 21.6, Coolant Surge Tank
5.1 If the coolant is low, fill the surge tank to

the MAX line with a 50/50 mixture of water
and the type of antifreeze currently in-
stalled in your vehicle.
For natural gas vehicles, use only Fleet-
05/21/2007 f462079
guard ES Compleat™ EG Premix 50/50
NOTE: Typical reservoir shown; configurations may engine coolant.
vary.
1. Filler Cap 5.2 If the surge tank was empty, start the en-
gine after refilling and check the level
Fig. 21.5, Power Steering Fluid Reservoir again when the engine is at operating
temperature.
NOTICE 6. Inspect visible engine wiring for damage or
looseness. Check for loose wiring, chafed insula-
Low coolant could result in engine overheating, tion, and damaged or loose hold-down clamps.
which could cause engine damage.
7. Inspect visible frame rails for missing bolts, shiny
IMPORTANT: The surge tank must be cool to areas, or rust streaks.
check the coolant level.
5. Check the engine coolant level in the radiator
Cab Inspection
surge tank. See Fig. 21.6. 1. Push the reset button on the dash-mounted air
intake restriction indicator, if equipped.
NOTICE 2. With the ignition switch in the OFF position,
check the air-pressure warning system.
Coolant must be filled to the COLD MAX line of
the surge tank. Low coolant could result in en- 2.1 If not previously drained, drain the air res-
gine overheating, which could cause engine dam- ervoirs using moderate brake applications
age. until pressure in both reservoirs is less
than 70 psi (483 kPa).
21.5
2.2 Turn the ignition to the ON position. The 5.2 Wait one minute and note the air pressure
ICU will complete a full gauge sweep and drop in psi (kPa) per minute from the pri-
bulb check, and an audible warning will mary air reservoir.
sound. Ensure the low air pressure lamp If the pressure drop exceeds the limits
(BRAKE AIR) remains illuminated and an
shown in Table 21.1, eliminate any leaks
audible warning continues to sound after before operating the vehicle.
the gauge sweep is complete.
6. Check the air pressure reserve.
3. Check air governor cut-in and cut-out pressures.
With the engine still off, make one full brake ap-
3.1 Start the engine and ensure the BRAKE plication and observe the pressure drop on the
AIR lamp goes out and the buzzer si- primary air gauge. If pressure drops more than
lences when pressure reaches approxi- 25 psi (172 kPa), eliminate any leaks before op-
mately 70 psi (483 kPa) in both air reser- erating the vehicle.
voirs.
The air governor should cut out at ap- Maximum Allowable Air Leakage
proximately 120 psi (827 kPa). For ve- Pressure Drop:
hicles with an optional dryer reservoir Description psi (kPa) Per Minute
module (DRM), the cut-out pressure is Released Applied
approximately 130 psi (896 kPa). Truck or Tractor Only 2 (14) 3 (21)
3.2 With the engine idling, apply the brake Truck or Tractor w/Single Trailer 3 (21) 4 (28)
pedal several times. The air governor Truck or Tractor w/Two Trailers 5 (35) 6 (42)
should cut in when pressure in the primary Table 21.1, Maximum Allowable Air Leakage
air reservoir (top air gauge) reaches ap-
proximately 100 psi (689 kPa).
4. Check air pressure build-up time. WARNING
4.1 With the air system fully charged, make
When cleaning windshields and windows, always
one full brake application and note the air
stand on the ground or on a secure ladder or
pressure reading on the primary air
platform. Use a long-handled window cleaner. Do
gauge.
not use the cab steps, tires, fenders, fuel tanks,
4.2 Further reduce air pressure using moder- engine, or under-hood components to access the
ate brake applications, then run the en- windshield or windows. Doing so could cause a
gine at governed rpm. fall and result in an injury.
4.3 Note the time that the pressure reaches 7. Inspect the mirrors, window glass, and wind-
the previously noted reading on the pri- shield for cracks or other damage.
mary air gauge, then note the time that 8. Ensure that the horn, windshield wipers, and
the air pressure reaches cut-out pressure.
windshield washers are operating properly.
4.4 If it takes longer than 30 seconds to reach These devices must be in good working order for
cut-out pressure after the primary air safe vehicle operation.
gauge passes the previously noted pres- 9. Ensure the heater and defroster are operating
sure (noted after one full brake applica-
properly.
tion), eliminate any leaks or replace the air
compressor before operating the vehicle. 10. Check the operation of all interior lights.
5. Check air leakage in the system. 10.1 Turn on the headlights and leave them on.
Ensure all equipped gauge bulbs illumi-
5.1 With the parking brake applied, the trans-
nate in the dash message center.
mission out of gear, and the air system
fully charged, release the service brakes 10.2 Ensure all equipped driver control
and shut down the engine. switches illuminate.
21.6
10.3 Ensure both turn signal indicator bulbs 11.3 Check that the brake lights, taillights,
illuminate in the dash message center headlights, turn signals, marker lights,
when the turn signal switch is activated. identification lights, and clearance lights
are working properly.
11. Check the operation of all exterior lights. See
Fig. 21.7. 12. Inspect the seat belts and tether belts.
11.1 Activate the high-beam headlights and
hazard warning lights.
8
9
8
7
10
1
5
2
3 4
02/03/2012 f544971
1. High-Beam Headlight 6. Side Turn Signal and Marker Light
2. Fog Light, or Auxiliary High-Beam Light 7. Clearance Light
3. Low-Beam Headlight 8. Stop Light, Taillight, and Turn Signal
4. Marker Light 9. Back-Up Light
5. Turn Signal 10. Identification Light
Fig. 21.7, Exterior Lights
11.2 Exit the cab and check that all exterior

lights and reflectors are clean and intact.
21.7
13. Check the fuel level in the fuel tank(s). To keep

WARNING condensation to a minimum, fuel tanks should be
filled at the end of each day.
Inspect and maintain seat belts. When any part of
a seat belt system needs replacement, the entire 14. Adjust the rearview and down view mirrors as
seat belt must be replaced, both retractor and necessary.
buckle side. Any time a vehicle is involved in an 15. Test the service brakes.
accident, and the seat belt system was in use,
the entire vehicle seat belt system must be re- 15.1 With the engine running and air system
placed before operating the vehicle. Do not at- fully charged, set the parking brake.
tempt to modify the seat belt system; doing so 15.2 Put the vehicle in the lowest gear and
could change the effectiveness of the system. gently attempt to move it forward. The ve-
Failure to replace worn or damaged seat belts, or hicle should not move.
making any modifications to the system, may re-
sult in personal injury or death. If the vehicle moves, the parking brakes
are not operating correctly and must be
12.1 Check the web for fraying, cuts, extreme repaired before the vehicle is operated.
dirt and dust, or for severe fading from
exposure to sunlight, especially near the 16. Test the backup alarm.
buckle latch plate and in the D-loop guide 16.1 Release the parking brake and put the
area. transmission in reverse.
12.2 Check operation of the buckle, latch, Kom- 16.2 Move the vehicle slightly backward to en-
fort Latch or Sliding Komfort Latch (if sure that the backup alarm is operating
equipped), web retractor, and upper seat correctly.
belt mount on the door pillar. Check all
visible components for wear or damage.
Natural Gas Fuel System Inspection
12.3 Check the seat belt and tether belt con-
nection points and tighten any that are WARNING
loose.
As with all pressure vessels, CNG/LNG storage
WARNING and fuel delivery systems are inherently danger-
ous and should be treated as such. Beyond the
Never fill fuel tanks to more than 95 percent of visual inspections listed below, all maintenance
their liquid capacity. This could make them more and repairs to compressed natural gas (CNG) or
likely to rupture from impact, possibly causing liquified natural gas (LNG) systems should be
fire and resulting in serious personal injury or performed by trained personnel. Individuals who
death by burning. are not trained in all aspects concerning CNG/
LNG fuel delivery systems are not permitted to
Do not mix gasoline or alcohol with diesel fuel.
service, maintain, test, or inspect a system in any
This mixture could cause an explosion, possibly
way. Failure to comply with safety regulations
resulting in serious personal injury or death. Do
may lead to fire or explosion, resulting in prop-
not fill the fuel tanks in the presence of sparks,
erty damage, personal injury, or death.
open flames, or intense heat. These could ignite
the fuel, possibly causing severe burns. 1. Inspect fuel tanks for dents, scratches, gouges,
or other signs of damage. Inspect the fuel lines
IMPORTANT: On engines that comply with and connections for leaks.
EPA07 or newer regulations, use ultralow-sulfur
diesel (ULSD) with 15 ppm sulfur content or Check that the fuel tanks are securely mounted.
less. Failure to use ULSD fuel may void the Look for signs of abrasion between components.
warranty on emission components. CNG Fuel System: Ensure that the CNG fuel cyl-
inder storage box is secured to the frame. In-
spect for signs of looseness.
21.8
(LNG Fuel System: Ensure that the LNG fuel

tank is secured to the mounting brackets and
that the mounting brackets are secured to the
frame. Ensure all rubber isolator straps are se-
cure around the LNG fuel tank.
2. Check for the presence of all required decals
present in the following locations:
• Gas detection system overhead console;
• Above the door handle on both doors;
• Left front bumper;
• End-of-frame crossmember;
• LNG fuel tank fill port (maximum psi), if
equipped.
3. Check for the presence of vent caps on pressure
relief valves and devices. See Fig. 21.8. If any
caps are missing, have the fuel system inspected
by a qualified technician.
CNG Fuel System: Each fuel cylinder should
have two caps (one on each end), which are vis- 02/05/2014 f470618
ible on the back of the CNG fuel cylinder storage
box. One additional cap is located on the pres- Fig. 21.8, CNG Vent Line Caps
sure relief valve on the inboard side of the CNG
fuel box, next to the fuel outlet line. If equipped fuel system utilizes coolant hoses between the
with saddle tanks, there are also two vent tubes engine and the vaporizer.
with caps between the back of the cab and the 7. If equipped with an LNG fuel system, check the
back-of-cab fuel tanks. fuel tank pressure gauge to ensure that pressure
LNG Fuel System: A red cap should be present is within the normal range of 120 to 150 psi (827
on the secondary relief valve. See Fig. 21.9. to 1034 kPa). If tank pressure exceeds 230 psi
(1586 kPa) and the pressure relief valve does
4. Inspect all plumbing components, including the not open automatically, vent the tank immedi-
fuel shutoff valve(s), primary and secondary relief ately.
valves, and the LNG vapor shutoff and excess
flow valves, if equipped, for signs of damage or 8. Inspect the LNG vaporizer for signs of damage
leaks. See Fig. 21.9 or Fig. 21.10. or leaks. See Fig. 21.9. Inspect the vaporizer
mounting brackets for signs of looseness.
Inspect the fuel fill fitting for signs of damage or
leaks. 9. On CNG systems, check the low pressure fuel
filter(s) at the engine for contamination.
Inspect all lines for signs of leaks or damage,
and check all threaded connections. 9.1 Turn the engine off and remove the key
form the ignition.
5. Inspect all fuel gauge components for signs of
leaks or damage. Inspect the fuel level sender 9.2 Slowly open the drain petcock and drain
cable and wiring. any fluid into an appropriate container.
6. Inspect all coolant hoses for signs of chafing, 10. When fluid stops, close the drain petcock.
kinks, or leaks. The CNG fuel system utilizes 11. Examine the fluid.
coolant hoses between the engine and the pres-
sure regulator inside the fuel panel. The LNG
21.9
7
8 9 10
6
5
4 11
2 12
1
02/04/2014 f470617
1. Pressure Control Regulator 7. Primary Relief Valve
2. Coalescing Filter 8. Tank Pressure Gauge
3. Fuel Fill Fitting 9. Fuel Shutoff Valve (liquid)
4. Vapor Shutoff Valve 10. Fuel Level Sender Box
5. Secondary Relief Valve (red cap) 11. Cover
6. Fill Vent Fitting 12. Fill Check Valve
Fig. 21.9, LNG Tank Plumbing Components
If more than approximately one ounce of oil or

1 2 other contaminants is found, have the system
checked at a qualified service center.
Weekly Post-Trip Inspections

H IG
H PRESS UR E CYLINDERS
INSPECT CYLINDERS
EVERY 36 MONTHS
LOW PRES S U
RE and Maintenance
OR 36000 MILES
WHICHEVER OCCURS FIRST
REGULATOR
INSPECT PRESSURE
RELIEF DEVICE
EVERY 2000 MILES
NATURAL
GAS
VEHICLE
Engine Compartment Inspection
110 PSIG
OPEN VALVE
FILTER ON
SLOWLY
DRAIN HOUSING
4
WARNING
3600 PSIG MAX. EVERY 1500 MILES
SERVICE PRESSURE REPLACE ELEMENT
VA T O AL
LV FF
EVERY 3000 MILES

U U
E
SH AN
3
M
Washer fluids may be flammable and poisonous.

Do not expose washer fluid to an open flame or
any burning material, such as a cigarette. Always
comply with the washer fluid manufacturer’s rec-
04/30/2010 f470556
ommended safety precautions.
1. High Pressure Gauge
2. Low Pressure Gauge 1. Check the windshield washer reservoir fluid level.
3. Manual Fuel Shutoff Valve The reservoir is usually located near the right-
4. Fuel Fill Port hand frame rail. See Fig. 21.11.
Fig. 21.10, CNG Fuel Panel
21.10
3. Inspect water evacuation components.

3.1 Inspect the vacuator valve(s) installed on
the hood interior and air cleaner. Make
sure the lips of each valve are undam-
aged and pliable, free of debris, and re-
main closed during inspection. See
Fig. 21.12 and Fig. 21.13.
3.2 Inspect the rain tray installed at the base
of the windshield. Ensure that the seal on
the forward edge of the rain tray is in
1 good condition.
3.3 Inspect the drain hoses installed on the
rain tray. Both hoses should be securely
attached to the rain tray and direct water
05/21/2007 f820442
down the aft side of the front fenders. See
Fig. 21.14.
1. Washer Fluid Filler Cap
4. If the vehicle is equipped with an Allison auto-
Fig. 21.11, Windshield Washer Reservoir matic transmission, check the automatic trans-
2. After resetting the air intake restriction indicator mission fluid level.
during the daily pretrip inspection, check the indi- 5. Check for water in the fuel/water separator, if
cator again with the engine off. equipped.
2.1 Check an indicator with graduations to see IMPORTANT: When draining fluid from a
if air restriction exceeds the value shown fuel/water separator, drain the fluid into an
in Table 21.2. appropriate container and dispose of it prop-
Check a go/no-go indicator without gradu- erly. Many jurisdictions now issue fines for
ations to see if the colored bar shows draining fuel/water separators onto the
through the clear window. ground.
Air Intake Maximum Restriction Values (inH2O) 5.1 Place a suitable container under the fuel/
Pre-EPA07 EPA07 and water separator.
Engine Make
Engines Newer Engines NOTE: A hose may be used to direct water
Cummins 25 25 into the container. Use a hose with a ½-inch
Detroit 20 22 pipe thread on DAVCO models.
Mercedes-Benz 22 22
5.2 If the engine is equipped with a built-in
Table 21.2, Air Intake Maximum Restriction Values water separator, loosen the drain valve,
and allow the water to run out. Close the
2.2 If air restriction exceeds the maximum al- drain valve, taking care not to overtighten
lowable value, operate the vehicle for one it.
more day, making sure not to run the en- 5.3 Alliance/Racor Models: Turn the drain plug
gine over rated rpm. Refer to the engine
counterclockwise to open it. See
operation manual for more information on
Fig. 21.15.
rated rpm for your engine.
DAVCO Models: Remove the vent cap
2.3 If air restriction exceeds the maximum and open the drain. See Fig. 21.16.
value again, replace the air cleaner. For
instructions, refer to Group 09 of the Cas- 5.4 Stop draining fluid when fuel begins to
cadia Workshop Manual. drain out.
21.11
3 4 5
02/17/2012 f090497
1. Air Cleaner 3. Rain Tray Seal 5. Drain Hose
2. Vacuator Valve 4. Rain Tray
Fig. 21.12, Rain Tray Assembly
6.1 Inspect tie rods, steering arms, and the

drag link for signs of looseness (i.e., shiny
spots or rust tracks). See Fig. 21.17 for a
rack and pinion steering gear; see
1 1 Fig. 21.18 for an integral steering gear.
6.2 Check the steering gear mounting bolts
and pitman arm nut, if equipped, for signs
of looseness.
6.3 Check the drag link nuts for missing cotter
03/08/2012 f090498 pins.
1. Vacuator Valves 6.4 Inspect the steering intermediate shaft and
end yokes for excessive looseness or
Fig. 21.13, Hood Interior
other damage.
Alliance/Racor Models: turn the drain plug
clockwise to close it. NOTICE
DAVCO Models: close the drain valve.
Install and hand-tighten the vent cap. Do not drive with a drive belt that is visibly worn
or damaged. If it fails, the lack of coolant flow
6. Inspect the steering components. could rapidly cause damage to engine compo-
nents.
7. Inspect the serpentine drive belts for signs of
glazing, frayed edges, breaks, cracks, or oil con-
tamination.
21.12
6
5
4
3
7
8
1
9
10
11
02/03/2010 f470552
1. Washers (qty 2) 7. Mounting Head
2. Nuts (qty 2) 8. Mounting Bolts (qty 2)
3. Frame Rail 9. Filter Element
4. Fuel Outlet Port 10. Sight Bowl
5. Fuel Inlet Port 11. Drain Plug
6. Priming Pump
Fig. 21.15, Alliance Fuel/Water Separator Assembly and
Installation
02/17/2012 f820466 NOTICE

Ensure drain hoses are securely attached to the rain tray
and drain down the aft side of the front fenders. If the external breather tube or breather cap is
missing or incorrectly installed, road dirt and de-
Fig. 21.14, Drain Hose bris can adversely affect the operation of the
brake chamber. Once inside of the chamber, dirt
Monthly Post-Trip Inspections and debris can cause the internal parts of the
and Maintenance chamber to deteriorate faster.
2. Inspect the exterior surfaces of brake chambers
Brake Component Inspection for damage. Make sure that breather holes are
Walk around the vehicle and inspect brake system open and free of debris.
components for visible damage. NOTE: Do not route air brake lines on top of
1. Inspect all visible brake system components for anything likely to be stepped on.
missing fasteners or signs of looseness, such as 3. Inspect air brake lines for dents, swelling, kinks,
rust tracks.
twisting, abrasion, and damage, especially near
moving parts.
4. Inspect flex air lines for deterioration or signs of
abrasion.
21.13
5. Inspect for cracked, worn, or oil-contaminated

brake linings and brake drums (or rotors).
10
6. Check the thickness of the brake linings. Re-
place brake linings on all brake assemblies on
the axle if any brake linings are worn to less than
9 approximately 1/4 inch (6.4 mm) at the thinnest
point.
8
Saddle Tank Areas Inspection
WARNING
7
When draining the air reservoir, do not look into
the air jets or direct them toward anyone. Dirt or
sludge particles may be in the airstream and
could cause injury.
6
5
NOTICE
If the water drained from the air reservoirs is
cloudy or oily, it may indicate a problem with the
compressor. If oil is allowed to contaminate the
air dryer, it will not remove the water from the air
4 brake system, which could adversely affect brak-
ing.
1. Drain the brake system air reservoirs (reservoirs
11 with automatic drain valves only).
3
12 NOTE: Battery locations vary between vehicles.
2. Inspect the batteries.
2
WARNING
Battery posts, terminals, and related accessories
contain lead and lead compounds, chemicals
known to the State of California to cause cancer
and reproductive harm. To prevent possible per-
1 13 sonal injury, always wash your hands after han-
dling battery parts and related accessories.
05/05/2009 f470530
1. Inlet Port/Check Valve 8. Vent Cap O-Ring 2.1 Remove the battery box cover and inspect
2. Lower Housing 9. Vent Cap all visible battery cables for loose wiring or
3. Bypass Valve 10. Collar damage.
4. Filter Element 11. 120VAC Pre-Heater
5. Spring 12. 12VDC Pre-Heater 2.2 Check that the battery hold-down is se-
6. Cover O-Ring 13. Drain Valve cure.
7. Clear Cover
IMPORTANT: Aerodynamic components de-
Fig. 21.16, DAVCO Fuel/Water Separator (Fuel Pro 482 crease drag force as a vehicle moves, thereby
shown) improving fuel efficiency. If replacement of an
21.14
1
1
6 3
4
5
1
2
1
3
07/27/2009 f462167
1. Steering Tie Rod Arm 4. Power Steering Fluid Lines 6. Steering Gear Mounting Bolts
2. Castellated Nut 5. Power Steering Fluid Line Fittings 7. Steering Gear Mounting Nuts
3. Outer Tie Rod
Fig. 21.17, Rack and Pinion Steering Gear Assembly
aerodynamic component is necessary, replace- • Battery access cover

ment components must meet or exceed the
drag reduction performance of the originally in- Engine Compartment Inspection and
stalled component in order to maintain compli- Adjustments
ance with greenhouse gas and full efficiency
regulations (GHG14). IMPORTANT: If replacement of the hood or
bumper is necessary, the replacement compo-
3. Inspect the following aerodynamic components, if nent must meet or exceed the drag reduction
equipped, for structural damage, cracks, or wear. performance of the originally installed item in
• Chassis fairings order to maintain compliance with greenhouse
gas and full efficiency regulations (GHG14).
• Roof fairing/deflector
1. Inspect the bumper and hood for structural dam-
• Side skirts
age, cracks, or wear.
• Cab/sleeper extenders
21.15
3.5 Ensure hose support brackets are se-

curely fastened. Make sure hoses are not
located near sources of wear, abrasion, or
high heat.
IMPORTANT: When replacing hoses, install
1
service-type knitted or braided yarn-reinforced
neoprene hose. Extended-service-life silicone
hoses may also be used. See the Alliance Parts
1 Catalog at www.alliancebrandparts.com or
contact your Freightliner Dealer.
4. Check the steering wheel for excessive play.
2 1
4.1 Start the engine. With the front tires
3 straight ahead, turn the steering wheel
3
until motion is observed at the front
wheels.
4.2 Align a reference mark on the steering
10/11/2001 f461916 wheel to a rule, then slowly turn the steer-
1. Steering Gear Mounting Bolts ing wheel in the opposite direction until
2. Pitman Arm Pinch Bolt Nut motion is again detected at the wheels.
3. Drag Link Nut 4.3 Measure the lash (free play) at the rim of
Fig. 21.18, Integral Steering Gear Fasteners the steering wheel. Excessive lash exists
if steering wheel movement exceeds 2-1/2
2. Check the hydraulic clutch reservoir, if equipped. inches (64 mm) with a 20-inch (508-mm)
If necessary, add DOT 4 brake fluid. steering wheel, or 2-1/4 inches (57 mm)
with an 18-inch (450-mm) steering wheel.
3. Inspect the radiator and heater hoses, including
the clamps and support brackets. 4.4 If there is excessive lash, check the steer-
ing system for wear or incorrect adjust-
3.1 Inspect the radiator and charge air cooler ment before operating the vehicle.
for damage and accumulated debris.
Straighten bent or damaged fins to permit
airflow across all areas of the cores.
NOTE: When traveling through areas of high
insect concentration, it may be necessary to
clean the exterior of the radiator or the
charge air cooler core as often as every 200
miles (320 km).
3.2 Make sure the radiator inlet and outlet
hoses are pliable and are not cracking or
ballooning.
3.3 Make sure the heater hoses are pliable
and are not cracking or ballooning.
3.4 Tighten hose clamps as necessary.
IMPORTANT: Do not overtighten hose
clamps, as hose life can be adversely af-
fected.
21.16
22
Cab Appearance
Cab Washing and Polishing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22.1
Care of Fiberglass Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22.1
Care of Chrome Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22.1
Care of Exterior Lights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22.1
Dashboard Care . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22.2
Vinyl Upholstery Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22.2
Velour Upholstery Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22.3
Cab Appearance
Cab Washing and Polishing • To prevent rust, have any nicks or other dam-
age on the finish touched up as soon as pos-
IMPORTANT: Carefully read all instructions be- sible.
fore using or applying any cleaner or product on • Park your vehicle in a sheltered area whenever
the vehicle or components. Failure to follow possible.
manufacturers’ recommendations can result in
damage to the finish.
Care of Fiberglass Parts
WARNING Wash unpainted fiberglass air fairings and shields
monthly with a mild detergent, such as dishwashing
Do not power wash or steam clean the engine liquid. Avoid strong alkaline cleansers.
bay in the area of vehicle electrical components
Apply a wax specifically designed for fiberglass.
such as the SAM Cab, SAM Chassis, or powernet
distribution box. Water intrusion can permanently
damage these components, which could result in Care of Chrome Parts
fire, personal injury, or property damage.
To prevent rust, keep chrome parts clean and pro-
To protect the finish of your new vehicle, follow these tected at all times. This is especially important during
guidelines carefully. winter driving and in coastal areas where there is
• During the first 30 days, rinse your vehicle fre- exposure to salt air.
quently with water. If the vehicle is dirty, use a When cleaning chrome parts, use clean water and a
mild liquid soap. Do not use detergent. soft cloth or sponge. A mild detergent may also be
• During the first 30 days, do not use anything used.
abrasive on your vehicle. Brushes, chemicals, Sponge gently, then rinse. If necessary, use a non-
and cleaners may scratch the finish. abrasive chrome cleaner to remove stubborn rust or
• During the first 120 days, do not wax your other material. Do not use steel wool.
vehicle. To help protect the chrome after cleaning, apply a
coat of polishing wax to the surface. Never use wax
To extend the life of your vehicle’s finish, follow these
on parts that are exposed to high heat, such as ex-
guidelines.
haust pipes.
• Avoid washing your vehicle in the hot sun.
• Always use water. After the cab is completely Care of Exterior Lights
washed, dry it with a towel or chamois.
Clean the headlight lenses by hand only, using a
• Do not dust painted surfaces with a dry cloth, flannel cloth with mild, non-caustic soap or detergent,
as this will scratch the paint. and water.
• Do not remove ice or snow from a painted sur-
face with a scraper of any sort. CAUTION
• To prevent damage to the finish, wax it regu- Do not use a power buffer, paper towels, chemi-
larly. Before waxing, if the finish has become cal solvents, or abrasive cleaners on the head-
dull, remove oxidized paint using a cleaner light lens, all of which can remove the UV coating
specifically designed for this purpose. Remove from the surface, and result in yellowing of the
all road tar and tree sap before waxing. lens.
Freightliner recommends that a quality brand of
cleaner or cleaner-polish and polishing wax be
used.
• Do not let diesel fuel or antifreeze stand on a
painted surface. If either should occur, rinse
the surface off with water.
22.1
Cab Appearance
Dashboard Care Chewing Gum

Harden the gum with an ice cube wrapped in a plas-
NOTICE tic bag, then scrape it off with a dull knife. Any re-
maining traces of gum can be removed with an all-
When cleaning the dashboard, instrument panel, purpose light oil (peanut butter will also work) and
or gauge lens covers, do not use Armor-All Pro- wiped off.
tectant®, STP Son-of-a-Gun®, window cleaner, or
other equivalent treatments. These cleaners con- Tars, Asphalts, and Creosote
tain vinyl plasticizers which can cause stress
crazing in the interior plastic panels and can re- Each of these items stains vinyl after prolonged con-
sult in cracking of the panels. Some cleaners can tact. They should be wiped off immediately and the
also have an adverse effect on the clear plastic area carefully cleaned, using a cloth dampened with
of instrument panels and gauge lens covers, re- naphtha.
sulting in a foggy or cloudy appearance. This
type of damage is not covered by vehicle war- Paint, Shoe Heel Marks
ranty.
Paint should be removed immediately. Do not use
To clean the dashboard, instrument panel, and gauge paint remover or liquid-type brush cleaner on vinyl.
lens covers, use a cloth dampened with warm soapy An unprinted cloth, dampened with naphtha or tur-
water. Make certain to wring the cloth out well before pentine may be used. Use care to prevent contact
cleaning, as excess water will damage the electrical with parts of the upholstery that are not vinyl.
components.
Sulfide Stains
Vinyl Upholstery Cleaning Sulfide compounds, such as those found in eggs and
To prevent soiling, frequent vacuuming or light brush- some canned goods, can stain after prolonged con-
ing to remove dust and dirt is recommended. Harsh tact with vinyl. These stains can be removed by plac-
cleaning agents can cause permanent damage to ing a clean, unprinted piece of cloth over the spotted
vinyl upholstery. To preserve the upholstery and pre- area and pouring a liberal amount of 6 percent hy-
vent damage, carefully review the following sections drogen peroxide onto the cloth. Allow the saturated
for recommended cleaning procedures. Waxing or cloth to remain on the spot for 30 to 60 minutes. For
refinishing improves soil resistance and cleanability stubborn spots, allow the hydrogen-peroxide satu-
for all vinyls. Any hard wax, such as that used on rated cloth to remain on the area overnight. Use cau-
automobiles, may be used. tion to prevent the solution from seeping into the
seams, or it will weaken the cotton thread.
Ordinary Dirt Nail Polish and Nail Polish Remover
Wash the upholstery with warm water and mild soap,
such as saddle or oil soap. Apply soapy water to a Prolonged contact with these substances causes per-
large area and allow to soak for a few minutes, then manent damage to vinyl. Careful blotting immediately
rub briskly with a cloth to remove the dirt. This can after contact minimizes damage. Do not spread the
be repeated several times, as necessary. liquid during removal.
If dirt is deeply imbedded, use a soft bristle brush Shoe Polish

after applying the soap.
Most shoe polishes contain dyes which penetrate
If dirt is extremely difficult to remove, wall-washing vinyl and stain it permanently. Shoe polish should be
preparations normally found around the home can be wiped off as quickly as possible using naphtha or
used. Powdered cleaners, such as those used for lighter fluid. If staining occurs, try the procedure used
sinks and tiles, are abrasive and must be used with for sulfide stains.
caution as they can scratch the vinyl or give it a per-
manent dull appearance.
22.2
Cab Appearance
Ball Point Ink Mildew

Ball point ink can sometimes be removed if rubbed Brush the dry fabric with a soft brush. Sponge with
immediately with a damp cloth, using water or rub- detergent, and blot. If the fabric is colorfast, dilute a
bing alcohol. If this does not work, try the procedure teaspoon of bleach in one quart (one liter) of cool
used for sulfide stains. water. Apply with a swab, directly on the mildew
stain. Dab repeatedly with clear, cool water, and blot
Miscellaneous dry.
If stains do not respond to any of the treatments de-
scribed above, it is sometimes helpful to expose the
vinyl to direct sunlight for up to 30 hours. Mustard,
ball point ink, certain shoe polishes, and dyes often
bleach out in direct sunlight, leaving the vinyl undam-
aged.
Velour Upholstery Cleaning

To prevent soiling, frequent vacuuming or light brush-
ing to remove dust and dirt is recommended. Spot
clean with a mild solvent or an upholstery shampoo,
or the foam from a mild detergent. When using a sol-
vent or a dry-cleaning product, follow the instructions
carefully, and clean only in a well-ventilated area.
Avoid any product that contains carbon tetrachloride
or other toxic materials. With either method, pretest a
small area before proceeding. Use a professional
upholstery cleaning service when extensive cleaning
is needed.
Grease and Oil-Based Stains

Dampen a small absorbent cloth with dry-cleaning
solvent or spot remover. Apply the cloth carefully to
the spot from the outer edge to the center. Pat and
blot the spot with a clean, dry cloth. Repeat several
times, as necessary, turning the cloths so that the
stain does not redeposit on the fabric.
Sugar and Water-Based Stains

Apply water-based detergent or cleaner, working in
circular motions. Pat and blot as dry as possible. Re-
peat, if necessary, before drying thoroughly.
Chewing Gum or Wax

Harden the gum or wax with an ice cube wrapped in
a plastic bag, then scrape it off with a dull knife. Ex-
cess wax can be absorbed by placing a thick white
blotter over the wax and heating with a warm (not
hot) iron. Remove the remainder by using the proce-
dure for grease and oil-based stains.
22.3
23
Headlight Aiming
Preliminary Checks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23.1
Checking Headlight Aim . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23.1
Adjusting Headlight Aim . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23.1
Headlight Aiming
Preliminary Checks
Before checking or adjusting the headlight aim, do
the following.
• Check that the hood is closed and latched.
• Remove any large amounts of mud or ice from
the underside of the fenders.
• Check the springs for sagging or broken
leaves.
• Check the suspension for proper functioning of
the leveling mechanism. On cabs with air sus-
pensions, make sure that the height is properly
adjusted.
• Check for damage to the hood and hinge as-
01/23/2012 f545869
sembly. Repair as necessary.
Measure beam height from the ground to the small dot
• With the vehicle unloaded, check that the tires roughly in the center of the headlight lens.
are inflated to the recommended air pressure.
Fig. 23.1, Headlight Beam Height Adjusting Dot
• Clean the headlight lenses. Use a soft cloth
with mild, non-caustic soap or detergent, and Table 23.1, adjust the vertical positioning of that
water. headlight.
Checking Headlight Aim Adjusting Headlight Aim

1. Park the vehicle on a level surface, 25 ft (7.6 m) NOTE: Freightliner vehicles are offered with
away from, and perpendicular to, a vertical various headlight assembly options. Because of
screen or wall. Shut down the engine and set the the various options, the location of adjustment
parking brake. Chock the tires. screws on your vehicle’s headlight assembly
2. Each headlight has a height adjusting dot. See may vary from what is shown here.
Fig. 23.1. Measure the distance from the ground The adjusting screw is located on the lower outside
to the height adjusting dot on each headlight corner of the headlight assembly. See Fig. 23.4. Turn
(Fig. 23.2, Item A). Note those distances. the adjusting screw clockwise to raise the beam and
3. On the screen or wall, mark the locations of each counterclockwise to lower it, until the beam pattern
headlight bulb center using the distances found meets the acceptable standard.
in step 2. See Fig. 23.2, Items 2 and 3.
4. Turn on the low-beam headlights.
5. Check the vertical adjustment of the low beams.
The center of each beam projection should fall
on or near the marks made during step 3. See
Fig. 23.3.
6. Use Table 23.1 to determine the maximum verti-
cal distance allowable between the marks on the
wall and the center of each low-beam projection.
If the distance between either projection center
and the mark made on the wall or screen is
greater than the maximum distance given in
23.1
Headlight Aiming
2
3
A A
B
B
7.6 m)
25 ft (
1
01/10/2012 f545850a
A. Measure the distance from the ground to the center of each headlight bulb.
B. Mark where the center of each headlight projection should appear.
1. Screen or Wall 3. Center of Left-Hand Headlight Projection
2. Center of Right-Hand Headlight Projection
Fig. 23.2, Headlight Aiming Screen/Wall
1
2
01/10/2012 f545851a
1. Low-Beam Angle Upper Limit 3. Low-Beam Angle Lower Limit
2. Ideal Low-Beam Projection
Fig. 23.3, Vertical Low-Beam Headlight Variation Limits
23.2
Headlight Aiming
06/18/2007 f545076
Fig. 23.4, Headlight Adjusting
Vertical Low-Beam Headlight Variation Limits

Distance Between Ground Desired Variation (Fig. 23.3, Upper Limit (Fig. 23.3, Item Lower Limit (Fig. 23.3, Item
and Headlight: in (mm) Item 2): in (mm) 1): in (mm) up 3): in (mm) down
22–36 (560–900) 0 3.9 (100) 3.9 (100)
36–48 (900–1200) 2 (50) down 2 (50) 6 (150)
48–54 (1200–1400) 2.5 (64) down 1.6 (40) 6.5 (165)
Table 23.1, Vertical Low-Beam Headlight Variation Limits
23.3
24
In an Emergency
Hazard Warning Lights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24.1
Fire Extinguisher . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24.1
Emergency Kit, Optional . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24.1
Emergency Filter Replacement, Davco . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24.1
Emergency Starting With Jumper Cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24.2
Towing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24.4
Fire in the Cab . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24.7
In an Emergency
Hazard Warning Lights WARNING

The hazard warning light switch is located on the
dash in what is referred to as the master module. Use extreme care when placing flares in emer-
See Fig. 24.1. The hazard lights can be activated gency situations that involve exposure to flam-
regardless of the ignition switch position. mable substances such as fuel. An explosion or
fire could occur causing serious personal injury.
To activate the hazard lights, push the center of the
switch once. The switch will blink at the same rate
that the hazard lights flash. Push the switch again to
Emergency Filter
turn them off. All the turn signal lights on the vehicle Replacement, Davco
and trailer, as well as the turn signal indicators in the
ICU, flash simultaneously when the hazard lights are If the filter cover on the Davco fuel/water separator is
activated. broken, it will not be possible to operate the vehicle.
A standard spin-on filter will correct this problem.
Refer to the Davco web site (www.davcotec.com)
for additional information.
To replace the filter on all Davco fuel/water separa-
tors, follow this procedure:
1. Drain the fuel until it is below the level of the col-
lar. See Fig. 24.2 for the model 232/233 fuel/
water separator and Fig. 24.3 for the model 382
fuel/water separator.
2. Remove the vent and seal.
NOTE: The vent and seal are not needed in the
1 2
03/20/2007 f610855 emergency replacement. They should be re-
1. Hazard Warning Switch tained for later installation at the time when the
2. Panel Lamps Switch cover is replaced.
Fig. 24.1, Master Module 3. Remove the collar using the DAVCO fuel-water
separator wrench. Do not use pliers or channel-
Fire Extinguisher lock pliers.
A fire extinguisher is located either in the cab by the 4. Remove the cover, cover seal, and spring. Re-
driver’s door, or in the baggage compartment. tain them for later assembly.
5. Remove the filter element and dispose of it prop-
Emergency Kit, Optional erly.
An optional emergency kit is located in the cab. The NOTE: Remove the rubber grommet from the
kit includes one or more of the following: a first aid stud.
kit, a reflective vest, a triangular reflector, a flare kit,
6. Install the standard engine spin-on filter (included
and (on vehicles with a Davco fuel/water separator) a
spin-on fuel filter element. in the emergency kit) on the threaded stud.
7. Install the cover, cover seal, and spring, as re-
If there is an emergency while driving, cautiously pull
off the road. Turn on the hazard warning lights. Place moved.
the flares and reflector along the side of the road to 8. Install the collar over the cover. Tighten the collar
alert other drivers that an emergency situation exists. finger-tight.
9. Start the engine and run it at increased rpm for
one minute to purge air from the fuel lines.
24.1
In an Emergency
6
10
11/14/2001 f470416
1. Vent 5. Cover Seal 8. Threaded Stud
2. Seal 6. Spring 9. Fuel Port
3. Collar 7. Filter Element 10. Drain
4. Cover
Fig. 24.2, Davco Model 232 and 233 Fuel/Water Separator
Emergency Starting With in the vicinity of the battery. Do not allow the ve-
hicles to touch each other. Do not lean over the
Jumper Cables batteries when making connections, and keep all
other persons away from the batteries. Failure to
When using jumper cables, follow the instructions follow these precautions could lead to severe
below. personal injury as a result of an explosion or
acid burns.
WARNING
Batteries release explosive gas. Do not smoke
CAUTION
when working around batteries. Put out all flames Make sure both electrical systems are the same
and remove all sources of sparks or intense heat voltage. Electronic devices on both vehicles can
24.2
In an Emergency
3
8
9
6
10
11
11/14/2001 f470417
1. Collar 5. Cover Seal 9. Fuel Port
2. Vent 6. Spring 10. Drain
3. Seal 7. Filter Element 11. Bottom-Plate Collar
4. Cover 8. Threaded Stud
Fig. 24.3, Davco Model 382 Fuel/Water Separator
be damaged when connected to a vehicle with a

different operating voltage. CAUTION
NOTE: On vehicles equipped with optional un- Always connect the battery, jumper cables, and
derhood jump start posts, connect to these charger correctly (positive-to-positive and
posts instead of the batteries. negative-to-negative). Connecting a charging de-
vice backwards (positive-to-negative) can se-
1. Apply the parking brakes and turn off the lights verely damage the vehicle electrical content and
and all other electrical devices. cause non-warrantable failures.
2. Remove the battery box cover by pulling on the 3. Connect the positive (+) jumper cable to the
end of each hold-down latch until the end clears positive battery post on the Cascadia needing
the catch, then pivoting the latches out of the the jump start, then connect the other end of the
way, and lifting off the cover. See Fig. 24.4. positive jumper cable to the positive battery or
24.3
In an Emergency
jump start post of the vehicle providing the jump. could occur near a battery, possibly resulting in
See Fig. 24.5. severe personal injury from explosion or acid
burns.
4. Connect one end of the second jumper cable to
the negative terminal of the booster battery, and
connect the other end of the cable to to the
negative battery post of the Cascadia needing
the jump start.
5. Start the engine of the vehicle with the booster
batteries, and let the engine run a few minutes to
charge the batteries of the other vehicle.
6. Attempt to start the engine of the vehicle with the
batteries receiving the charge. Do not operate
the starter longer than 30 seconds, and wait at
least two minutes between starting attempts to
allow the starter to cool.
7. When the engine starts, let it idle a few minutes.
WARNING
Do the next step exactly as instructed and do not
allow the clamps of one cable to touch the
06/12/2007 f545070 clamps of the other cable. Otherwise, a spark
could occur near a battery, possibly resulting in
Fig. 24.4, Battery Compartment severe personal injury from explosion or acid
burns.
A B 8. Disconnect the grounded cable from the frame or
other non-battery location, then disconnect the
other end of the cable.
+
9. Disconnect the remaining cable from the newly

charged battery (or jump-start post if equipped)
first, then disconnect the other end.
− − − −
10. Install the cover; be sure it is positioned properly

before fastening the latches.
C D
07/06/2007 f545111
Towing
A. – Battery Cable to Vehicle
B. + Battery Cable to Vehicle When it is necessary to tow the vehicle, make sure
C. + Jumper Cable (connect first and disconnect last) the instructions below are closely followed to prevent
D. – Jumper Cable (connect last and disconnect first) damage to the vehicle.
Fig. 24.5, Jumper Connections
WARNING
WARNING Do not tow an unbraked vehicle if the combined
weight of both vehicles is more than the sum of
Do the next step exactly as instructed and do not
allow the clamps of one cable to touch the
clamps of the other cable. Otherwise, a spark
24.4
In an Emergency
the gross axle weight ratings (GAWR) of the tow- 7. Lift the vehicle and secure the safety chains. If
ing vehicle. Otherwise brake capacity will be in- extra towing clearance is needed, remove the
adequate, which could result in personal injury or front wheels.
death.
NOTE: Due to the many variables that exist in
Front Towing Hookup towing, positioning the lifting and towing device
is the sole responsibility of the towing-vehicle
1. Disconnect the battery ground cables. operator.
8. Connect the clearance lights, taillights, and sig-
NOTICE nal lights. Connect any special towing lights re-
quired by local regulations.
Failure to remove the axle shafts when towing
the vehicle with the rear wheels on the ground
will result in damage to the transmission and WARNING
other drivetrain components.
Failure to chock the tires or connect the tow
2. Remove both drive axle shafts. On dual drive truck’s air brake system before releasing the
axles, if the vehicle is to be lifted and towed, re- spring parking brakes could allow the disabled
move only the rearmost drive axle shafts. vehicle to suddenly roll. This could cause prop-
On vehicles equipped with an air fairing, remove erty damage or personal injury.
both the forward and rearmost drive axle shafts if 9. Chock the tires on the disabled vehicle and con-
there is insufficient towing clearance. nect the towing vehicle’s air brake system to the
3. Cover the ends of the hubs with metal plates or vehicle being towed. Then, release the spring
plywood cut to fit the axle opening, and drilled to parking brakes and remove the chocks.
fit the axle shaft studs. This prevents lubricant
from leaking out and will keep contaminants from Rear Towing Hookup
getting into and damaging the wheel bearings
and axle lubricant. NOTICE
NOTICE Using a rear towing hookup on a vehicle
equipped with a roof fairing could cause damage
Failure to protect the frame rails from the chains to the cab structure.
could cause damage, leading to eventual frame
If reverse towing at speeds above 45 mph (70
failure.
kph) is necessary, note the following precau-
4. On dual drive axles, if the vehicle is to be lifted tions:
and towed, chain the forward rear-axle assembly • Remove the rubber flex extenders (for side
to the vehicle frame. Use protection to keep the
extenders equipped with middle brackets)
chains from damaging the frame.
or the side extender assemblies (without
5. Remove the bumper end caps and chrome bum- middle brackets). Failure to do so could
per (if equipped). cause damage to the side extenders and/or
loss of the rubber flex extenders.
6. Attach the towing device. Do not pass a sling (for
example, a rope or chain) from one tow hook to • Hold down the cab with tension straps
another to fasten for towing. Known as reeving, looped over the cab shocks and under the
this practice is not permissible in most industrial frame rails. Failure to do so could allow the
applications of towing and hoisting. Reeving can wind load to lift the cab unexpectedly, re-
overload the hooks and result in damage to the sulting in damage to the air springs and
vehicle. See Fig. 24.8. other components.
1. If the vehicle is equipped with side extenders,
and reverse towing at speeds above 45 mph (70
24.5
In an Emergency
OK
1
OK 2
07/05/2007 f880793
IMPORTANT: Do not reeve when towing.
1. Tow Hook 2. Chain
Fig. 24.6, Reeving
kph) is necessary, prepare the side extenders as 3. Place the front tires straight forward and secure
follows: the steering wheel in this position.
• If middle brackets are installed on the side 4. Disconnect the battery ground cables.
extenders, as shown in Fig. 24.7, remove
the rubber flex extenders. NOTICE
• If middle brackets are not installed on the
side extenders, remove the side extenders Failure to protect the frame rails from the chains
from the cab. could cause damage, leading to eventual frame
failure.
2. If the vehicle is equipped with cab air suspen-
sion, and reverse towing at speeds above 45 5. On dual drive axles, using protection to keep the
mph (70 kph) is necessary, hold down the cab as chains from damaging the vehicle frame, chain
follows: the forward-rear drive axle to the frame.
2.1 Drain the air from the cab air springs. 6. Attach the towing device.
2.2 Loop a 2-inch (5-cm) ratchet-style tension NOTE: Due to the many variables that exist in
strap (rated 2000 lb [900 kg] minimum towing, positioning the lifting and towing device
work load) over the top of the cab shock is the sole responsibility of the towing-vehicle
and under the frame rail. See Fig. 24.8. operator.
Tighten the strap for a snug fit. If the cab
is equipped with two or more shocks, re- 7. Lift the vehicle and secure the safety chains. If
strain the aftmost shock on each side of extra clearance is needed, remove the bumper
the vehicle. extension if equipped.
24.6
In an Emergency
05/13/2014 f602527
Fig. 24.8, Tension Strap Installed to Hold Down the Cab
WARNING
Urethane foam is flammable! Do not allow any
flames, sparks, or other heat sources such as
cigarettes or light bulbs to contact urethane
foam. Urethane foam in contact with such heat
sources could cause a serious, rapid fire, which
could result in death, severe burns, or gas poi-
soning, as well as damage to the vehicle.
In Case of a Cab Fire

01/05/2010 f602410
As quickly as possible, bring the vehicle to a safe
Fig. 24.7, Side Extender Middle Bracket stop, apply the parking brake, turn off the ignition,
and get out of the vehicle.
8. Connect the clearance lights, taillights, and sig-
nal lights. Also connect any special towing lights
required by local regulations.
Fire in the Cab

The incidence of fire in heavy- and medium-duty
trucks is rare, according to data from the National
Highway Traffic Safety Administration. Federal Motor
Vehicle Safety Standard #302 limits the flammability
of specified materials used inside the cab, but de-
spite this, most materials will burn. The cab of this
vehicle contains urethane foam, which is of concern
in this respect.
24.7
25
Natural Gas Vehicles
Natural Gas Vehicles, General Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25.1
Natural Gas Vehicles, Safety Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25.1
Natural Gas Fuel Tank Filling Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25.3
Natural Gas Detection System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25.5
Natural Gas Engine Starting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25.9
Major Repairs and Replacement of Natural Gas Components . . . . . . . . . . . . . . . . . . . . . . . . . . . 25.10
Natural Gas Vehicles, General • A fuel contents gauge that indicates the fuel
supply in the tank or cylinders.
Information Figure 25.1 shows the locations of various compo-
The vehicle can be equipped with a compressed nents of a CNG installation.
natural gas (CNG) fuel system, or a liquefied natural
gas (LNG) fuel system. CNG is made by compress- Natural Gas Vehicles, Safety
ing natural gas to less than 1% of its volume at stan-
dard atmospheric pressure. LNG is created by con- Precautions
densing natural gas into a liquid by cooling it to
approximately -259°F (-162°C). DANGER
When vaporized at ambient temperatures, natural
gas is less dense than air, and it rises and disperses. Natural gas is highly flammable. Failure to ob-
However, LNG is initially heavier than air due to its serve the following safety precautions could lead
cryogenic temperature. When released in large to the ignition of the natural gas, which could
amounts, it may drop or pool on the ground before cause serious bodily injury or death.
its temperature rises enough to vaporize. Cold at- CNG systems should be maintained and inspected
mospheric conditions may prevent natural gas from exclusively by trained personnel with certifications in
dispersing quickly when released in large amounts. accordance with the applicable codes. As with all
Natural gas is nontoxic, but it can cause asphyxiation pressure vessels, CNG storage and fuel delivery sys-
if present in very large concentrations. tems are inherently dangerous and should be treated
as such. Individuals involved in any aspect of CNG
CNG often contains an odor-producing chemical, fuel system maintenance, emergency response, ser-
while LNG does not have any odor. Users of natural- vicing, or testing must be properly trained and certi-
gas-fueled vehicles should never expect to detect fied. Individuals who are not trained and certified in
natural gas leaks by scent. all aspects concerning CNG fuel delivery systems
For natural gas to burn, it must first vaporize, then are not permitted to service, maintain, test, or inspect
mix with air in the proper proportions (flammable a system in any way.
range is 5 to 15% by volume in air), and then be Follow these safety precautions when operating or
ignited. repairing a natural gas vehicle.
A typical natural gas fuel system consists of: • Only certified LNG personal can fuel LNG
• Fuel supply cylinders that store compressed trucks.
gas at high pressure (CNG), or a tank that • Do not start the engine if a natural gas leak is
stores liquefied gas at an extremely low tem- detected.
perature (LNG).
• Transferring fuel is only allowed as long as a
• A vaporizer or heat exchanging device that non-static hose is used. if a non-approved
changes LNG to gaseous form (LNG fuel sys- hose is used, static can build up and ignite the
tems only). fuel. A correct hose can be obtained through
• Pressure relief and manual fuel shutoff valves. Agility fuel systems.
• A filling connection with a check valve that pre- • Do not attempt to cut any fuel supply piping
vents the gas from flowing back out of the fuel components.
filling line. • Avoid open flames or sparks near a natural
• High-pressure and low-pressure fuel filters. gas vehicle.
• A pressure control regulator that reduces the • Cover eyes and exposed skin when working on
high fuel tank or cylinder pressure to the lower a natural gas fuel system or fueling a natural
pressure needed for the engine. gas vehicle.
25.1
3 4
01/21/2014 f470613
1. Sleeper Leak Sensor (zone 3) 5. Shutoff Valve, Right Side Cylinder
2. Engine Compartment Leak Sensor (zone 2) 6. Shutoff Valve and System Components, Left Side
3. Leak Detection Control Panel (zone 1) (overhead Cylinder
console) 7. Fill Panel
4. Cylinder Shutoff Valve (back-of-cab box)
Fig. 25.1, CNG Component Locations
25.2
• Permit no smoking or other ignition sources in, Natural Gas Fuel Tank Filling
or within thirty feet of, a natural gas vehicle.
• Have CO2 fire extinguishers (ABC minimum)
Procedures
located in a highly visible and easily accessible CNG Vehicle Fueling
location.
CNG is moved from the fuel station storage tanks to
• Use Purple-K powder (PKP) or a similar dry the vehicle cylinders through a metered dispenser.
powder to extinguish an LNG fire. Do not at- During fueling, as pressure inside of the vehicle cyl-
tempt use water around an LNG fire. inders increases, so does the temperature. The dis-
• Always purge the fuel lines before performing penser shuts off when it determines the CNG cylin-
maintenance or repairs on a natural gas fuel ders are full.
system. Refer to the system manufacturer’s CNG fuel cylinders cannot be filled to their full capac-
service manual or the vehicle’s workshop ity of 3600 psi (24 800 kPa) in cooler weather. Since
manuals for the proper purging procedure. temperature change causes gas to expand and con-
• Always use a natural gas detector to test the tract, less pressure in the cylinders on a cold day is
system for leaks, whether an odor is present or equal to the same amount of gas at a higher pres-
not. Routinely inspect the fuel filtering and sure on a warm day. The fuel station dispenser has a
regulating mechanisms, and the fuel lines. An temperature-pressure compensating device, which
approved natural gas bubble solution can be accounts for ambient temperature during fueling. See
used to pinpoint the exact location of leaks. Do Table 25.1 for approximate full cylinder pressures at
not use soap and water. Soap and water can various temperatures.
cause premature failure of the O-rings in the
system. CNG Temperature/Pressure Compensation Values
Fill Station Pressure Set Point
• Make sure black caps are always on the PRD Temperature:
3000 psi (20 684 3600 psi (24 821
vent lines to reduce water build up in lines. °F (°C)
kPa) Set Point kPa) Set Point
• Do not store a natural gas vehicle indoors for 100 (37.8) 3415 (23 546) 4086 (28 172)
any extended period of time. Do not bring a 90 (32.2) 3276 (22 587) 3909 (26 952)
natural gas vehicle indoors unless the work- 80 (26.7) 3138 (21 636) 3754 (25 883)
shop is equipped with a methane detection and 70 (21.1) 3000 (20 684) 3600 (24 821)
ventilation system. 60 (15.6) 2861 (19 726) 3445 (23 752)
50 (10) 2723 (18 774) 3288 (22 670)
In Case of Emergency 40 (4.4) 2584 (17 816) 3131 (21 587)
If a vehicle has sustained damage or a leak has 30 (-1.1) 2446 (16 865) 2973 (20 498)
been discovered: 20 (-6.7) 2307 (15 906) 2814 (19 402)
10 (-12.2) 2169 (14 955) 2655 (18 306)
1. Turn the ignition switch off, and set the parking
brake. 0 (-17.8) 2031 (14 003) 2495 (17 202)
-10 (-23.3) 1893 (13 052) 2336 (16 106)
2. Exit the vehicle leaving as many doors and win- -20 (-28.9) 1755 (12 100) 2180 (15 031)
dows open as possible. Get at least 30 feet from -30 (34.4) 1616 (11 142) 2024 (13 955)
the vehicle, and allow it to vent until it is safe to -40 (-40) 1477 (10 184) 1868 (12 879)
do the steps below.
Table 25.1, CNG Temperature/Pressure Compensation
3. Remove all ignition sources from the area sur- Values
rounding the vehicle.
4. If it is safe to do so, close all fuel shutoff valves. Use the following steps to fuel a CNG vehicle.
5. Use a natural gas detector, or approved NG 1. Shut down the engine and apply the parking
bubble solution, to identify leaks in the fuel sys- brake.
tem.
25.3
IMPORTANT: Close all windows and doors dur-

ing the fueling process. Keeping windows and
2
doors closed allows for easier leak detection 3
inside the cab after fueling. 1
NOTE: If the fuel system has only back of cab

tanks, the fuel fill is located behind the fuel ac- 4
cess panel on the lower part of the cabinet, or
below the tank cabinet in a separate box. If
truck has saddle mount tanks, the fuel panel is
located on the back end of the left side tank.
Vehicles with back-of-cab cabinets and saddle
tanks are have the fuel fill panel on the back
end of the left side tank. See Fig. 25.2 for side
tanks, or Fig. 25.3 for back-of-cab cabinet
mounted fuel panel. 01/21/2014 f470615
1. High-Pressure Gauge
WARNING 2. Fuel Cylinder Information Sticker
3. Manual Shutoff Valve
Natural gas fuel tanks, lines, and valves are al- 4. Fuel Fill Port
ways pressurized. Always observe safety precau- Fig. 25.2, CNG Fuel Cylinder Fill Panel (side tank
tions. Failure to do so could lead to loss of con- shown)
trol over a filling hose or to ignition of the natural
gas, which could cause serious bodily injury,
death, or severe property damage. 1 2
2. Ensure all fuel cylinder shutoff valves are open.
See Fig. 25.2.
3. Ensure the vehicle fuel system main shutoff
valve is open. H IG
H PRESS UR E CYLINDERS
INSPECT CYLINDERS
EVERY 36 MONTHS
LOW PRES S U
RE
OR 36000 MILES
WHICHEVER OCCURS FIRST
4. If equipped, open the CNG fuel panel access REGULATOR

INSPECT PRESSURE
RELIEF DEVICE
EVERY 2000 MILES
NATURAL
GAS
door and remove the dust cap from the vehicle 110 PSIG
OPEN VALVE
VEHICLE
FILTER ON
fuel fill port. 3600 PSIG MAX.

SERVICE PRESSURE
DRAIN HOUSING
EVERY 1500 MILES
REPLACE ELEMENT
SLOWLY
4
VA T O AL
LV FF
EVERY 3000 MILES

U U
E
SH AN
3
M
5. Ensure the O-ring is present inside the fuel fill

port. If the O-ring has been dislodged or is miss-
ing, the station dispensing nozzle will not con-
nect securely to the fill port.
6. Turn the selector knob on the service pump to 04/30/2010 f470556
the VENT position, if equipped. 1. High Pressure Gauge
7. Connect the quick coupling on the dispensing 2. Low Pressure Gauge
3. Manual Fuel Shutoff Valve
nozzle securely to the vehicle fuel fill port. 4. Fuel Fill Port and Dust Cap
8. Turn the selector knob on the service pump to
Fig. 25.3, CNG Under Cabinet Fuel Panel (under
the FILL position, if equipped. cabinet shown)
IMPORTANT: If at any time the service pump or
vehicle begins to vent CNG uncontrollably, notify tion emergency shut-off switch to cease the flow
a station attendant or activate the service sta- of CNG.
25.4
9. Switch on the service pump. A slight hissing The AMGaDS III Plus is a natural gas detection sys-
noise may be heard as the fuel cylinders fill. tem. This device is meant to serve as a supplemen-
tal warning only. It is not intended to replace stan-
10. Watch the pressure gauge on the service pump.
dard safety practices that should be conducted
When the gauge reads approximately 3600 psi around flammable gases.
(24 800 kPa), or when the fill pressure stops
climbing, the CNG cylinders are full. The service IMPORTANT: To function properly, the gas de-
pump will shut itself down automatically. See tection system must be powered at all times.
Table 25.1 for pressure compensation values The gas detection system is directly powered by
based on ambient temperatures. the batteries, and can only be powered off by
11. Move the selector knob on the service pump to disconnecting the batteries. When servicing a
the VENT position, if equipped. A short hiss will natural-gas-fueled vehicle, disconnect the bat-
be heard as a small amount of natural gas is teries only when necessary, and do not leave
vented into the hose. the batteries disconnected for extended periods
of time.
WARNING The lower flammability limit (LFL) is the smallest
amount of the gas that supports a flame when mixed
Do not attempt to remove the fill station nozzle
with oxygen and ignited. Zero percent (0%) LFL indi-
from the tank fill fitting until venting of pressure
cates a gas-free atmosphere. One hundred percent
is noted. If no venting occurs, ask for assistance
(100%) LFL indicates that gas concentration has
from the station attendant. Removing an un-
reached its lower flammability limit (5% gas in air by
vented coupling could result in an uncontrolled
volume). The red warning light and audible alarm
hose, which could lead to property damage or
located in the overhead console activate when a sen-
personal injury.
sor detects gas fumes in concentrations above 50%
12. Remove the station dispensing nozzle from the LFL, and should allow ample time to utilize safety
vehicle fill port. procedures. However, individuals with special needs
should review the system with a professional safety
NOTE: Some fill ports and dust caps contain a engineer.
magnetic start interrupt sensor to prevent a
truck from being started and driven away with Alarm Procedure
the fill hose connected. These caps must be
installed correctly or vehicle will not start. Before operating the vehicle, the driver must be fa-
miliar with the procedures as shown on the interior
13. Install the dust cap on the vehicle fuel fill port sticker on the overhead panel (See Fig. 25.4) and
and close the fuel panel access door, if the exterior sticker on the door (See Fig. 25.5).
equipped.
IMPORTANT: If an audible alarm activates, do
LNG Vehicle Fueling not operate any electrical switch, including
lights. Avoid causing sparks and stay away from
Only certified LNG fueling personnel are authorized arcing switches and equipment. Do not use a
to fuel an LNG vehicle. telephone, including cellular phones or any
types of portable communication or electronic
Natural Gas Detection System devices that have a battery.
A gas detection system is standard in all Daimler If the vehicle is in motion when the audible alarm
Trucks natural-gas-fueled vehicles. This system has activates, bring it to a safe stop, shut down the en-
a sensor in the engine compartment, one in the cab, gine, and exit the vehicle. Do not open the hood.
and one in the sleeper (if equipped), all situated in If outside the vehicle when the audible alarm acti-
high areas to detect natural gas buildup as a result vates, do not open the cab door or hood.
of leaks.
In the event of an audible alarm, immediately follow
these procedures, as allowed by conditions:
25.5
2. Exit the vehicle leaving as many doors and win-

dows open as possible, and move at least 30
feet away from vehicle. If the vehicle is parked,
stay at lease 30 feet away until it is safe to do
the following.
3. Manually close all fuel shutoff valves, including
those on the LNG tank or CNG cylinders.
4. If the vehicle is indoors (as in a service shop),
immediately open shop windows and doors to
provide extra ventilation to the area. Do not start
the engine or any other type of equipment until
the gas leak is corrected and the area cleared of
natural gas.
5. Evacuate the area.
6. After the area is cleared of natural gas and the
04/28/2009 f080157
alarm is no longer active, have the vehicle in-
Fig. 25.4, Interior Warning Sticker spected by a qualified technician.
IMPORTANT: Do not consider the area clear
until all alarm indicators are off, and the alarm
panel light returns to green.
Sensors
Gas detection sensors are located on the cab over-
head console (zone 1), in the engine compartment
on the frontwall (zone 2), and in the sleeper, if
equipped (zone 3). The sensors are located in high
areas, where rising gas vapors will pass by or accu-
mulate. On some vehicles, there is a sensor located
under the cab floor (zone 4). Zone 4 is not used on
DTNA vehicles.
If the system detects that one of the sensors has
been disconnected or has malfunctioned, the sensor
fault light for that zone will illuminate. A failed sensor
may trigger and lock on an alarm. If this happens
have a qualified technician troubleshoot the system
and make appropriate repairs.
The sensors are sensitive to all hydrocarbon vapors.
An alarm may be triggered by the use of chemicals
such as cleaners, paint, polish, lacquer, gasoline,
silicone, silicone spray, or other harsh chemicals.
04/28/2009 f080158 The sensors will also detect hydrogen fumes from an
overcharged battery. If a sensor sends an alarm, but
Fig. 25.5, Exterior Warning Sticker no gas fumes are present, check for recent use of
1. Immediately shut off all engines. Extinguish any chemicals or a battery charger.
cigarettes, pilot lights, flames, or other sources of
ignition in the area and adjacent areas.
25.6
flash. There is no buzzer alarm for a trace

NOTICE level detection, and the large green light on the
alarm panel will remain illuminated.
Silicone-based chemicals and cleaners will per-
manently disable the sensors. When cleaning the • Significant Level: If either sensor detects gas
vehicle, cover the sensors with a plastic cover- fumes at a concentration greater than 50% to
ing. Keep the sensors covered until the area has 60% LFL (2.5% gas in air by volume), the
been cleared of any cleaning fumes. small red light next to the SIGNIFICANT indi-
cator for that zone will flash. After approxi-
Harsh chemicals, including some high alcohol mately 15 seconds, the large green light on the
cotenant washer fluids, and extremely high tem- alarm panel will switch off, the red light will illu-
peratures may damage the sensor. minate, and the buzzer will sound. All alarm
Puncture of or damage to the seal located inside indicators will remain on as long as fumes are
the sensor housing will significantly shorten the detected.
sensor life. • Sensor Fault: If the system detects that either
Frequent exposure to high concentrations of gas of the sensors has been disconnected or has
will accelerate sensor deterioration. malfunctioned, an amber light next to the Sen-
sor Fault indicator for that zone will illuminate.
Overhead Console The control module also has buttons used to test or
reset the the control module after an alarm. Red
The overhead console consists of an alarm panel on lights next to each button indicate when they are en-
the right side and the control module on the left side. gaged.
The alarm panel has a green light, a red light, a
• Shutdown Reset: If an alarm has been acti-
buzzer, and a sensor. See Fig. 25.6. It is located
vated and the Relay Engaged light is illumi-
within view from outside of the vehicle. The large
nated, the Shutdown Reset button will reset
green light is continuously illuminated during normal
the internal relay. Press the Shutdown Reset
operating conditions.
button only after the gas has cleared, the
Before entering the vehicle, always verify that the buzzer has turned off, and the alarm panel
green light is illuminated. If the green light is not illu- light has returned to green.
minated, do not enter the vehicle. Complete the
• Push To Silence: If an alarm has been acti-
alarm procedure previously outlined.
vated, the Push To Silence button will silence
The alarm panel meets the California Highway Patrol the buzzer.
Title 13-2008 and NFPA 52 2010 requirements. All
drivers and technicians using it should be trained re- See Table 25.2 for the functions of all lights and but-
garding the red and green lights, and the audible tons on the overhead console.
warning.
Testing
The control module, located on the center of the
overhead console, contains the status lights and con- Daimler Trucks North America strongly recommends
trol buttons for the system. The areas that the sen- that all operators follow California Code of Regula-
sors monitor are defined as Zone 1 (cab), Zone 2 tions (CCR) inspection requirements, regardless of
(engine compartment), and Zone 3 (sleeper, if where the vehicle is operated. Per Title 13 CCR §
equipped). The control module has lights assigned to 935 (2), gas detection systems should be tested
each zone that will illuminate if a sensor detects a three times per calendar year at equal intervals. The
trace level leak (between 20% and 30% LFL), a sig- testing procedure should simulate the same operat-
nificant level leak (above 50% LFL), or if a sensor is ing environment in which the vehicle is used, with the
disconnected or malfunctioning. same gaseous fuel.
• Trace Level: If either sensor detects gas fumes
at a concentration greater than 20% to 30%
LFL (1% gas in air by volume), the amber light
next to the Trace indicator for that zone will
25.7
10
9
11
8 14
7 12
6
13
5
1 2 3 4
02/06/2014 f470614
1. Green Light 6. Sensor Fault Indicator Lights 11 Silence Button
2. Red Light 7. Zone Numbers 12. Relay Reset Button
3. Sensor 8. Trace Leak Indicator Lights 13. Relay Engaged Light
4. Buzzer Alarm 9. Significant Leak Indicator Lights 14. Power Indicator Light
5. Test Button 10. Silence Engaged Light
Fig. 25.6, AMGaDS III Overhead Console
Control Module Functions

Item Display Function Action Required
Illuminated System is on. None required.
Ensure the batteries are
Green Power Light connected and replace any blown
Detection system is not
Unlit fuses. If the gas detection system
functioning.
is still not functioning, replace the
system immediately.
Suspend vehicle operation
SIGNIFICANT Gas Dangerous gas concentration
Red (illuminated) immediately and follow alarm
Concentration Lights detected.
procedures.
Trace Gas Concentration
Amber (flashing) Minor gas concentration detected. immediately and follow alarm
Lights
procedures.
Off Sensor is functioning properly. None required.
Sensor Fault Lights
On Sensor has malfunctioned. Replace the sensor immediately.
25.8
Control Module Functions

Item Display Function Action Required
Press to reset the system only
after the gas has cleared, the
Resets the system after an alarm
Shutdown Reset Button — buzzer has turned off, and the
activation.
alarm panel light has returned to
green.
Relay is engaged and test or
On Press the Shutdown Reset button.
Relay Engaged Light alarm is being cleared.
Off Normal condition. None required.
Press and hold for one minute to
Tests the overhead console
Test Button — to activate a test of all overhead
operation and circuitry.
console components.
Silence Button — Silences the alarm buzzer. Press to silence the alarm buzzer.
Indicates the buzzer is active but
On immediately and follow alarm
Silence Engaged Light silenced.
procedures.
Off Normal condition. None required.
Table 25.2, Control Module Functions
Test results validating the performance of the gas such as butane or propane does not satisfy CCR §
detection system within the parameters established 935 (2) or NFPA 52 regulations.
by the component manufacturer and NFPA 52 2010
should be maintained as a permanent part of the ve- Expose each sensor to qualified test gas for at least
30 seconds. The system will proceed through the
hicle service records. Use of alcohol, propane, and
alarm procedure consistent with a significant leak
other harsh liquids or gases are not acceptable
and the buzzer will sound after approximately 15
methods for testing.
seconds. If a sensor fails to respond after exposure
Always test the system and sensors after any com- to the test gas, replace the sensor.
ponent has been replaced, or if the vehicle has been
involved in an accident or fire. Ensure that the gas Natural Gas Engine Starting
detection system is wired directly to the battery.
It is recommended that the highest level of safety NOTE: Before starting the engine, read Chap-
validation be utilized if there are multiple validation ter 4 for detailed information on how to read the
requirements in the state or locality where the vehicle instruments and Chapter 5 for detailed informa-
is operated or domiciled. tion on how to operate the controls. Read the
operating instructions in the engine manufactur-
Overhead Console Test er’s operation manual before starting the en-
Press and hold the Push To Test button for one min- gine.
ute. The system will proceed with a self-diagnostic 1. Before engine start-up, complete the engine pre-
test that will include illumination of the Trace and Sig- trip and post-trip inspections and maintenance
nificant gas concentration lights, and the sensor fault procedures in Chapter 21.
lights. Verify the large red light and buzzer activate,
and that all lights illuminate or flash to ensure that all 2. Ensure the fuel shutoff valve is open.
bulbs are operational. 3. Set the parking brake.
Sensor Test 4. Ensure that the transmission shift control is in
Neutral (N), Park (P), or the Park Brake (PB) po-
The gas detection system sensors must be tested sition.
using qualified test gas, which can be purchased as
part of a test kit. Testing with alcohol or heavy gases
25.9
5. Without starting the engine, turn the ignition

switch to the ON position (Fig. 25.7). The elec-
Major Repairs and
tronic gauges on the instrumentation control unit Replacement of Natural Gas
(ICU) will complete a full sweep of their dials, the Components
warning and indicator lights will illuminate, and
the buzzer will sound for three seconds. IMPORTANT: All repairs to natural gas system
and components must be performed by certified
technicians.
If a natural-gas-fueled vehicle is involved in an acci-
dent, remove the fuel tank or cylinders from service
and have them inspected by a qualified technician.
Replace any leaking or damaged fuel tanks/cylinders
and fuel lines; repair or replace leaking or damaged
fittings. Install parts and components in accordance
with the manufacturer’s instructions.
07/19/2006 f610805
Fig. 25.7, Ignition Switch Positions
6. Turn the ignition switch to the START position.

Press down on the clutch pedal, if equipped, but
do not press down on the accelerator pedal.
Release the key the moment the engine starts.
7. Bring the engine up to operating speed gradually
as it warms up and develops stable oil pressure.
If the vehicle has not been operated previously in
a 24-hour period, allow the vehicle to idle for five
minutes.
NOTICE
Do not rev the engine if the oil pressure gauge
indicates no oil pressure. Shut down the engine
within approximately ten seconds to avoid engine
damage.
8. Check the oil pressure gauge for any drop in lu-
bricating oil pressure or mechanical malfunction
in the lubricating oil system.
25.10
26
Specifications
Fuses and Relays . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26.1
Replacement Bulbs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26.3
Fluids and Lubricants . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26.4
Specifications
Fuses and Relays SAM Cab Fuses

Part Name AMP
CAUTION F20 CGW 2
F21 Area Light 15
This vehicle may be equipped with a roof- ICU
mounted Citizens’ Band (CB) antenna. Operation F22 5
Horn Switch
of an amplified CB radio with output power
GPS
greater than FCC limits (4W AM/12W SSB) is ille-
gal, and may expose vehicle occupants to radio Driver Info Sys
frequency (RF) radiation that exceeds FCC maxi- F23 15
mum permissible RF exposure limits. Vehicle oc- Fleet Mgmt Sys
cupants with electronic medical devices should Pyrometer, Axle Temp, Eng
consult the device manufacturer’s user manual or Oil Temp Gauges
a physician for information on RF radiation expo- Diagnostic Conn
sure limit guidelines. F24 7.5*
ICU
SAM Cab Fuses Trans Temp Gauge/Shift
Select
Part Name AMP
F25 10†
F1 Power FD Spare 1 & 3 30 Phone
Cab/Slpr HVAC Ctrl Collision Warn Sys
F2 15
Trans Shift Pnl F26 SRS Airbags 5
F3 Power FD Spare 2 & 4 30 F27 Mirror Heat, L 10
F4 MSF 15 F28 Mirror Heat, R 10
OBD J1939 F29 SAM Relay Coils 3
F5 10 F30 Power Recp 6 20
OBD DCDI
F31 Power Recp 5 20
F6 Dash Power Recp 1 15
F32 Power FD Spare 5 & 6 25
F7 Dash Power Recp 2 15
F33 Spotlight 20
F8 Phone/Radio 15
F34 Baggage Comp Lamp 3
F9 Amplifier Power 20
F35 Dome Lamp 15
F10 Cab HVAC Motor 30
Aux Circulation Fan
F11 Sleeper HVAC Motor 30 F36 15
F12 Door Controls, L 20 Road Lamps
Door Lock Clock (cab & sleeper)
F13 20
Coll Warn Sys Driver Info Sys
F37 15
Fleet Mgm Sys CD Player
F14 25
CB Keyless Entry
F15 Sleeper Power Recp 3 20 F38 Door Controls, R 20
F16A Aux Cab Heater Enable 3 F39 Power Window, R 15
F16B Aux Coolant Heater 20 F40 Power Window, L 15
F17 Power Recp 4 20 F41 Aux Mirror Heat 10
GPS * F24 value on assemblies -005 and lower is 10 amps.
† F25 value on assemblies -005 and lower is 7.5 amps.
Tire Press Monitor
F18 15 Table 26.1, SAM Cab Fuses
Antitheft Warn
AuxiliaryTelematics
F19 Heated Seat 20
26.1
Specifications
SAM Cab Relays SAM Chassis Fuses

Position Function Source Part Name AMP
Power FD Spare 1 & 3 Elec Air Process. Unit
BR21 BAT F1 20
(EAPU)
Dash Power Recp 1
F2 Fuel/Water Separator Heat 20
Power FD Spare 2 & 4
BR22 BAT F3 ABS Bat 1 20
Slpr Power Recp 3 F4 ABS Bat 2 10
R3 Heated Seats IGN F5 Trailer Left-Turn Lamp 20
Dash Power Recp2 F6 ABS 15
EAPU/WIF
Fleet Mgmt Sys F7 10
Rear Camera
BR23 CB BAT
F8 Trailer Right-Turn Lamp 20
Aux Cab Heater F9 Trailer Marker Lamps 30
Aux Coolant Heater F10 SAM Relay Coils 5
GPS F11 Trailer ABS 30
F12 Trailer Stop Lamps 30
Driver Info Sys F13 Trailer Tail Lamps 20
R7 Fleet Mgmt Sys IGN F14 Trailer Power 30
Pyrometer, Axle Temp, Eng Table 26.3, SAM Chassis Fuses

Oil Temp Gauges
Diagnostic Conn
ICU SAM Chassis Relays
Position Function
Trans Temp/Shift Select
R8 IGN R1 Fuel/Water Separator Heat
Phone R2 Trailer Left-Turn Lamp
Coll Warn Sys ABS
SRS Airbags R3 EAPU/WIM

R9 Amplifier Power ACC Rear Camera
R10 Mirror Heat (L, R, & Aux) ACC R4 Trailer Right-Turn Lamp
Power Recp6 R5 Trailer Marker Lamps
Area Lighting R6 Trailer ABS
BR24 BAT R7 Trailer Stop Lamps
Baggage Comp Lamp R8 Trailer Power
Dome Lamp R9 Trailer Tail Lamps
Power Recp 4 & 5 Table 26.4, SAM Chassis Relays
BR25 Aux Circulation Fan BAT
Reading Lamp
R15 Power Windows ACC MEGA Fuse Junction Block (MFJB) Fuses, EPA07
Only
Table 26.2, SAM Cab Relays Part Name AMP
F1 Powertrain PDM 175
F2 SAM Cab 175
F3 SAM Chassis 125
Chassis-Mounted Trailer
F4 125
PDM
26.2
Specifications
MEGA Fuse Junction Block (MFJB) Fuses, EPA07 Replacement Bulbs

Only
Part Name AMP Replacement Bulbs
F5 Inverter 200 Lamp Assembly Replacement Bulb
Table 26.5, MEGA Fuse Junction Block (MFJB) Fuses, Headlight Hi/Low Beam, Fog WEE 12362LLBA
EPA07 Only light, Driving Light (H11)
Turn/Marker Lamp (in headlight
GE 3457
assy)
Incandescent Auxiliary Turn (on
Powernet Distribution Box (PNDB) Fuses, EPA10 and GE 2058U
fender)
Newer
Integral Stop/Tail/Backup Lights GE 1157/GE 1156
Fuse Function AMP Utility Light WEE 199
Aftertreatment Control Cab Dome Lamp, Clear,
A 30 GN12 BUL 050 R5WC
Module Outboard
B Emergency Power 20 Cab Dome Lamp, Clear, Inboard GN12 BUL 049 R10W
C Radio/Clock 5 Cab Dome Lamp (Red) GN12 BUL 050 R5WR
D Alternator Remote Sense 5 Sleeper Reading Lamp GRLSAP270
1 Powertrain PDM 175 Sleeper Dome Lamp GRLBUL049R10W
2 SAM Chassis 125 Sleeper Writing Desk Lamp GRLBUL027578
3 SAM Cab 175 Sleeper Bunk Lamp GRLBUL0142112
Table 26.6, Powernet Distribution Box (PNDB) Fuses, Footwell Lamp (Red) GRLBUL042W5W
EPA10 and Newer
Table 26.8, Replacement Bulbs
Trailer PDM Fuses and Relays

Position Function AMP
F1 Trailer Power Fuse 30
F2 Taillight Fuse 30
F3 Left-Turn Lamp Fuse 20
F4 Right-Turn Lamp Fuse 20
F5 Marker Lamp Fuse 30
F6 Stop Lamp Fuse 30
R1 Taillight Relay
R2 Right-Turn Relay
R3 Stop Lamp Relay
R4 Trailer Power Relay
R5 Left-Turn Relay
R6 Marker Lamp Relay
Table 26.7, Trailer PDM Fuses and Relays
26.3
Specifications
Fluids and Lubricants

Type Approved Fluid or Lubricant
Engines compliant with EPA07 or newer regulations: Engine lube oil with a sulfated ash level less
Engine Oil*
than 1.0 wt %; currently referred to as CJ-4 oil.
Engines compliant with EPA07 or newer regulations: Ultralow-sulfur diesel (ULSD) with 15 ppm
Fuel†
sulfur content or less, based on ASTM D2622 test procedure.
Power Steering Fluid ATF must meet TES 389 or Dexron III specifications
Hydraulic Clutch Fluid DOT 4
Manual Transmission MobilTrans SHC 50 (RN 2952 E-5), SAE 50W
Lubricant‡§ Synthetic transmission lubricant approved by Eaton, SAE 50W
Caterpillar Diesel Engine Antifreeze/Coolant. Contains supplement additives. Available as a
premixed solution.
Antifreeze
Detroit™ Power Cool, premixed solution with supplement additives.
Old World Industries, Fleet Charge™, with supplement additives.
Recommended SAE Viscosity Grade Ambient Temperature Range
75W –40°F to –15°F (–40°C to –26°C)
75W—80 –40°F to 80°F (–40°C to 27°C)
Drive Axle Lubricant 75W—90 –40°F to 100°F (–40°C to 38°C)
75W—140 –40°F and above (–40°C and above)
80W—90 –15°F to 100°F (–26°C to 38°C)
80W—140 10°F and above (–12°C and above)
* See the engine manufacturer’s manual for specifications.
† See the engine manufacturer’s manual for specifications.
‡ Do not mix types or brands of fluid. Multi-weight and extreme-pressure gear fluids are not recommended.
§ Call 1-800-826-4357 for a complete list of Eaton approved lubricants.
Table 26.9, Approved Fluids and Lubricants
26.4
Index
Subject Page Subject Page

A Seat Tilt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.3
Shock Absorber Adjustment . . . . . . . . . . . . . . . . 7.2
Accessory Heaters . . . . . . . . . . . . . . . . . . . . . . . . 8.5 Cascadia High-Back Seat . . . . . . . . . . . . . . . . . . . 7.3
Espar Heater . . . . . . . . . . . . . . . . . . . . . . . . . 8.6 Backrest Tilt . . . . . . . . . . . . . . . . . . . . . . . . . . 7.3
Webasto Heater . . . . . . . . . . . . . . . . . . . . . . . 8.7 Bottom Cushion Extension . . . . . . . . . . . . . . . . 7.3
Adjustable Steering Column Fore/Aft Isolator . . . . . . . . . . . . . . . . . . . . . . . . 7.3
Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.20 Fore/Aft Seat Slide . . . . . . . . . . . . . . . . . . . . . . 7.3
Adjusting Headlight Aim . . . . . . . . . . . . . . . . . . . 23.1 Front Cushion Height . . . . . . . . . . . . . . . . . . . . 7.3
Air Brake System . . . . . . . . . . . . . . . . . . . . . . . . 13.1 Heater . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.4
Automatic Slack Adjusters . . . . . . . . . . . . . . . . 13.3 Height Adjustment . . . . . . . . . . . . . . . . . . . . . . 7.3
Brake System Components . . . . . . . . . . . . . . . 13.1
Lumbar Support . . . . . . . . . . . . . . . . . . . . . . . 7.3
Brake System General Rear Cushion Height . . . . . . . . . . . . . . . . . . . . 7.3
Information . . . . . . . . . . . . . . . . . . . . . . . . . 13.1
Brake System Operation . . . . . . . . . . . . . . . . . 13.1 Shock Absorber . . . . . . . . . . . . . . . . . . . . . . . . 7.3
Air-Suspension Dump Valve . . . . . . . . . . . . . . . . . 19.1 Checking Headlight Aim . . . . . . . . . . . . . . . . . . . 23.1
Checklists . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20.1
Daily Pretrip Inspection
B Checklists . . . . . . . . . . . . . . . . . . . . . . . . . 20.1
Monthly Post-trip Inspection
Back-of-Cab Access . . . . . . . . . . . . . . . . . . . . . . . 2.4 Checklists . . . . . . . . . . . . . . . . . . . . . . . . . 20.2
Climbing Down from Back- Weekly Post-trip Inspection
of-Cab . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.5 Checklist . . . . . . . . . . . . . . . . . . . . . . . . . . 20.2
Entering Back-of-Cab . . . . . . . . . . . . . . . . . . . . 2.5
Climate Controls . . . . . . . . . . . . . . . . . . . . . . . . 5.17
Cab Climate Control . . . . . . . . . . . . . . . . . . . . 5.17
C Sleeper Climate Control . . . . . . . . . . . . . . . . . 5.18
Cab Amenities . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.1 Clutch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14.5
Cup Holders . . . . . . . . . . . . . . . . . . . . . . . . . . 9.1 Clutch Maintenance . . . . . . . . . . . . . . . . . . . . 14.7
Lighting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.1 Clutch Operation . . . . . . . . . . . . . . . . . . . . . . 14.6
General Information . . . . . . . . . . . . . . . . . . . . 14.5
Power Outlets . . . . . . . . . . . . . . . . . . . . . . . . . 9.1
Radio and CB . . . . . . . . . . . . . . . . . . . . . . . . . 9.2 Component GWR Label . . . . . . . . . . . . . . . . . . . . 1.1
Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.2 Component Information Label . . . . . . . . . . . . . . . . 1.1
Cab Climate Control Panel . . . . . . . . . . . . . . . . . . 8.1 Cruise Control . . . . . . . . . . . . . . . . . . . . . . . . . . 5.11
Fan Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.1 Cruise Control ("CC") Limiter . . . . . . . . . . . . . . 5.13
Mode Control Switch . . . . . . . . . . . . . . . . . . . . 8.2 Descent Control and
Deceleration Modes,
Temperature Control Switch . . . . . . . . . . . . . . . . 8.1 Detroit™ Automated
Cab Door Locks and Handles . . . . . . . . . . . . . . . . 2.1 Transmissions . . . . . . . . . . . . . . . . . . . . . . . 5.13
Cab Washing and Polishing . . . . . . . . . . . . . . . . . 22.1 Run Smart Predictive
Cab-to-Sleeper Access . . . . . . . . . . . . . . . . . . . . . 2.3 Cruise™ . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.12
Canadian Motor Vehicle Safety
Standard Labels . . . . . . . . . . . . . . . . . . . . . . . . 1.1
Care of Chrome Parts . . . . . . . . . . . . . . . . . . . . . 22.1
D
Care of Exterior Lights . . . . . . . . . . . . . . . . . . . . 22.1 Daily Pretrip Inspection and
Care of Fiberglass Parts . . . . . . . . . . . . . . . . . . . 22.1 Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . 21.1
Cascadia 2.0 High-Back Seat . . . . . . . . . . . . . . . . 7.2 Cab Inspection . . . . . . . . . . . . . . . . . . . . . . . 21.5
Armrest Angle . . . . . . . . . . . . . . . . . . . . . . . . . 7.3 Engine Compartment
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . 21.4
Bottom Cushion Extension . . . . . . . . . . . . . . . . 7.3
Natural Gas Fuel System
Fore/Aft Isolator . . . . . . . . . . . . . . . . . . . . . . . . 7.2 Inspection . . . . . . . . . . . . . . . . . . . . . . . . . 21.8
Height Adjustment . . . . . . . . . . . . . . . . . . . . . . 7.2 Saddle Tank Areas
Lumbar Support . . . . . . . . . . . . . . . . . . . . . . . 7.2 Inspection . . . . . . . . . . . . . . . . . . . . . . . . . 21.4
Recline . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.2 Suspension and Slack
Seat Fore/Aft Slide . . . . . . . . . . . . . . . . . . . . . . 7.3 Adjuster Inspection . . . . . . . . . . . . . . . . . . . 21.1
Seat Heating/Ventilation . . . . . . . . . . . . . . . . . . 7.2 Wheel and Tire Inspection . . . . . . . . . . . . . . . . 21.2
I-1
Index

Dashboard Care . . . . . . . . . . . . . . . . . . . . . . . . 22.2 General Information, Eaton
Dash-Mounted Brake Controls . . . . . . . . . . . . . . . 5.14 Fuller Splitter and Range-
Antilock Braking System . . . . . . . . . . . . . . . . . 5.15 Shift . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14.1
Parking Brake Control Valve . . . . . . . . . . . . . . . 5.14 Operation, Eaton Fuller
Splitter and Range-Shift . . . . . . . . . . . . . . . . 14.1
Trailer Air Supply Valve . . . . . . . . . . . . . . . . . . 5.14
Eaton Fuller AutoShift
Trailer Brake Lever . . . . . . . . . . . . . . . . . . . . . 5.15 Automated Transmissions . . . . . . . . . . . . . . . . 15.11
Detroit™ Automated General Information,
Transmissions . . . . . . . . . . . . . . . . . . . . . . . . . 15.1 AutoShift . . . . . . . . . . . . . . . . . . . . . . . . . . 15.11
Clutch Abuse Protection . . . . . . . . . . . . . . . . . 15.4 Operation, AutoShift with
Creep Mode . . . . . . . . . . . . . . . . . . . . . . . . . 15.3 SmartShift . . . . . . . . . . . . . . . . . . . . . . . . . 15.11
Detroit™ Multifunction Eaton Fuller UltraShift PLUS . . . . . . . . . . . . . . . 15.14
Control . . . . . . . . . . . . . . . . . . . . . . . . . . . 15.1 Auto Neutral . . . . . . . . . . . . . . . . . . . . . . . . 15.17
Driving Modes . . . . . . . . . . . . . . . . . . . . . . . . 15.2 Auto Start Gear Selection
eCoast . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15.3 and Override . . . . . . . . . . . . . . . . . . . . . . . 15.17
Engine Overspeed Alerts . . . . . . . . . . . . . . . . . 15.4 Automatic Mode (AUTO) . . . . . . . . . . . . . . . . 15.14
Gear Display Window . . . . . . . . . . . . . . . . . . . 15.2 Automatic Traction Control . . . . . . . . . . . . . . . 15.17
Low Transmission Air Clutch Abuse Protection . . . . . . . . . . . . . . . . 15.15
Warning . . . . . . . . . . . . . . . . . . . . . . . . . . . 15.4 Coasting . . . . . . . . . . . . . . . . . . . . . . . . . . . 15.17
Power Up and Shift into Creep Mode . . . . . . . . . . . . . . . . . . . . . . . . 15.16
Gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15.2
Engine Overspeed
Selected Gear . . . . . . . . . . . . . . . . . . . . . . . . 15.3 Protection . . . . . . . . . . . . . . . . . . . . . . . . . 15.16
Suggested Shift . . . . . . . . . . . . . . . . . . . . . . . 15.3 Hill Start Aid . . . . . . . . . . . . . . . . . . . . . . . . 15.16
Diesel Exhaust Fluid and Tank, Load-Based Shifting . . . . . . . . . . . . . . . . . . . 15.17
EPA10 and Newer Engines . . . . . . . . . . . . . . . . 12.3
Low (L) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15.15
DEF Tank . . . . . . . . . . . . . . . . . . . . . . . . . . . 12.4
Manual Mode (MAN) . . . . . . . . . . . . . . . . . . . 15.15
DEF Warnings and Engine
Limits . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12.5 Power Down . . . . . . . . . . . . . . . . . . . . . . . . 15.14
Diesel Exhaust Fluid . . . . . . . . . . . . . . . . . . . . 12.3 Power Up . . . . . . . . . . . . . . . . . . . . . . . . . . 15.14
Fuel/DEF Gauge . . . . . . . . . . . . . . . . . . . . . . 12.4 Reverse (R) . . . . . . . . . . . . . . . . . . . . . . . . . 15.14
Differential Locks . . . . . . . . . . . . . . . . . . . . . . . . 16.1 Shuttle Shifting . . . . . . . . . . . . . . . . . . . . . . 15.16
Driver-Controlled Differential Skip Shifting . . . . . . . . . . . . . . . . . . . . . . . . 15.17
Lock (DCDL) . . . . . . . . . . . . . . . . . . . . . . . . 16.1 Eaton Fuller UltraShift . . . . . . . . . . . . . . . . . . . . . 15.6
Single Drive Axles with General Information,
Traction Equalizer . . . . . . . . . . . . . . . . . . . . 16.2 UltraShift DM . . . . . . . . . . . . . . . . . . . . . . . 15.6
Tandem Drive Axles with Operation, UltraShift DM . . . . . . . . . . . . . . . . . 15.6
Interaxle Differential Lock . . . . . . . . . . . . . . . 16.1 Ultrashift Diagnostics . . . . . . . . . . . . . . . . . . 15.10
Driver Message Center . . . . . . . . . . . . . . . . . . . . 4.11 Electrical Power Distribution . . . . . . . . . . . . . . . . . . 3.1
ICU3/ICU4 . . . . . . . . . . . . . . . . . . . . . . . . . . 4.11 Cab Load Disconnect Switch . . . . . . . . . . . . . . . 3.3
ICU4Me . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.19 Circuit Protection Features . . . . . . . . . . . . . . . . 3.1
ICU4M . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.13 MEGA Fuse Junction Block,
EPA07 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.1
E Power Distribution Modules . . . . . . . . . . . . . . . . 3.1
Powernet Distribution Box,
Eaton Fuller 10-Speed Range- EPA10 and Newer . . . . . . . . . . . . . . . . . . . . . 3.1
Shift Transmissions . . . . . . . . . . . . . . . . . . . . . 14.4 Emergency Filter Replacement,
General Information, Eaton Davco . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24.1
Fuller Range-Shift . . . . . . . . . . . . . . . . . . . . 14.4 Emergency Kit, Optional . . . . . . . . . . . . . . . . . . . 24.1
Operation, Eaton Fuller Emergency Power Supply . . . . . . . . . . . . . . . . . . . 3.3
Range-Shift . . . . . . . . . . . . . . . . . . . . . . . . 14.4 SAM Cab Fault . . . . . . . . . . . . . . . . . . . . . . . . 3.4
Eaton Fuller 13-Speed and 18- SAM Chassis Fault . . . . . . . . . . . . . . . . . . . . . 3.4
Speed Splitter and Range-
Shift Transmissions . . . . . . . . . . . . . . . . . . . . . 14.1 Emergency Starting With
Jumper Cables . . . . . . . . . . . . . . . . . . . . . . . . 24.2
Emissions Labels . . . . . . . . . . . . . . . . . . . . . . . . . 1.1
I-2
Index

Aftertreatment System Fifth Wheel Lubrication . . . . . . . . . . . . . . . . . . 18.1
Indicators Label . . . . . . . . . . . . . . . . . . . . . . 1.1 Fire Extinguisher . . . . . . . . . . . . . . . . . . . . . . . . 24.1
Certified Clean Idle Label . . . . . . . . . . . . . . . . . 1.4 Fire in the Cab . . . . . . . . . . . . . . . . . . . . . . . . . 24.7
EPA Noise Emission Control In Case of a Cab Fire . . . . . . . . . . . . . . . . . . . 24.7
Label . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.3 Fluids Added . . . . . . . . . . . . . . . . . . . . . . . . . . . 20.2
Vehicle Emission Control Fluids and Lubricants . . . . . . . . . . . . . . . . . . . . . 26.4
Information Label . . . . . . . . . . . . . . . . . . . . . 1.4
Freightliner SmartShift Shift
Engine Brake . . . . . . . . . . . . . . . . . . . . . . . . . . 13.5 Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15.5
Engine Brake Operation . . . . . . . . . . . . . . . . . 13.5 General Information,
Engine Idle Limiting . . . . . . . . . . . . . . . . . . . . . . 11.2 SmartShift . . . . . . . . . . . . . . . . . . . . . . . . . 15.5
California Engine Idle Fuses and Relays . . . . . . . . . . . . . . . . . . . . . . . 26.1
Limiting . . . . . . . . . . . . . . . . . . . . . . . . . . . 11.2
Idle Shutdown Timer . . . . . . . . . . . . . . . . . . . . 11.2
Engine Operation . . . . . . . . . . . . . . . . . . . . . . . . 10.2 G
Cold-Weather Operation . . . . . . . . . . . . . . . . . 10.3 Grab Handles and Access
Engine Break-In . . . . . . . . . . . . . . . . . . . . . . . 10.3 Steps . . . . . . . . . . . . . . . . ............... 2.1
High-Altitude Operation . . . . . . . . . . . . . . . . . . 10.4 Entering the Driver Side . . . ............... 2.2
Normal Operation . . . . . . . . . . . . . . . . . . . . . . 10.3 Entering the Passenger Side ............... 2.2
Safety and Environmental Exiting the Driver Side . . . . ............... 2.2
Considerations . . . . . . . . . . . . . . . . . . . . . . 10.2 Exiting the Passenger Side . ............... 2.2
Engine Protection—Warning Greenhouse Gas Emissions
and Shutdown . . . . . . . . . . . . . . . . . . . . . . . . . 11.1 and Fuel Consumption
Engine Shutdown . . . . . . . . . . . . . . . . . . . . . . . . 10.4 Standards . . . . . . . . . . . . . . . . . . . . . . . . . . . 12.1
Engine Starting . . . . . . . . . . . . . . . . . . . . . . . . . 10.1
Cold-Weather Starting . . . . . . . . . . . . . . . . . . . 10.2
Starting After Extended
H
Shutdown . . . . . . . . . . . . . . . . . . . . . . . . . . 10.2 Hazard Warning Lights . . . . . . . . . . . . . . . . . . . . 24.1
Enhanced Stability Control . . . . . . . . . . . . . . . . . . 6.13 Holland Trailer Coupling . . . . . . . . . . . . . . . . . . . 19.1
EPA-Regulated Emissions General Information . . . . . . . . . . . . . . . . . . . . 19.1
Aftertreatment Systems . . . . . . . . . . . . . . . . . . . 12.1 Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . 19.1
ATS Warning Lamps . . . . . . . . . . . . . . . . . . . . 12.3 Hood Opening and Closing . . . . . . . . . . . . . . . . . . 2.5
EPA07 Engines . . . . . . . . . . . . . . . . . . . . . . . 12.1 To Return the Hood . . . . . . . . . . . . . . . . . . . . . 2.5
EPA10 and Newer Engines . . . . . . . . . . . . . . . 12.1 To Tilt the Hood . . . . . . . . . . . . . . . . . . . . . . . . 2.5
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . 12.3 Horn Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.7
Regeneration . . . . . . . . . . . . . . . . . . . . . . . . 12.2 Air Horn . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.7
Electric Horn . . . . . . . . . . . . . . . . . . . . . . . . . . 5.7
F
Federal Motor Vehicle Safety I
Standard Labels . . . . . . . . . . . . . . . . . . . . . . . . 1.1 Ignition Switch and Key . . . . . . . . . . . . . . . . . . . . 5.1
Fifth Wheel Coupling . . . . . . . . . . . . . . . . . . . . . 18.1 Instrumentation Control Units . . . . . . . . . . . . . . . . . 4.1
Fontaine and Holland Fifth Audible Alerts . . . . . . . . . . . . . . . . . . . . . . . . . 4.2
Wheels Coupling . . . . . . . . . . . . . . . . . . . . . 18.1
Ignition Sequence . . . . . . . . . . . . . . . . . . . . . . 4.1
Jost Fifth Wheel Coupling . . . . . . . . . . . . . . . . 18.3
Instruments . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.7
Fifth Wheel Slide . . . . . . . . . . . . . . . . . . . . . . . . 18.7
Air Intake Restriction Gauge . . . . . . . . . . . . . . . 4.7
Air Slide Operation . . . . . . . . . . . . . . . . . . . . . 18.9
Application Air Pressure
Manual Slide Operation . . . . . . . . . . . . . . . . . . 18.7 Gauge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.8
Fifth Wheel Uncoupling . . . . . . . . . . . . . . . . . . . . 18.4 Coolant Temperature Gauge . . . . . . . . . . . . . . . 4.9
Air-Actuated Uncoupling . . . . . . . . . . . . . . . . . 18.5 Drive Axle Oil Temperature
Manual Uncoupling . . . . . . . . . . . . . . . . . . . . . 18.4 Gauges . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.9
Fifth Wheels, General Engine Oil Pressure Gauge . . . . . . . . . . . . . . . . 4.9
Information . . . . . . . . . . . . . . . . . . . . . . . . . . . 18.1 Engine Oil Temperature
Air-Suspension Dump Valve . . . . . . . . . . . . . . . 18.1 Gauge . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.10
I-3
Index

Fuel Gauge, Pre-EPA10 . . . . . . . . . . . . . . . . . 4.10 LNG Vehicle Fueling . . . . . . . . . . . . . . . . . . . . 25.5
Fuel/Diesel Exhaust Fluid Natural Gas Vehicles, General
(DEF) Gauge, EPA10 and Information . . . . . . . . . . . . . . . . . . . . . . . . . . . 25.1
Newer . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.10 Natural Gas Vehicles, Safety
Primary and Secondary Air Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . 25.1
Pressure Gauges . . . . . . . . . . . . . . . . . . . . . 4.10 In Case of Emergency . . . . . . . . . . . . . . . . . . 25.3
Speedometer . . . . . . . . . . . . . . . . . . . . . . . . . 4.11
Tachometer . . . . . . . . . . . . . . . . . . . . . . . . . .
Transmission Fluid
4.11
O
Temperature Gauge . . . . . . . . . . . . . . . . . . . 4.11 OnGuard™ Collision Safety
Turbocharger Boost System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.7
Pressure Gauge . . . . . . . . . . . . . . . . . . . . . 4.11 Adaptive Cruise Control
Voltmeter . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.11 (ACC) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.8
Additional Features . . . . . . . . . . . . . . . . . . . . 6.10
L Collision Mitigation System
(CMS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.9
Lane Departure Warning Collision Warning System
Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.10 (CWS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.7
Lighting Controls . . . . . . . . . . . . . . . . . . . . . . . . . 5.2 Error Screens . . . . . . . . . . . . . . . . . . . . . . . . . 6.9
Exterior Lighting Controls . . . . . . . . . . . . . . . . . 5.2 OnGuard Display Unit . . . . . . . . . . . . . . . . . . . . 6.7
Interior Lighting Controls . . . . . . . . . . . . . . . . . . 5.6 Optimized Idle® . . . . . . . . . . . . . . . . . . . . . . . . . 11.2
Overhead Instrument Panel . . . . . . . . . . . . . . . . . 4.24
M
Major Repairs and
P
Replacement of Natural Gas ParkSmart™ HVAC System . . . . . . . . . . . . . . . . . . 8.3
Components . . . . . . . . . . . . . . . . . . . . . . . . . 25.10 Standard Vehicle
Meritor WABCO® Antilock Configuration . . . . . . . . . . . . . . . . . . . . . . . . 8.3
Braking System . . . . . . . . . . . . . . . . . . . . . . . . 13.3 Vehicles with Detroit Diesel
Automatic Traction Control . . . . . . . . . . . . . . . . 13.4 Optimized Idle . . . . . . . . . . . . . . . . . . . . . . . 8.5
ECAS Automatic Load Periodic Inspections and
Transfer (ECAS only) . . . . . . . . . . . . . . . . . . 13.4 Maintenance, General
Trailer ABS Compatibility . . . . . . . . . . . . . . . . . 13.4 Information . . . . . . . . . . . . . . . . . . . . . . . . . . . 20.1
Mirrors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.1 Power Steering System General
Monthly Post-Trip Inspections Information . . . . . . . . . . . . . . . . . . . . . . . . . . . 17.1
and Maintenance . . . . . . . . . . . . . . . . . . . . . . 21.13 Power Steering Systems . . . . . . . . . . . . . . . . . . . 17.1
Brake Component Inspection . . . . . . . . . . . . . 21.13 Rack and Pinion Steering
Engine Compartment System . . . . . . . . . . . . . . . . . . . . . . . . . . . 17.1
Inspection and Steering Gear System . . . . . . . . . . . . . . . . . . . 17.1
Adjustments . . . . . . . . . . . . . . . . . . . . . . . 21.15 Power Takeoff (PTO) Governor . . . . . . . . . . . . . . . 11.2
Saddle Tank Areas Powertrain Controls . . . . . . . . . . . . . . . . . . . . . . . 5.7
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . 21.14 Aftertreatment System
Regen Switches . . . . . . . . . . . . . . . . . . . . . . 5.7
N Axle Switches . . . . . . . . . . . . . . . . . . . . . . . . . 5.8
Engine Brake Switch . . . . . . . . . . . . . . . . . . . . 5.8
Natural Gas Detection System . . . . . . . . . . . . . . . 25.5 Engine Fan Switch . . . . . . . . . . . . . . . . . . . . . . 5.9
Alarm Procedure . . . . . . . . . . . . . . . . . . . . . . 25.5 Hill Start Aid Override Switch . . . . . . . . . . . . . . . 5.9
Overhead Console . . . . . . . . . . . . . . . . . . . . . 25.7 PTO Switch . . . . . . . . . . . . . . . . . . . . . . . . . . 5.9
Sensors . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25.6 Transmission Controls . . . . . . . . . . . . . . . . . . . 5.9
Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25.7 Preliminary Checks . . . . . . . . . . . . . . . . . . . . . . . 23.1
Natural Gas Engine Starting . . . . . . . . . . . . . . . . . 25.9 Progressive Low Voltage
Natural Gas Fuel Tank Filling Disconnect . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.4
Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . 25.3
CNG Vehicle Fueling . . . . . . . . . . . . . . . . . . . 25.3
I-4
Index

R Fifth Wheel Slide Control
Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.17
Replacement Bulbs . . . . . . . . . . . . . . . . . . . . . . 26.3 Trailer Auxiliary Switch . . . . . . . . . . . . . . . . . . 5.17
Roll Stability System . . . . . . . . . . . . . . . . . . . . . . 6.11
Hard-Braking Advisor . . . . . . . . . . . . . . . . . . . 6.13
Roll Stability Advisor . . . . . . . . . . . . . . . . . . . . 6.12
T
Roll Stability Control . . . . . . . . . . . . . . . . . . . . 6.12 Towing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24.4
Trip/Leg Totals . . . . . . . . . . . . . . . . . . . . . . . . 6.13 Front Towing Hookup . . . . . . . . . . . . . . . . . . . 24.5
RollTek Rollover Protection Rear Towing Hookup . . . . . . . . . . . . . . . . . . . 24.5
System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.9 Two-Speed Drive Axles . . . . . . . . . . . . . . . . . . . . 16.2
Identification . . . . . . . . . . . . . . . . . . . . . . . . . . 7.9 Axle Shift . . . . . . . . . . . . . . . . . . . . . . . . . . . 16.2
Inspection and Service . . . . . . . . . . . . . . . . . . 7.11
Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.9
V
S Velour Upholstery Cleaning . . . . . . . . . . . . . . . . . 22.3
Chewing Gum or Wax . . . . . . . . . . . . . . . . . . . 22.3
Sears Atlas Seat . . . . . . . . . . . . . . . . . . . . . . . . . 7.4 Grease and Oil-Based Stains . . . . . . . . . . . . . . 22.3
Armrest Angle . . . . . . . . . . . . . . . . . . . . . . . . . 7.5 Mildew . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22.3
Backrest Tilt . . . . . . . . . . . . . . . . . . . . . . . . . . 7.4 Sugar and Water-Based
Bottom Cushion Tilt . . . . . . . . . . . . . . . . . . . . . 7.5 Stains . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22.3
Fore/Aft Seat Slide . . . . . . . . . . . . . . . . . . . . . . 7.4 Vinyl Upholstery Cleaning . . . . . . . . . . . . . . . . . . 22.2
Isolator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.5 Ball Point Ink . . . . . . . . . . . . . . . . . . . . . . . . . 22.3
Lumbar Support . . . . . . . . . . . . . . . . . . . . . . . 7.4 Chewing Gum . . . . . . . . . . . . . . . . . . . . . . . . 22.2
Seat Extension . . . . . . . . . . . . . . . . . . . . . . . . 7.5 Miscellaneous . . . . . . . . . . . . . . . . . . . . . . . . 22.3
Suspension Inflation/ Nail Polish and Nail Polish
Deflation . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.5 Remover . . . . . . . . . . . . . . . . . . . . . . . . . . 22.2
Seat Belts and Tether Belts . . . . . . . . . . . . . . . . . . 7.5 Ordinary Dirt . . . . . . . . . . . . . . . . . . . . . . . . . 22.2
Seat Belt Inspection . . . . . . . . . . . . . . . . . . . . . 7.6 Paint, Shoe Heel Marks . . . . . . . . . . . . . . . . . 22.2
Seat Belt Operation . . . . . . . . . . . . . . . . . . . . . 7.6 Shoe Polish . . . . . . . . . . . . . . . . . . . . . . . . . 22.2
Seat Controls . . . . . . . . . . . . . . . . . . . . . . . . . . 5.19 Sulfide Stains . . . . . . . . . . . . . . . . . . . . . . . . 22.2
Seats, General Information . . . . . . . . . . . . . . . . . . 7.1 Tars, Asphalts, and Creosote . . . . . . . . . . . . . . 22.2
Sleeper Amenities . . . . . . . . . . . . . . . . . . . . . . . . 9.2 VORAD VS-400 System . . . . . . . . . . . . . . . . . . . . 6.1
Baggage Compartment Collision Warning System . . . . . . . . . . . . . . . . . 6.4
Doors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.2 Driver Interface Unit . . . . . . . . . . . . . . . . . . . . . 6.1
Lighting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.2 Failure Display Mode/Fault
Power Outlets . . . . . . . . . . . . . . . . . . . . . . . . . 9.2 Codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.6
Sleeper Access Door . . . . . . . . . . . . . . . . . . . . 9.2 Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . 6.6
Sliding Side Window . . . . . . . . . . . . . . . . . . . . 9.3 Side Object Detection . . . . . . . . . . . . . . . . . . . . 6.5
Sleeper Climate Control Panel . . . . . . . . . . . . . . . . 8.2 SmartCruise . . . . . . . . . . . . . . . . . . . . . . . . . . 6.5
Fan Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.2 Special Road Situations . . . . . . . . . . . . . . . . . . 6.6
Temperature Control Switch . . . . . . . . . . . . . . . . 8.3
Sleeper Door . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.3
Sleeper Luggage Door . . . . . . . . . . . . . . . . . . . . . 2.4
W
Steering Wheel Air Bag . . . . . . . . . . . . . . . . . . . . . 7.8 Warning and Indicator Lights . . . . . . . . . . . . . . . . . 4.3
Inspection and Service . . . . . . . . . . . . . . . . . . . 7.9 Engine Protection System . . . . . . . . . . . . . . . . . 4.7
Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.8 Weekly Post-Trip Inspections
and Maintenance . . . . . . . . . . . . . . . . . . . . . . 21.10
Suspension/Trailer Connection
Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.16 Engine Compartment
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . 21.10
Air Suspension Dump
Control Switch . . . . . . . . . . . . . . . . . . . . . . . 5.16 Windows . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.1
ECAS Remote Control Unit Windshield Wiper/Washer
(ECAS only) . . . . . . . . . . . . . . . . . . . . . . . . 5.16 Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.15
I-5

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Introduction performed. The EDR is designed to record data re-

Customer Assistance Center

Reporting Safety Defects

Canadian Motor Vehicle Safety

Federal Motor Vehicle Safety Emissions Labels

Fig. 1.2, Component GWR Label

Fig. 1.3, Vehicle Certification Label

Fig. 1.5, Incomplete Vehicle Certification Label

Fig. 1.6, Canadian National Safety Mark

A warning label on the driver-side visor contains im-

Fig. 1.4, Label Locations

EXHAUST AFTERTREATMENT SYSTEM INFORMATION

Fig. 1.7, ATS Indicators, EPA07

Applicable Emissions System Based on Build Date and EPA Regulations

IMPORTANT: Certain Freightliner incomplete

DEF Refill Needed Diesel Exhaust Fluid (DEF) level is

See operator’s manual for complete instructions. 24−01656−000

Fig. 1.8, ATS Indicators, EPA10 and Newer

Vehicle Emission Control Information 02/29/2012 f080181

Label Fig. 1.10, Vehicle Emission Control Information Label

Certified vehicles are equipped with a label placed

Fig. 1.11, CARB Clean Idle Label

Cab Door Locks and Handles

To unlock the door without unlatching it, pull the lock

Fig. 2.4, Passenger-Side Steps and Grab Handles

1. Using both hands, grasp the grab handle thats

Fig. 2.5, Sleeper Doors

Fig. 2.6, Sleeper Door Levers

Sleeper Luggage Door

WARNING 09/24/2007 f602335

External surfaces of the exhaust system remain 1. Steps 3. Deck Plate

Be careful not to get hands or feet tangled in

Climbing Down from Back-of-Cab

Hood Opening and Closing To Return the Hood

Electrical Power Distribution Auxiliary PDM

Cab Load Disconnect Switch

Emergency Power Supply

Fig. 3.4, SAM Cab Location

SAM Cab Fault • identification lights

If the emergency power supply system activates, do • front marker lights

Fig. 3.6, Cab Load Disconnect Switch, EPA07

1. Circuit Breaker 2. Self-Resetting Circuit

Type of Loads Shut Down Under Specific Conditions

Type of Loads Shut Down Under Specific Conditions

Heated seats, ignition*

Table 3.2, Load Designation

Instrumentation Control Units • "Driver Message Center"

The instrumentation control unit (ICU) provides the Ignition Sequence

Fig. 4.1, ICU3 Instrument Cluster (EPA10 shown)

Fig. 4.2, ICU4M Instrument Cluster (EPA10 shown)

Fig. 4.3, ICU4Me Instrument Cluster

PARKING BRAKE PARKING BRAKE

Common Warning and Indicator Lamps

Indicates the coolant temperature is above the maximum

Indicates air pressure in the primary or secondary reservoir

Indicates the engine oil pressure is below the minimum

Transmission Overheat Indicates high transmission temperature. Red

Indicates low transmission fluid level. Safely bring the

n = Number of If fault goes inactive, If fault goes inactive,

dlAG FAULT FAULT