Foreword

Introduction Environmental Concerns and

This manual provides information needed to operate Recommendations
and understand the vehicle and its components. More
detailed information is contained in the Owner’s War- Whenever you see instructions in this manual to discard
ranty Information for North America booklet, and in the materials, you should first attempt to reclaim and re-
vehicle’s workshop and maintenance manuals. cycle them. To preserve our environment, follow appro-
priate environmental rules and regulations when dispos-
Custom-built Sterling vehicles are equipped with various ing of materials.
chassis and cab components. Not all of the information
contained in this manual applies to every vehicle. For
details about components in your vehicle, refer to the
Event Data Recorder
chassis specification pages included in all new vehicles This vehicle is equipped with one or more devices that
and to the vehicle specification decal located inside the record specific vehicle data. The type and amount of
vehicle. data recorded varies depending on how the vehicle is
For your reference, keep this manual in the vehicle at equipped (such as the brand of engine, if an air bag is
all times. installed, or if the vehicle features a collision avoidance
system, etc.).
IMPORTANT: Descriptions and specifications in this
manual were in effect at the time of printing. Sterling
Truck Corporation reserves the right to discontinue Customer Assistance Center
models and to change specifications or design at any Having trouble finding service? Call the Customer As-
time without notice and without incurring obligation. De- sistance Center at 1-800-785-4357 or 1-800-STL-HELP.
scriptions and specifications contained in this publica- Call night or day, weekdays or weekends, for dealer
tion provide no warranty, expressed or implied, and are referral, vehicle information, breakdown coordination, or
subject to revisions and editions without notice. Fleetpack assistance. Our people are knowledgeable,
professional, and committed to following through to help
you keep your truck moving.

STI-401 (8/05P)
Printed in U.S.A.
Foreword
Reporting Safety Defects Canadian customers who wish to report a safety-
related defect to Transport Canada, Defect Investi-
If you believe that your vehicle has a defect which gations and Recalls, may telephone the toll-free
could cause a crash or could cause injury or hotline 1-800-333-0510, or contact Transport
death, you should immediately inform the National Canada by mail at: Transport Canada, ASFAD,
Highway Traffic Safety Administration (NHTSA) in Place de Ville Tower C, 330 Sparks Street,
addition to notifying Sterling Truck Corporation. Ottawa, Ontario, Canada K1A 0N5.
If the NHTSA receives similar complaints, it may For additional road safety information, please visit
open an investigation and if it finds that a safety the Road Safety website at: http://www.tc.gc.ca/
defect exists in a group of vehicles, it may order a roadsafety/menu.htm
recall and remedy campaign. However, NHTSA
cannot become involved in individual problems
between you, your dealer, or Sterling Truck Corpo-
ration.
To contact NHTSA, you may call the Vehicle
Safety Hotline toll-free at 1-888-327-4236 (TTY:
1-800-424-9153); go to http://www.safercar.gov; or
write to: Administrator, NHTSA, 400 Seventh
Street, SW, Washington, DC 20590. You can also
obtain other information about motor vehicle safety
from http://www.safercar.gov.

© 2000-2005 Freightliner LLC. All rights reserved.

No part of this publication, in whole or part, may be translated, stored in a retrieval system, or transmitted in any form
by any means, electronic, mechanical, photocopying, recording, or otherwise, without the prior written permission of
Freightliner LLC. For additional information, please contact Freightliner LLC, Service Systems and Documentation,
P.O. Box 3849, Portland OR 97208–3849 U.S.A. or refer to http://www.Freightliner.com and http://www.SterlingTrucks.
com.
 Contents
Chapter Page
Introduction, Environmental Concerns and Recommendations, Event
Data Recorder, Customer Assistance Center, Reporting Safety Defects . . . . . . . . . . . . . Foreword
1 Vehicle Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.1
2 Instruments and Controls Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.1
3 Vehicle Access and Features . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.1
4 Heater and Air Conditioner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.1
5 Seats and Seat Belts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.1
6 Steering and Brake Systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.1
7 Engines and Clutches . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.1
8 Transmissions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.1
9 Rear Axles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.1
10 Fifth Wheels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.1
11 Pretrip Inspection and Daily Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11.1
12 Cab Appearance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12.1
13 In an Emergency . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13.1
Index . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I.1
 1

Vehicle Identification
Vehicle Specification Decal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.1
Federal Motor Vehicle Safety Standard (FMVSS) Labels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.1
Canadian Motor Vehicle Safety Standard (CMVSS) Labels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.2
Tire and Rim Labels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.3
EPA Vehicle Noise Emission Control Label . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.3
Vehicle Identification
Vehicle Specification Decal Federal Motor Vehicle Safety
The vehicle specification decal lists the vehicle model, Standard (FMVSS) Labels
identification number, and major component models. It
NOTE: Due to the variety of FMVSS certification
also recaps the major assemblies and installations
shown on the chassis specification sheet. The specifica- requirements, not all of the labels shown will apply
tion decal is inside the rear cover of the Owner’s War- to your vehicle.
ranty Information for North America booklet. An illustra- Tractors with or without fifth wheels purchased in the
tion of the decal is shown in Fig. 1.1. U.S. are certified by means of a certification label
(Fig. 1.2) and the tire and rim labels (Fig. 1.3). These
labels are attached to the left side rear door jamb, as
USE VEHICLE ID NO.
COMPONENT INFORMATION WHEN ORDERING PARTS shown in Fig. 1.4.
DATE OF MFR
MANUFACTURED BY WHEELBASE
ENGINE NO.
MODEL TRANS NO. 1 2 3
VEHICLE ID NO. FRT AXLE NO.
ENGINE MODEL 1ST INT AXLE MODEL
1ST INT AXLE MODEL 2ND INT AXLE MODEL
2ND INT AXLE MODEL 3RD INT AXLE MODEL
3RD INT AXLE MODEL 4TH INT AXLE MODEL
4TH INT AXLE MODEL
5TH INT AXLE MODEL 5TH INT AXLE MODEL
TRANS MODEL MAIN REAR AXLE NO.
FRONT AXLE MODEL RATIO
REAR AXLE MODEL
FOR COMPLETE PAINT INFORMATION 11/21/96 f080053
PAINT MFR SEE VEHICLE SPECIFICATION SHEET
PAINT NO.

PART NO. 045−9904BB60−CA Fig. 1.2, Certification Label, U.S.

04/23/99 f080090 If purchased for service in the U.S., trucks built without
a cargo body have a certification label (Fig. 1.5) at-
Fig. 1.1, Vehicle Specification Decal, Canadian-Built tached to the left side rear door jamb. See Fig. 1.4. In
Vehicle Shown addition, after completion of the vehicle, a certification
NOTE: Labels shown in this chapter are examples label similar to that shown in Fig. 1.2 must be attached
by the final-stage manufacturer. This label will be lo-
only. Actual specifications may vary from vehicle to
cated on the left side rear door jamb and certifies that
vehicle.

1.1
 Vehicle Identification
1 2 3
GAWR TIRES RIMS PSI COLD

VEHICLE ID NO. FRONT AXLE

DATE OF MFR FIRST INTERMEDIATE AXLE
GVWR SECOND INTERMEDIATE AXLE
THIRD INTERMEDIATE AXLE
REAR AXLE

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

1
02/12/98 f080079

1. Date of manufacture by month and year.

2. Gross vehicle weight rating; developed by taking the
sum of all the vehicle’s gross axle ratings.
3. Gross axle weight ratings; developed by considering
each component in an axle system, including
suspension, axle, wheels, and tires. The lowest
component capacity is the value for the system.
Fig. 1.3, Tire and Rim Label 2
the vehicle conforms to all applicable FMVSS regula-
tions in effect on the date of completion.

Canadian Motor Vehicle Safety

Standard (CMVSS) Labels
In Canada, tractors with fifth wheels are certified by 04/23/99 f080092
means of a "Statement of Compliance" label and the 1. Tire and Rim Labels 2. Certification Label
Canadian National Safety Mark (Fig. 1.6), which are
attached to the left side rear door jamb. Tire and rim Fig. 1.4, Labels Location
labels (Fig. 1.3) are also attached to the left side rear
door jamb. If purchased for service in Canada, trucks built without
a cargo body and tractors built without a fifth wheel are

1.2
Vehicle Identification
Tire and Rim Labels
Tire and rim labels certify suitable tire and rim combina-
09/28/98 f080023
tions that can be installed on the vehicle for the given
gross axle weight rating. Tires and rims installed on the
Fig. 1.5, Incomplete Vehicle Certification Label, U.S. vehicle at the time of manufacture may have a higher
load capacity than that certified by the tire and rim la-
bel. If the tires and rims currently on the vehicle have a
lower load capacity than that shown on the tire and rim
label, then the tires and rims determine the load limita-
tions on each of the axles.
See Fig. 1.3 for U.S. and Canadian tire and rim labels.

EPA Vehicle Noise Emission

09/30/93 f080024
Control Label
A vehicle noise emission control label (Fig. 1.7) is at-
Fig. 1.6, Canadian National Safety Mark tached to the left side rear door jamb.
certified by a "Statement of Compliance" label, similar to
Fig. 1.2. This label must be attached by the final-stage VEHICLE NOISE EMISSION CONTROL INFORMATION
STERLING TRUCK CORPORATION DATE OF MANUFACTURE 01/99
manufacturer after completion of the vehicle. The label THIS VEHICLE CONFORMS TO U.S. EPA REGULATIONS FOR NOISE EMISSION
APPLICABLE TO MEDIUM AND HEAVY TRUCKS.
is located on the left side rear door jamb, and certifies THE FOLLOWING ACTS OR THE CAUSING THEREOF BY ANY PERSON ARE PROHIBITED BY
THE NOISE CONTROL ACT OF 1972:
A. THE REMOVAL OR RENDERING INOPERATIVE, OTHER THAN FOR PURPOSES OF
that the vehicle conforms to all applicable CMVSS regu- MAINTENANCE, REPAIR, OR REPLACEMENT, OF ANY NOISE CONTROL DEVICE OR
ELEMENT OF DESIGN (LISTED IN THE OWNER’S MANUAL) INCORPORATED INTO THIS
VEHICLE IN COMPLIANCE WITH THE NOISE CONTROL ACT.
lations in effect on the date of completion. B. THE USE THIS VEHICLE AFTER SUCH DEVICE OR ELEMENT OF DESIGN HAS
BEEN REMOVED OR RENDERED INOPERATIVE. 24−00273−020

04/23/99 f080091

Fig. 1.7, Vehicle Noise Emission Control Label

1.3
 Vehicle Identification
It is the owner’s responsibility to maintain the vehicle so
that it conforms to EPA regulations.
IMPORTANT: Certain Sterling incomplete vehicles
may be produced with incomplete noise control
hardware. Such vehicles will not have a vehicle
noise emission control information label. For such
vehicles, it is the final-stage manufacturer’s re-
sponsibility to complete the vehicle in conformity to
U.S. EPA regulations (40 CFR Part 205) and label
it for compliance.

1.4
 2

Instruments and Controls Identification

Instrument and Control Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.1
Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.1
Instrumentation Control Unit, Level I . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.16
Instruments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.24
Exterior Switches . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.31
NGI Instrument Cluster, Optional . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.31
Instruments and Controls Identification
Instrument and Control Panel will operate until the engine is started and the minimum
pressures are built up.
Figure 2.1 represents a typical instrument and control In the accessory position, the key is turned 45 degrees
panel equipped with all of the standard and many of the counterclockwise. With the ignition switch in the acces-
optional instruments and controls. sory position, the radio, windshield wipers, heated mir-
rors, power mirrors, and power windows are operable.
Controls
Power Window Switch, Optional
Ignition Switch and Key
The power window switch is located on the driver’s door
The ignition switch has four positions: off, start, on, and and controls the passenger window if there is a manual
accessory. See Fig. 2.2. The ignition key can be in- window regulator for the driver’s door. If there are two
serted and removed only in the off position. The ignition power window switches on the driver’s door, one switch
key also locks and unlocks the cab doors from the out- controls the driver’s window and one switch controls the
side. passenger’s window. See Fig.2.3. The passenger’s door
With the ignition switch in the off position, whether the also has a power window switch if both doors are con-
ignition key is inserted or not, the low-beam headlights, trolled electrically.
hazard warning lights, marker lights, clearance lights, Push the dimpled end of the power window switch to
dome lights, parking lights, and the brake lights will op- lower the window; push the raised end of the switch to
erate. raise the window.
To start the engine, turn the ignition key 90 degrees
clockwise until the engine starts. After the engine has Power Lock Switch, Optional
started, release the key and it will return to the on posi-
The power lock switch (Fig. 2.3) is located below the
tion.
door handle on the driver’s side and the passenger’s
In the on position, the key is turned 45 degrees clock- side of the cab. Press the L to lock the doors. Press the
wise. With the ignition switch in the on position, all the U to unlock the doors.
electrical systems are operable. The warning lights and
buzzer indicating low air pressure and low oil pressure

2.1
 Instruments and Controls Identification
7 8 9
5 6 10

20 25 35 45 55
4 15 30 25 65
10
15 75
5
5 85
0

1
11
16
17 15
16 12
10/06/99 14 13 f610338

NOTE: Instruments and controls and their locations may vary from those shown.
1. Ignition Switch 10. Instrument Panel Switches
2. Headlight and Parking Light Switch 11. Parking Brake Control Valve Knob
3. Turn Signal/Windshield Wiper Lever 12. Hot Posts
4. Marker Blink Switch 13. Trailer Air Supply Valve Knob
5. Control Panel Dimmer and Dome Light Switch 14. Electronic Sound System
6. Instrument Cluster 15. Climate Control Panel
7. Dash Message Center 16. Cruise Control Switch
8. Trailer Brake Valve Control 17. Horn
9. Instrument Panel Gauges
Fig. 2.1, Instrument and Control Panel Layout

2.2
Instruments and Controls Identification
2
1 3

4
1 2

09/30/99 f610344
1. Accessory 3. On 3
2. Off 4. Start

Fig. 2.2, Ignition Switch Positions

3
Power Mirror Switch, Optional 4
B
A
The position of the door-mounted mirrors is controlled 10/06/99 f720367
by the power mirror switch (Fig. 2.4) located near the A. Push here to lower window.
door handle on the driver’s side of the cab. Move the B. Push here to raise window.
lever toward the L to control the left mirror, and toward 1. Door Handle
the R to control the right mirror. Move the button to the 2. Power Mirror Switch
left or right to control the position of the mirror. 3. Power Window Switch
4. Power Lock Switch
Headlight and Parking Light Switch
Fig. 2.3, Power Lock, Window, and Mirror Switches
The headlight and parking light switch (Fig. 2.5) is lo-
cated above the ignition switch. Turn the switch 45 de- grees clockwise to turn the parking lights on. Turn the
switch 90 degrees clockwise to turn the headlights on.

2.3
 Instruments and Controls Identification
headlight switch is in the off position. The daytime run-
ning lights illuminate the headlights at a reduced inten-
sity during daytime driving. These lights are not to be
used in place of the headlights during reduced visibility
or nighttime driving conditions.
For vehicles built to operate in Canada, daytime running
lights are required.

09/15/99 f610363
WARNING
Fig. 2.4, Power Mirror Switch When the daytime running lights are on, only the
headlights are illuminated at a reduced intensity.
The marker lights, taillights, and trailer lights are
not illuminated. Turn the headlights on at dusk. Us-
ing the daytime running lights at night could cause
an accident resulting in personal injury or property
damage.

Marker Blink Switch

The marker blink (MARK BLNK) switch (Fig. 2.6) is a
09/22/1999 f610367
paddle switch located above and to the left of the head-
light and parking light switch. Push the paddle down to
Fig. 2.5, Headlight and Parking Light Switch turn the marker lights on. Push the paddle up to blink
the marker lights. When the paddle is in the center po-
Daytime Running Lights, Optional sition, the markers lights are off.

The daytime running lights are turned on when the en-

gine is started, the parking brake is released, and the

2.4
Instruments and Controls Identification

09/22/1999 f610366 09/22/1999 f610365

Fig. 2.6, Marker Blink Switch Fig. 2.7, Instrument and Control Panel Dimmer Switch

Lighted Mirrors, Optional Turn Signal Lever, United

The lights on the door-mounted mirrors act as marker Technologies
lights. Push the paddle on the marker blink (MARK Turn Signals
BLNK) switch (Fig. 2.6) down to turn on the mirror
lights. The turn signal lever (Fig. 2.8) is located on the left
side of the steering column. Push the lever up to turn
Instrument and Control Panel Dimmer the right-turn signal on. Pull the lever down to turn the
left-turn signal on. The turn signal lever will return to the
Switch neutral position after the turn has been completed.
The instrument and control panel dimmer switch
(Fig. 2.7) is located above and to the right of the head- High-Beam Headlights
light and parking light switch. The instrument and con- Push the turn signal lever away from you to change the
trol panel lights can be brightened by moving the lever headlights from low beam to high beam.
up, or dimmed by moving the lever down. The dome
light can be turned on by moving the switch all the way
up.

2.5
 Instruments and Controls Identification
fluid will continue to spray as long as the button is
2 pushed in.
1
Hazard Warning Lights
Push the hazard warning lights switch (Fig. 2.9) on top
of the steering column to turn the hazard warning lights
on. Push the switch again to turn the hazard warning
lights off.
10/06/99 f610361
1. Windshield Washer Button
2. Windshield Wiper Knob

Fig. 2.8, Turn Signal Lever, United Technologies

Flash to Pass
Pull the turn signal lever toward you and release the
lever to momentarily flash the high-beam headlights 09/22/1999 f610359
when the headlights are off.
Fig. 2.9, Hazard Warning Lights Switch
Windshield Wipers
Turn Signal Lever, Signal-Stat
To turn the windshield wipers on, turn the knob on the
end of the turn signal lever. There are seven intermittent Turn Signals
wiper speeds from slow to fast, a low speed, and a high The turn signal lever (Fig. 2.10) is located on the left
speed. side of the steering column. Push the lever up to turn
the right-turn signal on. Pull the lever down to turn the
Windshield Washer left-turn signal on. Return the turn signal lever to the
To turn the windshield washer on, push the button on neutral position after the turn has been completed.
the end of the turn signal lever in. Windshield washer

2.6
Instruments and Controls Identification
1
CAUTION
Do not move the wiper arms manually. Wiper motor
damage will occur if the arms are moved.

Windshield Washer
2 To turn the windshield washer on, push the knob on the
10/06/99 f610360 end of the turn signal lever in. Windshield washer fluid
1. Windshield Wiper/Washer Knob will continue to spray as long as the knob is pushed in.
2. Hazard Warning Lights Switch
Hazard Warning Lights
Fig. 2.10, Turn Signal Lever, Signal-Stat
Push the hazard warning lights switch underneath the
High-Beam Headlights turn signal lever to turn the hazard warning lights on.
Push the switch again to turn the hazard warning lights
Pull the turn signal lever toward you to change the off.
headlights from low beam to high beam.
Tilt or Tilt and Telescoping Steering
Flash to Pass
Wheel, Optional
Pull the turn signal lever toward you and release the
lever to momentarily flash the high-beam headlights
when the headlights are off. WARNING
Windshield Wipers Make sure that the steering column is locked before
driving the vehicle. Never tilt or telescope the steer-
To turn the windshield wipers on, turn the knob on the ing wheel while driving the vehicle. Doing so could
end of the turn signal lever. There are five intermittent cause loss of vehicle control, personal injury, and
wiper speeds, a low speed, and a high speed. property damage.

2.7
 Instruments and Controls Identification
To tilt the steering wheel, push the lever (Fig. 2.11) be-
low the steering wheel down and tilt the column to the
desired position. Release the lever to lock the steering
wheel in place.
To telescope the steering wheel, pull the lever up and
pull the steering wheel closer to you or push the steer-
ing wheel farther away. Release the lever to lock the
steering wheel in place.

Horn
Your vehicle is equipped with an electric horn and may
have an optional air horn.
To use the electric horn, press the center of the steering
wheel. To use the air horn, pull the cable located on the
ceiling above the driver’s seat.

Trailer Brake Hand Control Valve 1

Lever 09/25/99 f601857

The trailer brake hand control valve lever (Fig. 2.12) is 1. Tilt and Telescoping Lever
used to apply the trailer brakes without applying the
Fig. 2.11, Tilt or Tilt and Telescoping Steering Wheel
truck or tractor brakes and is mounted on the instru-
ment and control panel. Pull the lever down to apply the
brakes. When the lever is released, the lever will return Heater and Air-Conditioner Controls
to the upper position. Refer to Chapter 4 for detailed operating instructions of
the heater and air conditioner.

2.8
Instruments and Controls Identification

TRAILER NOT FOR 1

BRAKE
2
PARKING

03/10/99 f610291
1. Trailer Air Supply Valve Knob
09/25/99 f610343
2. Parking Brake Control Valve Knob
Fig. 2.12, Trailer Brake Hand Control Valve Lever Fig. 2.13, Brake Valve Knobs

Parking Brake Control Valve and supply valve knob must be pushed in (and should stay
in) to charge the trailer air supply system and release
Trailer Air Supply Valve the trailer spring parking brakes. Before disconnecting a
The yellow diamond-shaped knob (Fig. 2.13) operates trailer or when operating a vehicle without a trailer, the
the parking brake control valve. Pulling the knob out trailer air supply valve knob must be pulled out.
applies both the tractor and the trailer spring parking Refer to Chapter 6 under the heading "Air Brake Sys-
brakes. Pushing the knob in releases the tractor spring tem" for instructions regarding the use of the trailer air
parking brakes. Before the spring parking brakes can supply valve and the parking brake control valve.
be released, the air pressure in either air brake system
must be at least 65 psi (448 kPa). Hot Posts
The red octagonal-shaped knob (Fig. 2.13) operates
the trailer air supply valve. After the vehicle and its air Hot posts (Fig. 2.1) are provided as a source of power
hoses are connected to a trailer and the pressure in the within the cab to operate 12-volt electrical accessories.
air system is at least 65 psi (448 kPa), the trailer air A power and ground jack are included in the hot post.

2.9
 Instruments and Controls Identification
Mode/Reset Switch, Optional When the odometer reading is displayed and the park-
ing brake is released:
The mode/reset switch (Fig. 2.14) is located on the
right side of the instrument cluster. The mode/reset • Press the mode/reset switch once and the trip
switch is used to scroll through the displays on the distance will display.
message display screen, and to reset the trip distance • Press the mode/reset switch a second time and
and trip hours values to zero. When the mode/reset the trip hours (engine hours) will display.
switch is pressed for one second or less, the switch
acts as a mode switch. When the switch is pressed for • Press the mode/reset switch a third time and the
more than one second, the switch acts as a reset SELECT screen and the current units, MI or KM,
switch. will display.
• Press the mode/reset switch a fourth time to re-
turn to the odometer reading.
PUSH− Heated Mirror Switch, Optional
MODE One or both door-mounted mirrors can be heated to
keep them defrosted. Press the upper end of the
HOLD− heated mirror switch (Fig. 2.15) to heat the mirrors.
RESET When the heated mirror switch is pressed, the MIR
HEAT indicator on the dash message center comes on.
09/25/99 f610340
Wheel Lock Switch, Optional
Fig. 2.14, Mode/Reset Switch
The wheel lock switch locks together the wheels on the
To reset the value of the selected display to zero, press same axle. Push the wheel lock switch (Fig. 2.16) up to
the mode/reset switch for one second or longer. To engage the wheel lock. Move the switch to the center
toggle between MI (miles) of KM (kilometers), press the position to disengage the wheel lock. Refer to Chapter
mode/reset switch while in the SELECT screen. 9 for complete operating instructions.

2.10
Instruments and Controls Identification
axle lock switch (Fig. 2.17) up to engage the axle lock.
Move the switch to the center position to disengage the
axle lock.

09/15/99 f610362

Fig. 2.15, Heated Mirror Switch

10/01/99 f610377

Fig. 2.17, Axle Lock Switch

Exhaust Brake Switch, Optional

The exhaust brake restricts the flow of exhaust gasses
which slows the engine. Push the exhaust brake switch
(Fig. 2.18) up to engage the exhaust brake. Move the
10/01/99
switch to the center position to disengage the exhaust
f610376
brake. Refer to Chapter 7 under the heading "Exhaust
Fig. 2.16, Wheel Lock Switch Braking System, Optional" for additional information.

Axle Lock Switch, Optional Engine Brake Switch, Optional

The axle lock switch locks the forward drive and rear The three-position engine brake switch is available only
drive axles together on tandem drive axles. Push the on Mercedes-Benz MBE900 engines. Press the top of
the engine brake switch to apply both the engine brake

2.11
 Instruments and Controls Identification

EXH
BRK
ABS
DIAG
10/06/99 f610378 10/26/99 f610384

Fig. 2.18, Exhaust Brake Switch Fig. 2.19, ABS Diagnostic Switch

and exhaust brake. When the switch is in the center switch (Fig. 2.20) is used to provide increased traction
position, only the exhaust brake is applied. When the on soft surfaces such as snow, mud, or gravel by
bottom of the switch is pressed, the switch is off. slightly increasing the permissible wheel spin.

ABS Diagnostic Switch, Optional

The ABS diagnostic switch (Fig. 2.19) is a momentary
TRAC
switch that turns on the blink code diagnostic capabili- MUD/
ties. For information on troubleshooting with blink code SNOW
diagnostics, see Group 42 in the Acterra® Workshop
Manual.

Traction in Mud or Snow Switch,

10/26/99
Optional f610383

If the vehicle is equipped with Automatic Traction Con- Fig. 2.20, Traction in Mud or Snow Switch
trol, the traction in mud or snow (TRAC MUD/SNOW)

2.12
Instruments and Controls Identification
Cruise Control guard is positioned around the switch to prevent it
from being accidentally activated.
To turn the cruise control on, press the ON switch lo-
cated on the steering wheel. See Fig. 2.21. To Set a Speed
For the speed control to operate, the cruise control
must be on. Once you have reached the desired speed,
press the set/coast (SET/CST) switch located on the
steering wheel. See Fig. 2.22. The vehicle will travel at
the set speed until the brake pedal or clutch pedal is
ON
depressed, or until the cruise control OFF switch is
pressed.
The speed control may not operate until a minimum ve-
OFF hicle speed is reached. For more information, refer to
your diesel engine operation and maintenance manual.
When driving up a steep hill, the speed control may not
be able to maintain the preset speed in the transmis-
sion gear position selected. To maintain a preset speed
09/25/99 f610342 in this situation, downshift the transmission to a lower
gear.
Fig. 2.21, Cruise Control On/Off Switch
To Set a Higher Set Speed
WARNING There are three ways to set a higher set speed.

Do not activate the fifth wheel air slider control • Press and hold the resume/accelerate (RSM/
valve when the vehicle is in motion. Doing so could ACCL) switch (Fig. 2.22) located on the steering
result in damage to the fifth wheel member, kingpin, wheel until the higher set speed is reached. Then
cab, or trailer, and ultimately, to the drivetrain. A release the switch.

2.13
 Instruments and Controls Identification
To Set a Lower Set Speed
There are three ways to set a lower set speed.
• Press and hold the set/coast (SET/CST) switch
located on the steering wheel until the lower set
RSM/
ACCL
speed is reached. Then release the switch.
• Press and release the set/coast switch. Each
SET/ press of the switch will decrease the set speed
CST by 1 mph (1.6 km/h).
• Press and release the set/coast switch and de-
press the brake pedal until the desired speed is
reached. Then press the set/coast switch.
09/25/99 f610341
To Disengage the Speed Control
Fig. 2.22, Speed Control Switch Depress the brake pedal or the clutch pedal. Disengag-
ing the speed control will not erase the previously pro-
• Press and release the resume/accelerate switch.
grammed set speed. Pressing the OFF switch will erase
Each press of the switch will increase the set
the previously programmed set speed.
speed by 1 mph (1.6 km/h).
• Press and release the resume/accelerate switch To Return to a Set Speed
and depress the accelerator pedal until the de-
Press the resume/accelerate (RSM/ACCL) switch for
sired speed is reached. Then press the set/coast
about three seconds.
(SET/CST) switch.
You can accelerate with the throttle pedal at any time
IMPORTANT: The use of radio transmitting equip-
during cruise control usage. Releasing the throttle pedal ment that is not FCC approved may cause the
will return the vehicle to the previously programmed set speed control to malfunction. Therefore, use only
speed.

2.14
Instruments and Controls Identification
properly installed FCC approved radio transmitting The cruise control now functions as a throttle control.
equipment in your vehicle. To turn off the throttle control:
To Turn Off Cruise Control • Press the OFF switch located on the steering
wheel, or depress the throttle pedal or the clutch
To turn the cruise control off, press the OFF switch pedal.
(Fig. 2.21) located on the steering wheel. Once the
cruise control is turned off, the previously programmed Caterpillar 3126 Engines
set speed will be deleted.
The PTO will only operate if the vehicle is in neutral.
Stationary Throttle Control Operatio This feature can be overridden by a special service tool.
See your dealer or service representative for more
All Engines Except Caterpillar 3126 information.
The cruise control may also be used as a throttle con-
trol for PTO applications under the following conditions: Manual Transmission Controls
• the parking brake is set If so equipped, the transmission range control valve and
• the clutch and accelerator pedals are released splitter valve are attached to the gearshift knob. Trans-
mission shift pattern labels are located inside the cab.
To operate the cruise control:
Refer to Chapter 8 for complete manual transmission
• Press the ON switch located on the steering operating instructions.
wheel;
• Press and hold the set/coast (SET/CST) switch Automatic Transmission Controls
located on the steering wheel until the desired Refer to Chapter 8 for information on the automatic
rpm has been reached; transmission controls.
• Adjust the rpms by alternately pressing the set/
coast and resume/accelerate (RSM/ACCL)
switches.

2.15
 Instruments and Controls Identification
Message Display Screen The dash message center is the heart of the level I
ICU. It has two parts, a set of up to 26 warning and in-
The message display screen (Fig. 2.23) is located in dicator lights and a message display screen. The mes-
the center of the warning and indicator lights. Vehicle sage display screen is a one-line by seven-character
information and service diagnostics are shown on the liquid crystal display (LCD) that normally shows the
message display screen on a one-line display. odometer reading. Below the odometer reading is a
smaller one-line by three-character LCD that shows the
The message display screen displays the odometer
voltmeter reading.
reading and the voltage reading. The message display
screen will also display the trip distance, trip hours (en-
gine hours), and service diagnostics if the vehicle has Warning and Indicator Lights
this option. There can be up to 26 warning and indicator lights in-
Use the instrument and control panel dimmer switch to stalled in the level I ICU. See Fig. 2.23.
increase or decrease the brightness of the message There are four rows of lights in the dash message cen-
display screen. ter. Lights installed in the top row are optional and their
positions may vary. The lights in the bottom three rows
Instrumentation Control Unit, are installed in fixed positions on all vehicles. Most are
standard, but a few are optional.
Level I
The level I instrumentation control unit (level I ICU) is
Axle Lock Indicator, Optional
the standard instrumentation control unit. It receives The AXLE LOCK indicator comes on when the axle lock
information from the various sensors installed on the switch is turned on. The axle lock switch locks the for-
vehicle and sends it to the electronic gauges. Only air ward and rear drive axles (on tandem drives only) to-
gauges operate mechanically. gether.
There can be up to eight gauges on the instrument
Low Water Indicator
cluster, six electronic gauges and two mechanical
gauges. The level I ICU cannot drive gauges located on The LOW WATER (coolant) indicator comes on when
the control panel. the coolant level drops below the safe operating level.

2.16
Instruments and Controls Identification
1 1 2 3 4 1 5 6 1
7 8 9 10 11 12

13 14 15 16 17 18
19 20 21 23 24
22
12/01/99 f610379
Typical installation shown. Location of icons installed in the top row may vary, and other icons may be specified.
1. Optional Warning and Indicator Lights 13. Low Oil Pressure Warning
2. Axle Lock Indicator, Optional 14. High Coolant Temperature Warning
3. Low Water (coolant) Indicator 15. Fasten Seat Belt Warning
4. Wheel Lock Indicator, Optional 16. Brake System Warning and Parking Brake Indicator
5. Range Inhibit Indicator, Optional 17. Recirculated Air Indicator
6. Check Transmission Indicator, Optional 18. Air Filter Restriction Indicator
7. Check Engine Indicator 19. Left-Turn Signal Indicator
8. Engine Protection Warning 20. Low Battery Voltage Warning, Optional
9. No Charge Indicator, Optional 21. Message Display Screen
10. Tractor ABS Warning 22. High-Beam Indicator
11. Transmission Temperature Warning, Optional 23. Low Air Pressure Warning
12. Trailer ABS Warning, Optional 24. Right-Turn Signal Indicator
Fig. 2.23, Dash Message Center, Level I ICU
2.17
 Instruments and Controls Identification
Wheel Lock Indicator, Optional tem. Refer to Chapter 6 for more information on the
ABS.
The WHEEL LOCK indicator comes on when the wheel
lock switch is turned on. The wheel lock locks the The TRACTOR ABS warning light is also used during
wheels on the same axle together. diagnostics to display the blink codes. For troubleshoot-
ing with blink code diagnostics, see Group 42 in the
Check Engine Indicator Acterra® Workshop Manual.
The CHECK ENGINE indicator comes on when the Transmission Temperature Warning, Optional
coolant level is low, the coolant temperature is high, or
the oil pressure is low. It also illuminates when a fault The transmission temperature (TRANS TEMP) warning
code is detected or recorded. light comes on when the transmission to cooler oil tem-
perature reaches a maximum 300°F (149°C). If the
Engine Protection Warning warning light comes on, stop the vehicle and shift the
transmission to neutral. Accelerate the engine to 1200
The engine protection (ENGINE PROTECT) warning to 1500 rpm to allow the transmission to return to a nor-
light comes on when the engine protection system on mal temperature of 160 to 220°F (71 to 104°C) before
the engine has been activated. resuming operation. Check the transmission oil fluid
level.
No Charge Indicator, Optional
The NO CHARGE indicator comes on when the alterna- Trailer ABS Warning, Optional
tor is not charging the battery. The TRAILER ABS (antilock braking system) warning
light comes on when the safety circuit senses a failure
Tractor ABS Warning in any part of the ABS system. If the trailer ABS light
The TRACTOR ABS (antilock braking system) warning stays on after the engine has been started, there is a
light serves two purposes. It comes on when the safety malfunction in the antilock brake system. Refer to
circuit senses a failure in any part of the ABS system. If Chapter 6 for more information on the ABS.
the tractor ABS light stays on after the engine has been
started, there is a malfunction in the antilock brake sys-

2.18
Instruments and Controls Identification
Low Oil Pressure Warning moving at a speed greater than two miles per hour with
the parking brake set.
The low oil pressure warning light comes on and a
buzzer sounds when the engine oil pressure drops be- Recirculated Air Indicator
low a minimum level specified by the engine manufac-
turer. The recirculated air (RECIRC AIR) indicator comes on
when the air selection switch is in the MAX A/C position
High Coolant Temperature Warning and the air inside the cab is being recirculated.
The high coolant temperature warning light comes on Air Filter Indicator
and a buzzer sounds when the coolant temperature
rises above a maximum level specified by the engine The AIR FILTER indicator comes on when the air filter
manufacturer. needs changing or cleaning.

Fasten Seat Belt Warning Turn Signal Indicators

The fasten seat belt warning light comes on when the The left-turn and right-turn signal indicators flash on and
ignition key is in the on position. The warning light will off when the turn signal lever has been moved up or
stay on for a designated period of time before it turns down.
off.
Low Battery Voltage Warning, Optional
Brake System Warning and Parking Brake The low battery voltage warning light comes on when
Indicator the battery voltage is low.
The brake system warning and parking brake indicator
light comes on if there is a problem within the brake Low Air Pressure Warning
system or when the parking brake is applied. If the The low air pressure warning light comes on and the
warning light does not go off after releasing the parking buzzer sounds when the air pressure in the primary or
brake, correct the problem before continuing to operate secondary air reservoir drops below 64 to 76 psi (441 to
the vehicle. The buzzer sounds when the vehicle is 524 kPa).

2.19
 Instruments and Controls Identification
High Beam Indicator Check Transmission Indicator
The high-beam indicator comes on when the high The check transmission (CHECK TRANS) indicator is a
beam-headlights are turned on or when the high beams standard feature with some of the Allison automatic
are on momentarily in a flash-to-pass mode. transmissions. When the check transmission indicator
stays on after vehicle start-up, the ECU indicates a di-
Wheel Spin Indicator, Optional agnostic code. For more information on this feature, see
Chapter 8.
The WHEEL SPIN indicator comes on if the vehicle is
equipped with Automatic Traction Control (ATC) and if
one of the drive wheels spins during acceleration. This Level I ICU Ignition Sequence
indicator also comes on when the traction in mud or If the headlights are turned on, the message display
snow switch is pressed. Refer to Chapter 6 for more screen displays the odometer reading. See Fig. 2.24 for
information on ATC. a schematic of the level I ICU ignition sequence.
Intake Heater Indicator, Optional When the ignition is turned on, all the electronic gauges
complete a full sweep of their dials, the warning and
The INTAKE HEATER indicator comes on when the indicator lights light up, and the buzzer sounds for three
cold start manifold heater system is functioning. Refer seconds.
to Chapter 7 for more information on the cold start
manifold heater. NOTE: The air gauges do not sweep.
The following lights come on during the ignition se-
Range Inhibit Indicator quence:
The RANGE INHIBIT indicator is a standard feature of • high coolant temperature warning
the Allison 2000 Series and 2400 Series automatic
transmissions. The RANGE INHIBIT indicator comes on • low engine oil pressure warning
to alert the driver that transmission operation is being
• low air pressure warning
inhibited and that range shifts being requested by the
driver may not occur. For more information on this fea- • parking brake indicator
ture, see Chapter 8.
• engine protection warning

2.20
Instruments and Controls Identification

HEADLIGHTS ON POWER ON

IGNITION ON
888888.8
MI
ICU PERFORMS SELFTEST:
ODOMETER ELECTRONIC GAUGE NEEDLES
SCREEN SWEEP, WARNING/INDICATOR
LIGHTS COME ON, BUZZER SOUNDS

IF NO FAULTS IF FAULT DETECTED

WERE DETECTED

APU 190
123456.7
MI
FAULT CODE
12.3 VOLTS
SCREEN

PARK BRAKE
RELEASED − MOVING

123456.7 RELEASE PARK BRAKE

MI
12.3 VOLTS
07/30/98 f040420

Fig. 2.24, Level I ICU Ignition Sequence

2.21
 Instruments and Controls Identification
• check engine warning Mode/Reset Switch
• tractor ABS The mode/reset switch (Fig. 2.25) is located on the
• trailer ABS right side of the instrument cluster. The mode/reset
switch is used to scroll through the displays on the
NOTE: While the engine and ABS warning lights message display screen, and to reset the trip distance
come on during the ignition sequence, they are and trip hours values to zero.
not controlled by the level I ICU but by their own
system ECU (electronic control unit).
Once the ignition switch has been turned on, the level I
ICU performs a self-test to look for active faults. During
PUSH−
the first half of the self-test, all segments of the mes- MODE
sage display screen display 888888.8. The voltmeter
display also comes on with the value 18.8. During the
second half of the self-test, the software revision level is
HOLD−
displayed. RESET
If there are no active faults, the screen displays the
09/25/99 f610340
odometer reading.
If the level I ICU has received active fault codes from Fig. 2.25, Mode/Reset Switch
other devices, it displays them, one after the other, until
the parking brake is released or the ignition switch is See Fig. 2.26 for the state diagram for the LCD display
turned off. cycle.
A list of fault codes and definitions can be found in NOTE: The systems diagnostics test is used by
Group 54 of the Acterra® Workshop Manual. Once the trained personnel to retrieve fault codes and other
parking brake is released, the level I ICU displays the diagnostic information pertaining to the vehicle.
odometer reading again.
When the odometer reading is displayed and the park-
ing brake is applied:

2.22
Instruments and Controls Identification

123456.7
Default Odometer CLEAr
MI Hold Clear Defaults
12.3 VOLTS Dispay Screen

Push Push

123456.7 123456.7
TRIP MI Hold MI To Dispay Total Engine Miles
To Reset Trip Miles
12.3 VOLTS EC EC = Engine Control

Push Push

123456.7 123456.7
TRIP HOURS Hold To Reset Trip Hours HOURS To Dispay Total Engine Hours
12.3 VOLTS EC EC = Engine Control

Push Push

SELECt To Toggle between Units EnG oIL

Hold Hold Dispay Oil Level
MI MI<−−−−>KM *Lo
*Lo = Oil Level Low
HI = Oil Level High
Push Push Blank = Oil Level OK
− − = No Message

dIAG SEtUP
MI HOURS Hold **MI **HOURS Hold Dispay Service Interval
Dispay Diagnostics
n **no Cycle Screens
n = Number of Active Fault Codes **MI = CYCLE Miles Active Mode
MI = CYCLE Miles Enabled **HOURS = CYCLE Hours Active Mode
Push HOURS = Cycle Hours Enabled Push **no = Service CYCLE Inactive

03/26/2004 f040636a

Fig. 2.26, ICU3 Mode Reset LCD Display Cycle

2.23
 Instruments and Controls Identification
• Press the mode/reset switch once and the trip
distance will display. 1 2
• Press the mode/reset switch a second time and
20 25 45 55
the trip hours (engine hours) will display. 35
15 30 70
90
• Press the mode/reset switch a third time and the 25 50 65
SELECT screen and the current units, MI or KM, 10 110
30
will display. 15 75
• Press the mode/reset switch a fourth time to re- 5 10
130

turn to the odometer reading. 5 85

RPM km/h
0 X 100 MPH
To reset trip miles and/or trip hours to zero, press the
mode/reset switch for 1 second or longer. To toggle be-
tween MI (miles) of KM (kilometers), press the mode/
10/06/99 f610356
reset switch while in the SELECT screen.
1. Tachometer 2. Speedometer
Instruments Fig. 2.27, Tachometer/Speedometer
Tachometer, Optional Engine Oil Pressure Gauge
The tachometer (Fig. 2.27) indicates the engine speed The oil pressure gauge (Fig. 2.28) should read as
in hundreds of revolutions per minute (rpm) and serves shown in Table 2.1.
as a guide for shifting the transmission and keeping the
engine in the appropriate rpm range.
CAUTION
Speedometer
A sudden decrease or absence of oil pressure may
The speedometer (Fig. 2.27) registers speed in both indicate mechanical failure. Bring the vehicle to a
miles per hour (mph) and kilometers per hour (km/h).

2.24
Instruments and Controls Identification
safe stop and investigate the cause to prevent fur- Oil Pressure*
ther damage. Do not operate the engine until the
cause has been determined and corrected. Minimum Oil
Oil Pressure at
Pressure at Idle
Engine Model Rated RPM:
Speed:
psi (kPa)
psi (kPa)
Cummins ISB 10 (69) 50–65 (345–448)
50
Cummins ISC/ISL 10 (69) 40–50 (276–345)
Caterpillar 3126 10–20 (69–138) 30–45 (207–310)
PSI
MBE900 7 (50) 36 (250)
* Oil pressures are given with the engine at operating temperature. With
0 100 the engine cold, oil pressure may be higher.

OIL Table 2.1, Oil Pressure

09/10/99 f610350

Maximum Coolant Temperature

Fig. 2.28, Engine Oil Pressure Gauge
Normal Maximum
Coolant Temperature Gauge Engine Model Coolant Coolant
Temperature Temperature
The coolant temperature gauge (Fig. 2.29) should read Cummins ISB/ISC/ISL 185°F (85°C) 220°F (104°C)
as shown in Table 2.2. If the temperature remains be- Caterpillar 3126 185°F (85°C) 220°F (104°C)
low normal or exceeds the maximum, inspect the cool-
MBE900 203°F (95°C) 221°F (105°C)
ing system to determine the cause. Refer to Group 20
in the Acterra® Workshop Manual for troubleshooting Table 2.2, Maximum Coolant Temperature
and repair procedures.

Voltage Reading
The voltage reading indicates the vehicle charging sys-
tem voltage when the engine is running, and the battery

2.25
 Instruments and Controls Identification
voltage when the engine is stopped. By monitoring the On a vehicle equipped with a battery isolator system,
voltage reading, you can be aware of potential charging the voltage reading shows the average voltage of all the
system problems and have them fixed before the batter- batteries when the engine is running. When the engine
ies discharge enough to create starting difficulties. is stopped, the voltage reading shows only the gel cell
battery voltage and does not indicate the voltage of the
engine-starting batteries.

CAUTION
150 200
Gel cell batteries can be damaged if the battery
F
voltage is allowed to drop below 12.0 volts or if the
250 charging voltage is more than 14.1 volts. Start the
100
engine to recharge the gel cell before the battery
WATER becomes fully discharged. If an external charger is
needed, disconnect the gel cell battery and use only
09/28/1999 f610369
an external battery charger that has been approved
Fig. 2.29, Coolant Temperature Gauge
for gel cell batteries.

The voltage reading will normally show approximately Primary and Secondary Air Pressure
13.7 to 14.1 volts when the engine is running. The volt- Gauges
age of a fully charged battery is 12.7 to 12.8 volts when
the engine is stopped. A completely discharged battery Air pressure gauges (Fig. 2.30 and Fig. 2.31) register
will produce only about 12.0 volts. The voltage reading the pressure in the primary and secondary air systems.
will indicate lower voltage as the vehicle is being started Normal pressure, with the engine running, is 100 to 120
or when electrical devices in the vehicle are being used. psi (689 to 827 kPa) in both systems. A low air pressure
If the voltage reading shows an undercharged or over- warning light comes on and a buzzer sounds when air
charged condition for an extended period, have the pressure in either the primary or secondary system
charging system and batteries checked at a repair facil- drops below a minimum pressure of 60 psi (414 kPa).
ity. When the engine is started, the warning light and

2.26
Instruments and Controls Identification
buzzer remain on until air pressure in both systems ex- Fuel Gauge
ceeds minimum pressure.
The fuel gauge (Fig. 2.32) indicates the level of fuel in
the fuel tank(s).

50 100
P 1/2
PSI

0 150

AIR E F
09/10/99 f610353
FUEL
Fig. 2.30, Primary Air Pressure Gauge 09/10/99 f610351

Fig. 2.32, Fuel Gauge

Transmission Oil Temperature Gauge,

50 100 Optional
S
PSI During normal operation, the transmission oil tempera-
ture gauge (Fig. 2.33) reading should not exceed 250°F
0 150 (121°C).
AIR
09/10/99 f610354

Fig. 2.31, Secondary Air Pressure Gauge

2.27
 Instruments and Controls Identification
Under heavy loads, such as when climbing steep
grades, temperatures up to a maximum of 250°F
(121°C) are not unusual.
175 275
F
175 250
100 350
F
125 325
TRANS FWD OIL
REAR
TEMP
09/10/99 f610352 AXLE

Fig. 2.33, Transmission Oil Temperature Gauge

03/09/98 f610346

CAUTION Fig. 2.34, Forward Rear Axle Oil Temperature Gauge

A sudden increase in oil temperature that is not

caused by a load increase may indicate mechanical
failure. Bring the vehicle to a safe stop and investi- 175 250
gate the cause to prevent further damage. Do not
operate the engine until the cause has been deter- 125
F
325
mined and corrected. REAR OIL
REAR
TEMP
AXLE
Forward and Rear Axle Oil
Temperature Gauges, Optional 09/10/99 f610347
During normal operation, forward and rear axle oil tem- Fig. 2.35, Rearmost Axle Oil Temperature Gauge
perature gauges (Fig. 2.34 and Fig. 2.35) should read
between 150 to 230°F (65 to 110°C).

2.28
Instruments and Controls Identification
CAUTION
60 90
A sudden increase in oil temperature that is not
PSI
caused by a load increase may indicate mechanical
failure. Bring the vehicle to a safe stop and investi- 30 120
gate the cause to prevent further damage. Do not
APPL AIR
operate the engine until the cause has been deter- 0 PRESS
mined and corrected. 150

Application Air Pressure Gauge, 09/10/99 f610348

Optional Fig. 2.36, Application Air Pressure Gauge

An application air pressure gauge Fig. 2.36 registers NOTE: Rain or snow can wet the filter and cause
the air pressure being used to apply the brakes and
should be used for reference only. The gauge will not
a higher than normal reading temporarily.
register air pressure until the foot brake pedal is de-
pressed or the trailer hand brake is applied. Intake Air Restriction Indicator, Dash
Mounted, Optional
Intake Air Restriction Indicator
The intake air restriction indicator (Fig. 2.38) measures
The intake air restriction indicator (Fig. 2.37) measures the vacuum on the engine side of the air cleaner at the
the vacuum on the engine side of the air cleaner at the air cleaner outlet. Vacuum is measured in inH2O (inches
air cleaner outlet. Vacuum is measured in inH2O (inches of water). If the intake air restriction indicator stays
of water). If the intake air restriction indicator stays locked at or above the values shown in Table 2.3, the
locked at or above the values shown in Table 2.3, the air cleaner needs to be serviced. After the air cleaner is
air cleaner needs to be serviced. After the air cleaner is serviced, push the reset tab on the intake air restriction
serviced, push the reset button on the intake air restric- indicator to reset the indicator.
tion indicator to reset the indicator.

2.29
 Instruments and Controls Identification

25 6.2
22 5.5
15 3.7
11 2.7
8 2.0
IN
1 H 2 O kPa

AIR FILTER RESTRICTION

RESET

09/10/99 f610349

Fig. 2.38, Intake Air Restriction Indicator, Dash

Mounted

Intake Air Restriction Indicator Values

2
Engine Type Initial inH2O Service inH2O
Caterpillar 15 25
08/31/99 f090301 Cummins 10 25
1. Intake Air Restriction Indicator MBE900 10 22
2. Air Cleaner
Table 2.3, Intake-Air Restriction Indicator Values
Fig. 2.37, Intake Air Restriction Indicator

2.30
Instruments and Controls Identification
Exterior Switches
Battery Shutoff Switch, Optional
The battery shutoff switch cuts off all battery power to
the vehicle. The switch is used when workshop proce-
dures require that the batteries be disconnected. It is
also used when the vehicle is placed out of service for
extended periods to prevent battery discharge. The bat-
tery shutoff switch is located on the side of the battery
box. See Fig. 2.39.

NGI Instrument Cluster,

Optional
Instruments
11/02/1999 f150991
The NGI instrument cluster became an option in Janu-
ary of 2002.
Fig. 2.39, Battery Shutoff Switch
Each of its gauges is an individually replaceable unit.
The instrument control unit (ICU) is located in the Light Bar
speedometer and receives information from the various
sensors installed on the vehicle and feeds it to the elec- The light bar has three rows of seven warning lights.
tronic gauges. Only the air gauges operate mechani- See Fig. 2.40. The seven telltales on the top row of the
cally. light bar will vary depending on the vehicle configuration
and customer preference. The two lower rows contain
the following 14 standard telltales shown in Table 2.4.

2.31
 Instruments and Controls Identification
NGI Light Bar Standard Telltales
Light LED Color
Left Turn Signal Green
Check Engine Amber
Engine Protection Red
Fasten Seat Belt Symbol Red
High Beam Headlamps. Blue
Tractor ABS (Antilock Brake System) Amber
Parking/Emergency Brake Red
Air Intake Filter Restriction Amber
04/28/2003 f610506
Right Turn Signal Green
Fig. 2.40, NGI Light Bar Trailer ABS Amber
Water in Fuel Amber
Message Center Intake Heater Amber
Check A/C Amber
The NGI message center is a one row seven character
Low Air Red
liquid crystal display (LCD) located on the speedometer
that displays the following information: Table 2.4, NGI Light Bar Standard Telltales
• Odometer
The odometer, hour meter, and trip odometers are pri-
• Trip Odometers (two) mary screens. When a primary screen is displayed for 3
• Engine Hour Meter seconds or more it becomes the default screen. The
default screen is displayed at ignition and will remain so
• System Diagnostic Menu until manually adjusted using the Mode and Set but-
• NGI-specific warning messages tons.

2.32
Instruments and Controls Identification
Mode and Set Buttons 0
S
150
PSI

The Mode and Set buttons are located in the lower right
corner of the instrument cluster. See Fig. 2.41. Pressing 45
the Mode button cycles through the various functions. 35 55 1/2
Pressing the Set button selects the desired function.
See Fig. 2.42. In the Odometer mode, the Set button 25 MPH
km/h 65 1/4 3/4

toggles to MI or KM. In the Trip 1 and 2 Odometer E F

modes, the Set button resets the Trip meter to zero. In 15 75
the Engine hours mode, total engine hours are dis-
played. This is not resetable. In the System mode, the
5 85
Set button initiates the System Diagnostics test and will
display any warning messages that are present in the
system. To run the system diagnostics, the following 1 2
conditions must be met: 12/19/2002 f610635
1. Mode Button 2. Set Button
• Ignition on
• Park brake set Fig. 2.41, Mode and Set Buttons

• Road speed below 2 mph

• Engine RPM at or below 1000
• No low air pressure warning in effect
NOTE: The systems diagnostics test is used by
trained personnel to retrieve fault codes and other
diagnostic information pertaining to the vehicle.

2.33
 Instruments and Controls Identification
Yes

LOW AIR No
inactive?

Yes
Kilometers Clear Trip1 Clear Trip2
or Odometer Odometer
Miles No System Diagnostics
RPM
<1000? Test Loop

Set Set Set Yes

Set Any
warning
Road Speed No messages? No
< 25 MPH?

Mode

System Yes
Ignition Trip Trip2 Engine
Odometer Mode Yes Mode Mode Yes Diagnosis
on? Odometer Odometer Hours
Test
Mode

Park Brake
No
Set?
No

Entry via MODE

button press
NGI Specific Warning
Message Loop
Entry via panel Yes Yes Yes
lamp power Main Loop

is ODO is Trip 1 is Trip 2

Entry via Ignition No No
default? default? default? No

12/11/2002 f040637a

Fig. 2.42, State Diagram for LCD Display

2.34
 3

Vehicle Access and Features

Cab Door Locks and Handles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.1
Door Windows . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.1
Cab Entry and Exit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.2
Fuse, Relay, and Circuit Breaker Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.6
Hood Tilting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.6
Back-of-Cab Grab Handles, Steps, and Deck Plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.15
Vehicle Access and Features
Cab Door Locks and Handles
The key that operates the ignition switch also locks and
unlocks the cab doors from the outside. The lock cannot
be operated when the door is open.
To unlock the driver’s door from outside the cab, insert
the key in the lockset and turn the key counterclockwise
(Fig. 3.1). Pull the handle out to open the door. To lock
the driver’s door, insert the key in the lockset and turn
the key clockwise.
2
To unlock the passenger’s door from outside the cab, 1
insert the key in the lockset and turn the key clockwise.
Pull the handle out to open the door. To lock the pas-
senger’s door, insert the key in the lockset and turn the
key counterclockwise.
09/22/99 f720361
To lock the door from inside the cab, close the door, 1. Unlock 2. Lock
then push the lock button down or push the L on the
power lock switch. See Fig. 3.2 and Fig. 3.3. Fig. 3.1, Driver’s Door Lock and Handle
To open the door from the inside, pull the door handle
toward you. This will unlatch the door whether or not it Door Windows
was locked. To unlock the door without unlatching it,
If the vehicle has manual window regulators, lower the
pull up the lock button or press the U on the power lock
driver’s door window by turning the window regulator
switch.
handle clockwise. To lower the passenger’s door win-
dow, turn the window regulator handle counterclock-
wise.

3.1
 Vehicle Access and Features
dimpled end of the power window switch to lower the
window. Push the raised end of the power window
switch to raise the window.

Cab Entry and Exit

2
WARNING
Wet or dirty shoe soles greatly increase the chance
3 of slipping or falling. If your soles are wet or dirty,
be especially careful when entering or exiting the
vehicle.
1
4 Always maintain three-point contact with the cab
access system while entering and exiting the cab.
Three-point contact means both feet and one hand,
or both hands and one foot.
When entering or exiting the cab, use the grab handles
and cab access steps as indicated in the following in-
5 structions. See Fig. 3.4 and Fig. 3.5.
09/25/99 f720360
1. Door Grab Handle 4. Window Regulator
Entering the Driver’s Side When
2. Lock Button Handle There are Two Cab Access Steps
3. Door Handle 5. Door Light
1. Open the driver’s door and place anything that you
Fig. 3.2, Door Interior are carrying in the cab.

If the vehicle is equipped with power window switches, 2. Grasp the door grab handle with your left hand and
they are located on the door (Fig. 3.3). Push the the cab grab handle with your right hand.

3.2
Vehicle Access and Features

1
1 2 4

3
4 2
A B
10/06/99 f720367

A. Push here to lower the window. 3

B. Push here to raise the window.
1. Door Handle
2. Power Mirror Switch 10/08/99 f720362
3. Power Window Switch 1. Cab Grab Handle
4. Power Lock Switch 2. Top Cab Access Step
3. Bottom Cab Access Step
Fig. 3.3, Power Switches 4. Door Grab Handle
3. Place your right foot on the bottom step and pull Fig. 3.4, Driver’s Side Cab Access Steps and Grab
yourself up. Handles

3.3
 Vehicle Access and Features
4. Place your left foot on the top step.
5. Grasp the steering wheel with your left hand and
step into the cab with your right foot first.
6. Grasp the steering wheel with your right hand and
pull yourself into the seat.

3 4
Exiting the Driver’s Side When There
are Two Cab Access Steps
1. Do not attempt to exit the cab while carrying any
items in your hands.
2. Grasp the steering wheel with both hands and
place your left foot on the top step. Pivot your body
so you’re facing in to the cab.
2
3. Grasp the cab grab handle with your right hand.
4. Move your right foot to the bottom step.
1 5. Grasp the door grab handle with your left hand.
6. Step to the ground with your left foot first.
10/08/99 f720363
Entering the Passenger’s Side When
1. Bottom Cab Access Step
2. Top Cab Access Step There are Two Cab Access Steps
3. Cab Grab Handle
4. Door Grab Handle
1. Open the passenger’s door and place anything that
you are carrying in the cab.
Fig. 3.5, Passenger’s Side Cab Access Steps and Grab
Handles

3.4
Vehicle Access and Features
2. Grasp the cab grab handle with your left hand and 2. Grasp the door grab handle with your left hand and
the door grab handle with your right hand. the grab handle with your right hand.
3. Place your left foot on the bottom step and pull 3. Place your right foot on the cab access step.
yourself up.
4. Bring your left foot up to the cab floor and step up,
4. Place your right foot on the top step. bringing your right foot into place in the cab.
5. Grasp the seat with your left hand and step into the 5. Grasp the steering wheel with your left hand and
cab with your left foot first. pull yourself into the seat.
6. Pull yourself into the seat.
Exiting the Driver’s Side When There
Exiting the Passenger’s Side When is One Cab Access Step
There are Two Cab Access Steps 1. Do not attempt to exit the cab while carrying any
items in your hands.
1. Do not attempt to exit the cab while carrying any
items in your hands. 2. Grasp the door grab handle with your left hand.
2. Grasp the door grab handle with your right hand 3. Move your left foot to the cab access step and
and place your right foot on the top step. grasp the grab handle with your right hand.
3. Grasp the grab handle with your left hand. 4. Bring your right foot down to the ground, then bring
your left foot down to the ground.
4. Move your left foot to the bottom step.
5. Step to the ground with your right foot first. Entering the Passenger’s Side When
There is One Cab Access Step
Entering the Driver’s Side When
There is One Cab Access Step 1. Open the passenger’s door and place anything that
you are carrying in the cab.
1. Open the driver’s door and place anything that you
are carrying in the cab.

3.5
 Vehicle Access and Features
2. Grasp the grab handle with your left hand and the PDM is located under the hood on the frontwall. Refer
door grab handle with your right hand. to Fig. 3.6 and Table 3.1 for the internal PDM fuse, re-
lay, and circuit breaker identification. Refer to Fig. 3.7
3. Place your right foot on the cab access step. and Table 3.2 for the external PDM fuse, relay, and cir-
4. Bring your left foot up to the cab floor and step up, cuit breaker identification.
bringing your right foot into place in the cab.
5. Grasp the seat with your left hand and pull yourself Hood Tilting
into the seat.
A grab handle at the front of the hood provides a hand-
hold for hood tilting. Stop cables prevent the hood from
Exiting the Passenger’s Side When overtravel. In the operating position, the hood is se-
There is One Cab Access Step cured to the lower cab half-fenders by a hold-down
latch on each side of the hood.
1. Do not attempt to exit the cab while carrying any
items in your hands. To Tilt the Hood
2. Grasp the door grab handle with your right hand.
1. Apply the parking brakes.
3. Move your right foot to the cab access step, and
2. Release both hood hold-down latches by pulling the
grasp the grab handle with your left hand.
ends up. See Fig. 3.8.
4. Bring your left foot down to the ground, then bring
your right foot down to the ground.

Fuse, Relay, and Circuit

Breaker Identification
There are two power distribution modules (PDM) in the
vehicle. The internal PDM is located below the right-
side dash or the passenger-side dash. The external

3.6
Vehicle Access and Features

1 7 13 14 15 16 17 18
A H J K L M N P R1 R2 R3
2 8
B
3 9 19 20 21 22 23 24
C
4 10 R4 R5 R6 R7 R8 R9
D
E 5 11
25 26 27 28 29 30
F R13 R14 R15 R16 R17
6 12 R10 R11 R12
G
31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48
R18 R19 R20 R21 R22

11/02/1999 f542977

Fig. 3.6, Internal PDM Fuse, Relay, and Circuit Breaker Panel

3.7
 Vehicle Access and Features
Internal PDM Fuse, Relay, and Circuit Breaker Internal PDM Fuse, Relay, and Circuit Breaker
Identification Identification
Pos. Pos.
Description Part Number Rating Description Part Number Rating
No. No.
D9ZB-14A094-CA and D9ZB-14A094-CA and
1 — 10A 13 — 10A
F6HT-14526-CA F6HT-14526-CA
D9ZB-14A094-CA and D9ZB-14A094-CA and
2 Power Door Lock 10A 14 — 10A
F6HT-14526-CA F6HT-14526-CA
D9ZB-14A094-CA and D9ZB-14A094-EA and
3 Horn/Buzzer 10A 15 Radio System 20A
F6HT-14526-CA F6HT-14526-EA
Windshield F6HT-145264-NA and D9ZB-14A094-CA and
4 11/CB 16 Radio System 10A
Washer/Wiper F6HT-14526-NA F6HT-14526-CA
D9ZB-14A094-DA and Mirror, Heated, D9ZB-14A094-FA and
5 — 15A 17 25A
F6HT-14526-DA Power F6HT-14526-FA
D9ZB-14A094-CA and D9ZB-14A094-DA and
6 Air Dryer Heater 10A 18 Accessory Supply 15A
F6HT-14526-CA F6HT-14526-DA
D9ZB-14A094-CA and D9ZB-14A094-BA and
7 — 10A 19 — 5A
F6HT-14526-CA F6HT-14526-BA
D9ZB-14A094-DA and D9ZB-14A094-DA and
8 Axle Shift 15A 20 — 15A
F6HT-14526-DA F6HT-14526-DA
D9ZB-14A094-CA and D9ZB-14A094-CA and
9 — 10A 21 — 10A
F6HT-14526-CA F6HT-14526-CA
D9ZB-14A094-CA and D9ZB-14A094-CA and
10 Backup Lamp 10A 22 Ignition Run 10A
F6HT-14526-CA F6HT-14526-CA
D9ZB-14A094-CA and D9ZB-14A094-DA and
11 Open 10A 23 — 15A
F6HT-14526-CA F6HT-14526-DA
D9ZB-14A094-CA and D9ZB-14A094-DA and
12 — 10A 24 CB Radio Post 15A
F6HT-14526-CA F6HT-14526-DA

3.8
Vehicle Access and Features
Internal PDM Fuse, Relay, and Circuit Breaker Internal PDM Fuse, Relay, and Circuit Breaker
Identification Identification
Pos. Pos.
Description Part Number Rating Description Part Number Rating
No. No.
D9ZB-14A094-FA and D9ZB-14A094-CA and
25 Start, Ignition 25A 39 Fog/Road Lamp 10A
F6HT-14526-FA F6HT-14526-CA
ABS Hydraulic D9ZB-14A094-CA and 40 Open — —
26 10A
Pump F6HT-14526-CA 41 Open — —
27 Open — — Stop Lamp/Hazard D9ZB-14A094-GA and
42 30A
28 Open — — Warning Lamp F6HT-14526-GA
29 Open — — D9ZB-14A094-CA and
43 Engine 10A
30 Open — — F6HT-14526-CA
D9ZB-14A094-DA and D9ZB-14A094-CA and
31 Interior Light 15A 44 — —
F6HT-14526-DA F6HT-14526-CA
Marker Clearance D9ZB-14A094-DA and D9ZB-14A094-BA and
32 15A 45 ABS 5A
Lamp F6HT-14526-DA F6HT-14526-AA
Cluster Diagram D9ZB-14A094-DA and D9ZB-14A094-CA and
33 15A 46 — 10A
Connector F6HT-14526-DA F6HT-14526-CA
Left Side Power F6HT-14526-MA and D9ZB-14A094-BA and
34 18A/CB 47 ABS 5A
Window F6HT-14526-MA F6HT-14526-AA
Right Side Power F6HT-14526-MA and D9ZB-14A094-BA and
35 18A/CB 48 — —
Window F6HT-14526-MA F6HT-14526-BA
36 Utility/Trailer Lamp — — Right Side Power
R1 23-11276-011 —
D9ZB-14A094-DA and Window Relay
37 Head Lamp 15A Left Side Power
F6HT-14526-DA R2 23-11276-011 —
D9ZB-14A094-CA and Window Relay
38 Open — 2-Speed Axle
F6HT-14526-CA R3 23-11276-011 —
Relay

3.9
 Vehicle Access and Features
Internal PDM Fuse, Relay, and Circuit Breaker Internal PDM Fuse, Relay, and Circuit Breaker
Identification Identification
Pos. Pos.
Description Part Number Rating Description Part Number Rating
No. No.
R4 Ignition Run Relay 23-11276-011 — Electronic Engine
R21 680 545 00 05 —
Ignition Run/ Service Brake
R5 23-11276-011 —
Accessory Relay R22 Trans ABS 680 545 00 05 —
R6 Ignition Run Relay 23-11276-011 — Table 3.1, Internal PDM Fuse, Relay, and Circuit
R7 Fog/Road Lamp 23-11276-011 — Breaker Identification
R8 HVAC Blower — —
Hazard Warning
R9 — —
Lamps
R10 Open — —
Windshield Wiper/
R11 23-11276-011 —
Washer
R12 ABS Power 23-11276-011 —
R13 Transmission 680 545 00 05 —
R14 Brake Cut Out 680 545 00 05 —
R15 Open — —
R16 Open — —
Hydraulic Brake
R17 680 545 00 05 —
Pump
R18 Engine Brake 680 545 00 05 —
R19 ABS Lamp 680 545 00 05 —
2-Speed Axle,
R20 680 545 00 05 —
MBE

3.10
Vehicle Access and Features

R−W R−V R−U R−R R−P R−N

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

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

R−M R−L R−K R−J R−H R−G

R−F R−E R−D R−C R−B R−A

11/02/1999 f542976

Fig. 3.7, External PDM Fuse, Relay, and Circuit Breaker Panel

3.11
 Vehicle Access and Features
External PDM Fuse, Relay, and Circuit Breaker Identification
Pos. Description Part Number Rating
R–A Fuel Heater Relay (optional) F0AB-14B192-AA —
R–B Tail/Brake Lamp Relay (body builder) F0AB-14B192-AA —
R–C Marker Lamp Relay (body builder) F0AB-14B192-AA —
R–D Transmission, Backup Light Relay F0AB-14B192-AA —
R–E Trailer ABS ECU Constant Relay F80B-14B192-AA —
R–F Transmission Neutral Relay F0AB-14B192-AA —
R–G Not Used — —
R–H Not Used — —
R–J Not Used — —
R–K Not Used — —
R–L Not Used — —
R–M Not Used — —
R–N Trailer Left-Turn Relay F0AB-14B192-AA —
R–P Trailer Right-Turn Relay F0AB-14B192-AA —
R–R Trailer Park Lamp Relay F0AB-14B192-AA —
R–U Trailer Marker Lamp Relay F0AB-14B192-AA —
R–V Trailer Brake Lamp Relay F80B-14B192-AA —
R–W Not Used — —
A Power to R–A Fuel Heater (optional) E97B-14A094-BA and F6HT-14526-JA 40A Fuse 40A CB
B Feed F1, F2 (PDM electrical center) E97B-14A094-AA and F6HT-14526-LA 30A Fuse 30A CB
C Feed to R–B, R–C (body builder) E97B-14A094-BA and F6HT-14526-JA 40A Fuse 40A CB
D Feed F13, F14, F15 (PDM electrical center) E97B-14A094-BA and F6HT-14526-JA 40A Fuse 40A CB
E Power to R–2 (PDM electrical center) Left Door E97B-14A094-BA and F6HT-14526-JA 40A Fuse 40A CB
F Feed F36 (PDM electrical center) E97B-14A094-BA and F6HT-14526-JA 40A Fuse 40A CB

3.12
Vehicle Access and Features
External PDM Fuse, Relay, and Circuit Breaker Identification
Pos. Description Part Number Rating
Power to R–8 (PDM electrical center) HVAC
G E97B-14A094-BA and F6HT-14526-JA 40A Fuse 40A CB
Blower Motor
H Power to R–6 (PDM electrical center) Ignition Run E97B-14A094-BA and F6HT-14526-JA 40A Fuse 40A CB
J Ignition to R–5 (PDM electrical center) E97B-14A094-DA 60A Fuse 60A CB
K Feed F31, F32, F33 (PDM electrical center) E97B-14A094-BA and F6HT-14526-JA 40A Fuse 40A CB
L Feed F37 (PDM electrical center) Head Lamps E97B-14A094-BA and F6HT-14526-JA 40A Fuse 40A CB
M Feed F26 (PDM electrical center) ABS Power E97B-14A094-BA and F6HT-14526-JA 40A Fuse 40A CB
N Open — —
P Open — —
R Open — —
Feed F3, F4 (PDM electrical center) Windshield
S E97B-14A094-BA and F6HT-14526-JA 40A Fuse 40A CB
Wipers
Power to R–N, R–P Trailer Left and Right Turn
T E97B-14A094-BA and F6HT-14526-JA 40A Fuse 40A CB
Signals
U Feed F23, F24 (PDM electrical center) CB Radio E97B-14A094-BA and F6HT-14526-JA 40A Fuse 40A CB
V Power to R–1 (PDM electrical center) Right Door E97B-14A094-BA and F6HT-14526-JA 40A Fuse 40A CB
W Power to R–R, R–U Trailer Park/Marker E97B-14A094-BA and F6HT-14526-JA 40A Fuse 40A CB
X Open — 30A Fuse 30A CB
Y Open — 30A Fuse 30A CB
Feed F42 (PDM Electrical Center) Brake Lamp/
Z E97B-14A094-BA and F6HT-14526-JA 40A Fuse 40A CB
Flash
Feed PDM Electrical Center (A) Custom Access
AA E97B-14A094-BA and F6HT-14526-JA 40A Fuse 40A CB
Panel
BB Open — 30A Fuse 30A CB

3.13
 Vehicle Access and Features
External PDM Fuse, Relay, and Circuit Breaker Identification
Pos. Description Part Number Rating
CC Power to R–V Trailer Brake Lamp E97B-14A094-BA and F6HT-14526-JA 40A Fuse 40A CB
DD Open — —
EE Power to R–E Trailer E97B-14A094-BA and F6HT-14526-JA 40A Fuse 40A CB
FF Open — —
GG Open — —
Table 3.2, External PDM Fuse, Relay, and Circuit Breaker Identification

3. Using the front bumper step and the hood handle,

slowly tilt the hood until the stop cables support it.
See Fig. 3.9.

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

To Return the Hood

1. Grasp the hood handle and lift the hood to the 45- 10/01/93 f720073
degree position.
Fig. 3.8, Unlatch the Hood

3.14
Vehicle Access and Features
3. Make sure the hood is flush with the cowl, then se-
cure the hood by engaging both hood hold-down
latches.
IMPORTANT: Make sure that both hold-down
latches are fully engaged before operating the ve-
hicle.

Back-of-Cab Grab Handles,

Steps, and Deck Plate
When climbing onto the frame rails or deck plate, use
the side extender grab handle and the back-of-cab ac-
cess steps. Always maintain three-point contact with the
back-of-cab access system.

10/28/99 f880474

Fig. 3.9, Tilting the Hood

2. As the hood goes over center, use the bumper step

and the hood handle to control the rate of descent
to the operating position.

3.15
 4

Heater and Air Conditioner

HVAC General Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.1
Defogging and Defrosting Using Fresh Air . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.2
Heating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.2
Air Conditioning, Optional . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.3
Fresh Air . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.4
Heater and Air Conditioner
HVAC General Information A four-speed fan forces fresh or recirculated air through
the air outlets at the windshield, door windows, dash
A dash-mounted climate control panel (Fig. 4.1 or panel, and cab floor.
Fig. 4.2) allows you to control all of the heating, air con- A temperature control switch is used to select the de-
ditioning, defrosting, and ventilating functions. sired temperature. Turn the switch counterclockwise for
cool air, or clockwise for warm air.
2
1 An air selection switch controls the direction of warm or
cool air either through the dash panel louvers, the dash
panel louvers and floor outlets, the floor outlets, the
3 floor and defrost (windshield) outlets, or the defrost
09/21/1999 f610372 outlets.
1. Fan Switch The dash panel louvers can be adjusted left and right,
2. Temperature Control Switch and up and down. Close the louver by moving the con-
3. Air Selection Switch trol toward the solid circle; open the louver by moving
the control toward the open circle (Fig. 4.3).
Fig. 4.1, Climate Control Panel With Air Conditioning
Fresh air is forced through the air outlets when the air
selection switch is in the A/C (air conditioning), PANEL,
1 2 PANEL & FLOOR, FLR (floor), FLR & DEF (defrost),
and DEF positions. Recirculated air is forced through
the air outlets when the air selection switch is in the
3 MAX A/C (maximum air conditioning) position. Dusty or
10/04/99 f610371 smoky outside air is prevented from being drawn inside
1. Fan Switch the cab when the air selection switch is in the OFF
2. Temperature Control Switch position.
3. Air Selection Switch
IMPORTANT: To prevent the buildup of fumes or
Fig. 4.2, Climate Control Panel Without Air odors (for example from smoking) and to prevent
Conditioning oxygen depletion inside the cab, do not operate

4.1
 Heater and Air Conditioner
Defogging and Defrosting
Using Fresh Air
1. Turn the temperature control switch all the way
clockwise for warm air, and turn the fan switch to
LO before starting the engine.
2. Remove any ice or snow from the outside of the
windshield, door windows, and fresh air inlet grille.
3. With the engine at operating temperature, turn the
1 2 fan switch to the highest speed. Leave it in this po-
09/28/99 f610345
sition for 30 seconds. This will clear the system of
1. Closed Position 2. Open Position moist air.
Fig. 4.3, Dash Panel Louver 4. Move the air selection switch to the defrost (DEF)
position. In this position warm, dry air is directed to
the air conditioning system in the MAX A/C mode the windshield.
for more than 20 minutes.
NOTE: If your vehicle is equipped with air condi-
NOTE: An engine heater supply gate valve is op- tioning, the air conditioner automatically comes on
tional on the Acterra. Shutting off the heater sup- in the defrost mode. Operating in this mode dries
ply gate valve limits the ability to control the air the air.
conditioning temperature in the cab. With the valve
shut off, warm coolant is no longer available from
the engine and the controls on the climate control
Heating
panel can’t be used to change the air temperature. 1. With the engine at operating temperature, move the
temperature control switch all the way clockwise for
heat.
2. Turn on the fan switch to the desired speed.

4.2
Heater and Air Conditioner
3. Move the air selection switch to the desired setting. 2. Move the air selection switch to a non-air condition-
ing panel position and turn the fan switch to LO be-
IMPORTANT: If the windows start to fog, move the fore starting the engine.
air selection switch to defrost (DEF) and make
sure the fan is on. 3. Start the engine.

NOTE: In mild weather the fan switch can be kept 4. Move the air selection switch to either one of the air
in the LO position since forward motion of the ve- conditioning settings. With the switch at the A/C
setting, fresh air is drawn into the cab. With the
hicle will provide airflow through the heater. switch at MAX A/C, the air inside the cab is recircu-
4. When a comfortable temperature has been lated. A recirculated air (RECIRC AIR) indicator on
reached, adjust the fan switch setting and tempera- the dash message center illuminates when the air
ture control switch as needed to maintain the tem- inside the cab is recirculated.
perature.
IMPORTANT: To prevent the buildup of fumes or
odors (for example from smoking) and to prevent
Air Conditioning, Optional oxygen depletion inside the cab, do not operate
IMPORTANT: Operate the air conditioner at least the air conditioning system in the MAX A/C mode
five minutes each month, even during cool for more than 20 minutes.
weather. This helps prevent drying and cracking of 5. Move the temperature control switch counterclock-
tubing seals, reducing refrigerant leaks in the sys- wise for cool air. In this position, no heat is given off
tem. Operate the air conditioner only after the en- by the heater.
gine compartment is warm, and the interior of the 6. Turn the fan switch to the highest speed.
cab is 70°F (21°C) or higher. During cold weather,
the heater can be operated at the same time to 7. As soon as cool air is flowing from the dash panel
prevent discomfort. louvers, close the windows. Adjust the fan switch
setting as desired.
1. If the cab is hot inside, temporarily open the win-
dows to let the hot air out.

4.3
 Heater and Air Conditioner
8. If the air from the outlets is too cold, move the tem-
perature control switch clockwise for warmer air
flow.
IMPORTANT: If the outside air is dusty or smoky,
set the air selection switch to MAX A/C and keep
the windows and vent closed to prevent drawing in
dust or smoke. The air selection switch can also
be set to OFF to prevent drawing in dust or
smoke.

Fresh Air
1. Move the air selection switch to the desired posi-
tion.
2. Move the temperature control switch counterclock-
wise for no heating, or move it clockwise for heat.
3. Set the fan switch at the desired speed.

4.4
 5

Seats and Seat Belts

Seats . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.1
Seat Belts and Tether Belts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.6
Seats and Seat Belts
Seats of road shock by isolating the occupant from the
motion of the vehicle and allowing the upper seat to
General Information move in a simple pendulum motion. A lockout fea-
ture is used when the isolator is not desired.
Unless otherwise noted, all seat adjustments should be
made while seated and before the engine is started. 4. Height Adjustment: The entire seat moves up or
down when adjusting the height. The adjustment is
either manually controlled or air controlled depend-
WARNING ing on the type of seat.

Keep hands, tools, and other objects away from the 5. Bottom Cushion Angle or Fore and Aft Bottom
scissor points under the seats. Failure to do so Cushion Height: This feature lets the occupant raise
could cause personal injury. or lower the front or back of the bottom cushion.
This adjustment is easier to perform when all
Seat Adjustment weight is removed from the seat.

The following is a description of adjustments that can 6. Fore and Aft Seat or Seat Track Adjustment: The
be made to various Sterling-installed seats. Not all entire seat moves forward or backward when this
seats have all of the adjustments listed below. See adjustment is made.
Fig. 5.1 for illustrations of the seat adjustments. 7. Head Rest Adjustment: When this adjustment is
1. Back Cushion Tilt: This adjustment tilts the back made, the angle of the head rest changes to pro-
cushion forward or backward. vide support to the head.

2. Lumbar Support: Lumbar support changes the 8. Weight Adjustment: On seats with weight adjust-
shape of the back of the seat to give more or less ment, the feature is fully automatic. When you sit
support to the occupant’s lumbar (lower back) area. on the seat, a leveling valve places you in the cen-
This adjustment is either mechanical or air con- ter of the ride zone. Additional adjustments are pos-
trolled depending on the type of seat. sible by using the height adjustment feature.

3. Isolator: This feature (also referred to as back-slap

isolator or Chugger-Snubber®) reduces the amount

5.1
 Seats and Seat Belts

1
3 4
2
7

6
5

10/27/99 f910429
1. Back Cushion Tilt 5. Bottom Cushion Angle (fore and aft cushion height)
2. Lumbar Support 6. Fore and Aft Seat Adjustment (seat track adjustment)
3. Isolator Feature 7. Head Rest Adjustment
4. Height Adjustment
Fig. 5.1, Seat Adjustments

5.2
Seats and Seat Belts
National Nonsuspended Seat
Back Cushion Tilt
To tilt the back cushion, turn the back cushion tilt knob
(Fig. 5.2) and lean forward or backward.

Fore and Aft Seat Adjustment

To adjust the fore and aft position of the entire seat,
move the fore and aft seat adjustment lever to the left
and slide the seat forward or backward to the desired
position. 1
Fore and Aft Bottom Cushion Adjustment
3
To adjust the fore and aft position of the bottom cushion
only, pull the fore and aft bottom cushion adjustment
handle out and slide the bottom cushion forward or
backward to the desired position. 2

National 2000 Series Seat

10/07/99 f910430
Back Cushion Tilt
1. Back Cushion Tilt Knob
To tilt the back cushion, turn the back cushion tilt knob 2. Fore and Aft Seat Adjustment Lever
(Fig. 5.3) until the desired position is reached. 3. Fore and Aft Bottom Cushion Adjustment Handle

Height Adjustment Fig. 5.2, National Nonsuspended Seat

To raise or lower the height of the seat, use the height

adjustment switch on the side of the seat.

5.3
 Seats and Seat Belts
Fore and Aft Seat Adjustment
To adjust the fore and aft position of the entire seat,
move the fore and aft seat adjustment lever to the left
and slide the seat forward or backward to the desired
position. Move the lever back to its original position to
lock the seat in place.
7
Rear Cushion Adjustment
To adjust the height of the rear of the seat cushion, re-
6 move your weight from the seat and turn the rear cush-
ion adjustment knob to one of three positions.

1 Isolator
5
Also called a Chugger Snubber®, the isolator reduces
the amount of road shock by isolating the occupant
2 from the motion of the vehicle and allowing the seat to
4 3 move in a simple pendulum motion. To use the isolator
feature, turn the isolator handle to the horizontal posi-
tion. Turn the isolator handle down when the isolator
11/14/2000 f910445 feature is not desired.
1. Back Cushion Tilt Knob
2. Lumbar Support Switch Lumbar Support
3. Height Adjustment Switch
To adjust the lumbar support, use the lumbar support
4. Fore and Aft Seat Adjustment Lever
5. Bottom Cushion Front Height Adjustment Handle
switch on the side of the seat to give more or less sup-
6. Isolator Handle port to your lower back.
7. Rear Cushion Adjustment Knob
Fig. 5.3, National 2000 Series Seat

5.4
Seats and Seat Belts
Bottom Cushion Front Height
To adjust the height of the front of the bottom cushion,
lift the bottom cushion front height adjustment handle,
and pull forward or push back to the desired setting.

Bostrom Talladega™ 915 Seat

Back Cushion Tilt
To tilt the back cushion, lean forward slightly to remove
pressure from the cushion and hold the back cushion tilt
lever (Fig. 5.4) down. Lean backward slowly to the de-
sired position and release the lever to lock the cushion
1
in place.

Height Adjustment
5
To raise the seat, push up on the height adjustment
2
switch. To lower the seat, push down on the height ad-
3
justment switch.
4
Fore and Aft Seat Adjustment 09/24/1999 f910428

Move the fore and aft seat adjustment lever to the side 1. Back Cushion Tilt Lever
to adjust the seat to the desired fore-aft position. Move 2. Upper and Lower Lumbar Support Switches
the lever back to its original position to lock the fore-aft 3. Height Adjustment Switch
position. 4. Bottom Cushion Tilt Adjustment Knob
5. Fore and Aft Seat Adjustment Lever

Fig. 5.4, Bostrom Talladega 915 Seat

5.5
 Seats and Seat Belts
Bottom Cushion Tilt Adjustment quirements. They are recommended for all persons
weighing over 50 pounds (23 kg).
Turn the bottom cushion tilt adjustment knob to increase
or decrease the bottom cushion tilt. A child restraint system should also be provided for
each child weighing 50 pounds (23 kg) or less. It should
Lumbar Support meet the requirements of Federal Motor Vehicle Safety
Standard 213, "Child Restraint Systems." When provid-
For seats with air lumbar support, use the upper and ing such a restraint system, carefully read and follow all
lower lumbar support switches to adjust the top lumbar instructions pertaining to installation and usage for the
and bottom lumbar supports. child. Make certain the child remains in the restraint
system at all times when the vehicle is in motion.
Two-Passenger Bench Seat In addition to seat belt assemblies, tether belts are in-
The two-passenger bench seat is stationary. The bottom stalled on suspension-type seats. Tether belts help se-
seat cushion lifts up to access an additional storage cure the seat to the floor and are intended to restrain
area under the seat. the seat and seat belt in case of an accident or sudden
stop.
Seat Belts and Tether Belts IMPORTANT: Seat belts have a finite life which
may be much shorter than the life of the vehicle.
General Information Regular inspections and replacement as needed
Seat belt assemblies are designed to secure persons in are the only assurance of adequate seat belt se-
the vehicle to help lessen the chance of injury or the curity over the life of the vehicle.
amount of injury resulting from accidents or sudden See Chapter 11 for the seat belt inspection procedure.
stops. For this reason, Sterling Truck Corporation urges
the driver and all passengers, regardless of age or Seat Belt Operation
physical condition, to use seat belts when riding in the
vehicle. Three-Point Seat Belt With Komfort® Latch
Seat belt assemblies in the vehicle meet Federal Motor While your vehicle is in motion, the combination lap and
Vehicle Safety Standard 209, "Type 1" and "Type 2" re- shoulder belt adjusts to your movement. However, if

5.6
Seats and Seat Belts
you brake hard, corner hard or if your vehicle receives more than one inch (2.5 cm) of slack between your
an impact of 5 mph (8 km/h) or more, the lap and chest and the shoulder harness. See Fig. 5.5. More
shoulder belt locks and prevents you from moving. slack can significantly reduce the seat belt’s effec-
tiveness in an accident or a sudden stop. While
holding the belt slack, press the Komfort latch lever
WARNING up, clamping the belt’s webbing. See Fig. 5.6.
Wear three-point seat belts only as described be-
low. Three-point seat belts are designed to be worn
by one person at a time. In case of an accident or
sudden stop, personal injury or death could result
from misuse.
A
WARNING
Fasten the seat belts before driving. Fastening a
three-point seat belt while driving creates a hazard.
1. Pull the lap-shoulder portion of the belt from the
retractor so that the shoulder portion of the belt
crosses your shoulder and chest. Insert the belt
tongue into the proper buckle until you hear a snap
and feel it latch. 01/06/95 f910048a

2. Tighten the lap portion of the belt, pull up on the A. 1 Inch (2.5 cm) Maximum
shoulder piece until it fits you snugly. The belt
Fig. 5.5, Adjusting Shoulder Harness Clearance
should rest as low on your hips as possible.
3. If desired, engage the Komfort latch as follows: 4. To unbuckle the three-point seat belt, push the but-
ton on the buckle as shown in Fig. 5.7. If the Kom-
Pull on the shoulder strap to lessen the pressure of fort latch was used, release it by giving the shoul-
the strap on your shoulder and chest. Allow no der belt a quick tug. If you lean forward against the

5.7
 Seats and Seat Belts

11/02/95 f910144

Fig. 5.6, Locking the Komfort Latch

shoulder belt, the Komfort latch will automatically 01/18/95 f910049a

release and will need to be reset.
Fig. 5.7, Releasing the Three-Point Seat Belt
NOTE: The Komfort Latch does not have to be
released in an emergency situation. The Komfort Lap Belt Without a Retractor
Latch will release by itself under rough road or The center lap belt on a two-passenger seat does not
other abnormal conditions. Make sure the three- have a retractor and therefore should be shortened and
point seat belt is completely retracted when it is fastened when being used. To lengthen the belt, tip the
not in use. belt tongue at a right angle to the belt and pull the belt
over your lap until the tongue reaches the buckle.

5.8
Seats and Seat Belts
1. Pull the belt across your hips and insert the tongue
into the correct buckle on your seat until you hear a
snap and feel it lock.
2. Make sure the buckle is securely fastened.
3. Adjust the belt so that it fits snugly around your
hips. If you need to lengthen the belt, unfasten it
and repeat the previous steps. If you need to
shorten the belt, pull on the loose end of the belt.

5.9
 6

Steering and Brake Systems

Steering System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.1
Air Brake System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.2
Hydraulic Brake System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.9
Steering and Brake Systems
Steering System Power Steering System
General Information The power steering system consists of a steering gear
(which includes a manual steering mechanism, a hy-
When there is no load on the vehicle and the front tires draulic control valve, and a hydraulic power cylinder),
are pointed straight ahead, the steering wheel spokes hydraulic hoses, power steering pump, power steering
should be at the 4 o’clock and 8 o’clock positions, or reservoir, and other components. Some models are also
within 10 degrees of these positions. See Fig. 6.1. For equipped with a separate hydraulic power cylinder on
steering wheel adjustment procedures, see Group 46 of the right side of the front axle. The power steering
the Acterra® Workshop Manual. pump, driven by the engine, provides the power assist
for the steering system. If the engine is not running,
there is no power assist.
If the power-assist feature does not work due to hydrau-
lic fluid loss, steering pump damage, or some other
cause, bring the vehicle to a safe stop. Do not drive the
vehicle until the cause of the problem is corrected.

10° 10° WARNING

Driving the vehicle without the power-assist feature
of the steering system requires much greater effort,
1 2 especially in sharp turns or at low speeds, which
could result in an accident and possible injury.
10° 10°
01/04/2000 f461750 Drivers should use the power available with a power
steering system carefully. If the front tires become
1. 8 o’Clock 2. 4 o’Clock
lodged in a deep chuckhole or rut, drive the vehicle out
Fig. 6.1, Steering Wheel Centered instead of using the steering system to lift the tires from
the hole. Also, avoid turning the tires when they are

6.1
 Steering and Brake Systems
against a curb as this places a heavy load on steering tinue to operate the rear service brakes and trailer
components and could damage them. brakes.
IMPORTANT: When air pressure is lost in one of
Air Brake System the air systems, the air compressor will operate
but will not replenish the air supply in the system
General Information that is not leaking. There will only be enough air in
A dual air brake system operates two independent air the non-leaking system to get the vehicle stopped.
brake systems through one set of brake controls. Each Therefore, it is important to bring the vehicle to a
system has its own reservoir, plumbing, and brake safe stop as soon as possible. Do not attempt to
chambers. The primary air system operates the service drive the vehicle again until the problem is cor-
brakes on the rear axles; the secondary air system op- rected.
erates the service brakes on the front axle. Either or
both the primary and secondary sytems can operate the Trucks are equipped with spring brake modulation. If an
trailer brakes. air pressure loss occurs in the primary air system, the
rear spring brakes will be modulated (applied and re-
leased) according to how hard the brake pedal is being
WARNING pushed. There will only be enough air in the secondary
system for two to four brake applications, then the park
Do not operate the vehicle with the front brakes brake valve will pop out and lock the brakes.
backed off or disconnected. Backing off or discon-
necting the front brakes will not improve vehicle Before driving your vehicle, allow time for the air com-
handling and may lead to loss of vehicle control pressor to build up a minimum pressure of 95 psi (655
resulting in property damage or personal injury. kPa) in both air systems. Monitor the air pressure sys-
tem by observing the primary and secondary air pres-
If the primary air system loses pressure, the rear ser- sure gauges and the low air pressure warning light and
vice brakes will not work but the secondary air system buzzer. The warning light and buzzer shut off when air
will continue to operate the front axle and trailer brakes. pressure in both systems reaches 64 to 76 psi (441 to
If the secondary air system loses air pressure, the front 524 kPa).
brakes will not work but the primary air system will con-

6.2
Steering and Brake Systems
The low air pressure warning light and buzzer come on the vehicle if a complete loss of air pressure oc-
if air pressure drops below 64 to 76 psi (441 to 524 curred. This could result in serious personal injury
kPa) in either system. If this happens, check the air or vehicle damage.
system pressure gauges to determine which system
has low pressure. Although the service brakes will still IMPORTANT: Connect to a towing vehicle or
slow the vehicle, one set of the service brakes will not chock the tires before caging the spring parking
be operating and the vehicle will require a longer dis- brakes.
tance to stop. Bring the vehicle to a safe stop and have
NOTE: Before a vehicle with insufficient system air
the air system repaired before continuing.
pressure can be moved, the spring parking brakes
If if a tractor-trailer loses pressure in both the primary must be released by connecting an external air
and secondary air systems, the trailer service brakes or source at the gladhands, or by manually caging
spring parking brakes will automatically activate when (manually releasing) the parking brake springs.
the air pressure drops below 35 to 45 psi (241 to 310
kPa). The tractor spring parking brakes will automati-
cally activate when the air pressure drops below 20 to Operation
30 psi (138 to 207 kPa). On trucks, spring parking Before driving the vehicle, make sure all occupants are
brakes will come on when the air pressure drops below wearing seat belts. Secure all loose items in the cab so
20 to 30 psi (138 to 207 kPa). The activation is gradual that they will not fly forward during a full brake applica-
but irreversible. Do not wait for automatic activation of tion.
the brakes. When the low air pressure warning light and
buzzer first come on, immediately bring the vehicle to a In a normal stop, push in the clutch pedal (if the vehicle
safe stop. Correct the cause of the air loss before at- has one) as the vehicle approaches a halt and shift the
tempting to drive the vehicle again. transmission to neutral. Set the spring parking brakes
after coming to a stop, if the vehicle is to be parked.
WARNING IMPORTANT: In the event of a total loss of service
brakes with full system air pressure, use the park-
Do not drive the vehicle with the parking brakes ing brake control valve (the yellow knob) to bring
caged. If the vehicle is driven with the parking the vehicle to a complete stop in the safest loca-
brakes caged, there would be no means of stopping tion possible.

6.3
 Steering and Brake Systems
The yellow diamond-shaped knob (Fig. 6.2) on the con- the supply valve open, releasing the trailer spring park-
trol panel activates the parking brake valve. Pulling out ing brakes and charging the trailer air supply system .
the knob puts on both the tractor and the trailer spring
The red knob should be out to block the trailer air sup-
parking brakes and causes the trailer air supply valve
ply before disconnecting a trailer. If pressure in both air
knob to pop out.
systems drops to 35 to 45 psi (241 to 310 kPa) the red
knob automatically pops out, exhausting the trailer air
supply and applying the trailer service or spring parking
1 brakes. Braking increases as pressure falls, until as
2
pressure approaches zero, the brakes are fully set.

CAUTION
Do not use the spring parking brakes if the service
brakes are hot, such as after descending a steep
grade. Also, do not use the spring parking brakes
03/10/99 f610291 during freezing temperatures if the service brakes
1. Trailer Air Supply Valve Knob are wet. To do so could damage the brakes if hot, or
2. Parking Brake Control Valve Knob cause them to freeze during cold weather.
Fig. 6.2, Parking Brake Control Valve and Trailer Air If the brakes are wet, drive the vehicle in low gear
Supply Valve Knobs and lightly apply the brakes to heat and dry them.
Allow hot brakes to cool before using the spring
Pulling the red octagonal knob (Fig. 6.2) on the control parking brakes. Always chock the tires.
panel opens the trailer air supply valve, exhausting the
pressurized air from the system and setting the parking If the brakes are wet, drive the vehicle in low gear and
spring brakes. When the air hoses from the vehicle are lightly apply the brakes to heat and dry them.
connected to the trailer and the pressure in both air Allow hot brakes to cool before using the spring parking
systems reaches at least 65 psi (448 kPa), the red knob brakes.
must be pushed in. It should remain pushed in to keep

6.4
Steering and Brake Systems
If the trailer is not equipped with spring parking brakes, tem that works with the air brake system. ABS passively
pulling out the yellow knob applies the tractor spring monitors vehicle wheel speed at all times, but controls
parking brakes and the trailer service brakes. When the wheel speed during an emergency or reduced-traction
tractor and trailer parking brakes (or trailer service stop. In normal braking applications, the standard air
brakes) are both applied, the trailer brakes can be re- brake system works as they always have and ABS has
leased by pushing in the red knob, leaving the tractor no active role.
parking brakes applied. Air pressure in the primary or
secondary reservoir must be at least 64 psi (441 kPa) IMPORTANT: For proper ABS system operation,
before the tractor spring parking brakes, or the trailer use tires of the factory installed size. The sizes of
service or spring parking brakes, can be released. the tires installed during production are pro-
grammed into the electronic control unit. Installing
On trailers without spring parking brakes, chock the
trailer tires before disconnecting the tractor when park-
different size tires could result in reduced braking
ing just the trailer. When parking a tractor with a trailer, ability leading to longer stopping distances.
if the trailer is not equipped with spring parking brakes, ABS reads from signal-generating tone wheels and sen-
set the tractor spring parking brakes. sors located in the wheel hubs of each sensed axle.
The sensors transmit vehicle wheel speed information
WARNING to an electronic control unit (ECU). The main circuit of
the ECU interprets the speed sensor signals and con-
Do not use the trailer service brakes for parking; stantly compares wheel speeds, wheel braking rates,
they are not designed for this purpose. If air bleeds and vehicle speed. If it senses a wheel is beginning to
out of the trailer air tank during parking, the vehicle lock, the ECU signals the appropriate solenoid control
could roll causing serious personal injury or prop- valve to reduce braking in that wheel, preventing a skid.
erty damage. During emergency braking, the solenoid control valve
prevents wheel lockup by controling air pressure in the
brake chambers.
Meritor™ WABCO® Antilock Braking
System (ABS), Air Brake Systems The ECU also has a safety circuit which constantly
monitors the wheel sensors, solenoid control valves and
The Meritor WABCO Antilock Braking System (ABS) is the electrical circuitry. In a vehicle equipped only with a
an electronic wheel speed monitoring and control sys- tractor ABS system, when the ignition switch is turned

6.5
 Steering and Brake Systems
on the TRACTOR ABS warning light comes on. The • If the lamp comes on momentarily during vehicle
warning light goes out only if all of the tractor ABS com- operation then shuts off, a fault was detected and
ponents are working properly. corrected.
• If the lamp comes on and stays on during vehicle
CAUTION operation, there is a problem with the trailer ABS.
Repair the trailer ABS system immediately to en-
An accumulation of road salt, dirt, or debris on the sure full antilock braking capability.
ABS tone wheels and sensors can cause the ABS
warning light to come on. If the ABS light does The Trailer ABS lamp will not light up unless a compat-
come on, the tone rings and sensors should be in- ible trailer is connected to the tractor.
spected for corrosion and serviced if necessary. IMPORTANT: If a compatible trailer is connected
The service should include cleaning of the tone and the lamp does not flash on briefly when the
rings and sensors. If any tone ring on a vehicle ignition key is turned on, it is possible that the
shows severe corrosion, all tone rings on that ve-
hicle should be replaced.
lamp is burnt out.
Automatic Traction Control is an option available on
During winter months in areas where corrosive ma- ABS-equipped vehicles with air brake systems. It helps
terials are used on the highways, periodically clean improve traction when vehicles are on slippery surfaces
the underside of the vehicle, including the tone by keeping drive wheels from spinning. ATC works auto-
rings and sensors, to ensure proper ABS function matically in two ways.
and to protect the components from corrosion.
Clean more frequently when unusually corrosive • If a drive wheel starts to spin, ATC decreases air
chemicals are being used. pressure to brake the wheel. This transfers en-
gine torque to the wheels with better traction.
The dash-mounted TRAILER ABS light will operate as
follows when a compatible trailer is properly connected • If all of the drive wheels spin, ATC reduces en-
to a tractor: gine torque to provide improved traction.
• When the ignition key is turned to the on position, If the vehicle is equipped with Automatic Traction Con-
the trailer ABS lamp will illuminate briefly, then trol (ATC), any wheel spin during acceleration turns on
turn off. the WHEEL SPIN indicator light. The light goes out

6.6
Steering and Brake Systems
when the wheel stops spinning. When the light comes
on, partially release the throttle pedal until the light goes WARNING
out. If slippery road conditions continue, turn the axle
lock switch on. See Chapter 9 for axle lock instructions. Failure to disable the ATC before dynamometer test-
ing could result in serious personal injury and dam-
age to the vehicle.
CAUTION
Vehicles with ATC must have the ATC disabled to test
Do not turn the differential lock and/or interaxle lock the vehicle on a dynamometer. To disable the ATC,
switch on while the WHEEL SPIN indicator light is press and hold the ABS diagnostic switch for at least
on. To do so could damage the rear axle. three seconds. Once the system configuration code be-
gins, ATC has been disabled. The WHEEL SPIN indica-
ATC turns itself on and off. Drivers do not have to se- tor comes on and stays on while disabled.
lect this feature. If drive wheels spin during accelera-
tion, the WHEEL SPIN indicator comes on, indicating The Meritor WABCO ABS system combines one front-
ATC is active. It goes out when the drive wheels stop axle control channel with either one rear axle (the four-
spinning. sensor system), or two rear axles (the six-sensor sys-
tem) to form one control circuit. For example, the
The ATC option includes a mud or deep snow (TRAC sensor and solenoid control valve at the left-front axle
MUD/SNOW) switch. This switch is used to improve form a control circuit with the sensor(s) and solenoid
traction on soft surfaces such as snow, mud, or gravel valve(s) on the right rear axle(s). During vehicle opera-
by slightly increasing the permissible wheel spin. When tion, if the safety circuit senses a failure in any part of
the mud or deep snow switch is pressed, the WHEEL the ABS system (a sensor, solenoid control valve, wiring
SPIN indicator comes on. connection, short circuit, etc.), the TRACTOR ABS
The ABS diagnostic (ABS DIAG) switch is a momentary warning light comes on and the control circuit where the
switch that turns on the blink code diagnostic capabili- failure occurred is switched to normal braking action.
ties. It may also be used to disable the traction control ABS will continue to work on the remaining control cir-
for dynamometer testing as described in the next para- cuit. Even if the ABS system is not working to some
graph. For information on troubleshooting with blink degree, normal braking ability is maintained. A possible
code diagnostics, see Group 42 of the Acterra® Work-
shop Manual.

6.7
 Steering and Brake Systems
exception would be if a solenoid control valve or combi- 20, 1994. Automatic slack adjusters should never be
nation solenoid control valve is damaged or not work- manually adjusted except during routine maintenance of
ing. Since these valves are an integral part of the air the foundation brakes (e.g., replacing shoes), during
brake system, normal braking may be reduced or may slack adjuster installation or in an emergency situation.
not work at all and if they are malfunctioning the vehicle
When the brake pushrod stroke exceeds the legal brake
must be parked as quickly and safely as possible.
adjustment limit on a vehicle, there is likely a mechani-
IMPORTANT: If any of the ABS warning lights do cal problem with the foundation brake components or
not work as described above or come on while the adjuster is improperly installed.
driving, repair the ABS system immediately to en- Visit a repair facility as soon as possible when brakes
sure full antilock braking capability. equipped with automatic slack adjusters are determined
to be out of adjustment.
During emergency or reduced-traction stops, push the
brake pedal steadily until the vehicle comes to a safe
stop. Do not pump the brake pedal. If the driver pushes WARNING
the brake pedal hard enough to lock the wheels, the
ABS system will control braking to provide steering con- Manually adjusting an automatic slack adjuster to
trol and the shortest possible stopping distance. bring the pushrod stroke within legal limits is likely
masking a mechanical problem. Adjustment is not
Although the ABS system improves vehicle control dur-
repairing. In fact, continual adjustment of automatic
ing emergency braking situations, the driver still has the
slack adjusters may result in premature wear of the
responsibility to drive appropriately for the existing traffic
adjuster itself. Further, the improper adjustment of
and road conditions. For example, the ABS system can-
some automatic slack adjusters may cause internal
not prevent an accident if the driver is speeding or fol-
damage to the adjuster, thereby preventing it from
lowing too closely, or going too fast in slippery road
properly functioning.
surfaces.

Automatic Slack Adjusters

Automatic slack adjusters are required on all vehicles
equipped with air brakes manufactured after October

6.8
Steering and Brake Systems
Hydraulic Brake System A
General Information
The hydraulic brake system includes a Hydro-Max®
power booster, master cylinder, hydraulic brake reser-
voir (Fig. 6.3), hydraulic lines, a brake rotor on each
wheel hub, and a brake caliper and pad assembly at
each rotor.
IMPORTANT: Fill the master cylinder reservoir to
the bottom of the narrow ring of the filler neck.
Use only heavy-duty DOT 3 brake fluid in the hy- B
draulic brake system.
The master cylinder supplies hydraulic pressure to the
brakes. It is attached to the front of the Hydro-Max
power booster. The power booster receives pressurized
automatic transmission fluid (ATF) from the power steer- 10/31/94 f460513a
ing system. (The power steering system contains ATF, A. Open caps and check fluid level.
not the product specifically called power steering fluid.) B. Fill to this level.
An electrically powered "reserve" pump cuts in, if fluid
pressure falls between the power steering pump and Fig. 6.3, Hydraulic Brake Reservoir
the power booster. The brake system warning light
comes on if there is a problem within the system. For hydraulic brake system troubleshooting and adjust-
ment procedures, see Group 42 of the Acterra® Work-
If the light comes on, bring the vehicle to a safe shop Manual.
stop and correct the problem immediately. Do not
attempt to drive until the problem is found and cor-
rected.

6.9
 Steering and Brake Systems
Operation stalled during production are programmed into the
electronic control unit (SUV). Installing different
Before driving the vehicle, secure all loose items in the sized tires could result in inaccurate wheel speed
cab so that they will not fly forward during a full brake signals to the ECU, reduced braking force and
application. Make sure all occupants are wearing seat longer stopping distances. This could lead to an
belts. Check that the brake system warning light is off
after releasing the parking brake. If the warning light
accident, property damage and personal injury.
does not go off, find and correct the problem before ABS uses signal-generating tone wheels and sensors
continuing to operate the vehicle. located in the wheel hubs of each sensed axle to mea-
During normal brake stops, pushing the brake pedal sure their speeds. The sensors transmit the wheel
slows the vehicle. As the vehicle slows almost to a stop, speed information to the ECU which compares wheel
push in the clutch pedal if there is one, and shift the speeds and a vehicle reference speed. If the calcula-
transmission to neutral. After coming to a stop, apply tions indicate a wheel is about to lock, the ECU signals
the parking brake if the vehicle is to be parked. the brake pressure modulator to increase or decrease
braking pressure.
Meritor™ WABCO® Antilock Braking The ECU also has a safety circuit which constantly
monitors the wheel sensors, brake pressure modulator,
System (ABS), Hydraulic Brake and the electrical circuitry. The TRACTOR ABS warning
Systems light comes on after the ignition is switched on. The
warning light goes out only if all the tractor ABS compo-
The Meritor WABCO Antilock Braking System (ABS) is nents are working properly.
an electronic wheel speed monitoring and control sys-
tem which works with the hydraulic brake system. ABS The ABS warning light comes on and stays lit when the
watches each braking wheel’s speed at all times, then ignition is switched on. It should go off when the vehicle
controls wheel speed during an emergency or reduced- exceeds four miles per hour. If it does not go off over
traction stop. In normal braking the standard hydraulic four miles per hour, there may be an active fault in the
brake system is in effect, the ABS does nothing. hydraulic ABS. If the ABS warning light comes on and
stays on, then goes off after the vehicle goes over four
IMPORTANT: For proper ABS system operation,
do not change tire sizes. The sizes of the tires in-

6.10
Steering and Brake Systems
miles per hour, there may be a stored fault in the hy- shows severe corrosion, all tone rings on that ve-
draulic ABS. Have the ABS system checked if either hicle should be replaced.
situation occurs.
During winter months in areas where corrosive ma-
If during vehicle operation the safety circuit senses a terials are used on the highways, periodically clean
failure in any part of the ABS system (a sensor, brake the underside of the vehicle, including the tone
pressure modulator, wiring connection, short circuit, rings and sensors, to ensure proper ABS function
etc.) the TRACTOR ABS warning light comes on and and to protect the components from corrosion.
the control circuit where the failure occurred is switched Clean more frequently when unusually corrosive
to normal braking action. Even if the ABS system is par- chemicals are being used.
tially or completely inoperative, normal braking ability is
maintained. An exception would be if the brake pres- Before ignition, the dash mounted TRAILER ABS lamp
sure modulator, or hydraulic fluid line is damaged. As will operate as follows when a compatible trailer is prop-
these components are an integral part of the hydraulic erly connected to a tractor:
brake system, normal braking may be impaired or inop- • When the ignition key is turned to the on position,
erative. the trailer ABS lamp will illuminate momentarily,
then turn off.
CAUTION • If the lamp comes on momentarily during vehicle
operation, then shuts off, a fault was detected
An accumulation of road salt, dirt, or debris on the and corrected.
ABS tone wheels and sensors can cause the ABS
warning light to come on. If the ABS light does • If the lamp comes on and stays on during vehicle
come on, the tone rings and sensors should be in- operation, there is a fault with the trailer ABS.
spected for corrosion and serviced if necessary. Repair the trailer ABS system immediately to en-
The service should include cleaning of the tone sure full antilock braking capability.
rings and sensors. If any tone ring on a vehicle The Trailer ABS lamp will not illuminate unless a com-
patible trailer is connected to the tractor.
IMPORTANT: If any of the ABS warning lights do
not work as described above or come on while

6.11
 Steering and Brake Systems
driving, repair the ABS system immediately to en- Vehicles with ATC must have the ATC disabled to test
sure full antilock braking capability. the vehicle on a dynamometer. To disable the ATC,
press and hold the ABS diagnostic switch for at least
During emergency or reduced-traction stops, fully de- three seconds. Once the system configuration code be-
press the service brake until the vehicle comes to a gins, ATC has been disabled. The WHEEL SPIN indica-
safe stop. Do notpump the pedal. With the service tor comes on and stays on while disabled.
brake pedal depressed, the ABS system will control all
wheels to provide steering control and a reduced brak-
ing distance.
Although the ABS system improves vehicle control dur-
ing emergency braking situations, the driver still has the
responsibility to change driving styles depending on the
existing traffic and road conditions. For example, the
ABS system cannot prevent an accident if the driver is
speeding or following too closely on slippery road sur-
faces.
The ABS diagnostic (ABS DIAG) switch is a momentary
switch that turns on the blink code diagnostic capabili-
ties. It may also be used to disable the traction control
for dynamometer testing. For information on trouble-
shooting with blink code diagnostics, see Group 42 of
the Acterra® Workshop Manual.

WARNING
Failure to disable the ATC before dynamometer test-
ing could result in serious personal injury and dam-
age to the vehicle.

6.12
 7

Engines and Clutches

Engine Starting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.1
Cold Weather Starting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.5
Starting After an Extended Shutdown or Oil Change . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.6
Engine Break-In . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.6
Engine Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.7
Cold Weather Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.12
Engine Shutdown . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.15
High Altitude Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.18
Exhaust Braking System, Optional . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.18
Engine Braking System, Optional . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.22
Clutches . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.22
Engines and Clutches
Engine Starting IMPORTANT: Ring gear and starter pinion damage
caused by improper starting procedures is not
NOTE: Before starting the engine, read Chapter 2 warrantable.
for detailed information on how to read the instru-
ments and operate the controls. Whenever you start an engine, watch for any signs of
engine problems. If the engine vibrates, misfires, or
makes unusual noises, turn the engine off as soon as
CAUTION possible and determine the cause of the problem. Fre-
quently, engine damage may be avoided by a quick re-
When starting a vehicle equipped with a manual sponse to early indications of problems.
transmission and clutch lock out switch, the clutch
pedal must be fully depressed during the entire Pre-Start
start sequence. Failure to do so can cause the pin-
ion to release and re-engage, which could cause NOTE: These pre-start steps apply to all engines.
ring gear and starter pinion damage.
1. Perform the engine pretrip inspection and daily
If a vehicle does not start on the first attempt, make maintenance checks in Chapter 11.
sure that the engine has completely stopped rotat-
ing before reapplying the starter switch. Failure to 2. Set the parking brake.
do so can cause the pinion to release and re- 3. For manual transmissions, place the transmission in
engage, which could cause ring gear and starter neutral and disengage the clutch.
pinion damage.
For automatic transmissions, make sure the trans-
Moving a vehicle with the starter and/or using the mission shift control is in neutral or park.
starter to bump the engine for maintenance proce-
dures is strictly prohibited. Use of these methods to NOTE: On vehicles equipped with a neutral start
bump the engine over or move the vehicle can switch, the transmission must be in neutral before
cause the pinion to release and re-engage, which the engine can be started. For air start systems,
could cause ring gear and starter pinion damage. check the air supply before starting the engine.
There must be 100 psi (689 kPa) of air pressure
available.

7.1
 Engines and Clutches
Starting Precautions, All Engines Mercedes-Benz
NOTE: Before doing these steps, do the steps in
WARNING "Pre-Start."
Do not use any starting aid, such as ether, in en-
gines with an intake air preheater. This could cause CAUTION
an explosion, resulting in serious personal injury or
death. Never attempt to start any Mercedes-Benz elec-
tronic engine using ether or any other starting fluid.
Serious engine damage could result.
CAUTION
1. Turn the ignition switch to the on position (Fig. 7.1).
Don’t crank the engine for more than 30 seconds at All the electronic gauges on the instrument and
a time during any of the following procedures. Wait control panel complete a full sweep of their dials,
two minutes after each try to allow the starter to the warning and indicator lights light up, and the
cool. Failure to do so could cause starter damage. buzzer sounds for three seconds.
NOTE: Some starters are equipped with optional IMPORTANT: On vehicles equipped with an intake
overcrank protection. If overcranking occurs, a air preheater, wait until the INTAKE HEATER indi-
thermostat breaks the electrical circuit to the cator goes out before attempting to start the en-
starter motor until the motor has cooled. gine.
2. Turn the ignition switch to the start position. Without
CAUTION touching the throttle pedal, start the engine.

Protect the turbocharger during the start-up by not 3. Idle the engine for one to three minutes at 600 rpm
opening the throttle or accelerating the engine (700 rpm for 4-cylinder engines) before operating
above 1000 rpm until normal engine idle oil pres- the engine under load.
sure registers on the gauge. 4. Check the oil pressure gauge for any drop in lubri-
cating oil pressure or mechanical malfunction in the

7.2
Engines and Clutches
2 Caterpillar
1 3 NOTE: Before doing these steps, do the steps in
"Pre-Start."
1. Turn the ignition switch to the on position (Fig. 7.1).
4 The CHECK ENGINE indicator comes on for five
seconds. The INTAKE HEATER indicator comes on
for a minimum of two seconds, regardless of cool-
ant temperature.
09/30/99 f610344 IMPORTANT: If the INTAKE HEATER indicator
1. Accessory 3. On stays on for more than two seconds, wait until the
2. Off 4. Start indicator goes out before attempting to start the
Fig. 7.1, Ignition Switch Positions engine.
2. Turn the ignition switch to the start position. Re-
lubricating oil system. Minimum oil pressure at idle
lease the switch the moment the engine starts.
is 7 psi (50 kPa).
2.1 If the engine does not start after 15 to 20
CAUTION seconds of cranking, turn the ignition switch
off.
Do not rev the engine if the oil pressure gauge indi- 2.2 Wait two minutes to allow the starter motor
cates no oil pressure. Shut down the engine if no to cool. Turn the ignition switch back to the
oil pressure appears within approximately ten sec- on position and try to start the engine again.
onds. Check to determine the cause of the problem.
Operating the engine with no oil pressure will dam- 2.3 As soon as the engine starts, release the
age the engine. ignition switch allowing the engine to run at
a slow idle.

7.3
 Engines and Clutches
INTAKE HEATER indicator comes on for a mini-
CAUTION mum of two seconds, regardless of coolant tem-
perature. Leave the ignition switch on until the
If the oil pressure is too low, shut down the engine CHECK ENGINE indicator goes out.
immediately to prevent serious damage. If the ve-
hicle is equipped with an automatic shutdown sys- IMPORTANT: If the INTAKE HEATER indicator
tem, the engine will shut down after 30 seconds. stays on for more than two seconds, wait until the
indicator goes out before attempting to start the
3. The engine may be operated at low load and speed
engine.
once the engine oil pressure has reached 10 psi
(69 kPa) and air pressure (if applicable) has 2. Turn the ignition switch to the start position. After
reached 64 to 76 psi (441 to 524 kPa). the engine starts, release the key.
4. When the engine has reached the minimum operat- 3. Bring the engine up to operating speed gradually as
ing temperature of 160°F (71°C), the engine may it warms up and develops stable oil pressure.
be operated at full load.
NOTE: When the engine is started, it takes a short
Cummins time to build up a lubricating oil film between the
shafts and bearings, and between the pistons and
liners. The oil pressure gauge indicates any drop
CAUTION in lubricating oil pressure within 15 seconds of en-
gine start-up.
Never attempt to start any Cummins IS series elec-
tronic engine (ISB, ISC, ISL) using ether or any 4. If minimum engine oil pressure at idle of 10 psi (69
other starting fluid. Serious engine damage could kPa) does not register within 15 seconds, shut
result. down the engine.
NOTE: Before doing these steps, do the steps in
"Pre-Start." CAUTION
1. Turn the ignition switch to the on position (Fig. 7.1). Protect the turbocharger during the start-up by not
The CHECK ENGINE indicator will come on. The opening the throttle or accelerating the engine

7.4
Engines and Clutches
above 1000 rpm until minimum engine idle oil pres- air preheater warms up. After the indicator goes out,
sure registers on the gauge. Failure to do so could start the engine. If the engine doesn’t start after about
damage the tubocharger. 30 seconds of cranking, turn the key to the off position
and wait two minutes, then repeat the starting proce-
5. Idle the engine for three to five minutes at 1000 dure.
rpm before operating the engine under load.
NOTE: If the engine doesn’t start on the second
Cold Weather Starting try, wait at least five minutes before using the in-
take air preheater again.
WARNING Caterpillar
Do not use any starting aid, such as ether, in en- Caterpillar truck engines with direct injection are de-
gines with an intake air preheater. This could cause signed to start at temperatures above 32°F (0°C) with-
an explosion, resulting in serious personal injury or out using start systems. If the temperature is below
death. 32°F (0°C), startability will be improved by the use of an
automatic ether injection system and/or a jacket water
Modern electronic engines do not normally require spe-
heater.
cial starting aids. At low temperatures, intake air pre-
heaters, manifold preheaters, or water jacket heaters
are sometimes used to assist in starting. CAUTION
Mercedes-Benz Directing ether at the heater element in the intake
air preheater could cause extensive engine damage.
The intake air preheater is activated by turning the igni-
The intake air preheater is activated by turning the igni-
tion switch to the on position (Fig. 7.1). If the engine is
tion switch to the on position (Fig. 7.1). If the engine is
at normal temperature, the INTAKE HEATER indicator
at normal temperature, the INTAKE HEATER indicator
goes out after two seconds.
goes out after two seconds.
If the temperature is low enough to require the heater,
If the temperature is low enough to require the heater,
the INTAKE HEATER indicator stays on while the intake
the INTAKE HEATER indicator stays on while the intake

7.5
 Engines and Clutches
air preheater warms up. After the indicator goes out,
start the engine.
Starting After an Extended
IMPORTANT: Attempting to start the engine before
Shutdown or Oil Change
the INTAKE HEATER indicator has gone off could Do the following steps after an oil change or after the
result in excessive white smoke at start-up. engine has been shut down for more than three days:
If the engine doesn’t start after 15 to 20 seconds of 1. Disconnect the electrical connector from the fuel
cranking, turn the key to the off position and wait two pump solenoid valve.
minutes; then repeat the starting procedure.
2. Crank the engine until oil pressure shows on the
gauge.
Cummins
3. Connect the electrical connector to the fuel pump
The cold start system approved for use on Cummins solenoid valve.
engines has been based upon starting aid capabilities
to –25°F (–32°C). 4. Start the engine. After one minute, shut down the
engine and check for leaks.
Turn the ignition switch to the on position (Fig. 7.1). If
the engine is at normal temperature, the INTAKE 5. Allow five minutes for the oil to settle, then check
HEATER indicator goes out after two seconds. the engine oil level and add oil if needed. Do not
overfill.
If the temperature is low enough to require the heater,
the INTAKE HEATER indicator stays on while the intake
air preheater warms up. After the indicator goes out, Engine Break-In
start the engine.
Run the engine slightly above idle until oil pressure
Mercedes-Benz
shows on the gauge. If oil pressure doesn’t show on the Every Mercedes-Benz engine is tested on a dynamom-
gauge within 30 seconds of starting, turn the key to the eter before shipment. Therefore, no break-in period is
off position and wait one minute; then repeat the start- necessary for the MBE900 engine. Before running the
ing procedure. engine for the first time, follow the instructions in Chap-
ter 2 of the MBE900 Engine Operator’s Manual.

7.6
Engines and Clutches
Caterpillar IMPORTANT: Do not maintain wide-open throttle
operation below 1200 rpm for extended periods of
Every Caterpillar engine must pass a full-load operation time (more than 30 seconds).
test on a dynamometer before shipment, eliminating the
need for a break-in period. Only an initial operational 5. Checking the oil level frequently during the break-in
check is necessary. period.

Cummins Engine Operation

Cummins engines are run on a dynamometer before Operating vehicles with diesel engines in areas where
being shipped from the factory. In most applications, the there are concentrated flammable vapors (such as die-
engine can be put to work immediately, but during the sel, gasoline, or propane fumes) can create a hazard-
initial 100 hours or 3000 miles (5000 km) of service the ous situation. These vapors can be drawn into the en-
operator has an opportunity to establish conditions for gine through the air intake and cause engine
the best service life by: overspeed. Be especially cautious of low-lying or
1. Operating as much as possible at three-quarter closed-in areas and always check for signs that flam-
load. mable vapors may be present.

2. Avoiding operation at engine idle speeds or at

maximum horsepower levels longer than five min- DANGER
utes.
Don’t operate the engine in an area where flam-
3. Developing the habit of closely watching the engine mable vapors such as gasoline or diesel fumes are
instruments during operation. Let up on the throttle present. Shut down the engine when in an area
if the oil temperature reaches 250°F (121°C) or if where flammable liquids or gases are being
the coolant temperature exceeds 195°F (91°C). handled. Failure to observe these precautions could
result in serious injury or death.
4. Operating with a power requirement that allows ac-
celeration to governed speed when conditions re- All diesel engines have been built to comply with the
quire more power. requirements of the Federal (U.S.) Clean Air Act. Once
an engine is placed in service, the responsibility for

7.7
 Engines and Clutches
meeting both state and local regulations is with the 2. Depending on the vehicle gearing, the posted
owner/operator. Good operating practices, regular main- speed limit can sometimes allow operation in either
tenance, and correct adjustments are factors which will of the top two gears; however, for improved operat-
help to stay within the regulations. ing efficiency (fuel economy and engine life), oper-
ate in the top gear at reduced rpm rather than in
Proper maintenance of the engine, which is the respon- the next lower gear at the maximum rpm.
sibility of the owner/operator, is essential to keep the
emission levels low. 3. Cruise at partial throttle whenever road conditions
and speed requirements permit. This driving tech-
The driver should be familiar with the vehicle warning nique permits operating within the most economical
system in order to bring the vehicle to a safe stop if the power range of the engine.
engine malfunctions. If the driver doesn’t understand
how the warning system works, an engine shutdown 4. Use lower gears in steep downhill driving. Normally,
could occur, causing a safety hazard. See Chapter 2 the gear used to descend a hill is the same gear
for information on the instrument and control panel. used to climb a hill of the same grade.
5. Never allow the engine to exceed the rated speed.
Mercedes-Benz Use the exhaust brake and the optional constant-
While you are driving, watch for any signs of engine throttle brake, if installed, to lower engine rpm be-
problems. If the engine overheats, uses excessive fuel low the rated speed.
or lubricating oil, vibrates, misfires, makes unusual 6. Never allow the engine to idle for more than 30
noises, or shows an unusual loss of power, turn the en- minutes. Excessive idling can cause oil to leak from
gine off as soon as possible and determine the cause of the turbocharger.
the problem. Frequently, engine damage may be
avoided by a quick response to early indications of
problems. CAUTION
1. Use the tachometer to determine when to shift. Fol- Stop the engine at the first sign of malfunction. Al-
low the pattern on the shift lever when moving most all malfunctions give some warning to the op-
through the gears. erator before significant damage occurs. Many en-
gines are saved because alert operators heed the

7.8
Engines and Clutches
warning signs (sudden drop in oil pressure, un- engine malfunctions. If the driver doesn’t understand
usual noises, etc.) and immediately shut down the how the warning system works, an engine shutdown
engine. could cause a safety hazard.
NOTE: Long periods of idling are not good for an The electronic control system can monitor engine oil
engine because the combustion chamber tempera- pressure, coolant temperature, intake manifold air tem-
tures drop so low the fuel may not burn com- perature, and coolant level. There are four customer
pletely. This will cause carbon to clog the injector programmable levels for Caterpillar engine monitoring:
off, warning (factory default), derate, and shutdown.
spray holes and piston rings, and may result in
stuck valves. In the engine monitoring off mode the ECM will ignore
the oil pressure sensor and coolant level sensor (if in-
If the engine coolant temperature becomes too stalled). Engine monitoring warning mode uses oil pres-
low, raw fuel will wash the lubricating oil off the sure, coolant temperature, intake manifold temperature,
cylinder walls and dilute the crankcase oil, causing and the coolant level sensor (if installed and enabled).
all moving parts of the engine to suffer from poor The CHECK ENGINE indicator will flash when the diag-
lubrication. nostic code is active. Engine monitoring derate and
shutdown modes allow the ECM to alter engine perfor-
Caterpillar mance or stop the engine to help the engine avoid
damage and return to normal conditions.
Proper operation and maintenance are key factors in
obtaining the maximum life and economy of a vehicle
IMPORTANT: If a winterfront is used on a vehicle
engine. Follow the directions in the Caterpillar Opera- with an electronic engine equipped with a charge
tion and Maintenance Manual and this manual for air cooler, make sure that there are slit openings
trouble-free, economical engine operation. distributed across the face of the winterfront to
allow airflow through the entire charge-air-cooler
Caterpillar electronic engines can be equipped with a
variety of options designed to warn the driver of engine
core. Do not use a winterfront with closed areas
malfunctions. The driver of a vehicle equipped with that block uniform air flow across all sections of
these engines should know the extent of the warning
system in order to bring the vehicle to a safe stop if the

7.9
 Engines and Clutches
the charge-air-cooler crossflow tubes. This will ad- It is not necessary to accelerate Caterpillar elec-
versely affect the operation and durability of the tronic engines to governed speed in the lower
charge air cooler. gears to get the vehicle moving, except in a high
power demand situation such as starting on a
1. Operate the engine at low load. After normal oil grade.
pressure is reached and the temperature gauge
needle begins to move, the engine may be oper- 3. Continue to upshift until cruising speed is reached.
ated at full load. Use only the rpm needed to make an upshift into
the next gear. The engine speed needed to make
Caterpillar electronic engines automatically idle at an upshift increases as the truck speed increases.
900 to 1000 rpm for the correct warm-up time after If the truck can be operated in a higher gear after
a cold engine start when the air temperature is reaching the desired speed, select the highest gear
lower than 40°F (5°C). These electronic engine sys- available that will pull the load. Experience with
tems will reduce the idle speed to 600 rpm when your truck will show you what rpm is needed to
the engine has warmed sufficiently to operate the make upshifts under various conditions. This pro-
vehicle. gressive shifting technique will lower fuel costs be-
IMPORTANT: Fuel heaters used on vehicles with cause the engine will be operating at the lowest
rpm needed to pull the load.
Caterpillar electronic engines could cause exces-
sive fuel temperatures that affect engine perfor- Caterpillar electronic engines can be programmed
mance and operation of the electronic engine con- to limit engine rpm while the truck is operated in the
trols. If a fuel heater is used, make sure it has lower and higher gears. This feature assists the
thermostatic controls. If the fuel heater has a driver in following progressive shifting techniques.
timer, set the timer to activate only for a limited 4. On uphill grades, begin downshifting when the en-
period of time before the engine starts. Make sure gine rpm falls to 1200 rpm. Fuel economy will be
the fuel heater is used only for starting the engine. best if you let the engine lug back to around this
speed before you downshift. Downshift until a gear
2. Select a gear that allows a smooth, easy start with- is reached in which the engine will pull the load. Let
out increasing engine speed above low idle or slip- the engine lug down if you can make it to the top of
ping the clutch. Engage the clutch smoothly. Jerky a hill without downshifting.
starts waste fuel and put stress on the drivetrain.

7.10
Engines and Clutches
IMPORTANT: Do not allow Caterpillar electronic "wound up" to deliver the required horsepower at
engines to exceed 2300 rpm (2100 rpm if the wheels. These characteristics may also result in
equipped with an exhaust brake). less shifting and make shifting at lower rpm (to
peak torque) more practical.
5. On a downhill grade, do not coast or put the trans-
mission in neutral. Select the correct gear that does 2. Depending on the vehicle gearing, the posted
not allow the engine to exceed its maximum speed. speed limit can sometimes allow operation in either
Use the brakes to limit the truck speed. of the top two gears; however, for improved operat-
ing efficiency (fuel economy and engine life), oper-
A simple rule to follow is to select the same gear ate in the top gear at reduced rpm rather than in
(or one gear lower) that would be needed to go up the next lower gear at the maximum rpm.
the grade.
3. Cruise at partial throttle whenever road conditions
6. As with any engine, prolonged idling of Caterpillar and speed requirements permit. This driving tech-
engines is not recommended. An idling engine nique permits operating within the most economical
wastes fuel and, if left unattended, is also unsafe. power range of the engine.
Caterpillar engines can be programmed to shut off 4. When approaching a hill, open the throttle smoothly
automatically after a specified idling time. The ve- to start the upgrade at full power, then shift down
hicle transmission must be in neutral and the park- as desired to maintain the optimum vehicle speed.
ing brake must be set for the automatic shutoff op- The high torque of Cummins engines may permit
tion to work. topping some grades without shifting.

Cummins 5. Cummins engines are designed to operate over a

wide speed range. More frequent shifting than nec-
Follow the directions in the Cummins Operation and essary does not allow proper utilization of this flex-
Maintenance Manual and in this manual for trouble-free, ibility. The driver who stays in top gear and uses
economical vehicle engine operation. the wider speed range will achieve the best fuel
economy.
1. Cummins diesel engines produce high horsepower
and peak torque characteristics at low rpm. Be- 6. The Cummins diesel engine is effective as a brake
cause of this, it is not necessary to keep the engine on downhill grades, but care must be used not to

7.11
 Engines and Clutches
overspeed the engine going downhill. The governor versely affect the operation and durability of the
has no control over engine speed when the engine charge air cooler.
is being pushed by the loaded vehicle.
Never turn off the ignition switch while going down- Mercedes-Benz
hill. With the engine still in gear, fuel pressure will
build up against the shutdown valve and may pre- Special precautions must be taken during cold weather.
vent it from opening when the ignition key is turned For service products to use in cold weather, see Chap-
on. ter 5 of the MBE900 Engine Operator’s Manual.
IMPORTANT: At outside air temperatures below
CAUTION –4°F (–20°C), a coolant preheater is recom-
mended.
Do not allow the engine to exceed its governed
speed, or serious engine damage could result. 1. Check for cracks in the battery cases, for corrosion
of the terminals, and for tightness of the cable
7. Use a combination of brakes and gears to keep the clamps at the terminals. Run a load test to deter-
vehicle under control at all times and to keep the mine full or partial charging. Charge the batteries to
engine speed below the rated governed rpm. full capacity. Replace any battery that is unable to
hold full charge or is physically damaged.
Cold Weather Operation 2. Check the alternator output. Check the condition
and tension of the poly-V belt.
IMPORTANT: If a winterfront is used on a vehicle
with an electronic engine equipped with a charge 3. Periodically check the coolant mixing ratio (concen-
air cooler, make sure that there are slit openings tration of antifreeze in the coolant). Add more if
distributed across the face of the winterfront to necessary. The coolant mixing ratio should never
allow airflow through the entire charge-air-cooler rise above 55 percent antifreeze.
core. Do not use a winterfront with closed areas 4. Use low-viscosity lubricating oils for adequate lubri-
that block uniform air flow across all sections of cation.
the charge-air-cooler crossflow tubes. This will ad-

7.12
Engines and Clutches
5. At temperatures below 32°F (0°C), do not use For cold weather operation, use the following guide-
summer-grade (2-D) diesel fuel. To avoid fuel prob- lines:
lems due to paraffin separation, use winter-grade
(1-D or winterized 2-D) diesel fuel only. 1. When starting the engine in temperatures below
32°F (0°C), use engine lubricants of lower viscosity.
See the engine operation and maintenance manual
WARNING for specifications.

The addition of kerosene lowers the flash point of 2. When operating in temperatures below 32°F (0°C),
diesel fuel. To prevent fire and risk of injuries due use sufficient antifreeze solution in the cooling sys-
to burning, do not smoke or use open flames tem to prevent freezing.
around fuel mixed with kerosene. Comply with all 3. During cold weather, give more attention to the con-
appropriate safety regulations. dition of the batteries. Test them frequently to en-
6. When winter-grade diesel fuel is not adequate, it is sure sufficient power for starting. Inspect all
possible to mix kerosene with the diesel fuel. Add switches and connections in the electrical system
the kerosene only when refilling the tank, and be- and keep them in good condition to prevent losses
fore adding the diesel fuel. through poor contacts. See Group 15 of the Ac-
terra® Workshop Manual for detailed information.
NOTE: Engine power may drop according to the
4. If so equipped, turn off the battery disconnect
proportion of kerosene. For this reason, never add
switch after the engine is stopped to prevent battery
more than 50 percent kerosene to the fuel. discharge while the starter motor is cooling.
Caterpillar For starting below 0°F (–18°C), an optional cold
weather starting assist is recommended. For tem-
If the engine is in good mechanical condition and the peratures below –10°F (–23°C), consult your Cater-
precautions necessary for cold weather operation are pillar dealer for recommendations.
taken, ordinary cold weather will not cause difficulty in
starting or loss of efficiency.
If the engine does not start, prime the fuel system.

7.13
 Engines and Clutches
and maintenance procedures. The lower the tempera-
WARNING tures the greater the amount of modification required,
and yet with the modifications applied, the engines must
Do not use any starting aid, such as ether, in en- still be capable of operation in warmer climates without
gines with a cold start manifold heater. This could extensive changes.
cause an explosion and serious personal injury or
death. The following information is provided to engine owners,
operators, and maintenance personnel on how the
5. Customer parameters may include cold mode op- modifications can be applied to get satisfactory perfor-
eration. When the coolant temperature is below mance from their diesel engines.
64°F (18°C), the system puts the engine in cold
There are three basic objectives:
mode, limiting engine power, advancing timing, and
adjusting the low idle to 600 rpm to improve 1. Reasonable starting characteristics followed by
warm-up time. The system will keep the engine in practical and dependable warm up of the engine
cold mode until coolant temperature rises above and equipment.
64°F (18°C) or until the engine has been running
for 12 minutes. The system will then stop the cold 2. A unit or installation which is as independent as
mode and allow the engine to operate normally. possible from external influences.

6. Fuel cloud point is the temperature at which wax 3. Modifications which maintain satisfactory operating
crystals become visible, which is generally above temperatures with a minimum increase in mainte-
the pour point of the fuel. To keep the fuel filter ele- nance of the equipment and accessories.
ments from plugging with wax crystals, the cloud If satisfactory engine temperature is not maintained,
point should be no higher than the lowest ambient higher maintenance cost will result due to increased
temperature at which the engine must start. engine wear.
Special provisions to overcome low temperatures are
Cummins definitely necessary, whereas a change to a warmer
Satisfactory performance of a diesel engine operating in climate normally requires only a minimum of revision.
low ambient temperatures requires modification of the Most of the accessories should be designed in such a
engine, surrounding equipment, operating practices,

7.14
Engines and Clutches
way that they can be disconnected so there is little ef- temperatures to –64°F (–53°C). Contact the near-
fect on the engine when they are not in use. est Freightliner dealer or Cummins engine dealer,
to obtain the special items required.
The two most commonly used terms associated with
preparation of equipment for low-temperature operation
are "winterization" and "arctic specifications." CAUTION
Winterization of the engine and/or components so that
"Antileak" antifreezes are not recommended for use
starting and operating are possible in the lowest tem-
in Cummins engines. Although these antifreezes are
perature to be encountered requires:
chemically compatible with DCA water treatment,
• Proper lubrication with low-temperature lubricat- the "antileak" agents may clog the coolant filters.
ing oils.
IMPORTANT: Fuel heaters used on vehicles with
• Protection from the low-temperature air. The Cummins CELECT engine systems could cause
metal temperature does not change, but the rate high fuel temperatures that affect engine perfor-
of heat dissipation is affected. mance and operation of the electronic engine con-
• Fuel of the proper grade for the lowest tempera- trols. If a fuel heater is used, make sure it has
ture. thermostatic controls. If the fuel heater has a
timer, set the timer to activate only for a limited
• Heat to raise the engine block and component
temperatures to at least –25°F (–32°C) for start-
period of time before the engine starts. Make sure
ing in lower temperatures. the fuel heater is used only for starting the engine.
• Electrical equipment capable of operating in the
lowest expected temperature. All switches, con-
Engine Shutdown
nections, and batteries in the electrical system Mercedes-Benz
should be inspected and kept in good condition to
prevent losses through poor contacts. If any the following occur, shut down the engine imme-
Arctic specifications refer to the design of mate- diately.
rial and specifications of components necessary
for satisfactory engine operation in extremely low

7.15
 Engines and Clutches
• The oil pressure swings back and forth or falls IMPORTANT: Bearings and seals in the turbo-
sharply. charger are subjected to the high heat of combus-
• Engine power and rpm fall, even though the ac- tion exhaust gases. While the engine is running,
celerator pedal remains steady. this heat is carried away by oil circulation, but if
the engine is stopped suddenly the turbocharger
• The exhaust pipe gives off heavy smoke. temperature may rise as much as 115°F (46°C).
• The coolant and/or oil temperature climb abnor-
mally. CAUTION
• Abnormal sounds suddenly occur in the engine or
turbocharger. Except in emergency, do not shut down the MBE900
engine when the coolant temperature is above
1. With the vehicle stopped, apply the parking brakes 194°F (90°C). To do so could damage the engine.
and put the transmission in neutral.
3. Turn off the ignition switch and shut down the
engine.
CAUTION
Idle the engine one to two minutes before shutting
Caterpillar
it down, if this can be done without damage to the
engine. After hard operation, shutting down the en- CAUTION
gine without idling may cause damage to the turbo-
charger. Stopping the engine immediately after it has been
working under load can result in overheating and
2. Allow the engine to idle one to two minutes before
accelerated wear of the engine components. Exces-
shutting it down. This allows the lubricating oil and
sive temperatures in the turbocharger centerhous-
the coolant to carry heat away from the combustion
ing will cause oil coking problems. Follow the pro-
chambers, bearings, shafts, and seals. The extreme
cedure, outlined below, to allow the engine to cool.
heat may cause bearings to seize or oil seals to
leak. 1. With the vehicle stopped, apply the parking brakes.

7.16
Engines and Clutches
2. Reduce the engine speed to low idle. freezing to the lowest expected outside tempera-
ture. Add permanent-type antifreeze if required.
3. Place the transmission shift lever in neutral.
9. Repair any leaks, perform minor adjustments,
NOTE: If the engine has been operating at low tighten loose bolts, etc. Observe the vehicle mile-
loads, run it at low idle for 30 seconds before age or the service meter reading, if so equipped.
stopping. If the engine has been operating at high- Perform periodic maintenance as instructed in the
way speed or at high loads, run it at low idle for Lubrication and Maintenance Chart in the Caterpil-
three minutes to reduce and stabilize internal en- lar Operation and Maintenance Management.
gine temperatures before stopping.
4. Turn off the ignition key to shut down the engine.
Cummins
5. If equipped with an idle shutdown timer, it can be 1. With the vehicle stopped, apply the parking brakes
set to shut the engine down after a preset amount and put the transmission in neutral.
of time. Ninety seconds before the preset shutdown 2. It is important to idle an engine three to five min-
time, the CHECK ENGINE indicator will begin to utes before shutting it down. This allows the lubri-
flash at a rapid rate. If the position of the clutch cating oil and the water to carry heat away from the
pedal or service brake changes during this final combustion chambers, bearings, shafts, etc. This is
ninety seconds (diagnostic lamp flashing) the idle especially important with turbocharged engines.
shutdown timer will be disabled until reset.
Bearings and seals in the turbocharger are sub-
6. After stopping the engine, fill the fuel tank. jected to the high heat of combustion exhaust
gases. While the engine is running this heat is car-
7. Check the crankcase oil level while the engine is
ried away by oil circulation, but if the engine is
stopped. Maintain the oil level between the ADD
stopped suddenly, the turbocharger temperature
and FULL marks on the dipstick.
may rise as much 115°F (46°C). The extreme heat
8. If temperatures below 32°F (0°C) are expected, al- may cause bearings to seize or oil seals to leak.
low the engine water jacket expansion tank to cool,
3. Do not idle the engine for excessively long periods.
then check the coolant for proper antifreeze protec-
Long periods of idling are not good for an engine
tion. The cooling system must be protected against
because the combustion chamber temperatures

7.17
 Engines and Clutches
drop so low the fuel may not burn completely. This rated for higher altitudes than naturally aspirated en-
will cause carbon to clog the injector spray holes gines.
and piston rings and may result in stuck valves.
An engine will have smoky exhaust at high altitudes
If the engine coolant temperature becomes too low, unless a lower gear is used. The engine will not de-
raw fuel will wash the lubricating oil off the cylinder mand full fuel from the fuel system unless the engine is
walls and dilute the crankcase oil causing all mov- altitude-compensated by the use of a turbocharger. Shift
ing parts of the engine to suffer from poor lubrica- gears as needed to avoid excessive exhaust smoke.
tion.
4. If the engine is not being used, shut it down by Exhaust Braking System,
turning the ignition switch off.
Optional
CAUTION General Information
Stop the engine at the first sign of malfunction. Al- An exhaust brake is an optional auxiliary braking sys-
most all malfunctions give some warning to the op- tem that assists but does not replace the service brake
erator before significant damage occurs. Many en- system. The exhaust brake switch, located on the con-
gines are saved because alert operators heed the trol panel, in combination with the accelerator and
warning signs (sudden drop in oil pressure, un- clutch pedals, allows the driver to make maximum use
usual noises, etc.) and immediately shut down the of the exhaust brake in off-highway and mountain driv-
engine. ing as well as in traffic or high speed highway driving.
The exhaust brake is a butterfly type valve mounted in
High Altitude Operation the exhaust pipe. When the driver’s foot is not on the
accelerator pedal and the exhaust brake switch is in the
Engines lose horsepower when operated at high alti- on position, an air cylinder shuts the butterfly valve
tude because the air is too thin to burn as much fuel as which restricts the flow of exhaust gases and retards
at sea level. This loss is about three percent for each the engine. This retarding action is carried through the
1000 feet (300 m) altitude above sea level for a natu- engine and drivetrain, slowing the vehicle and reducing
rally aspirated engine. Most turbocharged engines are the need for frequent service brake applications.

7.18
Engines and Clutches
Exhaust brakes are not intended for use as the primary Exhaust Brake Operating Characteristics
braking system during vehicle operation.
When you remove your feet from both the accelerator
Starting the Engine and clutch pedals and the exhaust brake switch is in
the on position, the exhaust brake is applied. The fol-
Before starting the engine, make sure that the exhaust lowing conditions should exist if the brake is operating
brake switch is in the off position. Do not turn the ex- properly:
haust brake on until the engine has reached normal op-
erating temperatures. • A slight change in the sound of the engine may
be noticed when the exhaust brake is applied.
Driving Downhill • Exhaust smoke should appear normal.
While approaching a steep grade, make sure that the • Engine temperature should remain in the normal
exhaust brake switch is in the on position. The exhaust operating range.
brake comes on as soon as you remove your foot from
the accelerator pedal. While going down the grade, use • Road speed usually decreases when the exhaust
a low enough gear to safely descend with a minimum brake is applied during a descent. When the ve-
application of the service brakes. As a general guide- hicle is carrying a heavy load or the grade is ex-
line, use the same gear as you would to ascend the hill. tremely steep, you may need to apply the service
brakes occasionally.
WARNING • Do not expect a retarding effect similar to sudden
hard application of the service brakes. The ex-
Do not use the exhaust brake when driving on slip- haust brake retards the vehicle with a smooth
pery or low traction road surfaces. Failure to follow braking effect.
this precaution could result in a loss of vehicle con-
• During a descent, the tachometer usually shows
trol and possible personal injury or property dam-
a drop in rpm depending on the grade and the
age.
vehicle load.
• Depending on the grade and vehicle load, you
may or may not feel the retarding force acting

7.19
 Engines and Clutches
against your body when the brake is applied. The On some applications, when the Pacbrake is in use, it
retarding force of the brake may not always be may be necessary to check that the cruise control is not
noticed, but it is actually preventing the vehicle set and that the throttle is in the idle position.
from going much faster.
On some applications the engine, transmission, cruise
Shutting Off the Engine control, and the Pacbrake exhaust brake may electroni-
cally interact with each other, which automatically oper-
Make sure the exhaust brake is turned off before shut- ates their functions. Following are some examples of
ting off the engine. the programmed options that may be available with the
cruise control in the on position:
Pacbrake® Exhaust Brake • The coast mode engages the Pacbrake when the
The Pacbrake exhaust brake is intended as a supple- service brake is applied and disengages when
ment to the service brakes and will not bring the vehicle the service brake is released.
to a complete stop. The Pacbrake will assist in the con- • The latch mode engages the Pacbrake when the
trol or reduction of road speed in conjunction with, or service brake is applied and the Pacbrake re-
independent of, the service brakes. The amount of re- mains on after the service brake is released. The
tarding or braking force is controlled by the driver. Pacbrake is disengaged when another input (de-
pressing the throttle or clutch, engine speed
Pacbrake Operation drops below 800 rpm, or the exhaust brake
The Pacbrake is controlled by the exhaust brake switch switch is turned off) is supplied.
and the throttle pedal. All applications are additionally • The manual mode does not require the cruise
affected, controlled, or governed by engine speed control switch to be on and operates the
through transmission gear selection. The Allison Pacbrake manually at the driver’s discretion.
MD3060 transmission has automatic downshifting when
the exhaust brake is requested. See the information on The amount of braking power the engine will develop is
the "Allison World Transmission" later in this chapter. related to the speed (rpm) of the engine. The higher the
engine rpm, the greater the retarding power.

7.20
Engines and Clutches
Certain conditions may require that the transmission be
downshifted in order to generate adequate rpm for the A
A
amount of retarding power required. Pacbrake exhaust
brakes are designed and approved for safe use at 300 A
rpm above the engine’s maximum governed rpm. Refer
to individual engine manufacturer’s specifications.
The Pacbrake will function best if it is used all of the
time. However, if the vehicle is used inconsistently or
seasonally, it may be necessary to perform a preventive
maintenance procedure.
1. With the engine shut down, use any oil-free or non-
petroleum based high-heat lubricant and spray or
coat a sufficient amount on the restricter valve shaft
and the attaching locations at each end of the ac- 03/06/2000 f490228
tuation cylinder. See Fig. 7.2. A. Lubrication Point
2. With your hands or a pair of pliers, motion the valve Fig. 7.2, Pacbrake Exhaust Brake and Air Cylinder
several times to distribute the lubricant down the
shaft and the attaching locations. ommended that normal operating temperatures be
attained before shutting down the engine.
NOTE: Starting the engine and idling for short pe-
riods of time is not recommended. During a cold Allison World Transmission
engine start-up, enough moisture is developed
within the engine and the exhaust system to cre- Pacbrake exhaust brakes on engines that are used with
ate a corrosion hazard that could affect the future the Allison World Transmission MD series, are inter-
operation of the Pacbrake. The brake housing may faced with the transmission electronic control module
(ECM). An exhaust brake enabled transmission ECM
trap water in the valve shaft bore causing corro-
will usually provide converter lockup in gears two
sion in an improper or nonfunctioning brake. If it is through six. Effective exhaust braking begins when the
necessary to periodically start the engine, it is rec-

7.21
 Engines and Clutches
transmission automatically downshifts into fifth gear (62 switch is used to apply the exhaust and/or engine
mph or less). Once on, the Pacbrake exhaust brake will brakes. When the top of the engine brake switch is
control road speed and/or slow the vehicle sufficiently pressed, both the engine brake and exhaust brakes are
that the transmission will automatically downshift, if nec- applied. Using the engine brake and exhaust brake pro-
essary, to Allison’s preselect mode. vides the best braking performance. With the switch in
the center position, only the exhaust brake is applied.
The preselect mode is normally assigned to second When the bottom of the switch is pressed, the switch is
gear; however, the transmission can be reprogrammed off.
by an Allison Transmission Distributor to third or fourth
gear should the operator desire. If additional retarding
power is required before the automatic downshifting oc- Clutches
curs, you can select a lower transmission gear on the
Allison shift selector. General Information
The major reason clutches wear out too soon is exces-
Engine Braking System, sive heat. Clutches are designed to absorb and dissi-
pate more heat than encountered in typical operation.
Optional The temperatures developed in typical operation will not
break down the clutch friction surfaces. However, if a
Mercedes-Benz Engine Brake/ clutch is slipped excessively or required to do the job of
Constant Throttle Valves a fluid coupling, high temperatures develop quickly and
destroy the clutch. Temperatures generated between
To increase braking performance, the MBE900 engine the flywheel, driven discs, and pressure plates can be
can be equipped with constant throttles in each com- high enough to cause the metal to flow and the friction
bustion chamber. Small valves built into the cylinder facing material to char and burn.
head allow a small amount of compressed air to escape
through the exhaust port during the combustion stroke.
The constant-throttle valves are open during the entire CAUTION
time that the engine brake is activated.
Do not allow sustained slippage of the clutch; this
When a vehicle is equipped with both an exhaust brake could severely damage the clutch disc, pressure
and an engine brake, a three-position engine brake

7.22
Engines and Clutches
plate, or flywheel. Damage caused by clutch slip-
page due to improper break-in is not warrantable. CAUTION
Slipping and excessive heat are practically nonexistent Never apply the clutch brake when making down-
when a clutch is fully engaged. But during the moment shifts or upshifts. The clutch pedal should never be
of engagement, when the clutch is picking up the load, fully depressed before the transmission is put in
it generates considerable heat. An incorrectly adjusted neutral. If the clutch brake is applied with the trans-
or slipping clutch will rapidly generate sufficient heat to mission still in gear, a reverse load will be put on
destroy itself. the gear. At the same time, it will have the effect of
The most important items that a driver should be aware trying to stop or decelerate the vehicle with the
of to ensure long service life of the clutch include: start- clutch brake. Rapid wear of the friction discs will
ing in the right gear, recognizing clutch malfunctions, take place necessitating frequent replacement. Con-
and knowing when to adjust a clutch. siderable heat will be generated, which will be detri-
mental to the release bearings and transmission
Clutch Operation front bearings.

Gear Shifting Techniques Vehicle Overload, or Overloading the Clutch

Many drivers upshift into the next gear or even skip- Clutches are designed for specific vehicle applications
shift into a higher gear before the vehicle has reached and loads. These limitations should not be exceeded.
the correct speed. This type of shifting is almost as bad
as starting off in a gear that is too high since the engine
rpm and vehicle speeds are too far apart, requiring the CAUTION
clutch to absorb the speed difference by generating
heat. For transmission operating instructions, see Overloading will not only result in damage to the
Chapter 8. clutch, but also to the entire power train.

Apply the clutch brake by fully depressing the clutch Riding the Clutch Pedal
pedal. The purpose of the clutch brake is to stop the
transmission gears from rotating in order to engage the Riding the clutch pedal is destructive to the clutch since
transmission gears quickly in making an initial start. partial clutch engagement permits slippage, generating

7.23
 Engines and Clutches
excessive heat. Riding the clutch pedal will also put a disc rpm could cause the clutch facing to be thrown
constant thrust load on the release bearing which can off the disc. Flying debris could cause injury to per-
thin out the lubricant. Release bearing failures can be sons in the cab.
attributed to this type of misuse.
Engaging the Clutch While Coasting
Holding the Vehicle on an Incline With a
Engaging the clutch while coasting can result in tremen-
Slipping Clutch dous shock loads and possible damage to the clutch as
A slipping clutch accumulates heat faster than it can be well as to the entire drivetrain.
dissipated, resulting in early clutch failures. Never use
the clutch as a hill holder. Reporting Erratic Clutch Operation Promptly
Reporting erratic clutch operation as soon as possible
Coasting With the Clutch Released (Pedal will give maintenance personnel a chance to inspect the
Depressed) and the Transmission in Gear clutch components.
Do not allow the vehicle to coast with the clutch re- On mechanical clutch linkages, free-pedal travel should
leased and the transmission in gear. If the transmission be included and commented on daily in the driver’s re-
remains in a low gear and the vehicle gains speed, port, since clutch free-pedal travel is the maintenance
which may occur on a downgrade, the input shaft and department’s guide to the condition of the clutch and
clutch driven disc will turn at speeds that are higher the release mechanism.
than normal. This occurs because the rear wheels and
the driveline become the input for the transmission, and
a higher-than-normal speed for a given transmission CAUTION
gear translates to a higher rpm value for the clutch
driven disc. Operating the vehicle with incorrect clutch pedal
free-travel could result in clutch damage. See Group
25 of the Acterra® Workshop Manual for free-pedal
WARNING adjustment procedures and specifications.
Do not coast with the clutch released (pedal de-
pressed) and the transmission in gear. High driven

7.24
Engines and Clutches
Clutch Adjustments
Some clutches have an internal adjustment. See the
applicable section in Group 25 of the Acterra® Work-
shop Manual for clutch adjustment procedures and
specifications.

CAUTION
Operating the vehicle with the clutch incorrectly ad-
justed could result in clutch or clutch brake failure.

Lubrication
The release bearing should be lubricated at frequent
intervals. See Group 25 of the Acterra® Maintenance
Manual for intervals and procedures.

CAUTION
Failure to lubricate the release bearing as recom-
mended could result in release bearing damage and
damage to the clutch.

7.25
 8
Transmissions
Freightliner SmartShift Shift Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.1
Eaton Fuller AutoShift Automated Transmissions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.3
Eaton Fuller UltraShift™ . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.8
Eaton Fuller Straight-Shift Transmissions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.17
Eaton Fuller Range-Shift Transmissions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.19
Eaton Fuller Deep-Reduction Transmissions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.23
Mercedes-Benz Manual Transmissions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.26
TTC Manual Transmissions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.27
Allison On-Highway Transmissions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.28
Allison MD Series Transmissions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.33
Allison AT/MT Series Transmissions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.37
Mercedes-Benz Automated Transmissions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.41
Transmissions
Freightliner SmartShift Shift out. The slide switch allows the driver to choose auto-
matic (AUTO) or manual (MAN) mode.
Control In AUTO mode, gears shift automatically, without driver
The SmartShift transmission control is an electronic interaction. Manual gear shifts are accomplished by a
transmission control device. It is installed with the fol- momentary pull or push on the control in the plane per-
lowing transmissions: pendicular to the steering wheel. Pull upward (toward
you) on the control to upshift and push downward
• Eaton® Fuller® AutoShift™ (away from you) to downshift. The control is spring-
• Eaton Fuller UltraShift™ loaded and returns to mid-position when released after
an upshift or downshift.
• Mercedes-Benz Automated Gear Shift (AGS)
For the Eaton Fuller automated transmissions
It replaces either the typical floor-mounted shift lever or (Fig. 8.1), a four-position (R, N, D, L) selector switch is
dash-mounted push button control. located at the end of the lever. For the Mercedes-Benz
AGS (Fig. 8.2), a three-position (R, N, D) selector
SmartShift accepts driver requests for transmission
switch is located at the end of the lever.
functions and transmits them through hard wiring to the
transmission control unit (TCU). SmartShift is a true Embedded in the selector switch is a small neutral lock
shift-by-wire system. button to prevent accidental shifts into gear from neu-
tral. Any time you shift through N, press down on the
SmartShift offers two main advantages over conven-
neutral lock button to move the switch from neutral (N)
tional transmission control devices. Without a floor-
to another gear, such as drive (D), low (L), or reverse
mounted shift control, usable cab space is increased.
(R). When shifting to N, it is not necessary to press the
The SmartShift control mounts to the right-hand side of
neutral lock button.
the steering column and is operated by the fingers of
the driver’s right hand, allowing both hands to remain
on the steering wheel.
A two-position slide switch (Fig. 8.1) is mounted on the
body of the control lever just before the paddle widens

8.1
 Transmissions
5 6 5 6
7
7
4 8 4
3 3 8

9 9
1 1
2 2
10 10
11
12 11
01/24/2003 f270120 11/11/2002 f270080
To upshift manually, pull the lever up (towards you). To To upshift manually, pull the lever up (towards you). To
downshift manually, push the lever down (away from downshift manually, push the lever down (away from
you). you).
1. SmartShift Control Lever 1. SmartShift Control Lever
2. Slide Switch (forward driving mode switch) 2. Slide Switch
3. MAN Mode (of slide switch) 3. MAN Position (of slide switch)
4. AUTO Mode (of slide switch) 4. AUTO Position (of slide switch)
5. Upshift Direction 5. Upshift Direction
6. Reverse Position (of selector switch) 6. Reverse Position (of selector switch)
7. Selector Switch 7. Selector Switch
8. Neutral Lock Button 8. Neutral Lock Button
9. Neutral Position (of selector switch) 9. Neutral Position (of selector switch)
10. Drive Position (of selector switch) 10. Drive Position (of selector switch)
11. Low Position (of selector switch) 11. Downshift Direction
12. Downshift Direction
Fig. 8.2, SmartShift Control (with Mercedes-Benz AGS)
Fig. 8.1, SmartShift Control (with Eaton Fuller AutoShift
and UltraShift)

8.2
Transmissions
Eaton Fuller AutoShift
Automated Transmissions 1
A
Refer to the Eaton website for additional information,
www.roadranger.com. A connection to the Internet is 2
required.
IMPORTANT: Before starting the vehicle, always
do the following:
• Be seated in the driver’s seat. B
3
• Place the transmission in neutral.
• Set the parking brakes.
11/23/99 f270114
• Press the clutch pedal down to the floor.
A. Pull the shift control in this direction to upshift.
B. Push the shift control in this direction to downshift.
General Information, AutoShift
1. Steering Wheel 3. Steering Column
The AutoShift ASX is a partially automated 6-speed or 2. Shift Control
7-speed Eaton Fuller transmission. The AutoShift AS2 is
a partially automated 10-speed Eaton Fuller transmis- Fig. 8.3, SmartShift Control Operation
sion. On all models, the driver must use the clutch and increases or decreases engine speed. When engine
put the transmission in neutral to start and stop the ve- speed is correct, the transmission engages the next
hicle. The SmartShift transmission shift control gear and signals the engine controller to resume opera-
(Fig. 8.3) is used with the AutoShift transmission. tion.
The driver does not need to break torque or increase or The AutoShift transmission can be operated in an auto-
decrease engine speed to synchronize the shift. The matic (AUTO) mode or a manual (MAN) mode. Select
transmission signals the engine controller when to
break torque and the engine controller automatically

8.3
 Transmissions
the mode you want to use by moving the slide switch Operation, SmartShift With Eaton
on the shift control.
Fuller AutoShift
Gear information is presented to the driver on a gear
display module mounted on the dashboard (Fig. 8.4). In
automatic mode, the number of the forward gear cur- WARNING
rently selected appears continually on the display when
in drive. If the engine cranks in any gear other than neutral,
have the vehicle serviced immediately. If the vehicle
The display also flashes the next gear to be engaged is started in gear it will suddenly move forward or
while the transmission is in neutral during a gear backward, which could result in personal injury and
change. In manual mode, the current gear is displayed damage to property and the transmission.
until a new gear is requested. When neutral is selected,
N will appear on the display. Automatic and Manual Modes
If the gear display continues to flash after releasing the A two-position slide switch (forward driving mode
clutch pedal, gear engagement is not complete. Press switch) is located near the end of the control. See
down the clutch again and wait for the gears to fully en- Fig. 8.1. The switch positions are labelled MAN (manual
gage. shift mode) and AUTO (automatic drive mode).
When reverse (R) is engaged on 10-speed AutoShift NOTE: In automatic drive mode, upshifts and
transmissions, either "RL" or "RH" will appear on the downshifts require no driver interaction. Move the
message display screen. AutoShift transmissions with selector switch to the drive (D) position, disengage
fewer speeds do not have a dual range reverse gear. the clutch to engage the gear selected, engage
"R" will appear when reverse is engaged.
the clutch and drive the vehicle. In manual shift
IMPORTANT: The information shown on the digital mode, upshifts and downshifts require either a pull
display indicates the state of the transmission only, upward or push downward on the control.
not the state of the SmartShift control.
Start-Up
1. With the parking brake applied, press the clutch all
the way down to the floor.

8.4
Transmissions
2. Check to make sure the transmission is in neutral.
IMPORTANT: To start the engine, the transmission
must be in neutral.
3. Start the engine.
4. With the transmission in neutral, release the clutch
1 A pedal.
NOTE: This allows the speed sensor on the input
2 shaft to get a reading.
SOLID
5. Press down on the clutch again and release the
3 parking brake.
SOLID 6. Select the desired starting gear.

4 7. Release the clutch.

FLASHING
IMPORTANT: If you have to leave the cab with the
engine running:
5
SOLID • Place the transmission in neutral.
02/17/98 B f270062
• Set the parking brakes.
A. Gear Display Module B. Module Detail
1. Current Gear • Chock the tires.
2. 9th Gear Engaged
3. In 9th Gear, Preselected Toward 10th Reverse
4. Out Of Gear, Waiting For Engine/Transmission rpm 1. To engage reverse (R), slide the selector switch
To Synchronize upward to the next position above the neutral posi-
5. 10th Gear Engaged
tion and disengage the clutch.
Fig. 8.4, Gear Display Module

8.5
 Transmissions
NOTE: AutoShift 10-speed transmissions have a Selecting a Starting Gear
dual-range reverse. Reverse low (RL) is the de-
1. In automatic mode, select drive (D) by sliding the
fault reverse gear. selector switch downward to the next position below
2. Select reverse high (RH) by pulling upward on the the neutral position.
control. 2. Disengage the clutch to engage the gear selected.
NOTE: Reverse may be engaged below a pro- Engage the clutch and drive the vehicle.
grammable forward speed in order to rock the ve- NOTE: To select a starting gear other than the de-
hicle. If reverse is selected above the programmed fault starting gear, either pull upward or push
forward speed, an audible warning will sound and downward on the control while the vehicle is
a message indicating that the gear is not available stopped and in drive (either manual or automatic
will appear on the message display screen. mode).
Neutral Each pull upward on the control increases the
starting gear by one gear, but no higher than 4th
Neutral (N) is used for starting, parking, or any station-
ary operation. No gear is selected. The transmission gear. The number of the gear selected will flash
must be in neutral before the engine can be started. on the message display screen until the driver en-
gages the clutch.
Select neutral by moving the mode selector switch to N
while depressing the clutch pedal. Verify that the letter This gear will be stored in memory as the default
N appears on the auxiliary display. Set the parking starting gear until either a different starting gear is
brakes and slowly release the clutch pedal. selected by the driver or the engine is shut down.
NOTE: Neutral is always available during vehicle The transmission may also be programmed so
operation. When in neutral, upshift and downshift that it is not possible to select a starting gear other
requests are ignored. If the mode selector switch than the preprogrammed default starting gear.
is moved from N to D (drive) while the vehicle is
moving, the transmission will select an appropriate
gear for the road speed.

8.6
Transmissions
Upshifting An unavailable requested upshift is not stored in
memory. The upshift must be requested again.
In drive (D), the transmission selects the starting gear
and automatically selects gears between the starting Downshifting
gear and the top gear.
1. To select drive, move the selector switch to D while NOTE: With the transmission in drive (D) in the
depressing the clutch pedal. Slowly release the automatic mode, downshifts require no driver inter-
clutch pedal and drive the vehicle. action.
NOTE: With the transmission in drive (D) in the 1. With the transmission in drive in the manual mode,
automatic mode, upshifts require no driver interac- request a downshift by pushing downward on the
control. If the requested gear is available, the trans-
tion.
mission will downshift.
2. With the transmission in drive in the manual mode,
request an upshift by pulling upward on the control. NOTE: A single, momentary push downward on
See Fig. 8.3. If the requested gear is available, the the control selects the next lower gear when it is
transmission will upshift. available. Two consecutive, momentary downward
pushes will cause a skip shift, when the next two
NOTE: A single, momentary pull upward on the lower gears are available and conditions are right.
control selects the next higher gear when it is
available. Two consecutive, momentary upward 2. To skip shift, move the control two times in less
pulls will cause a skip shift when the next two than 1/2 second. The number of the gear engaged
will appear on the message display screen.
higher gears are available and conditions are right.
3. To skip shift, move the control two times in less NOTE: If a requested gear is not available, an au-
than 1/2 second. The number of the gear engaged dible warning will sound and the message display
will appear on the message display screen. screen will indicate that the requested gear is not
available. Unlike upshifting, an unavailable re-
NOTE: If a requested gear is not available, an au- quested downshift is stored in memory and the
dible warning will sound and the message display shift will be made when the gear is available. The
screen will indicate that the gear is not available.

8.7
 Transmissions
time limit for this memory is a programmable pa- The UltraShift transmission uses the four-position
rameter. SmartShift control lever on the steering column to select
gears. To know what gear the transmission is in, look at
Low Gear Operation the round current gear indicator on the right-hand con-
trol panel as shown in Fig. 8.5. All forward shifts can be
Use low (L) when descending steep hills and using made either manually or automatically, at the driver’s
compression braking. Engine speed will be increased choice.
by 200 rpm and shift points will be offset by 200 rpm.
The efficiency of the exhaust brake will be maximized. Operation, UltraShift ASW
Select low by moving the mode switch selector while Power Up
depressing the clutch pedal if the vehicle is stopped. If
L is selected while the vehicle is moving, the transmis- 1. With the parking brake set, select neutral (N) by
sion downshifts at the earliest opportunity for maximum moving the selector switch to the N position.
engine braking.
2. With the transmission in neutral, turn on the ignition
Using the Clutch switch. The "CHECK TRANS" and "TRANS TEMP"
telltale lights come on and go out again (bulb
Use the clutch to start and stop the vehicle. Be sure to check). See Fig. 8.6.
put the transmission in neutral and apply the parking
brake before shutting down the engine. 3. After the ignition is turned on, the current gear indi-
cator shows the dot display, arranged in a square
pattern. All dots in the pattern should light up, with-
Eaton Fuller UltraShift™ out gaps or spaces. See Fig. 8.7.
General Information, UltraShift ASW 4. Wait for the current gear indicator to show a solid
"N." When the "N" is solid, rather than flashing, the
UltraShift ASW is a fully-automated six-speed medium- UltraShift ASW transmission control unit (TCU) is
duty transmission. No clutch pedal is required to oper- powered up. Start the engine and apply the service
ate the vehicle. This transmission uses a "wet" clutch brake.
system in which the drive and driven discs rotate in a
bath of automatic transmission fluid (Dexron III).

8.8
Transmissions
1 1 2

CHECK
TRANS
2
TRANS
TEMP

BRAKE

10/27/2003 f610677
1. "CHECK TRANS" Light
2. "TRANS TEMP" Light

12/22/2003 f270079a
Fig. 8.6, Telltale Lights

To know what gear the transmission is in, look at the brake. The gear is displayed on the current gear
current gear indicator. indicator.
1. Current Gear Indicator
2. SmartShift Control NOTE: When D is selected, the transmission
starts up in default starting gear, either first or sec-
Fig. 8.5, Shift Controls and Indicators, UltraShift ond.
Transmissions
6. On a level grade, release the service brake and
5. Select drive (D) by pressing in the neutral lock but- press down on the throttle pedal to allow the ve-
ton and moving the selector switch downward to hicle to move forward.
the position below neutral. Release the parking

8.9
 Transmissions
7.1 To start from a full stop on 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 engine
power to prevent rollback.
7.2 To stop on a hill or grade, press and hold
the brake pedal to keep the vehicle from
moving.
On steep hills, set the parking brake and
chock the tires, front and/or rear. Never hold
a hill with the throttle pedal. This will cause
the clutch to overheat.
10/13/2003 f610678
Power Down
Fig. 8.7, Power Up Dot Display
1. Apply the service brakes.

WARNING 2. Select neutral (N) by moving the selector switch to

N. When the "N" on the current gear indicator is
When starting or stopping on hills and grades, use solid, rather than flashing, the ASW TCU is ready to
extra care to prevent the vehicle from rolling back. power down.
A rollback accident could cause death, serious per- 3. With the transmission in neutral, set the parking
sonal injury, or property damage. brake.
7. Prevent the vehicle from rolling backwards when 4. Turn off the ignition key and shut down the engine.
stopped on a hill or grade, or when the vehicle is
starting from a stop on a hill or grade.

8.10
Transmissions
Automatic and Manual Modes To change mode at any time, move the slide switch in
the desired direction. This allows the driver to respond
The SmartShift control has a slide switch located on the flexibly to a wide range of driving conditions, such as
body of the control lever just before the paddle widens blind corners, tight curves, and steep hills.
out. See Fig. 8.8. The slide switch controls the forward
driving mode, automatic or manual. IMPORTANT: Whatever the mode, it is always
possible to shift manually by moving the lever up
or down as needed. When the engine speed is
within 75 revolutions per minute (rpm) of the load-
based shift point for an automatic shift, the ASW
TCU will advance the shift.
In either mode, the gear indicator displays the current
gear. See Fig. 8.9.
At the start of a shift, the current gear continues to dis-
1 2
play until the transmission has been pulled into neutral.
At this point, as the transmission is synchronizing for
3
the new (target) gear, the gear indicator flashes the
number of the new gear.
When the shift is complete, the new gear displays solid,
without flashing.

Automatic Mode (AUTO)

01/21/2004 f270079c
In automatic drive mode (AUTO), upshifts and down-
1. Slide Switch (controls forward driving mode)
shifts are made by the transmission without driver inter-
2. Selector Switch (controls gear selection)
vention. Press in the neutral lock button, move the se-
3. Neutral Lock Button (prevents accidental shift into
gear) lector switch to drive (D), and press down on the
throttle pedal. The transmission will shift automatically.
Fig. 8.8, Switches, UltraShift Transmissions

8.11
 Transmissions
Manual Mode (MAN)
In manual drive mode (MAN), upshifts and downshifts
are made by the driver:
• To shift up, pull the lever up (towards you).
• To shift down, push the lever down (away from
you).
The system will hold the current gear until the driver
requests a shift. In downhill situations in particular, the
driver must be alert to vehicle speed by downshifting
and/or using the service brakes as needed.
A shift request will still be refused if the selected gear
would cause engine overspeed or excessive lugging.
10/13/2003 f610680
NOTE: The gear indicator displays the current gear. In Selecting Gears
this example, it displays first gear. Reverse
Fig. 8.9, Current Gear Display Reverse (R) is at the upper end of the four-position se-
lector switch located at the end of the SmartShift control
If driving conditions require, it is still possible to request lever. To select R, press in the neutral lock button and
a manual shift. The transmission will make the shift if move the selector switch upward to the position above
the engine speed is within 75 rpm of the load-based neutral. When reverse is selected, the letter "R" dis-
shift point for that gear. plays on the current gear indicator. See Fig. 8.10.
If the driver presses down on the throttle pedal after a
IMPORTANT: Under normal conditions, do not se-
manual downshift in automatic mode, the transmission
will upshift again if the ASW TCU requires it. lect reverse with the vehicle moving forward.

8.12
Transmissions
Neutral
IMPORTANT: Always start the engine with the
transmission in neutral, the parking brake set, and
the service brakes applied.
Neutral (N) is directly below R on the four-position se-
lector switch located at the end of the SmartShift control
lever. To select N, move the selector switch to the posi-
tion below R. When neutral is selected, the letter "N"
displays on the current gear indicator. See Fig. 8.11.

10/14/2003 f610681

Fig. 8.10, Reverse Gear Display

The vehicle must be moving at less than two miles per

hour (3 km/h) before selecting reverse. If reverse is se-
lected when the vehicle is moving faster, an audible
warning will sound and continue sounding at three-
second intervals until the control lever is returned to the
D position. When the vehicle is moving at the proper
speed, reverse can be engaged.
10/13/2003 f610679

Fig. 8.11, Neutral Display

8.13
 Transmissions
The vehicle starts up in either first or second gear, de-
WARNING pending on load and grade.

Do not coast in neutral. Coasting in neutral can The ASW UltraShift controller adapts to the working
cause an accident, possibly resulting in severe per- conditions of each vehicle and its driver. After power up
sonal injury or death. or a load change, it needs to learn the new conditions.
While learning, it may hold a gear too long before up-
Neutral is always available during operation, whatever shifting. Start the upshift manually. It may take three or
the vehicle speed. When in neutral, requests to upshift four shifts before ASW succeeds in learning the new
or downshift are ignored. If the selector switch is moved load-based shift points, but after that it will handle the
from neutral to drive while the vehicle is moving, the shifting automatically.
transmission will shift into a gear within the engine’s
operating torque range. Low
Before shutting down the engine, return the selector Low (L) is located at the lower end of the four-position
switch to N. When the ignition is turned off, the trans- selector switch located at the end of the SmartShift con-
mission will reset to neutral in a few minutes regardless trol lever. To select L, press in the neutral lock button
of the position of the shift lever. and move the selector switch to the position below D.
When in low, the current gear is maintained. Requests
Drive
to upshift are not enabled.
Drive (D) is directly below N on the four-position selec-
tor switch located at the end of the SmartShift control IMPORTANT: If the engine is approaching over-
lever. To select D, press in the neutral lock button and speed, the ASW TCU will override the current gear
move the selector switch to the position below N. When setting and upshift to prevent engine damage.
drive is selected, the number of the currently selected
To enhance engine braking, downshifts are performed
forward gear (1, 2, 3, 4, 5, or 6) displays on the gear
at higher rpm than normal.
indicator. See Fig. 8.9.
If L is selected from neutral while stopped, the vehicle
When in drive, requests to upshift or downshift are en-
starts up in first gear and stays there until the engine
abled. Either manual or automatic mode can be se-
approaches overspeed.
lected on the slide switch.

8.14
Transmissions
Upshifting For best engine braking, select low while moving. In
low, downshifts are performed at higher rpm than in
To request an upshift with the transmission in drive, pull drive.
the control lever up (towards you). If the gear is avail-
able, the transmission upshifts and the new gear dis- IMPORTANT: If the engine is approaching over-
plays on the gear indicator. No skip shifts are available speed, the ASW TCU will override the current gear
while upshifting. setting and upshift to prevent engine damage.
No upshifts are available in low, except to prevent en- If the gear requested is unavailable, a tone will sound.
gine overspeed. An unavailable request to downshift is not stored in
If the transmission does not upshift quickly enough after memory. The downshift must be requested again.
power-up or a load change, begin the shift manually. When coasting to a stop, the ASW TCU does not finish
The ASW TCU will learn the new load-based shift con- the downshift until the driver presses down on the
ditions after three or four shifts. throttle pedal again.
If the gear requested is unavailable, a tone will sound. IMPORTANT: A downshift request can never result
An unavailable request to upshift is not stored in in a shift into neutral, even if the vehicle is in the
memory. The upshift must be requested again. drive position in the lowest possible gear.
Downshifting Before starting down a hill, slow down. Downshift to a
speed that you can control without hard pressure on the
NOTE: The driver can manually downshift at any service brakes.
time, even when the slide switch is set to AUTO
mode. Before entering a curve, slow down to a safe speed.
Downshift if necessary. This lets you use some power
To request a downshift with the transmission in drive or through the curve to help the vehicle be more stable on
low, push the control lever down (away from you). If the the turn. It also allows you to regain speed faster as
gear is available, the transmission downshifts and the you come out of the curve.
new gear displays on the gear indicator. Skip shifts are
available while downshifting.

8.15
 Transmissions
Ultrashift Diagnostics • Using high idle with the vehicle in gear

Clutch Calibration The ASW TCU is programmed to prevent clutch abuse.

When the clutch overheats, the following alerts take
The ASW TCU automatically adjusts for clutch wear. place:
The calibration takes place whenever the following con-
ditions are met: • The "TRANS TEMP" light comes on

• The engine is at normal operating temperature • The current gear indicator displays "CA"

• The vehicle is stopped • A warning tone sounds at one-second intervals

• The engine is at idle speed The alerts continue until the clutch cools, the throttle is
released, or the clutch is fully engaged.
• The selector switch on the controller is in neutral
System Problem
Calibration may take up to two minutes to complete.
The engine may slow and return to normal idle several In the event of a problem, do the following steps:
times during calibration.
1. Note the driving conditions at the time the problem
To stop calibration at any time, select one of the drive occurred.
positions on the selector switch (R, D, or L).
2. Record the status of the transmission at the time of
Clutch Protection Fault the problem (AUTO or MAN mode, gear setting R,
N, D, or L, current gear, engine speed, etc.)
Excessive clutch slippage creates heat and reduces the
life of the clutch. These are some conditions which lead 3. Reset the system, using the procedure below.
to clutch abuse:
Reset Procedure
• Using the throttle to hold the vehicle on a grade Transmission operation can sometimes be restored by
• Starting the vehicle in too high a gear doing the following reset procedure:
• Overloading the vehicle 1. Stop the vehicle when it is safe to do so. Set the
parking brake.

8.16
Transmissions
2. Place the selector switch in neutral and turn off the 3. With the service brakes applied, release the parking
ignition. brake.
3. Check all harness connectors as described in 4. Make sure the selector switch is in neutral and turn
Chapter 11. on the ignition key. Do not attempt to start the en-
gine at his time.
4. Wait at least two minutes with the engine shut
down. 5. If necessary to get the transmission to shift into
neutral, release the pressure on the brake pedal
5. Restart the engine. slightly.
If the problem continues, contact an authorized Freight- 6. Once the ASW TCU reaches neutral, a solid "N" will
liner or Eaton service facility. appear on the current gear indicator and the vehicle
will start. Make sure the service brakes are applied
Locked In Gear
and the parking brake is set.
If the transmission becomes locked in gear, a dash (-)
will appear on the current gear indicator when the ve- If the current gear indicator continues to display a dash,
hicle is restarted during the reset procedure. contact an authorized Freightliner or Eaton service facil-
ity.
NOTE: If the transmission becomes locked in gear
while the vehicle is moving, increased braking ef- Eaton Fuller Straight-Shift
fort may be required to stop the vehicle.
If the current gear indicator displays a dash during
Transmissions
power-up with the selector switch in neutral, do the fol- Refer to the Eaton website for additional information,
lowing steps: www.roadranger.com. A connection to the Internet is
1. Make sure the parking brake is set. Turn off the ig- required.
nition and wait at least two minutes.
2. Apply the service brakes.

8.17
 Transmissions
General Information, Straight-Shift
Eaton Fuller 5-speed FS models are fully synchronized.
They have five forward speeds and one reverse. See R 1 3 5
Fig. 8.12 for the shift pattern.
Neutral

R 2 4 2 4 6
11/23/99 f261048
Neutral
Fig. 8.13, Shift Pattern, 6-Speed FS and FSO Models
1 3 5
11/23/99 f261049
R 2 4 6
Fig. 8.12, Shift Pattern, 5-Speed FS Models

Eaton Fuller 6-speed FS and FSO models are fully syn- Neutral
chronized. They have six forward speeds and one re-
verse. See Fig. 8.13 for the shift pattern.
1 3 5 7
Eaton Fuller 7-speed T models are not synchronized.
They have seven forward speeds and one reverse. See 11/23/99 f261051
Fig. 8.14 for the shift pattern.
These transmissions are designed for use with on- Fig. 8.14, Shift Pattern, 7-Speed T Models
highway, fuel economy engines where a minimum of
shifting is desired and less gear reduction is acceptable.

8.18
Transmissions
Operation, Straight-Shift clutch brake, if so equipped, causing premature
clutch brake wear.
1. Always use 1st gear when starting to move the ve-
hicle forward. IMPORTANT: Do not rest your foot on the clutch
pedal while driving. This causes partial clutch dis-
2. Accelerate to build up the engine speed (rpm) engagement which could cause premature clutch
needed to shift into 2nd gear. Disengage the clutch wear.
and move the shift lever to 2nd gear. Engage the
clutch and accelerate again. This is known as pro- NOTE: On synchronized models, disengage the
gressive shifting. clutch completely when shifting gears. Double-
3. Continue upshifting using the same progressive se- clutching is unnecessary. On unsynchronized mod-
quence described in the previous step. Follow the els, use double-clutching to engage 1st gear or
pattern on the shift lever. reverse.
4. When downshifting, shift progressively down
through each successive lower gear as follows: Eaton Fuller Range-Shift
When the engine speed drops to the same rpm to Transmissions
which it fell immediately after upshifting to that
same gear, press the clutch pedal down and move Refer to the Eaton website for additional information,
the shift lever to the next lower gear. Engage the www.roadranger.com. A connection to the Internet is
clutch smoothly. required.

Continue downshifting as required using the same General Information, Range-Shift

sequence described above.
Eaton Fuller 9-Speed RT Models
CAUTION Eaton Fuller 9-speed RT models have nine forward
speeds and two reverse speeds, consisting of a
If the vehicle is moving when shifting, depress the 5-speed front section and a 2-speed auxiliary section.
clutch pedal just far enough to disengage the The first position in the front section is used only as a
clutch. Pressing it to the floor will engage the starting gear. The other four ratios are used once in LO

8.19
 Transmissions
range and once again in HI range. See Fig. 8.15 for the Eaton Fuller 10-Speed RT Models
shift patterns.
Eaton Fuller Roadranger 10-speed RT and FR models
After shifting out of the first position, use the have ten forward speeds and two reverse speeds. The
Roadranger® repeat H shift pattern. LO range and HI gear shift lever mechanically engages and disengages
range are selected with the range knob or range lever. five forward gears and one reverse gear in the trans-
It is used once during the upshift sequence and once mission front section. The range lever on the
during the downshift sequence. roadranger valve allows the driver to control an air
Always preselect the range shift. After preselection, the shifted auxiliary section to provide a LO and HI range.
transmission will automatically make the synchronizer The five forward gears selected in LO range are used
range shift as the shift lever passes through neutral. again in HI range to provide the 10 progressive forward
gear ratios. See Fig. 8.16 for the shift patterns. See
Table 8.1 for the shift progressions.
HI
5 7
LO 1 3 HI 7 9
R
LO 2 4
A
N
A

6 8 B N
LO
2 4
11/23/99 f261047 B
6 8 10
A. High Range B. Low Range 1 3 5
12/15/1999 f261053
Fig. 8.15, Shift Pattern, 9-Speed RT Models
A. High Range B. Low Range
Fig. 8.16, Shift Pattern, 10-Speed RT and FR Models

8.20
Transmissions
Once the highest shift lever position (5th gear) is Operation, Range-Shift
reached in LO range, the driver preselects the range
shift lever for HI range. The range shift occurs automati- 1. When operating off-highway or under adverse con-
cally as the shift lever is moved from 5th gear position ditions, always use the low gear when starting to
to the 6th gear position. move the vehicle.
When downshifting, the driver preselects the range le- When operating on-highway, with no load or under
ver for LO range and the range shift occurs automati- ideal conditions, use 1st gear when starting to
cally during the shift lever movement to the next gear move the vehicle.
position. For all conditions, use the highest gear that is still
low enough to start the vehicle moving with the en-
Eaton Fuller Shift Progressions gine idling and without excessively slipping the
LO Range clutch.
Model HI Range
Off-Highway On-Highway 2. Use the clutch brake to stop gear rotation when
9-Speed R R 5 7 shifting into low (or 1st) or reverse when the vehicle
1 3 1 3 R
Direct or is stationary. The clutch brake is applied by de-
Overdrive LOW 6 8 pressing the clutch pedal all the way to the floor.
2 4 2 4
(RT) f260322 f260323 f260324
For normal upshifts and downshifts, only a partial
10-Speed R R R
7 9 disengagement of the clutch is necessary to break
2 4 2 4 engine torque.
Direct or
Overdrive 6 8 10 3. Do not make range shifts with the vehicle moving in
1 3 5 1 3 5
(RT) f260329 f260329 f260330 reverse gear.
Table 8.1, Eaton Fuller Shift Progressions 4. Never attempt to move the range preselection lever
with the gear shift lever in neutral while the vehicle
is moving. Preselection with the range preselection
lever must be made prior to moving the shift lever
out of gear into neutral.

8.21
 Transmissions
5. Do not shift from high range to low range at high high range. As the shift lever passes through neu-
vehicle speeds. tral, the transmission will automatically shift from
low range to high range.
6. Double-clutch between all upshifts and downshifts.
6. With the transmission in high range, shift progres-
7. After your shifting ability improves, you may want to sively up through each of the high range gears,
skip some of the ratios. This may be done only double-clutching between shifts.
when operating conditions such as load, grade, and
road speed permit. Downshifting
Upshifting 1. With the transmission in high range, shift progres-
sively down to the bottom gear in high range,
1. Position the gear shift lever in neutral. Start the en- double-clutching between shifts.
gine and bring the air system pressure up to 100 to
120 psi (689 to 827 kPa). 2. When in the bottom gear of the high-range shift
pattern and ready for the next downshift, push the
2. Position the range preselection lever down into low range preselection lever down into low range.
range. Double-clutch through neutral and shift into the top
3. Press the clutch pedal to the floor. Shift into low or gear of the low-range shift pattern. As the shift lever
1st gear, then engage the clutch with the engine at passes through neutral, the transmission will auto-
or near idle speed to start the vehicle moving. Ac- matically shift from high range to low range.
celerate to 80 percent of engine governed speed. 3. With the transmission in low range, downshift
4. Shift progressively up from low or 1st gear to the through the low range gears as conditions require.
top gear in low range, double-clutching between Never use the clutch brake when downshifting or as
shifts and accelerating to 80 percent of engine gov- a brake to slow the vehicle.
erned speed.
5. While in the top gear of the low-range shift pattern
and ready for the next upshift, flip the range prese-
lection lever up into high range. Double-clutch
through neutral and shift into the bottom gear in

8.22
Transmissions
Eaton Fuller Deep-Reduction 10-Speed RT–LL Models
Transmissions Eaton Fuller 10-speed deep-reduction transmissions
have a 5-speed front section, and a 2-speed rear range
Refer to the Eaton website for additional information, section, with a deep reduction button. The deep reduc-
www.roadranger.com. A connection to the Internet is tion (low-low) gear is used only when operating under
required. adverse conditions. Low gear in the front section is
used only for rough, off-highway conditions, as a start-
General Information, Deep Reduction ing ratio. The remaining four forward positions are used
once in the low range and once in the high range. See
IMPORTANT: Not all lever positions are used in each Fig. 8.17 for the shift pattern.
range and the shift patterns vary between transmis-
sions. Be sure to read the shift pattern decal on the Operation, Deep Reduction
dash for the operating instructions for the specific trans-
mission installed in your vehicle. IMPORTANT: The shifter knob has an interlock
feature that prevents the deep reduction button
9-Speed RT–L Models from being moved forward when the range prese-
Eaton Fuller 9-speed deep-reduction transmissions lection lever is up (in high range); when in low
have a 5-speed front section, and a 2-speed rear-range range and the deep reduction button is in the for-
section, with a deep reduction button. The deep reduc- ward position, the range preselection lever cannot
tion (low-low) gear is used only when operating under be moved up.
adverse conditions. Low gear in the front section is
used only for rough, off-highway conditions, as a start- 1. For all driving conditions, use the highest gear that
ing ratio. Both the low gear and 1st gear in the low is still low enough to start the vehicle moving with
range can be split, using the deep reduction button, for the engine idling, and without slipping the clutch
another reduction ratio in those shift lever positions. The excessively.
remaining four forward positions are used once in the 2. Use the clutch brake to stop gear rotation when
low range and once in the high range. Reverse in the shifting into low-low, low-1st (whichever is used as
low range can also be split with the deep reduction but-
ton for a lower ratio.

8.23
 Transmissions
4. Never move the shift lever into low gear while in
1 high range.
5 7
1 3 5. Do not preselect with the deep reduction button.
When making the shift from a deep reduction ratio
A to a low range ratio, move the deep reduction but-
N ton from a forward position to a rearward position,
then complete the shift immediately.
B 6 8 6. Never move the deep reduction button from a rear-
2 4
C D ward position to a forward position when the trans-
12/14/1999 f261055 mission is in high range.
A. High Range 7. Do not shift from high range to low range at high
B. Low Range vehicle speeds.
C. Deep Reduction IN (forward)
D. Deep Reduction OUT (rearward) 8. Do not make range shifts with the vehicle moving in
reverse gear.
1. Deep Reduction Button
9. Never attempt to move the range preselection lever
Fig. 8.17, Eaton Fuller 10-Speed Deep-Reduction with the gear shift lever in neutral while the vehicle
Transmission Shift Patterns is moving. Preselection with the range preselection
a starting ratio) or reverse, when the vehicle is sta- lever must be made prior to moving the shift lever
tionary. The clutch brake is actuated by depressing out of gear into neutral.
the clutch pedal all the way to the floor. 10. After your shifting ability improves, you may want to
For normal upshifts and downshifts, only a partial skip some of the ratios. This may be done only
disengagement of the clutch is necessary to break when operating conditions permit, depending on the
engine torque. load, grade, and road speed.

3. Double-clutch between all upshifts and downshifts.

8.24
Transmissions
Upshifting 6. From low gear, shift upward to the top gear in low
range, double-clutching between shifts, and accel-
There are several patterns of upshifting, depending on erating to 80 percent of engine governed speed.
the vehicle load and the road conditions. Deep reduc-
tion gears are best suited for heavy loads and steep 7. While in the top gear of the low range shift pattern,
inclines. Low gear (in 10-speed transmissions) is best and ready for the next upshift, flip the range prese-
suited for off-highway use. lection lever up into high range. Double-clutch
through neutral, and shift into the bottom gear in
The following instructions are recommended for starting high range. As the shift lever passes through neu-
a loaded vehicle moving, under adverse conditions. tral, the transmission will automatically shift from
1. Position the gear shift lever in neutral. Start the en- low range to high range.
gine, and bring the vehicle air system pressure up 8. With the transmission in high range, shift progres-
to 100 to 120 psi (689 to 827 kPa). sively upward through each of the high range
2. Position the range preselection lever down, into low gears, double-clutching between shifts.
range.
Downshifting
3. Move the deep reduction button to the forward posi-
tion, to engage the deep reduction gears. 1. With the transmission in high range, shift progres-
sively downward to the bottom gear in high range,
4. Depress the clutch pedal to the floor; shift into low- double-clutching between shifts.
low gear; then engage the clutch, with the engine at
or near idle speed, to start the vehicle moving. Ac- 2. When in the bottom gear of the high range shift
celerate to 80 percent of engine governed speed. pattern, and ready for the next downshift, push the
range preselection lever down into low range.
5. When ready for the next upshift, move the deep Double-clutch through neutral, and shift into the top
reduction button rearward, then break the torque on gear of the low range shift pattern. As the shift lever
the gears by momentarily releasing the accelerator passes through neutral, the transmission will auto-
or depressing the clutch pedal. Do not move the matically shift from high range to low range.
shift lever.
3. With the transmission in low range, downshift
through the low range gears, as conditions require.

8.25
 Transmissions
IMPORTANT: Never use the clutch brake when An unloaded vehicle can be started in 2nd gear on level
downshifting, or as a brake to slow the vehicle. roads or slight grades. Loaded vehicles, or vehicles on
substantial grades, must be started only in 1st gear.
Mercedes-Benz Manual While traveling, check the tachometer regularly to be
sure the engine speed is within the most economical
Transmissions range (1400-2000 rpm).
On level roads, drive in the highest usable gear, keep-
CAUTION ing engine speed down.
Operating a manual transmission with the fluid level
higher or lower than recommended can result in CAUTION
transmission damage.
Do not rest your hand on the gear shift lever while
Mercedes-Benz (MBT) transmissions use a simple driving. This can cause synchronizer damage.
6-speed gear pattern as shown in Fig. 8.18.
When approaching an uphill grade, shift down ahead of
time to prevent loss of engine rpm. When approaching
a downhill grade, shift down ahead of time to prevent
1 3 5 runaway speed.
Change gears only when absolutely necessary. Skip
N gears if needed.

R 2 4 6 When shifting, always press the clutch pedal all the way
down. Do not force the gear lever.
05/03/2001 f261098
Before shifting into reverse, be sure the engine is idling
Fig. 8.18, Shift Pattern, MBT Transmissions and the vehicle is not moving.

8.26
Transmissions
CAUTION
6
If the transmission locks up while driving, making R 2 4
further shifting impossible, continue driving in the
gear already selected to reach service assistance,
as circumstances allow. Or, safely park the vehicle N
off the roadway and contact your nearest Sterling
dealer or other qualified service provider for road- 1 3 5
side assistance. To prevent further transmission 7
damage, do not move the vehicle from a standing
03/12/96 f260118
start unless this can be accomplished safely, taking
into account the gear that is engaged and the load
Fig. 8.19, TTC 7-Speed Transmission Shift Pattern
on the vehicle.
Operation, TTC
TTC Manual Transmissions 1. Always use 1st gear when starting to move the ve-
Refer to the TTC website for additional information, ww- hicle forward.
w.ttcautomotive.com. A connection to the Internet is
2. To save fuel, use progressive shifting techniques. It
required.
is usually not necessary to go all the way to gov-
erned speed before upshifting.
General Information, TTC
3. Double-clutch only when shifting out of neutral, or
TTC (Spicer) 7-speed series transmissions are synchro- when shifting down into 1st.
nized in all gears except 1st and reverse. They have
seven forward gears and one reverse gear. See NOTE: 1st gear, like reverse, is not synchronized.
Fig. 8.19 for the shift pattern.

8.27
 Transmissions
Upshifting the clutch smoothly while accelerating the engine to
keep the vehicle moving at the desired speed.
1. Position the gear shift lever in neutral, then start the
engine. Bring the air system pressure up to 100 to 2. Continue downshifting, as conditions require, using
120 psi (689 to 827 kPa). the same sequence described above. When shifting
down into 1st gear, remember that 1st gear isn’t
2. To shift, press down on the clutch and wait for the synchronized. Double-clutch when shifting down
clutch to release completely. Move the shift lever into 1st gear.
into 1st gear and engage the clutch (remove your
foot from the lever).
Allison On-Highway
3. Accelerate until your rpm is high enough to shift
into 2nd. Press down on the clutch and move the Transmissions
shift lever to second gear. Engage the clutch and
continue driving. The Allison on-highway transmissions are fully auto-
matic and include the 1000 Series™, 2000 Series™, and
4. Use this progressive shifting technique to shift into 2400 Series™. Refer to the Allison website for additional
each higher gear. See Fig. 8.19 for the shift pat- information, www.allisontransmission.com. A connection
tern. to the Internet is required.
IMPORTANT: As you approach top speed, it will
be necessary to accelerate closer and closer to
Safety Precautions, On-Highway
governed speed before allowing the engine rpm to Transmissions
drop down at the next shift point. 1000 Series
Downshifting On vehicles with Allison 1000 series transmissions, do
the following steps if you have to leave the cab with the
When downshifting, shift progressively down through engine running (for example, when checking the trans-
each successive lower gear, as follows: mission fluid):
1. Depress the clutch pedal enough to release the
torque, shift into the next lower gear, and engage

8.28
Transmissions
Without Park Position 2000 Series
1. Bring the vehicle to a complete stop using the ser- On vehicles with Allison 2000 series transmissions, do
vice brake. the following steps if you have to leave the cab with the
engine running (for example, when checking the trans-
2. Ensure that the engine is at low idle rpm.
mission fluid):
3. Put the transmission in neutral.
Without Auto-Apply Parking Brake
4. Apply the parking brake, and make sure it is prop-
erly engaged. Follow the instructions for vehicles with 1000 series
transmissions, under the heading "Without Park Posi-
5. Chock the rear tires and take any other steps nec- tion."
essary to keep the vehicle from moving.
With Auto-Apply Parking Brake
With Park Position
1. Bring the vehicle to a complete stop using the ser-
1. Bring the vehicle to a complete stop using the ser- vice brake.
vice brake.
2. Ensure that the engine is at low idle rpm.
2. Ensure that the engine is at low idle rpm.
3. Put the transmission in PB (auto-apply parking
3. Put the transmission in P (park). brake).
4. Apply the parking brake (if equipped), and make 4. Apply the parking brake (if equipped), and make
sure it is properly engaged. sure it is properly engaged.
5. Engage the park range by slowly releasing the ser- 5. Chock the rear tires and take any other steps nec-
vice brake. essary to keep the vehicle from moving.
6. Chock the rear tires and take any other steps nec-
essary to keep the vehicle from moving.
2400 Series
On vehicles with 2400 series transmissions, follow the
instructions for vehicles with 1000 series transmissions.

8.29
 Transmissions
Range Inhibit Indicator, 2000 and • The TCM will prevent shifts from park or neutral
to range when auxiliary equipment, such as a
2400 Series power takeoff unit (PTO), is in operation.
A RANGE INHIBIT indicator is a standard feature of the
2000 series and 2400 series transmissions. The Operating Instructions, On-Highway
RANGE INHIBIT indicator comes on to alert the driver Transmissions
that transmission operation is being inhibited and that
the range shifts being requested by the driver may not Allison automatic transmissions are electronically con-
occur. When certain operating conditions are detected trolled. The shift selector provides five or six forward
by the TCM (transmission control module), the controls ranges and one reverse range. A lever shift selector
will lock the transmission in the current operating range. (Fig. 8.20) is used by the driver to select the ranges.
Shift inhibits occur under the following conditions:
• Shifts from neutral to reverse or from neutral to a
forward range when the engine is above idle,
greater than 900 rpm.
P R PB
• Forward/reverse directional shifts are typically not R N R
permitted if appreciable output shaft speed is de- N D N
tected. D 3 D
3 2 3
• When some types of unusual transmission oper- 2 2
ating conditions are detected by the TCM, the 1 1 1
TCM temporarily limits transmission operation
until the vehicle can be driven to a service loca-
tion. When this type of situation is detected, the 12/09/99 f270115
TCM will lock the transmission in a safe gear
range. Fig. 8.20, Lever Shift Selectors

8.30
Transmissions
P (Park, optional on 1000 and 2400 Series) Do not idle in reverse for more than 5 minutes. Select P
(park), PB (auto-apply parking brake), or N (neutral)
Use park when turning the engine on or off, to check when time at idle exceeds 5 minutes.
vehicle accessories, to operate the engine in idle for
longer than 5 minutes, and for stationary operation of NOTE: The shift into reverse may not succeed if a
the power takeoff, if equipped. This position places the range inhibitor is active. Check for illumination of
transmission in neutral and engages the park pawl of the RANGE INHIBIT indicator.
the transmission.
N (Neutral)
NOTE: This does not apply the parking brake.
The neutral position places the transmission in neutral.
PB (Auto-Apply Parking Brake, optional on This position is used when starting the engine and for
2000 Series) stationary operation.
The auto-apply parking brake places the transmission in
neutral and applies the parking brake. WARNING
R (Reverse) Failure to apply the vehicle parking brakes when
the transmission is in neutral may allow the vehicle
Reverse is used to back the vehicle. When the selector to move unexpectedly, possibly causing property
is in reverse, the reverse warning signal will sound. Al- damage or personal injury.
ways bring the vehicle to a complete stop before shift-
ing from a forward range to reverse, or from reverse to When neutral is selected, the vehicle service brakes,
a forward range. parking brake, or emergency brake must be applied.
Selecting neutral does not apply vehicle brakes unless
an auxiliary system to apply the parking brake is in-
CAUTION stalled.
Extended idling in reverse may cause transmission
overheating and damage.

8.31
 Transmissions
through each available range up to fourth range or fifth
WARNING range. As the vehicle slows, the transmission will down-
shift automatically.
Do not coast in neutral. Coasting in neutral can
cause an accident, possibly resulting in severe per- When going downhill, downshift to a lower transmission
sonal injury or death. range to increase engine braking and to help maintain
control. The transmission has a feature to prevent auto-
Do not let the vehicle coast in neutral. If the vehicle is matic upshifting above the lower range selected. How-
allowed to coast in neutral, the engine brake will not ever, during downhill operation, the transmission may
work and you could lose control of the vehicle. upshift to the next higher range, if the engine is exceed-
ing its governed speed in the lower range.
CAUTION
CAUTION
Coasting in neutral can cause severe transmission
damage. Do not idle in drive for more than 5 minutes. Ex-
tended idling in drive may cause transmission over-
D (Drive) heating and damage. Always select PB (auto-apply
parking brake) or P (park) if time at idle is longer
WARNING than 5 minutes.
NOTE: The shift into drive may not succeed if a
When going downhill, use a combination of down- range inhibitor is active. Check for illumination of
shifting, braking, and other retarding devices to
the RANGE INHIBIT indicator.
control vehicle speed and the engine’s rated gov-
erned speed. Failure to do so could reduce vehicle
4 and 3 (Fourth and Third Ranges, optional)
braking, possibly causing loss of vehicle control
and resulting in personal injury or property damage. Use the fourth or third range for city traffic and for brak-
ing on steep downgrades.
In the drive position, the transmission will initially go into
first range when drive is selected. As vehicle speed in-
creases, the transmission will upshift automatically

8.32
Transmissions
3 and 2 (Third and Second Ranges, Safety Precautions
standard)
Use the third or second range for heavy city traffic and WARNING
for braking on steeper downgrades.
Do not leave the vehicle unattended with the engine
1 (First Range) running. If you leave the vehicle and the engine is
running, the vehicle can move suddenly, which
Use first range when pulling through mud or deep snow,
could result in personal injury or property damage.
when maneuvering in tight spaces, or when driving up
or down very steep grades. First range provides the On vehicles with MD series transmissions, do the fol-
vehicle with its maximum driving torque and maximum lowing steps if you have to leave the cab with the en-
engine braking effect. gine running (for example, when checking the transmis-
sion fluid):
NOTE: To have the transmission select these
ranges automatically, leave the selector lever in D 1. Bring the vehicle to a complete stop using the ser-
(drive). vice brake.
2. Put the transmission in N (neutral).
Allison MD Series 3. Ensure that the engine is at low idle rpm (below
Transmissions 1000).
4. Apply the parking brake and emergency brakes,
Refer to the Allison website for additional information,
and make sure they are properly engaged.
www.allisontransmission.com. A connection to the Inter-
net is required. 5. Chock the rear tires and take any other steps nec-
essary to keep the vehicle from moving.

Operating Instructions, MD Series

The Allison MD transmission is electronically controlled
and comes with a push-button shift selector. See

8.33
 Transmissions
Fig. 8.21. It provides five or six forward ranges and one vehicle to a complete stop and let the engine return to
reverse range. idle before shifting from a forward range to reverse, or
from reverse to a forward range.
1
2
CAUTION
Extended idling in reverse may cause transmission
overheating and damage.
3
R Do not idle in reverse for more than 5 minutes. Select
neutral when time at idle exceeds 5 minutes.
N
NOTE: The shift into reverse may not succeed if a
D range inhibitor is active. When reverse is selected,
always be sure that R is not flashing.
N (Neutral)
11/23/99 f270113
1. Digital Display 3. Mode Button WARNING
2. Mode Identification

Fig. 8.21, Allison Push-Button Shift Selector When starting the engine, make sure that the ser-
vice brakes are applied. Failure to apply the service
The push-button shift selector has an R (reverse), an N brakes may result in unexpected vehicle movement
(neutral), a D (drive), an up arrow, a down arrow, a which could cause severe personal injury or death.
mode button, and a digital display.
Press the N button to select neutral. The digital display
R (Reverse) will display N when neutral is selected. It is not neces-
sary to press neutral before starting the vehicle. The
Press the R button to select reverse. The digital display ECU (electronic control unit) automatically places the
will show R when reverse is selected. Always bring the transmission in neutral at start-up.

8.34
Transmissions
D (Drive)
WARNING
When the D button is pushed, the highest forward
Failure to apply the vehicle parking brakes when range will appear in the display. The transmission will
the transmission is in neutral may allow the vehicle normally go into first range when drive is selected (ex-
to move unexpectedly, possibly causing property cept for those units programmed to start in second
damage or personal injury. range). As vehicle speed increases, the transmission
will upshift automatically through each range. As the
When neutral is selected, the vehicle service brakes, vehicle slows, the transmission will downshift automati-
parking brake, or emergency brake must be applied. cally.
Selecting neutral does not apply vehicle brakes unless
an auxiliary system to apply the parking brake is in-
stalled. CAUTION
Do not idle in drive for more than 5 minutes. Ex-
WARNING tended idling in drive may cause transmission over-
heating and damage. Always select neutral if time at
Do not coast in neutral. Coasting in neutral can idle is longer than 5 minutes.
cause an accident, possibly resulting in severe per-
sonal injury or death. NOTE: The shift into drive may not succeed if a
range inhibitor is active. When drive is selected,
Do not let the vehicle coast in neutral. If the vehicle is
allowed to coast in neutral, the engine brake will not
always be sure that D is not flashing.
work and you could lose control of the vehicle.
5, 4, 3, and 2 (Fifth, Fourth, Third, and
Always select neutral before turning off the engine. Second Ranges)
Neutral is also used during stationary operation of the
power takeoff if your vehicle is equipped with a PTO. Occasionally, road conditions, load, or traffic conditions
will make it desirable to restrict automatic shifting to a
lower range. Lower ranges provide greater braking for
going down grades. The lower the range, the greater
the braking effect.

8.35
 Transmissions
Push the up or down arrows on the push-button shift engine braking effect. Push the down arrow until the
selector to select individual forward ranges. The digital first range appears on the display.
display will display your choice of range. When a lower
range is selected, the transmission may not downshift Up and Down Arrows
until the vehicle speed is reduced.
When a lower range is desired, after D has been
pressed, press the down arrow until the desired range
WARNING is shown on the display. Pressing the down arrow con-
tinuously causes the range position to continue to go
When going downhill, use a combination of down- down until the button is released or the lowest range is
shifting, braking, and other retarding devices to attained.
control vehicle speed and the engine’s rated gov-
erned speed. Failure to do so could reduce vehicle When the transmission is in drive and the down arrow
braking, possibly causing loss of vehicle control has the transmission in a lower range position, press
and resulting in personal injury or property damage. the up arrow to shift to a higher selector position.
Pressing the up arrow continuously causes the range
When going downhill, downshift to a lower transmission position to continue to rise until the button is released
range to increase engine braking and to help maintain or the highest available position is attained.
control. The transmission has a feature to prevent auto-
matic upshifting above the lower range selected. How- Pressing the up or down arrows does not override the
ever, during downhill operation, if the engine governed transmission automatic shifting operation. If a higher or
speed is exceeded in the lower range, the transmission lower position is selected, the transmission continues
may upshift to the next higher range. shifting through the ranges according to the vehicle op-
erating characteristics until the highest or lowest se-
1 (First Range) lected position is reached.

Use the first range when pulling through mud or deep Mode Button
snow, when maneuvering in tight spaces, or when driv-
ing up or down steep grades. First range provides the The MODE button starts a specialized input or output
vehicle with its maximum driving torque and maximum function that has been previously programmed into the
ECU. Pressing the mode button changes transmission
operation for a specific function.

8.36
Transmissions
When the MODE button is pressed, the mode indicator • Apply the parking brake and emergency brakes
comes on. A mode identification label, located above and make sure they are properly engaged.
the MODE button, identifies the function associated with
a mode change. • Chock the rear tires and take any other steps
necessary to keep the vehicle from moving.

Allison AT/MT Series PB (Auto-Apply Parking Brake, optional)

Transmissions When the shift selector does not have an auto-apply
parking brake, always put the shift selector in neutral
Refer to the Allison website for additional information, and apply the parking brake to hold the vehicle when it
www.allisontransmission.com. A connection to the Inter- is unattended and before turning off the engine.
net is required.
R (Reverse)
Allison AT 500 Series
Reverse is used to back the vehicle. Completely stop
The Allison AT 500 Series transmissions provide four the vehicle before shifting from a forward range to re-
forward ranges and one reverse range. A lever shift se- verse, or from reverse to a forward range. The reverse
lector (Fig. 8.20) is used by the driver to select the warning signal will sound when the selector is in re-
ranges. verse.

WARNING N (Neutral)
Place the shift selector in neutral before starting the en-
Do not leave the vehicle unattended with the engine gine. When the shift selector has no park provision, al-
running. If you leave the vehicle and the engine is ways put the shift selector in neutral and apply the
running, the vehicle can move suddenly, which parking brake to hold the vehicle when it is unattended
could result in personal injury or property damage. and before turning off the engine. The neutral position is
If you must leave the engine running, do not leave the also used during stationary operation of the power take-
vehicle until you do the following. off if your vehicle is equipped with a PTO.

• Put the transmission in neutral.

8.37
 Transmissions
WARNING WARNING
Do not let the vehicle coast in neutral. If the vehicle When going downhill, use a combination of down-
is allowed to coast in neutral, the engine brake will shifting, braking, and other retarding devices to
not work and you could lose control of the vehicle. control vehicle speed and the engine’s rated gov-
This can cause an accident possibly resulting in erned speed. Failure to do so could reduce vehicle
personal injury or property damage. Coasting in braking, possibly causing loss of vehicle control
neutral can also cause severe transmission dam- and resulting in personal injury or property damage.
age.
IMPORTANT: When descending a hill, downshift to
D (Drive) a lower transmission range to increase engine
braking and to help you maintain control. The
In the drive position, the transmission will initially attain transmission has a feature to prevent automatic
1st range and as the vehicle speed increases, the upshifting above the lower range selected. How-
transmission will upshift to second range, third range,
and fourth range automatically. As the vehicle slows
ever, during downhill operation, if the engine gov-
down, the transmission will downshift to the correct erned speed is exceeded in the lower range, the
range automatically. transmission may upshift to the next higher range.

3 and 2 (Third and Second Ranges) 1 (First Range)

Third range and second range are used when road, The first range is used when pulling through mud or
load, or traffic conditions make it desirable to restrict the snow, or when driving up and down steep grades. This
automatic shifting to a lower range. When conditions range provides the vehicle with maximum driving power
improve, return the selector to the drive position. The and maximum braking power.
third and second ranges also provide greater engine
braking for going down grades. The lower the range, Allison MT 600 Models
the greater the braking effect.
The Allison MT 643 transmission provides four forward
ranges and one reverse range. The Allison MT 653DR

8.38
Transmissions
transmission provides five forward ranges and one re- N (Neutral)
verse range. A lever shift selector (Fig. 8.20) is used by
the driver to select the ranges. Place the shift selector in neutral before starting the en-
gine. Shift to neutral and set the parking brake any time
the vehicle is parked with the engine running. The neu-
WARNING tral position is also used during stationary operation of
the power takeoff if your vehicle is equipped with a
Do not leave the vehicle unattended with the engine PTO.
running. If you leave the vehicle and the engine is
running, the vehicle can move suddenly, which
could result in personal injury or property damage. WARNING
If you must leave the engine running, do not leave the Do not let the vehicle coast in neutral. If the vehicle
vehicle until you do the following. is allowed to coast in neutral, the engine brake will
• Put the transmission in neutral. not work and you could lose control of the vehicle.
This can cause an accident possibly resulting in
• Apply the parking brake and emergency brakes personal injury or property damage. Coasting in
and make sure they are properly engaged. neutral can also cause severe transmission dam-
age.
• Chock the rear tires and take any other steps
necessary to keep the vehicle from moving.
D (Drive)
R (Reverse) In the drive position, the MT 643 transmission will ini-
tially attain first range and, as vehicle speed increases,
Reverse is used to back the vehicle. Completely stop
the transmission will upshift to second range, third
the vehicle before shifting from a forward range to re-
range, and fourth range. In the drive position, the MT
verse or from reverse to a forward range. The reverse
653DR transmission will initially attain second range
warning signal will sound when the selector is in re-
and as the vehicle speed increases, the transmission
verse.
will upshift to third range, fourth range, and fifth range
automatically. As the vehicle speeds slows down, the

8.39
 Transmissions
transmission will downshift to the correct range auto- braking, possibly causing loss of vehicle control
matically. and resulting in personal injury or property damage.

4, 3, and 2 (Fourth, Third, and Second IMPORTANT: When going downhill, downshift to a
Ranges) lower transmission range to increase engine brak-
ing and to help you maintain control. The trans-
On the MT 643 transmission, the third range and sec- mission has a feature to prevent automatic upshift-
ond range are used when road, load, or traffic condi- ing above the lower range selected. However,
tions make it desirable to restrict the automatic shifting during downhill operation, if the engine governed
to a lower range. When conditions improve, return the
speed is exceeded in the lower range, the trans-
selector to the drive position. The third and second
ranges also provide greater engine braking for going mission may upshift to the next higher range.
down grades. The lower the range, the greater the brak-
ing effect. 1 (First Range)
On the MT 653DR transmission, the fourth, third, and On the MT 643 transmission, the first range is used
second ranges are used when road, load, or traffic con- when pulling through mud or snow, or when driving up
ditions make it desirable to restrict the automatic shift- and down steep grades. This range provides the vehicle
ing to a lower range. When conditions improve, return with maximum driving power and maximum braking
the selector to the drive position. power.

On the MT 653DR transmission, the third and second On the MT 653DR transmission, the first range is used
ranges are used for vehicle speed control up or down for off-highway operation or when pulling through mud
steep grades or for undesirable road conditions. or snow. It is recommended that full power shifts not be
made from first range to second range, or from second
range to first range.
WARNING
When going downhill, use a combination of down-
shifting, braking, and other retarding devices to
control vehicle speed and the engine’s rated gov-
erned speed. Failure to do so could reduce vehicle

8.40
Transmissions
Mercedes-Benz Automated 1
Transmissions
General Information, AGS 2
The AGS Automated Gear Shift is a fully automated
6-speed medium-duty transmission. The clutch is acti-
vated by a hydraulic system that is integral to the trans-
mission. No clutch pedal is needed to operate the ve-
hicle.
AGS transmissions use the SmartShift control lever on
the steering column to select gears. A manual shift is
possible at any time by moving the SmartShift lever up
or down as needed.
The transmission control unit (TCU) can direct all for-
ward shifts in response to driving conditions and the 10/13/2003 f270079
driver’s pressure on the brake and throttle pedals. To
know which gear the transmission is in, look at the To know which gear the transmission is in, look at the
round current gear indicator on the right-hand control current gear indicator.
panel as shown in Fig. 8.22. 1. Current Gear Indicator
2. SmartShift Control
The TCU always selects first gear to start the vehicle in
motion. It is possible, in manual mode, to start an un- Fig. 8.22, Shift Controls and Indicators, AGS
loaded vehicle in second gear. In most cases, second Transmissions
gear is acceptable for downhill starts. In other situa-
tions, for best results always start moving in first gear.
Loaded vehicles, or vehicles on substantial grades,
must start moving only in first gear.

8.41
 Transmissions
1
CAUTION 2

At the first sign of a transmission malfunction, take CHECK

TRANS
the vehicle out of service immediately. Depending
on the type of problem, further shifting may not be TRANS
TEMP
possible, and driveline torque may be interrupted.

Operation, AGS BRAKE

Power Up
1. With the parking brake set and/or the brake pedal
pressed down, select neutral (N) by moving the se- 10/27/2003 f610677
lector switch to the center position.
1. "CHECK TRANS" Light
2. With the transmission in neutral, turn on the ignition 2. "TRANS TEMP" Light
switch. The "CHECK TRANS" and "TRANS TEMP"
telltale lights come on and go out again (bulb Fig. 8.23, Telltale Lights
check). See Fig. 8.23.
shows "N." See Chapter 13 for jump starting infor-
3. On power up, the current gear indicator shows the mation.
dot display, arranged in a square pattern. All dots in
the pattern should light up, without gaps or spaces. 5. Select drive (D) by pressing in the neutral lock but-
See Fig. 8.24. ton and moving the selector switch downward to
the position below neutral. Release the parking
4. When the current gear indicator shows "N," start brake and/or service brake pedal. The gear is dis-
the engine. played on the current gear indicator.
NOTE: No matter what the circumstances, do not NOTE: When D is selected, the transmission
start the engine unless the current gear indicator starts up in first gear. To start up in second gear
(downhill start, vehicle unloaded or lightly loaded),

8.42
Transmissions
A rollback accident could cause death, serious per-
sonal injury, or property damage.
7. Prevent the vehicle from rolling backwards when
stopped on a hill or grade, or when the vehicle is
starting from a stop on a hill or grade.
7.1 To start from a full stop on a hill or grade,
quickly move your foot from the brake pedal
and press firmly on the throttle pedal.
On steep hills, set the parking brake and
release it only when there is enough engine
power to prevent rollback.
7.2 To stop on a hill or grade, press and hold
10/13/2003 f610678 the brake pedal to keep the vehicle from
moving.
Fig. 8.24, Power-Up Dot Display On steep hills, set the parking brake. Never
hold a hill with the throttle pedal. This will
pull up on the SmartShift lever when the current
cause the clutch to overheat.
gear indicator displays "1."
6. On a level grade, press down on the throttle pedal Power Down
to allow the vehicle to move forward. The vehicle 1. Bring the vehicle to a complete stop.
will not move until the pedal is depressed.
2. Set the parking brake.
WARNING 3. Move the selector switch to N. Wait until "N" ap-
pears on the current gear indicator.
When starting or stopping on hills and grades, use
extra care to prevent the vehicle from rolling back.

8.43
 Transmissions
WARNING
Always apply the parking brake before shutting
down the engine. AGS will shift into neutral after
shutdown, regardless of the position of the shift
lever. If you do not set the parking brake, the ve-
hicle could roll and cause an accident resulting in
death, serious personal injury, or property damage.
1 2
4. Turn the ignition switch off and shut down the en-
gine. 3

5. If the current gear indicator flashes "PB" when the

engine is shut down, set the parking brake and
move the selector switch to "N."

Automatic and Manual Modes

01/19/2004 f270079b
The SmartShift control has a slide switch located on the
body of the lever just before the paddle widens out. See 1. Slide Switch (controls forward driving mode)
Fig. 8.25. The slide switch controls the forward driving 2. Selector Switch (controls gear selection)
3. Neutral Lock Button (prevents accidental shift into
mode, automatic or manual.
gear)
To change mode at any time, move the slide switch in
the desired direction. This allows the driver to respond Fig. 8.25, Switches, AGS Transmission
to a wide range of driving conditions, such as blind cor- In either mode, the gear indicator displays the current
ners, tight curves, and steep hills. gear. See Fig. 8.26.
IMPORTANT: Whatever the mode, it is always
possible to shift manually by moving the lever up
or down as needed.

8.44
Transmissions
If driving conditions require, it is still possible to request
a manual shift. The transmission will make the shift un-
less the selected gear would cause engine overspeed.
If the driver presses down on the throttle pedal after a
manual downshift in automatic mode, the transmission
will upshift again if the TCU requires it.
On downgrades, the transmission holds the current
gear until the driver requests a shift, or presses the
throttle pedal.

WARNING
While driving off-road or with locked differential in
10/13/2003 f610680 AUTO mode, use extra caution. Shifts of the AGS
NOTE: The gear indicator displays the current gear. In could interrupt power to the drive wheels, causing a
this example, it displays first gear. rollback accident while climbing steep grades at
low speeds. A rollback accident could cause death,
Fig. 8.26, Current Gear Display serious personal injury, or property damage.
Automatic Mode (AUTO) Manual Mode (MAN)
Automatic drive mode (AUTO) is recommended for
Manual mode may be required under certain conditions,
most driving conditions. For the best fuel economy, al-
such as:
ways use AUTO mode.
• In difficult or slippery conditions
In AUTO mode, upshifts and downshifts are made by
the transmission without driver intervention. Press in the • On hills, steep grades, or other situations where
neutral lock button, move the selector switch to drive driveline torque interruption is not desirable
(D), and press down on the throttle pedal. The transmis-
sion will shift automatically through the forward gears.

8.45
 Transmissions
• During off-road driving or driving with a locked Cruise Control
differential
Cruise control is fully functional with AGS transmission
• In downhill driving where control of engine brak- in either AUTO or MAN mode.
ing is needed
In AUTO, the TCU will adjust the gear selections to
• If necessary to hold a specific gear on a down- maintain the speed settings as desired. No driver action
grade is necessary.
In manual drive mode (MAN), upshifts and downshifts In MAN, the vehicle speed settings must be within the
are made by the driver: engine speed range for the gear selected. If the engine
• To shift up, pull the lever up (towards you). cannot maintain set speed due to changes in road
grade, the driver must downshift or upshift as neces-
• To shift down, push the lever down (away from sary.
you).
For vehicles equipped with a power take-off (PTO) unit,
The system will hold the current gear until the driver two modes of operation are possible, stationary and
requests a shift. In downhill situations in particular, the mobile. For PTO operation, see Chapter 7.
driver must be alert to vehicle speed and maintain ve-
hicle control by downshifting and/or using the service Selecting Gears
brakes as needed. Reverse
When braking or slowing in MAN, downshift as neces- Reverse (R) is at the upper end of the three-position
sary to prevent lugging the engine when speed is re- selector switch located at the end of the SmartShift con-
sumed. If the vehicle comes to a complete stop, the trol lever. To select reverse (R), press in the neutral lock
TCU resets the transmission to neutral. button and move the selector switch upward to the posi-
tion above neutral. When reverse is selected, the letter
NOTE: A downshift request will be refused if the
"R" displays on the current gear indicator. See
selected gear would cause engine overspeed. Fig. 8.27.
IMPORTANT: The vehicle must come to a com-
plete stop before selecting reverse. If reverse is

8.46
Transmissions
move the selector switch to the center position. When
neutral is selected, the letter "N" displays on the current
gear indicator. See Fig. 8.28.

10/14/2003 f610681

Fig. 8.27, Reverse Gear Display

selected with the vehicle moving forward, an au- 10/13/2003 f610679

dible alert will sound and continue sounding at
three-second intervals until the selector switch is Fig. 8.28, Neutral Display
returned to N or D.
Once the vehicle has come to a complete stop, reverse WARNING
can be engaged.
Do not coast in neutral. Coasting in neutral can
Neutral cause an accident, possibly resulting in severe per-
sonal injury or death.
Neutral (N) is in the center of the three-position selector
switch located at the end of the SmartShift control lever. Neutral is always available during operation, whatever
Always start the engine in neutral. To select neutral, the vehicle speed. When in neutral, requests to upshift

8.47
 Transmissions
or downshift are ignored. If the selector switch is moved and move the selector switch to the position below N.
from neutral to drive while the vehicle is moving, the When drive is selected, the number of the currently se-
transmission will shift into a gear within the operating lected forward gear (1, 2, 3, 4 , 5, or 6) displays on the
torque range of the engine. gear indicator. See Fig. 8.26.

WARNING Upshifting
NOTE: The driver can manually upshift at any
Always apply the parking brake before shutting time, even when the slide switch is set to AUTO
down the engine. AGS will shift into neutral after mode.
shutdown, regardless of the position of the shift
lever. If you do not set the parking brake, the ve- To request an upshift with the transmission in drive, pull
hicle could roll and cause an accident resulting in the control lever up (towards you). If the gear is avail-
death, serious personal injury, or property damage. able, the transmission upshifts and the new gear dis-
plays on the gear indicator.
Before shutting down the engine, return the selector
switch to "N." When the ignition is turned off, the trans- As in a manual transmission, upshifting too early
mission will reset to neutral during power down. causes engine lugging and uneven operation.

Drive To achieve smooth operation in MAN mode, upshift

when the engine speed reaches approximately 2000
IMPORTANT: The vehicle must come to a com- revolutions per minute (rpm). Heavy loads or steep
plete stop before selecting drive. If drive is se- grades require higher rpm; lighter loads require lower
lected with the vehicle moving in reverse, an au- rpm.
dible alert will sound and continue sounding at An unavailable request to upshift is not stored in
three-second intervals until the selector switch is memory. The upshift must be requested again.
returned to N or R.
Drive (D) is at the lower end of the three-position selec-
tor switch located at the end of the SmartShift control
lever. To select drive, press in the neutral lock button

8.48
Transmissions
Downshifting the turn. It also allows you to regain speed faster as
you come out of the curve.
NOTE: The driver can manually downshift at any
time, even when the slide switch is set to AUTO AGS Diagnostics
mode.
To request a downshift with the transmission in drive, CAUTION
push the control lever down (away from you). If the
gear is available, the transmission downshifts and the At the first sign of a transmission malfunction, take
new gear displays on the gear indicator. the vehicle out of service immediately. Depending
Downshifts are not available if the engine speed after on the type of problem, further shifting may not be
the shift would exceed 2700 rpm. If the gear requested possible, and driveline torque may be interrupted.
is unavailable, an audible alert will sound. An unavail- System Malfunction
able request to downshift is not stored in memory. The
downshift must be requested again. If the "CHECK TRANS" telltale light comes on while
driving, the audible alert sounds, and the current gear
IMPORTANT: A downshift request can never result indicator begins to flash between the current gear and
in a shift into neutral, even if the vehicle is in the "SM" (system malfunction), there is a problem which
drive position in the lowest possible gear. may or may not be apparent to the driver. Bring the ve-
hicle at once to a safe stopping place and call an au-
To achieve smooth operation in MAN mode, downshift thorized Freightliner service facility for assistance.
when the engine speed reaches approximately 1200
rpm. Clutch Overload
Before starting down a hill, slow down. Downshift to a If the "TRANS TEMP" telltale light comes on while driv-
speed that you can control without hard pressure on the ing and the current gear indicator begins to flash be-
service brakes. tween the current gear and "CO" (clutch overload), the
Before entering a curve, slow down to a safe speed. clutch has begun to overheat.
Downshift if necessary. This lets you use some power The clutch overload may have been caused by im-
through the curve to help the vehicle be more stable on proper driving practices such as frequent and rapid

8.49
 Transmissions
start/stop driving, or hillholding with the throttle pedal. In
this case, allow the clutch to cool, and continue on, but
cease the improper driving practices.
If the clutch overload message returns or continues, the
clutch is worn or damaged. Bring the vehicle at once to
a safe stopping place and call an authorized Freightliner
service facility for assistance.

Low Hydraulic Fluid Level

IMPORTANT: The only hydraulic fluid permitted in
this system is Pentosin CHF 11S. No other fluid
can be substituted.
If the "CHECK TRANS" telltale light comes on while
driving and the current gear indicator begins to flash
between the current gear and "FL" (fluid level), there
has been an unusual loss of hydraulic fluid. Bring the
vehicle at once to a safe stopping place and call an au-
thorized Freightliner service facility for assistance. The
hydraulic reservoir holds about 1.05 quarts (one liter) of
Pentosin CHF 11S.
NOTE: After hydraulic fluid loss, a special proce-
dure is required to fill the hydraulic reservoir. This
procedure must be carried out by an authorized
Freightliner service facility.

8.50
 9

Rear Axles
Meritor™ Drive Axles With Wheel Lock . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.1
Meritor™ Wheel Lock Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.1
Meritor™ Tandem Drive Axles With Axle Lock . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.2
Meritor™ Axle Lock Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.3
Rear Axles
Meritor™ Drive Axles With WARNING
Wheel Lock
Be especially careful when driving under slippery
The Meritor wheel lock is a driver-controlled traction conditions with the differential locked. Though for-
device operated from the vehicle cab. The wheel lock ward traction is improved, the vehicle can still slip
switch (Fig. 9.1) allows the driver to lock the wheels on sideways, causing possible loss of vehicle control,
the same axle together. The wheel lock indicator light personal injury, and property damage.
comes on when the wheel lock is turned on.
Meritor™ Wheel Lock
Operation
To lock the wheels and obtain maximum traction under
slippery conditions, push the wheel lock switch up.

WARNING
Lock the wheels only when the vehicle is standing
10/01/99 f610376
still or moving less than 25 mph (40 km/h). Never
Fig. 9.1, Wheel Lock Switch lock the wheels when the vehicle is traveling down
steep grades or when the wheels are slipping. This
The wheel lock provides maximum traction under slip- could damage the differential or lead to loss of ve-
pery conditions. When the wheel lock is engaged, the hicle control, causing personal injury and property
clutch collar completely locks the differential case, gear- damage.
ing, and axle shafts together, maximizing the traction of
both wheels and protecting against spinout.
NOTE: On some vehicles, the wheel lock system
is connected through the low speed range of the
Under normal traction conditions, do not use the wheel
lock feature.

9.1
 Rear Axles
transmission. If this system is used, the transmis-
sion must be in the low speed range for the A
wheels to fully lock.
If the vehicle is moving, maintain a constant vehicle
speed when the wheel lock is turned on. Briefly let up
on the accelerator to relieve torque on the gearing, al- B
lowing the wheels to fully lock. The wheel lock indicator
comes on when the wheel lock is turned on. When the
wheels are fully locked, the turning radius will increase
because the vehicle understeers. See Fig. 9.2. Drive
cautiously and do not exceed 25 mph (40 km/h).
02/09/96 f350079a
To disengage the wheel lock, move the wheel lock A. Turning Radius When the Wheel Lock is Engaged
switch to the center position. Briefly let up on the accel- (understeer condition)
erator to relieve torque on the gearing, allowing the B. Turning Radius When the Wheel Lock is
wheels to fully unlock. Disengaged
NOTE: If the wheel lock system is connected Fig. 9.2, Turning Radii
through the low speed range of the transmission,
shifting out of low speed range will also disengage Meritor™ Tandem Drive Axles
the wheel lock.
With Axle Lock
When the wheel lock is disengaged, the wheel lock indi-
cator will turn off. Meritor tandem drive axles have an axle lock feature.
The axle lock is controlled by the axle lock switch
(Fig. 9.3) on the control panel.
When the axle lock is not engaged, there is differential
action between the two axles. The differential compen-
sates for different wheel speeds and variations in tire

9.2
Rear Axles
tions, push the axle lock switch up while maintaining
vehicle speed. Let up momentarily on the accelerator to
engage the axle lock. Proceed over poor road condi-
tions with caution. Do not wait until traction is lost and
the tires are spinning before engaging the axle lock.

CAUTION
Do not turn the differential lock and/or interaxle lock
10/01/99 f610377 switch on while the WHEEL SPIN indicator light is
on. To do so could damage the rear axle.
Fig. 9.3, Axle Lock Switch
To disengage the axle lock after leaving poor road con-
size. Keep the axle lock disengaged when driving on ditions, move the axle lock switch to the center position
roads where traction is good. while maintaining vehicle speed. Let up momentarily on
When the axle lock is engaged, the axles are locked the accelerator to allow the shift, then resume driving at
together and the driveshaft becomes a solid connection normal speed.
between the two axles. Power entering the forward axle
is transmitted straight through to the rear axle so that
both axles turn together at the same speed. The axle
lock should be used when the vehicle encounters poor
traction conditions; however, it also increases drivetrain
and tire wear and should be used only when improved
traction is required.

Meritor™ Axle Lock Operation

To engage the axle lock and achieve maximum pulling
power when approaching slippery or poor road condi-

9.3
 10

Fifth Wheels
Holland Fifth Wheels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.1
Fontaine® Fifth Wheels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.4
Fifth Wheels
Holland Fifth Wheels The Type B kingpin lock mechanism (Fig. 10.2) utilizes
two spring-loaded lock halves. The final forward motion
3500 Series Stationary Models of the kingpin into the open lock halves forces the locks
to close around the kingpin. The kingpin can be re-
Holland 3500 Series stationary fifth wheels are best leased only by pulling the release handle all the way
suited for applications where the axle loading, kingpin out. The lock adjustment nut will compensate for wear
setting, and vehicle combination length all remain con- on the lock or kingpin.
stant throughout the fleet. The stationary fifth wheel can
be a plate mount or an angle mount. See Fig. 10.1.

3 3
2 2
4 4

A B
11/10/1999 f310823

A. Plate Mount B. Angle Mount

1. Release Handle 3. Top Plate
2. Lock Adjustment Nut 4. Lock Mechanism
Fig. 10.1, Holland 3500 Series Fifth Wheels

10.1
 Fifth Wheels
2 2
A B
1
1

3
3
5
4
07/11/2000 f310841

A. Closed Position, Locked B. Open Position, Unlocked

1. Release Handle and Spring 3. Lock Halves 5. Sliding Yoke
2. Adjustment Nut 4. Lock Pivot

Fig. 10.2, Type B Kingpin Lock Mechanism (bottom view)

Fifth Wheel Locking Operation WARNING

Locking the Fifth Wheel Mechanism
Keep the fifth wheel plate lubricated to prevent
1. Make sure the coupling area is level and clear of binding between the tractor and trailer. A binding
persons and obstacles. fifth wheel could cause erratic steering and loss of
2. The fifth wheel plate must be completely lubricated vehicle control, possibly resulting in serious per-
with chassis grease. For lubrication instructions, sonal injury or death.
see Group 31 of the Acterra® Maintenance Manual. 3. Make sure the locks are open. If the locks are
closed, pull the release handle all the way out.

10.2
Fifth Wheels
4. Position the tractor so that the fifth wheel lock 11. Make a visual inspection for proper kingpin lockup.
opening is in line with the trailer kingpin. Make sure the lock is closed and that the adjust-
ment nut is snug against the fifth wheel.
5. Back the tractor close to the trailer and stop.
6. Chock the trailer wheels. WARNING
7. Apply the trailer brakes.
The coupling procedure is not complete without an
8. Adjust the trailer height so that the fifth wheel will inspection. You must get out of the tractor and
lift the trailer. The trailer should contact the fifth verify that the fifth wheel is properly coupled to the
wheel four to six inches (10 cm to 15 cm) behind kingpin. Failure to verify that the fifth wheel is prop-
the fifth wheel bracket pin. erly coupled to the kingpin could cause the trailer
9. Slowly back the tractor in to the trailer. to detach from the tractor, possibly resulting in seri-
ous personal injury or death.
10. Test for kingpin lockup by pulling on the trailer
against the chocks. Check for correct maximum 12. After lockup is completed, connect the tractor-to-
clearance between the lock halves. If more than trailer air system lines and electrical cable to the
1/8-inch (3.2-mm) clearance exists between the trailer. Take care to prevent dirt or foreign material
lock halves, the lock must be adjusted. See Group from entering the air lines.
31 of the Acterra® Workshop Manual for adjustment 13. Charge the air brake system with air. Make sure
procedures. that the air connections do not leak.
14. Retract the trailer landing gear and secure the
WARNING ratchet handle.
Adjust the locks correctly to a maximum clearance 15. Remove the chocks from the trailer tires.
of 1/8 inch (3 mm). Incorrect adjustment of the lock 16. The load distribution on the front steering axle and
could cause the trailer to disconnect, possibly re- rear drive axle(s) will have a direct effect on the
sulting in serious personal injury or death. steering control of the vehicle.

10.3
 Fifth Wheels
Determine the front and rear axle weights by weigh-
ing the vehicle on scales designed for this purpose. WARNING
The maximum axle weight ratings are shown on the Do not use the trailer service brakes for parking;
Federal Motor Vehicle Safety Standard (FMVSS) they are not designed for this purpose. If air bleeds
label or Canadian Motor Vehicle Safety Standard out of the trailer air tank during parking, the vehicle
(CMVSS) label attached to the left rear door post of could roll causing serious personal injury or prop-
the tractor. The desired load on the axle is no less erty damage.
than 80 percent of the maximum axle weight rating,
but in no instances should the axle load exceed the 4. Lower the trailer landing gear until the weight is re-
maximum axle weight rating given on the FMVSS moved from the fifth wheel.
or CMVSS label.
5. Disconnect the tractor-to-trailer air system lines and
electrical cable. Plug the air lines to prevent dirt or
WARNING foreign material from entering the lines.

Do not overload any tractor axle by improperly 6. Release the kingpin locking mechanism by pulling
loading the trailer. This could cause erratic steering the release handle (Fig. 10.1) all the way out.
and loss of vehicle control, possibly resulting in 7. Slowly drive the tractor away from the trailer.
serious personal injury or death.

Unlocking the Fifth Wheel Lock Mechanism Fontaine® Fifth Wheels

1. Apply the tractor parking brakes. 6000/7000 Series No-Slack® II
2. Pull the trailer air supply valve to cut off the air sup- Stationary Models
ply to the trailer.
On Fontaine fifth wheels, kingpin release is accom-
3. Chock the front and rear of the trailer tires to pre- plished by pulling the release handle located on the
vent the trailer from moving. side of the fifth wheel. Kingpin lockup occurs when the
kingpin is forced into the jaws and the release handle
moves to the locked position.

10.4
Fifth Wheels
The fifth wheel top plate is mounted to the tractor frame
2 A
using a mounting angle. The fifth wheel should be
mounted in a position that best distributes the trailer
load over the tractor axles. 1

Fifth Wheel Lock Mechanism for

Trailer Kingpin
The Fontaine fifth wheel lock mechanism (Fig. 10.3) for
the trailer kingpin consists of a spring-loaded jaw and a 3
sliding wedge. The jaw and wedge each have a pin per-
manently attached. The pin on the jaw and the pin on B C
the wedge fit into elongated notches in the release
handle. The notches in the handle control the limit of
movement for both the jaw and wedge. The notches are
arranged so that the wedge is actuated first during re-
lease of the kingpin.
During lockup, the jaw is moved first with the spring-
01/04/95 f310184c
loaded wedge being allowed to slip into place against
the jaw. A timing bracket ensures that the wedge and NOTE: Kingpin correctly entering the lock. Note how the
jaw are moved at the correct time. steel tongue allows lock halves to close completely
around the neck and shoulder of the kingpin.
Placing the release handle in the unlocked position
moves the wedge away from the jaw. This action un- A. Unlocked Position C. Locked
B. Locking
locks the jaw so that it can be moved by the trailer king-
pin. When the tractor is moved out from under the 1. Wedge 3. Trailer Kingpin
trailer, the kingpin moves the jaw until the kingpin is out 2. Jaw
of the mechanism. With the jaw in the unlocked posi- Fig. 10.3, Fontaine Kingpin Lock Mechanism
tion, the release handle will remain in the unlocked po-
sition until manually moved by the operator.

10.5
 Fifth Wheels
During coupling, the motion of the kingpin entering the tion, and the fifth wheel plate must be completely
jaw will move the jaw and wedge. The jaw will move lubricated with chassis grease. If the fifth wheel is
behind the kingpin, followed by the wedge. The purpose equipped with a retractable handle, the handle will
of the wedge is to reinforce the jaw and take up slack not be fully extended. For lubrication instructions,
around the pin. Any wear on the jaw is immediately see Group 31 of the Acterra® Maintenance Manual.
taken up by the wedge so there is no slack in the con-
nection.
WARNING
Correct adjustment of the wedge stop rod is important
to the proper functioning of the locking mechanism. For Keep the fifth wheel plate lubricated to prevent
adjustment instructions, see Group 31 of the Acterra® binding between the tractor and trailer. A binding
Maintenance Manual. fifth wheel could cause erratic steering and loss of
vehicle control, possibly resulting in serious per-
Special precautions must be taken during cold weather
sonal injury or death.
to ensure that the Fontaine® No-Slack® locking mecha-
nism operates freely. Ice and sludge can build up and 3. Position the tractor so that the fifth wheel lock
lubricants become thick and binding at low tempera- opening is in line (both vertically and horizontally)
tures. When the temperature drops below freezing, Fon- with the trailer kingpin. The kingpin should be in a
taine recommends the use of a cleaner or degreaser on position to enter the throat of the locking mecha-
the latching mechanism, making sure that the moving nism, as shown in Fig. 10.3. Adjust the trailer land-
parts operate freely. This should be followed by an ap- ing gear to give enough alignment height for posi-
plication of 90-weight oil to all moving parts. tive kingpin lockup.
4. With the fifth wheel lock opening aligned with the
Fifth Wheel Locking Operation trailer kingpin, back the tractor slowly toward the
Locking the Fifth Wheel Lock Mechanism trailer, making sure that the kingpin enters the
throat of the locking mechanism. Continue back-
1. Chock the front and rear of the trailer tires to pre- ward motion until positive lockup occurs.
vent the trailer from moving.
5. Apply the tractor parking brakes.
2. The kingpin lock mechanism must be fully open,
the release handle should be in the extended posi-

10.6
Fifth Wheels
6. Make a visual and physical check for positive king- 8. After lockup is completed, connect the tractor-to-
pin lockup. When lockup has occurred, the fifth trailer air system lines and the electrical cable to
wheel release handle will have moved to the locked the trailer. Take care to prevent dirt or foreign mate-
position. See Fig. 10.4. rial from entering the air system lines.
7. Release the tractor parking brakes. Test for kingpin 9. Charge the air brake system with air. Make sure
lockup by pulling on the trailer against the chocks. that the air connections do not leak.

A 1 B
1

2 3

11/12/99 f310825
NOTE: Make sure the safety latch is down when the control handle is locked.
A. Locked B. Unlocked
1. Release Handle 2. Jaw 3. Wedge

Fig. 10.4, Fontaine 6000/7000 Series Fifth Wheel, Locked and Unlocked (bottom view)

10.7
 Fifth Wheels
10. With the trailer wheels chocked and the brakes set, (CMVSS) label attached to the left rear door post of
check for clearance between the kingpin and the the tractor. The desired load on the axle is no less
fifth wheel jaws by moving the tractor forward and than 80 percent of the maximum axle weight rating,
backward against the locked kingpin. There should but in no case should the axle load exceed the
be no slack between the tractor and the trailer. If maximum axle weight rating given on the FMVSS
slack is present, uncouple the trailer. or CMVSS label.
For adjustment instructions, refer to the manufactur-
er’s service information. WARNING
Do not overload any tractor axle by improperly
WARNING loading the trailer. This could cause erratic steering
and loss of vehicle control, possibly resulting in
Eliminate slack between the trailer and the tractor.
serious personal injury or death.
Incorrect fifth wheel adjustment could cause the
trailer to disconnect, possibly resulting in serious
Unlocking the Fifth Wheel Lock Mechanism
personal injury or death.
1. Apply the tractor parking brakes.
11. Retract the trailer landing gear, and secure the
ratchet handle. 2. Pull the trailer air supply valve to cut off the air sup-
ply to the trailer.
12. Remove the chocks from the trailer tires.
3. Chock the front and rear of the trailer tires to pre-
13. The load distribution on the front steering axle and
vent the trailer from moving.
rear drive axle(s) will have a direct effect on the
steering control of the vehicle.
Determine the front and rear axle weights by weigh-
WARNING
ing the vehicle on scales designed for this purpose.
Do not use the trailer service brakes for parking;
The maximum axle weight ratings are given on the they are not designed for this purpose. If air bleeds
Federal Motor Vehicle Safety Standard (FMVSS) out of the trailer air tank during parking, the vehicle
label or Canadian Motor Vehicle Safety Standard

10.8
Fifth Wheels
could roll causing serious personal injury or prop-
erty damage.
4. Lower the trailer landing gear until the weight is re-
moved from the fifth wheel.
5. Disconnect the tractor-to-trailer air system lines and
electrical cable. Plug the air lines to prevent dirt or
foreign material from entering the lines.
6. Release the kingpin locking mechanism by pulling
the release handle to the unlocked position. See
Fig. 10.4.
7. Slowly drive the tractor away from the trailer.

10.9
 11

Pretrip Inspection and Daily

Maintenance
Pretrip Inspection Checklist . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11.1
Pretrip Inspection and Daily Maintenance Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11.3
Pretrip Inspection and Daily Maintenance
Pretrip Inspection Checklist 4. Check the fluid level in the windshield washer res-
ervoir.
The following pretrip inspection checklist helps ensure 5. If equipped with oil-lubricated wheel bearings,
that the vehicle components are in good working condi- check the front hub lubricant level.
tion before each trip.
6. Check the power steering hoses for chafing.
Pretrip inspections cannot be done quickly. In checklist
form, the sequence below may seem to be overly time- 7. Check the coolant level in the surge tank and check
consuming. However, careful pretrip inspections save the radiator and charge air cooler cooling fins for
time by eliminating stops later to adjust items over- clogging or damage. Check the radiator for coolant
looked or forgotten. leaks.
Each checklist step corresponds with detailed instruc- 8. Check the condition of the coolant hoses and
tions found under "Pretrip Inspection and Daily Mainte- heater hoses.
nance Procedures." If any system or component does
9. Check the condition of the drive belts.
not pass this inspection, it must be corrected before
operating the vehicle. See the Acterra® Workshop 10. Inspect the engine for fuel, oil, and coolant leaks.
Manual for repair procedures and specifications, and
the Acterra® Maintenance Manual for lubricant recom- 11. Check the engine oil level.
mendations, specifications, and maintenance intervals 12. If equipped with automatic transmission, check the
and procedures. automatic transmission oil level.
NOTE: Apply the parking brakes and chock the 13. If equipped with a fuel/water separator, check the
tires. fuel/water separator for contaminants.
1. If equipped with an air brake system, drain the air 14. Inspect the engine and chassis wiring.
reservoirs.
15. Inspect the intake-air system for leaks or damage.
2. Inspect the batteries and battery cables. Check the intake-air restriction indicator if it is
mounted on the intake-air system.
3. Tilt the hood. Examine the steering gear compo-
nents.

11.1
 Pretrip Inspection and Daily Maintenance
16. If equipped with hydraulic brakes, check the fluid 25. Close the hood and engage the hood hold-down
level in the hydraulic brake fluid reservoir. latches. Close the drain valves on the air brake
system air tanks.
17. If equipped with a hydraulic clutch control, check
the fluid level in the hydraulic clutch fluid reservoir. 26. Check for excessive play at the steering wheel.
18. Inspect the fuel tank(s) and fuel line connections. If 27. Adjust the driver’s seat, then align the rearview and
equipped with fuel tank shutoff valves, be sure the downview mirrors.
valves are open.
28. If equipped with mechanical clutch linkages, check
19. Check the fuel level in the fuel tank(s) and be sure the clutch pedal free-travel.
the fuel cap vent area is clean. If equipped with a
fuel/water separator, check it for leaks. If needed, 29. Check the seat belts for secure mounting and for
prime the fuel tank system. damage.

20. If equipped with a transmission oil cooler, check the 30. Secure or remove loose items and in the cab.
oil cooler for debris and for leaks. 31. Check the air restriction indicator if it is dash
21. If equipped with a fifth wheel, inspect the fifth wheel mounted.
and check it for adequate lubrication. 32. Turn on the ignition and start the engine. If
22. Inspect the front and rear suspension components, equipped with air- and oil-pressure warning sys-
including the springs, shocks, and suspension tems, be sure the systems are operating. Leave the
brackets. engine running.

23. Clean the headlights, the rearview and downview 33. Make sure the electric horn, air horn, windshield
mirrors, the outer windshield, and all window glass. wipers and washer, heater, defroster, and heated
Check the condition of the windshield wiper arms mirrors, if equipped, are operating properly.
and blades. 34. Check the operation of the backup alarm if so
24. Clean the inside of the windshield, the gauges on equipped.
the dash, and all window glass. 35. Turn on the lights. Check the operation of all gauge
lights and interior lights. Leave the lights on.

11.2
Pretrip Inspection and Daily Maintenance
36. On tractor-trailer combinations, inspect the 7-way 46. Test the service brakes before leaving the lot.
trailer cable receptacle(s) for good connections.
47. Test the parking brakes on a 20 percent grade.
37. If not already done, hook the trailer(s) to the vehicle
and inspect the trailer system.
Pretrip Inspection and Daily
38. Make sure all of the lights are working, including
the brake lights, fog lights (if equipped), high- and
Maintenance Procedures
low-beam headlights, turn signals, clearance lights, Whenever equipment requires adjustment, replacement,
and hazard warning lights. Check the condition of repair, addition of lubricants, or a change of lubricants,
the reflectors. Turn the lights off. see the Acterra® Workshop Manual for repair proce-
39. Check the outer surfaces of the hood, cab, and dures and specifications, and the Acterra® Maintenance
trailers for visible surface breaks and damage. Manual for lubricant recommendations, specifications,
Make sure the trailer doors are secure. and maintenance intervals and procedures.

40. If equipped with an air brake system, inspect the

brake chamber pushrods, air reservoirs, and air WARNING
lines.
Failure to drain the air reservoirs as instructed
41. Check brake lining wear on vehicles with air could cause sludge formation in the air brake sys-
brakes. tem. Sludge could adversely affect braking, causing
loss of control, which could cause death, personal
42. Make sure the brakes are adjusted on all axles.
injury, or property damage.
43. Check the tire inflation pressures and inspect each
tire for bulges, cracks, cuts, and penetrations.
NOTE: If the air tanks are not equipped with auto-
Check tire wear. matic drain valves, they must be drained daily. If
they are equipped with automatic drain valves,
44. Check for indications of loose wheel nuts or rim they must be drained in this same manner at least
nuts, and examine each rim and wheel component. once a week.
45. Check the air brake system for proper operation.

11.3
 Pretrip Inspection and Daily Maintenance
1. Air reservoirs are storage tanks for compressed air. 1.3 Water and oil emulsion often forms pockets
They collect water condensed from the air, and which will not drain while compressed air is
small amounts of oil from the air compressor. Water in the reservoirs. Because of these pockets,
and oil normally enter the reservoir in the form of leave the valves blocked open during the
vapor because of the heat generated during com- first part of the pretrip inspection.
pression.
2. Inspect the batteries and battery cables.
After the water and oil condense, they collect near
the tank drain valves. Drain the resulting emulsion
as follows: WARNING
1.1 Open the wet tank valve (the drain cock or Battery posts, terminals, and related accessories
pull-chain drain located on the forward end contain lead and lead compounds, chemicals
of the supply air reservoir which is con- known to the State of California to cause cancer
nected directly to the air compressor). Block and reproductive harm. To prevent possible per-
the valve open. sonal injury, always wash your hands after handling
battery parts and related accessories.
WARNING 2.1 Be sure the battery hold-down is secure. If it
is loose, tighten the hold-down bolts. If it is
When draining the air reservoir, do not look into the broken, replace it.
air jets or direct them toward anyone. Dirt or sludge
particles may be in the airstream and could cause
injury. CAUTION
1.2 Exhaust the remaining air and moisture from Take care to keep the vent plugs tight so that the
the system by opening the drain cocks on neutralizing solution does not enter any of the bat-
the bottoms of the remaining air reservoirs. tery cells and damage the battery.
Block the valves open.

11.4
Pretrip Inspection and Daily Maintenance
2.2 Remove any corrosion from the hold-down ply with the washer fluid manufacturer’s recom-
and the top of the battery. Use diluted am- mended safety precautions.
monia or a soda solution to neutralize the
acid present, then rinse off the ammonia or 5. Check the level of the wheel bearing lubricant in
soda solution with clean water. the front hub caps and, if needed, fill the hubs to
the level indicated on the hub cap. See Group 33
If the battery posts or cable terminals are of the Acterra® Maintenance Manual for recom-
corroded, disconnect the terminals from the mended lubricants.
posts. Clean them with a soda solution and
a wire brush. After cleaning, connect the ter- IMPORTANT: Before removing the fill plug, always
minals to the battery posts, then apply a thin clean the hub cap and plug.
coat of petroleum jelly to the posts and ter- 6. Check the power steering hoses for leakage around
minals to help retard corrosion. the fittings. Replace any damaged hoses and
3. Examine the steering gear mounting bolts, pitman tighten all fittings to stop leakage.
arm nut, and the drag link nuts for tightness. Be
sure the steering driveline and the U-joints are in CAUTION
roadworthy condition without cracks, breaks, loose-
ness or other damage. Tighten loose nuts and re- Coolant must be filled to the full line of the surge
place damaged parts as needed. See Group 46 of tank. Low coolant could result in engine overheat-
the Acterra® Workshop Manual. ing, which could cause engine damage.
4. Check the fluid level in the windshield washer res- 7. If the coolant level is low, check the amount of anti-
ervoir. Add windshield washer fluid as needed. freeze protection. If the protection is adequate, add
a 50/50 mixture of water and antifreeze. If addi-
WARNING tional protection is needed, add antifreeze only. Fill
to the level of the bottom of the surge tank fill neck.
Washer fluids may be flammable and poisonous. Do Good airflow through the radiator core and the
not expose washer fluid to an open flame or any charge air cooler core is essential for proper engine
burning material, such as a cigarette. Always com- cooling. The cores allow air passage, but form a

11.5
 Pretrip Inspection and Daily Maintenance
particle barrier which tends to collect insects and Silicone hoses, having an extended service life, can
airborne debris. be substituted for the reinforced neoprene type. Re-
fer to the Service Parts Catalog or contact your
Inspect for clogged fins. Use compressed air or wa-
Sterling Dealer.
ter directed from the fan side of the core to back-
flush any material restricting airflow. Tighten hose clamps as necessary, but do not over-
tighten as hose life can be adversely affected.
On vehicles equipped with air conditioning and/or a
charge air cooler, also inspect and clean these Be sure the hose support brackets are securely fas-
components. If clogged, the airflow through the ra- tened. Make sure the hoses are not located near
diator could be restricted. sources of wear, abrasion, or high heat.
Bent or damaged fins should also be straightened 9. Check the fan belt(s), alternator belt, and refrigerant
to permit airflow across all areas of the cores. compressor belt for signs of glazing, wear (frayed
Repair or replace the radiator if it is leaking. See edges), damage (breaks or cracks), or oil contami-
Group 20 of the Acterra® Workshop Manual for in- nation. If a belt is glazed, worn, damaged, or oil
structions. soaked, replace the belt following the instructions in
Group 01 of the Acterra® Workshop Manual.
NOTE: When traveling through areas of high in- Check all of the belts for proper tension. Use your
sect concentrations, it may be necessary to clean index finger to apply approximately 25 pounds (11
the exterior of the radiator or charge air cooler kg) of force at the center of the belt free-span. See
core as often as every 200 miles (320 km). Fig. 11.1. Deflection should be one belt thickness
8. Make sure the radiator inlet and outlet coolant per 1 foot (300 mm) of belt free-span. If the tension
hoses and heater hoses are pliable and are not is more than or less than this value, measure it with
cracking or ballooning. Replace hoses that show a belt-tension gauge and adjust it to the proper ten-
signs of cracking, weakening, or ballooning. Re- sion. See Group 01 of the Acterra® Workshop
place all hoses, including heater hoses, at the Manual for instructions.
same time. Service-type knitted or braided yarn- NOTE: On Cummins engines, a belt tensioner au-
reinforced neoprene hose is acceptable. tomatically adjusts the fan and alternator belt to

11.6
Pretrip Inspection and Daily Maintenance
CAUTION
Operating the engine with the oil level below the
low mark or above the high mark could result in en-
gine damage.
A
NOTE: The automatic transmission fluid must be
B warm to ensure an accurate check. The fluid level
rises as temperature increases.
10/31/94 f200036a 12. With the vehicle on a level surface, check the oil
level in the transmission using the hot check or cold
A. Deflection B. Belt Free-Span
check procedure.
Fig. 11.1, Checking Belt Tension 12.1 Hot Check
the correct tension. If the belt slips, repair or re- • Operate the transmission in a drive
place the tensioner. For instructions, see the Cum- range until normal operating tempera-
mins Shop Manual B Series Engines. ture, 160 to 200°F (71 to 93°C), is
reached.
10. Inspect the engine for fuel, oil, and coolant leaks
and correct any leaks found. • Park the vehicle. Shift to neutral (N)
and apply the parking brake. Let the
11. The engine oil level should show between the up- engine run at idle.
per and lower marks on the dipstick. Add enough
oil to bring the level up to the operating range. Re- • Wipe the dipstick clean and check the
fer to the engine manufacturer’s operation and fluid level. A safe operating level is
maintenance manual for recommended lubricants any level within the HOT RUN (upper)
and capacities. band on the dipstick.

11.7
 Pretrip Inspection and Daily Maintenance
• If the fluid is not within this range, add open the drain valve under the collection bowl and
or drain fluid as needed to bring the drain water and contaminants as needed.
level to the top of the HOT RUN band.
See Group 26 of the Acterra® Mainte- 14. Inspect the engine and chassis for loose wiring,
nance Manual for fluid capacities. chafed insulation, and damaged or loose hold-down
clamps. Tighten loose wires or hold-down clamps.
12.2 Cold Check Replace damaged wiring or clamps.
• A cold check may be made when the 15. Check the intake-air restriction indicator to deter-
sump temperature is 60 to 104°F (15 mine if the air cleaner filter element needs to be
to 40°C). changed. Replace the filter element if the yellow
signal stays locked at 25 inH2O for Cummins or
• Run the engine for at least one minute Caterpillar engines or 22 inH2O for Freightliner en-
to clear the fluid system of air. gines. See Group 09 of the Acterra® Workshop
• With the engine running, wipe the dip- Manual for filter element replacement instructions.
stick clean and check the fluid level. Check the engine air intake piping from the air
Any level within the COLD RUN cleaner to the engine intake. Inspect the piping for
(lower) band is satisfactory for operat- loose connections, cracks, torn or collapsed hoses,
ing the vehicle. If the level is not punctures, and other damage. Tighten loose con-
within the COLD RUN band, add or nections and replace damaged components. Make
drain fluid until it reaches the middle sure the piping system is airtight so that all of the
of the COLD RUN band. intake air passes through the air cleaner.
• Perform a hot check at the first oppor-
tunity after the normal operating tem- CAUTION
perature of 160 to 200°F (71 to 93°C)
is reached. Failure to maintain a sealed air intake system could
13. If equipped with a fuel/water separator, check it for allow the entry of dirt and contaminants into the
contaminants. With the engine shut down, partially engine. This could adversely affect engine perfor-
mance and result in engine damage.

11.8
Pretrip Inspection and Daily Maintenance
NOTE: After replacing the filter element, reset the 17. The clutch fluid reservoir is full when the fluid level
restriction indicator by pressing the reset button. is up to the MAX mark. The fluid level must always
be above the MIN mark. Use only heavy-duty brake
16. If needed, fill the hydraulic brake fluid reservoir up fluid, DOT 3, in the hydraulic-clutch system.
to the flange that surrounds the reservoir. Use only
heavy-duty brake fluid, DOT 3. See Fig. 11.2. 18. Replace leaking fuel tanks. Repair or replace any
lines or connections that are leaking. For proce-
dures, see Group 47 of the Acterra® Workshop
A Manual.
If equipped with fuel tank shutoff valves, be sure
the valves are fully open.

WARNING
Never operate the engine with the fuel tank shutoff
valves partly closed. This could damage the fuel
pump causing sudden loss of engine power, possi-
bly resulting in serious personal injury due to re-
B duced vehicle control.
Never fill fuel tanks to more than 95 percent of their
liquid capacity. This could make them more likely to
rupture from impact, possibly causing fire and re-
sulting in serious personal injury or death by burn-
10/31/94 f460513a ing.
A. Open caps and check fluid level.
B. Fill to this level.
19. To keep condensation to a minimum, fill the fuel
tanks at the end of each day but not to more than
Fig. 11.2, Hydraulic Brake Fluid Reservoir 95 percent of liquid capacity. Select the proper

11.9
 Pretrip Inspection and Daily Maintenance
grade of fuel as specified by the engine manufac-
turer. CAUTION
Don’t crank the engine for more than 30 seconds at
WARNING a time during any of the following procedures. Wait
two minutes after each try to allow the starter to
Do not mix gasoline or alcohol with diesel fuel. This cool. Failure to do so could cause starter damage.
mixture could cause an explosion. When filling fuel
tanks, do not smoke or use an open flame near the IMPORTANT: Before doing any of the following
fuel tanks. Combustion of diesel fuel oil or fuel va- procedures, make sure there is an adequate
pors could result, possibly causing personal injury amount of fuel in the tank(s). Do not fill the
or property damage. tank(s) to more than 95 percent of liquid ca-
IMPORTANT: Use only low-sulfur diesel fuels. pacity.
Low-sulfur diesel fuels have a maximum 0.05 19.3 On vehicles equipped with a single tank,
percent sulfur content, compared to a 0.26 to prime the fuel system, if needed. On ve-
0.30 percent sulfur content. Failure to use low- hicles with dual tanks, go to the next sub-
sulfur diesel fuels may void the warranty on step.
emission components. If the engine is equipped with a priming
19.1 Always strain or filter fuel before filling it into pump, do the following:
the tanks. This will lengthen the life of the Unlock and operate the engine priming
engine fuel filter and reduce the chances of pump plunger until resistance is felt.
dirt entering the engine.
Push the plunger in and tighten it by hand.
19.2 Before installing the fuel cap, check the vent
line for debris. Clean the area around the Start the engine. If it doesn’t start, more
fuel tank cap with a rag or, if necessary, priming is needed. Once the engine has
clean the fuel tank cap with solvent. started, it may run rough. If this occurs, run
the engine at low idle until it runs smoothly.

11.10
Pretrip Inspection and Daily Maintenance
If the engine is not equipped with a prim- 20. If equipped with a transmission oil cooler, remove
ing pump, do the following: debris and repair leaks as needed.
Remove the fuel tank cap. 21. If equipped with a fifth wheel, check it for adequate
Loosen the fuel supply line at the fuel trans- lubrication.
fer pump.
Partially cover the fuel tank opening with WARNING
your hand. Using an air hose, apply no more
than 5 psi (35 kPa) air pressure to the fuel Check to be sure that the trailer is securely con-
tank and look for a constant fuel flow at the nected to the tractor. Failure to achieve complete
loosened fuel supply line. fifth wheel lockup may allow disengagement of the
tractor from the trailer, possibly resulting in serious
Remove the air hose and tighten the fuel personal injury or death.
supply line.
21.1 If the vehicle is a truck-trailer combination,
Start the engine. Once the engine has be sure the trailer hitch is locked and the
started, it may run rough. If this occurs, run safety cable or chains are connected. Be
the engine at low idle until it runs smoothly. sure air hoses and the light cable are con-
IMPORTANT: To prevent fuel loss or entry of nected.
air into a fuel line, make sure that all fuel line
connections are tight. WARNING
19.4 On vehicles equipped with dual tanks and Check the lock mechanisms described above. Oth-
single suction and return lines (with cross- erwise the trailer could disengage from the tractor,
over line), prime the fuel system if needed. possibly resulting in serious personal injury or
Use the same procedure provided in the death.
previous substep for vehicles equipped with
a single tank. Do the procedure on the tank
equipped with the supply line.

11.11
 Pretrip Inspection and Daily Maintenance
21.2 If the vehicle is a tractor-trailer combination, • Incorrect jaw locking action and
check that the fifth wheel lock mechanism is cracks or wear on the jaw locking
locked to the trailer kingpin. See Chapter 10 mechanism. Replace the mechanism
for instructions. if cracked or worn. Repair it if the jaw
locking action is incorrect.
WARNING • Gouges or wear on the fifth wheel
plate. Replace the plate if damaged or
Repair or replace damaged or worn fifth wheel com- worn.
ponents. The use of damaged or worn components
could cause the trailer to detach from the tractor, • Fatigue or cracking of welds, which
possibly resulting in serious personal injury or must be repaired according to the
death. manufacturer’s specifications.

NOTE: For adjustment and replacement in-

structions, see Group 31 of the Acterra®
WARNING
Workshop Manual. Keep the fifth wheel plate lubricated to prevent
21.3 With the trailer unhooked from the tractor, binding between the tractor and trailer. A binding
inspect the fifth wheel (daily) for the follow- fifth wheel could cause erratic steering and loss of
ing conditions: vehicle control, possibly resulting in serious per-
sonal injury or death.
• Loose nuts or broken bolts on the fifth
wheel assembly, slider mechanism, 21.4 Lubricate the fifth wheel top plate and other
and mounting brackets. Replace bro- grease points at least once a week, and
ken bolts and tighten loose nuts. more often in severe service.

• Cracks or wear on the fifth wheel as- Before connecting the fifth wheel to the
sembly and mounting brackets. Re- trailer kingpin, always be sure that the fifth
place each damaged or worn compo- wheel plate is completely lubricated with
nent. chassis grease.

11.12
Pretrip Inspection and Daily Maintenance
21.5 Clean all foreign material from the fifth wheel 23. Be sure the windshield wiper blades are tensioned
top plate. Lubricate the top plate surface, against the windshield. Inspect the wiper blades for
pickup ramps, and mounting bracket pivot damage and deteriorated rubber. Replace the wiper
pins using a waterproof or multipurpose arms if the wiper blades are not tensioned against
chassis lubricant. Lubricate the jaw mecha- the windshield. Replace damaged or deteriorated
nism on all units. wiper blades.
22. Check the front and rear suspensions for broken
spring leaves, loose U-bolts, cracks in the suspen- WARNING
sion brackets, and loose fasteners in the spring
hangers and shackles. Inspect the shock absorbers Replace wiper arms and blades when necessary to
for loose fasteners and leaks. maintain good visibility. Poor visibility could inter-
fere with the driver’s ability to control the vehicle,
Tighten all loose fasteners and replace any compo- possibly resulting in serious personal injury or
nent that is worn, cracked, or otherwise damaged. death.
24. Clean the inside of the windshield, the gauges on
WARNING the dash, and all window glass.
Do not replace individual leaves of a damaged front 25. Close the hood and engage the hood hold-down
or rear suspension leaf spring assembly; replace latches.
the complete spring assembly. Visible damage,
such as cracks or breaks, to one leaf causes hidden 26. Check the steering wheel for excessive play. With
damage to other leaves. Replacement of only the the front tires straight ahead, turn the steering
visibly damaged part(s) is no assurance that the wheel until motion is observed at the front wheels.
spring is safe. If cracks or breaks exist on front Align a reference mark on a ruler, then slowly turn
spring assemblies in either of the two top leaves, a the steering wheel in the opposite direction until
loss of vehicle control could occur. Failure to re- motion is again detected at the wheels. Measure
place a damaged spring assembly could cause an the lash (free play) at the rim of the steering wheel.
accident resulting in serious personal injury or See Fig. 11.3.
property damage.

11.13
 Pretrip Inspection and Daily Maintenance
Excessive lash exists if steering wheel movement pedal stroke. With the clutch pedal in this range,
exceeds 4-3/4 inches (121 mm) with a 18-inch the clutch is fully engaged and the only resistance
(470-mm) steering wheel. If there is excessive lash, to clutch pedal movement is return spring tension.
check the steering system for wear or incorrect ad- Clutch pedal free-travel should be approximately
justment of the linkage and steering gear before 1-1/2inches (38 mm). If the clutch pedal free-travel
operating the vehicle. is less than 3/4 inch (19 mm), the clutch must be
adjusted internally. For instructions, see Group 25
of the Acterra® Workshop Manual.

CAUTION
A
Excessive clutch free pedal may prevent complete
clutch disengagement; insufficient clutch pedal
free-travel causes slippage and short clutch life.
Never wait for the clutch to slip before making a
clutch adjustment.
29. Inspect the seat belts and tether belts, if equipped.
See Fig. 11.4.
01/04/2000 f461749

A. Lash Area WARNING

Fig. 11.3, Measuring Lash at the Steering Wheel Inspect and maintain seat belts as instructed below.
Worn or damaged seat belts could fail during a sud-
27. Adjust the driver’s seat, then align the rearview and den stop or crash, possibly resulting in serious in-
downview mirrors. jury or death.
28. The main indicator for assessing clutch wear is NOTE: When any part of a seat belt system
clutch pedal free-travel. Clutch pedal free-travel is a needs replacement, the entire seat belt must
decreased resistance felt at the top of the clutch
be replaced, both retractor and buckle side.

11.14
Pretrip Inspection and Daily Maintenance
29.1 Check the web for fraying, cuts, or extreme
1 wear, especially near the buckle latch plate
1
and the D-loop guide area.
29.2 Check the web for extreme dirt or dust and
for severe fading from exposure to sunlight.
2
29.3 Check the buckle and latch for operation
and for wear or damage.
29.4 Check the Komfort® Latch for function and
cracks or other damage.
4
29.5 Check the web retractor for function and
3 damage.
29.6 Check the mounting bolts for tightness and
tighten any that are loose.

5 30. Secure or remove loose items in the cab.

6
31. Check the dash mounted intake-air restriction indi-
cator to determine if the air cleaner filter element
needs to be changed. Replace the filter element if
the yellow signal stays locked at 25 inH2O for Cum-
09/30/96 f910173 mins or Caterpillar engines or 22 inH2O for
1. Worn Web 4. Komfort Latch Mercedes-Benz engines. See Group 09 of the Ac-
2. Web 5. Retractor terra® Workshop Manual for filter element replace-
3. Buckle 6. Tether Belt ment instructions.
Fig. 11.4, Seat Belt Inspecting 32. When the engine is started, oil-pressure and air-
pressure warnings will come on until the oil pres-
sure rises above a preset minimum and the air

11.15
 Pretrip Inspection and Daily Maintenance
pressure in both the primary and secondary air res- 35. Turn on the headlights, dash lights, and hazard
ervoir systems goes above 64 to 76 psi (441 to 524 warning lights and leave them on. Check the opera-
kPa). If the air pressure in both systems is above tion of the dome light.
64 to 76 psi (441 to 524 kPa) when the engine is
If any of the gauge lights, the dome light, or the
started, test the low pressure warning system by
right- and left-turn signal indicators are not working,
lowering the pressure to below this range or until
replace the bulb.
the warning system comes on.
If the warning systems do not come on when the 36. On tractor-trailer combinations, inspect the 7-way
ignition is turned on, repair the systems. trailer cable receptacle(s) for good connections.
Clean and grease the 7-way socket and plug regu-
CAUTION larly, especially in regions where magnesium chlo-
ride or calcium chloride are used as road de-icers.
Failure to repair the engine shutdown/warning sys- These chemicals are highly corrosive to brass and
tem could result in a sudden engine shutdown, copper, the base materials for the contact pins used
without warning, during vehicle operation. in the 7-way receptacles. Clean the socket and plug
with a plug brush and apply a moderate amount of
33. Make sure that both the electric horn and the air dielectric grease to both the socket and plug pins.
horn work. Then check the wiper and washer con- See Group 15 of the Acterra® Maintenance Manual
trol. During cold weather, check the operation of the for an approved dielectric grease.
heater and defroster controls and, if equipped with
optional mirror heat, turn on the mirror heat switch 37. Whether or not the trailer was already hooked to
and make sure the system is working. the vehicle, check the following:

These devices must be in good working order for

safe vehicle operation. If they are not working, re- WARNING
pair them before trip departure.
Check the lock mechanisms described above. Oth-
34. If equipped with a backup alarm, make sure the erwise the trailer could disengage from the tractor,
alarm is working. possibly resulting in serious personal injury or
death.

11.16
Pretrip Inspection and Daily Maintenance
37.1 Make sure all fifth wheel connections are Replace light bulbs or sealed beam units that are
engaged and locked. Check that all connec- not working.
tions to the dolly or trailer hitch and safety
Be sure all reflectors and lenses on the tractor and
chains are secure.
trailer(s) are in good condition and are clean. Re-
37.2 Make sure the gladhands in front of each place any broken reflectors or lenses. Turn the
trailer are engaged and that all air hoses are lights off.
properly suspended.
39. Check the outer surfaces of the hood, cab, and
37.3 Make sure the air shutoff valves are turned trailers for visible surface breaks and damage.
on and air is available to the lines on the Make sure the trailer doors are secure.
trailer(s).
40. If equipped with an air brake system, check the air
Make sure that the air shutoff valve at the brake components for worn pins on brake chamber
back of the last trailer is turned off. pushrods, and missing or damaged cotter pins on
the brake chamber pushrod pins. Replace worn
37.4 Make sure all light cables are connected and pins and install new cotter pins if necessary.
correctly suspended.
Inspect the front air brake lines for leaks at the fit-
Check that all trailer lights are working. ting where the lines enter the air chamber.
37.5 On trailers, make sure the landing gear sup- With an assistant, turn the wheels to full lock in one
ports are raised and the handles are secure. direction and hold down the service brake pedal.
Refer to the trailer manufacturer’s detailed Carefully inspect the front brake air lines where the
trailer inspection procedures for additional lines enter the air chambers. Turn the wheels to full
information. lock in the other direction, hold down the service
pedal, and repeat the inspection.
38. Be sure the brake lights, taillights, side marker
lights, fog lights (if equipped), headlights, turn sig- If there is a leak, replace the hose. See Group 42
nal lights, clearance, and identification lights are of the Acterra® Workshop Manual for the hose re-
working and are clean. See Fig. 11.5. Test the high placement procedure.
beams and low beams of the headlights.

11.17
 Pretrip Inspection and Daily Maintenance
5 surfaces of the reservoirs are painted to prevent
4 4 corrosion damage. Inspect the reservoir surfaces
for damage, such as cracks and dents. Replace
corroded or damaged reservoirs with new ones. Do
not repair damaged reservoirs. Old or used reser-
voirs are not acceptable as replacements. If a res-
ervoir requires replacement, see Group 42 of the
Acterra Workshop Manual for instructions.
Inspect the air lines as follows:
3 1
40.1 Check the clearance between the hoses,
exhaust manifold, and turbocharger or other
hot spots. Excessive heat will cause the ma-
2
terial in the hoses to deteriorate rapidly or
become brittle. Provide at least six inches
1 (150 mm) of clearance. More clearance is
needed if the hose is located above the heat
source.
40.2 Check for kinks, dents, or swelling of the
11/17/99 f601856 hoses. If a hose is damaged, replace it with
1. Headlight 4. Clearance Light the same size and type.
2. Turn Signal Light 5. Identification Lights 40.3 Do not route the hose on top of anything
3. Side Marker Light likely to be stepped on or walked on.
Fig. 11.5, Exterior Light Locations 40.4 Check for damage to hoses located near
moving parts such as drivelines, trailer bod-
Check for rusted connections, missing snap rings,
ies, kingpins, suspensions, and axles. If the
and damaged camshaft grease seals. Repair or
moving parts are catching or pinching the
replace damaged or missing parts. Check the air
lines, correct as needed.
reservoir band fasteners. Make sure the outside

11.18
Pretrip Inspection and Daily Maintenance
40.5 Check for hose damage caused by abrasion.
If a hose is abraded, replace it. Check for
the cause of abrasion such as loose or dam-
aged hose clamps. Repair or replace the
clamps as needed.
40.6 Observe the hose cover condition, especially
hoses exposed to water splash and ice. If
any hose is dried out or ragged (the wire or
liner is showing through the cover), replace
11/03/94 A f420329a
the hose.
NOTE: Center of the hose bend radius should be well
40.7 Inspect air tubing, especially tubing made of away from the fitting.
nylon. In cold weather, nylon tubing is sensi-
A. Bend Radius
tive to damage such as nicks or cuts. Re-
place nicked or cut tubing, even if it is not Fig. 11.6, Bend Radius
leaking.
40.9 Check straight hose installations (those
40.8 Check the bend radii of all hoses. See hoses that do not bend along their routings).
Fig. 11.6. The minimum bend radius of a Pressure changes can cause a hose to
hose is that bend which the hose will with- lengthen up to two percent or shorten up to
stand without experiencing damaging four percent. A 100-inch (2540-mm) length of
stresses or kinking. For minimum bend ra- hose, for example, can contract to 96 inches
dius values, see Group 42 of the Acterra® (2440 mm). If the hose has no slack when it
Workshop Manual. is exhausted of air, replace it with one of
When a rubber hose does not meet mini- adequate length to avoid a possible blow-off
mum bend radius requirements, the outside from the fitting during vehicle operation.
may appear smooth even if the inner tube is
40.10 Check for kinked or twisted hoses. A seven-
kinked. Reroute the hose or replace it with
percent twist in the hose can reduce its life
one of adequate length if the bend radius is
by up to 90 percent. Also, a twisted hose
not within minimum specifications.

11.19
 Pretrip Inspection and Daily Maintenance
under pressure tends to untwist. This could Before checking lining wear when the wheel
cause it to loosen the fitting. Reconnect and hub assembly are removed, review the
hoses that are twisted. brake lining exposure warnings above.
41. Check the brake lining wear on vehicles with air To minimize the possibility of creating airborne
brakes. brake lining dust, clean the dust from the
brake drum, brake backing plate, and brake
WARNING assembly using an industrial-type vacuum
cleaner equipped with a high-efficiency filter
Breathing brake lining dust (asbestos or nonasbes- system. Then, using a rag soaked in water
tos) could cause lung cancer or lung disease. Un-
and wrung until nearly dry, remove any re-
less exposure can be reduced below legal limits,
wear an air purifying respirator approved by MSHA maining dust. Do not use compressed air or
or NIOSH at all times when servicing the brakes, dry brushing to clean the brake assembly.
starting with removal of the wheels and continuing 41.1 Apply the parking brakes. Chock the tires to
through assembly. prevent vehicle movement.
To reduce asbestos exposure below legal limits, ap- 41.2 If the axle assembly is equipped with a dust
ply one of the following methods: (1) An enclosed- shield or backing plate, remove the access
cylinder vacuum system equipped with a High Effi- plug from the dust shield or backing plate.
ciency Particulate Air (HEPA) filter; (2) A solvent
spray system that keeps the asbestos-contaminated NOTE: If unable to accurately measure the
parts wet until they can be placed in a sealed and brake lining, remove the wheel and hub as-
labelled plastic bag. sembly for a thorough inspection.
IMPORTANT: It is necessary to check brake 41.3 Measure the brake lining thickness. If any of
lining wear on all vehicles, including those with the brake linings are worn to less than 1/4
automatic slack adjusters. inch (6.5 mm) at the thinnest point, replace
the linings on all brake assemblies on that
axle.

11.20
Pretrip Inspection and Daily Maintenance
NOTE: To replace the brake linings, see the IMPORTANT: The load and cold inflation pres-
applicable brake section in Group 42 of the sure must not exceed the recommendations of
Acterra® Workshop Manual. the rim or wheel manufacturer, even though
the tire may be approved for a higher load or
41.4 If removed, install the access plug. Remove
the chocks from the tires. inflation. Some rims and wheels are stamped
with a maximum load and maximum cold infla-
42. Make sure the brakes are adjusted on all axles. tion rating. See Group 40 of the Acterra®
Adjust the brakes if necessary. See Group 42 of Workshop Manual for the correct tire inflation
the Acterra® Workshop Manual for checking and pressure for the vehicle load or consult the rim
adjusting procedures. or wheel manufacturer if they are not stamped.
If the load exceeds the maximum rim or wheel
IMPORTANT: Brake checking and adjusting is nec-
capacity, the load must be adjusted or re-
essary for all vehicles, including trucks equipped
duced.
with automatic slack adjusters.
43.1 Overinflation gives the treaded surface of
43. Check the inflation pressures of the tires before
the tire a convex shape (Fig. 11.7). This
each trip, using an accurate tire pressure gauge.
causes extreme tire wear in the middle part
Tires should be checked when cool. See
of the tire since this section is primarily in
Table 11.1, Table 11.2, Table 11.3, or Table 11.4
contact with the road.
for the correct tire inflation pressure for the vehicle
load. When traveling at unusual speeds, use Underinflation gives the tread surface a con-
Table 11.5 to adjust tire pressure. Be sure the valve cave shape (Fig. 11.7). This causes exces-
stem caps are on every tire and that they are sive tire wear on the outer edges of the tire
screwed on finger-tight. Inflate the tires to the appli- since they are primarily in contact with the
cable pressures if needed. road.

11.21
 Pretrip Inspection and Daily Maintenance
Tire Load Limits, Michelin Radial Ply Tubeless Tires at Various Cold Inflation Pressures
Load Max Pressure in psi (kPa)
Range Speed
Size Axle 85 90 95 100 105 110 115 120 125 130 131
Ply mph
Rating (km/h) (586) (621) (655) (689) (724) (758) (793) (827) (862) (896) (903)
Front 65 4540
9R22.5 F/12 — — — — — — — — — —
Rear (105) 4300
Front 65 5150
10R22.5 F/12 — — — — — — — — — —
Rear (105) 4740
Front 65 5680
10R22.5 G/14 — — — — — — — — — —
Rear (105) 5080
Front 65 6175 6175
11R22.5 G/14 — — — — — — — — —
Rear (105) 5750 5840
Front 75 6175
11R22.5 G/14 — — — — — — — — — —
Rear (120) 5750
Front 65 6610 6610
11R22.5 H/16 — — — — — — — — —
Rear (105) 5950 6005
Front 75 6610
11R22.5 H/16 — — — — — — — — — —
Rear (120) 5950
Front 65 6430 6610
11R24.5 G/14 — — — — — — – — —
Rear (105) 6000 6005
Front 75 6430
11R24.5 G/14 — — — — — — — — — —
Rear (120) 6000
Front 65 7030 7160
11R24.5 H/16 — — — — — — — — —
Rear (105) 6330 6610
Front 7390
12R22.5 H/16 55 (88) — — — — — — — — — —
Rear 6750

11.22
Pretrip Inspection and Daily Maintenance
Tire Load Limits, Michelin Radial Ply Tubeless Tires at Various Cold Inflation Pressures
Load Max Pressure in psi (kPa)
Range Speed
Size Axle 85 90 95 100 105 110 115 120 125 130 131
Ply mph
Rating (km/h) (586) (621) (655) (689) (724) (758) (793) (827) (862) (896) (903)
Front 65 7390 7390
12R22.5 H/16 — — — — — — — — —
Rear (105) 6750 6780
Front 75 3640
225/70R19.5 F/12 — — — — — — — — — —
Rear (120) 3415
Front 65 4675
235/80R22.5 G/14 — — — — — — — — — —
Rear (105) 4410
Front 65 4080
245/70R19.5 F/12 — — — — — — — — — —
Rear (105) 3860
Front 65 4805
245/70R19.5 G/14 — — — — — — — — — —
Rear (105) 4540
Front 65 5510
255/70R22.5 H/16 — — — — — — — — — —
Rear (105) 5070
Front 65 5205
255/80R22.5 G/14 — — — — — — — — — —
Rear (105) 4810
Front 65 5510
255/70R22.5 H/16 — — — — — — — — — —
Rear (105) 5070
Front 65 5205
255/80R22.5 G/14 — — — — — — — — — —
Rear (105) 4810
Front 65 5355
265/70R19.5 G/14 — — — — — — — — — —
Rear (105) 5070
Front 65 6175
275/80R22.5 G/14 — — — — — — — — — —
Rear (105) 5675

11.23
 Pretrip Inspection and Daily Maintenance
Tire Load Limits, Michelin Radial Ply Tubeless Tires at Various Cold Inflation Pressures
Load Max Pressure in psi (kPa)
Range Speed
Size Axle 85 90 95 100 105 110 115 120 125 130 131
Ply mph
Rating (km/h) (586) (621) (655) (689) (724) (758) (793) (827) (862) (896) (903)
Front 75 6175
275/80R22.5 G/14 — — — — — — — — — —
Rear (120) 5675
Front 75 6940
275/80R22.5 G/14 — — — — — — — — — —
Rear (120) 6175
Front 75 6175
275/80R22.5 H/16 — — — — — — — — — —
Rear (120) 5675
Front 65 6945
275/70R22.5 H/16 — — — — — — — — — —
Rear (105) 6395
Front 65 6175
275/80R24.5 G/14 — — — — — — — — — —
Rear (105) 5675
Front 65 6175
285/70R19.5 H/16 — — — — — — — — — —
Rear (105) 5675
Front 65 7390
295/80R22.5 H/16 — — — — — — — — — —
Rear (105) 6780
Front 9000
315/80R22.5 L/20 55 (88) — — — — — — — — — —
Rear 8255
Front 65 9000
315/80R22.5 L/20 — — — — — — — — — —
Rear (105) 8255
Front 62 9920
385/65R22.5 J/18 — — — — — — — — — —
Rear (100) —
Front 65 9370
385/65R22.5 J/18 — — — — — — — — — —
Rear (105) —

11.24
Pretrip Inspection and Daily Maintenance
Tire Load Limits, Michelin Radial Ply Tubeless Tires at Various Cold Inflation Pressures
Load Max Pressure in psi (kPa)
Range Speed
Size Axle 85 90 95 100 105 110 115 120 125 130 131
Ply mph
Rating (km/h) (586) (621) (655) (689) (724) (758) (793) (827) (862) (896) (903)
Front 65
425/65R22.5 L/20 — — — — — — — — — — —
Rear (105)
Table 11.1, Tire Load Limits, Michelin Radial Ply Tubeless Tires at Various Cold Inflation Pressures

Tire Load Limits, Goodyear Tubeless Tires at Various Cold Inflation Pressures
Pressure in psi (kPa)
Load Range Max Speed
Size Axle 100 105 110 115 120 125
Ply Rating mph (km/h)
(689) (724) (758) (793) (827) (862)
Front 5150
10R22.5 F/12 65 (105) — — — — —
Rear 4875
Front 5680
10R22.5 G/14 65 (105) — — — — —
Rear 5250
Front 6175
11R22.5 G/14 65 (105) — — — — —
Rear 5750
Front 6175
11R22.5 G/14 75 (120) — — — — —
Rear 5750
Front — 6610
11R22.5 H/16 65 (105) — — — —
Rear 5800 —
Front — 6610
11R22.5 H/16 75 (120) — — — —
Rear 5800 —

11.25
 Pretrip Inspection and Daily Maintenance
Tire Load Limits, Goodyear Tubeless Tires at Various Cold Inflation Pressures
Pressure in psi (kPa)
Load Range Max Speed
Size Axle 100 105 110 115 120 125
Ply Rating mph (km/h)
(689) (724) (758) (793) (827) (862)
Front 6430
11R24.5 G/14 65 (105) — — — — —
Rear 6000
Front 6430
11R24.5 G/14 75 (120) — — — — —
Rear 6000
Front — 7030
11R24.5 H/16 65 (105) — — — —
Rear 6170 —
Front — 7030
11R24.5 H/16 75 (120) — — — —
Rear 6170 —
Front 7390
12R22.5 H/16 65 (105) — — — — —
Rear 6750
Front 5510
255/70R22.5 H/16 75 (120) — — — — —
Rear 5070
Front — 5205
265/75R22.5 G/14 65 (105) — — — —
Rear 4805 —
Front — 5205
265/75R22.5 G/14 75 (120) — — — —
Rear 4805 —
Front 6610
275/70R22.5 H/16 75 (120) — — — — —
Rear 6175
Front — 6175
285/75R24.5 G/14 65 (105) — — — —
Rear 5675 —
Front — 6175
295/75R22.5 G/14 75 (120) — — — —
Rear 5675 —
Front — 6610
295/75R22.5 H/16 75 (120) — — — —
Rear 6005 —

11.26
Pretrip Inspection and Daily Maintenance
Tire Load Limits, Goodyear Tubeless Tires at Various Cold Inflation Pressures
Pressure in psi (kPa)
Load Range Max Speed
Size Axle 100 105 110 115 120 125
Ply Rating mph (km/h)
(689) (724) (758) (793) (827) (862)
Front 7830
295/80R22.5 H/16 75 (120) — — — — —
Rear 6940
Front 8270
315/80R22.5 J/18 65 (105) — — — — —
Rear 7610
Front 8270
315/80R22.5 J/18 75 (120) — — — — —
Rear 7610
Front 8820
315/80R22.5 J/18 75 (120) — — — — —
Rear 7390
Front 9000
315/80R22.5 L/20 55 (88) — — — — —
Rear 7750
Front 9370
385/65R22.5 J/18 65 (105) — — — — —
Rear —
Front 10500
425/65R22.5 J/18 65 (105) — — — — —
Rear —
Front 11400
425/65R22.5 L/20 65 (105) — — — — —
Rear —
Table 11.2, Tire Load Limits, Goodyear Tubeless Tires at Various Cold Inflation Pressures

tires and make the tires and rims more susceptible

to damage, possibly leading to rim or tire failure
WARNING and loss of vehicle control, resulting in serious per-
sonal injury or death.
Do not operate the vehicle with underinflated or
overinflated tires. Incorrect inflation can stress the

11.27
 Pretrip Inspection and Daily Maintenance
43.2 If a tire has been run flat or underinflated, pressure loss of 4 psi (28 kPa) or more in a
check the wheel for proper lockring and side tire may indicate damage and the tire should
ring seating, and possible wheel, rim, or tire be inspected and repaired or replaced.
damage before adding air.
Tire Load Limits, Michelin Tube-Type Tires at Various
43.3 Moisture inside a tire can result in body ply
separation or a sidewall rupture. During tire Cold Inflation Pressures-Maximum 65 mph (105 km/h)
inflation, compressed air reservoirs and lines Pressure in psi
Load
must be kept dry. Use well-maintained inline (kPa)
Size Range Ply Axle
moisture traps and service them regularly. 95 115 120
Rating
(655) (793) (827)
Front 5150
9.00R20 F/12 — —
Rear 4740
Front 6610
10.00R20 H/16 — —
Rear 5950
Front 7390
11.00R20 H/16 — —
Rear 6610
A B C Front 7660
11.00R22 H/16 — —
11/03/94 f400062a Rear 6900
A. Tire correctly inflated. Front 8270
12.00R20 H/16 — —
B. Tire overinflated. Rear 3751
C. Tire underinflated. Table 11.3, Tire Load Limits, Michelin Tube-Type Tires
at Various Cold Inflation Pressures-Maximum 65 mph
Fig. 11.7, Tire Inflation (105 km/h)
43.4 Inspect the tires for bulges, cracks, cuts, or
penetrations. A tire pressure check will assist
in uncovering hidden damage. A weekly

11.28
Pretrip Inspection and Daily Maintenance
Tire Load Limits, Goodyear Tube-Type Tires at Variations in Load and Inflation Limits According to
Various Cold Inflation Pressures-Maximum 65 mph Speed
(105 km/h) Inflation Percent
Load Pressure in psi (kPa) Speed Range Pressure Increase/
Range mph (km/h) Increase in psi Decrease in
Size Axle 95 100 105 110 120
Ply (kPa) Load
Rating (655) (689) (724) (758) (827) 70–75 (113–121) 10 (69) –10
Front 6175 61–70 (98–113) 10 (69) 0
10.00R20 G/14 — — — —
Rear 5750 51–60 (82–97) 0 0
Front — 6610 41–50 (66–80) 0 +9
10.00R20 H/16 — — —
Rear 5800 —
31–40 (50–64) 0 +16
Front — 6590
11.00R20 G/14 — — — 21–30 (34–48) 10 (69) +24
Rear 5780 —
11–20 (18–32) 15 (103) +32
Front 7390
11.00R20 H/16 — — — —
Rear 6750 Table 11.5, Variations in Load and Inflation Limits
Front — 7660 According to Speed
11.00R22 H/16 — — —
Rear 6720 —
Front — 8130 43.6 If the tires are wearing irregularly, rotate
11.00R24 H/16 — — —
Rear 7130 — them. If the front steering axle tires become
Table 11.4, Tire Load Limits, Goodyear Tube-Type irregularly worn, move them to the drive axle
Tires at Various Cold Inflation Pressures-Maximum 65 (Fig. 11.8). Have the front axle alignment
mph (105 km/h) checked to determine the cause of irregular
tire wear. In a dual assembly, if one tire
wears faster than its mate, reverse the posi-
43.5 Tires should also be inspected for oil con- tion of the two tires. See Fig. 11.9.
tamination. Fuel oil, gasoline, and other pe-
troleum derivatives, if allowed to contact the 43.7 Government regulations require the removal
tires, will soften the rubber and destroy the of front axle tires at 4/32-inch (3-mm) re-
tire. maining tread depth and rear axle tires at

11.29
 Pretrip Inspection and Daily Maintenance

12/02/99 f400155
12/02/99 f400154
Fig. 11.8, Front Axle to Rear Axle Rotation

2/32-inch (1.5-mm) remaining tread depth. Fig. 11.9, Dual Assembly Rotation
However, front axle tires may be rotated to loose wheel nuts. See Group 40 of the Acterra®
the drive or trailer axles to use the remaining Maintenance Manual for torque specifications and
2/32-inch (1.5-mm) tread rubber. See Group the correct tightening sequence.
40 of the Acterra® Workshop Manual for ad-
ditional information on tire matching, spacing Examine the wheel assembly components (includ-
of dual tires, and causes of abnormal tire ing rims, rings, flanges, studs, and nuts) for cracks
wear. or other damage.
44. Check the wheel nuts or rim nuts for indications of See Group 33 and Group 35 of the Acterra® Work-
looseness. Remove all dirt and foreign material shop Manual for service procedures on the studs
from the assembly. Dirt or rust streaks from the and hubs, and see Group 40 of the Acterra® Work-
stud holes, metal buildup around stud holes, or out- shop Manual for wheel and tire servicing. Replace
of-round or worn stud holes may be caused by broken, cracked, badly worn, bent, rusty, or sprung

11.30
Pretrip Inspection and Daily Maintenance
rings and rims. Be sure that the rim base, lockring, out pressures. Run the engine at fast idle.
and side ring are matched according to size and The air governor should cut out the air com-
type. pressor at approximately 125 psi (862 kPa).
With the engine idling, make a series of foot
valve applications. The air governor should
WARNING cut in the air compressor at approximately
Have any worn or damaged wheel components re- 95 psi (655 kPa). If the air governor does
placed by a qualified person using the wheel manu- not cut in and out as described above, it
facturer’s instructions and the wheel industry’s must be adjusted to these specifications. If
standard safety precautions and equipment. Other- the air governor cannot be adjusted or re-
wise a vehicle or workshop accident could occur, paired, replace it before operating the ve-
possibly resulting in serious personal injury or hicle.
death. 45.2 Check the air pressure buildup time as fol-
lows:
CAUTION For vehicles without a trailer air brake
hookup, release the parking brakes on the
Insufficient wheel nut (rim nut) torque can cause vehicle by pushing in the parking brake con-
wheel shimmy, resulting in wheel damage, stud trol valve knob.
breakage, and extreme tire tread wear. Excessive
wheel nut torque can break studs, damage threads, For vehicles with a trailer air brake hookup,
and crack discs in the stud hole area. Use the rec- release the parking brakes on the vehicle by
ommended torque values and follow the proper pushing in the parking brake control valve
tightening sequence. knob. Apply the trailer parking brakes by
pulling out the trailer air supply valve knob.
45. Check the components of the air brake system for See Fig. 11.10.
correct operation as follows:
With the air system fully charged to 125 psi
45.1 Release the parking brakes on the vehicle (862 kPa), make one full brake application
by pushing in the parking brake control valve and note the air pressure reading on the
knob. Check the air governor cut in and cut gauge. Continue to reduce the air pressure

11.31
 Pretrip Inspection and Daily Maintenance
by moderate brake applications to a maxi- than 25 psi (172 kPa), all areas of leakage
mum of 90 psi (620 kPa), then run the en- must be eliminated before operating the ve-
gine at governed rpm. If the time required to hicle.
raise the air pressure to 125 psi (862 kPa)
(from the pressure noted after one brake 45.4 Check the air leakage in the system. On ve-
application) is more than 30 seconds, elimi- hicles with a trailer air brake hookup, charge
nate any leaks or replace the air compressor the trailer-brake system with air by pushing
before operating the vehicle. in the trailer air supply valve knob.
With the parking brakes applied, the trans-
mission out of gear, and the tires chocked,
1
charge the air system until cutoff pressure of
2 125 psi (862 kPa) is reached.
With the service brakes released, shut down
the engine, wait one minute and note the air
pressure gauge reading. Observe the air
pressure drop in psi (kPa) per minute.
Charge the air system until cutoff pressure
of 125 psi (862 kPa) is reached. With the
03/10/99 f610291
parking brakes released and the service
1. Trailer Air Supply Valve Knob brake applied, shut down the engine, wait
2. Parking Brake Control Valve Knob one minute and note the air pressure gauge
reading. Observe the air pressure drop in psi
Fig. 11.10, Parking Brake Valve and Trailer Air Supply (kPa) per minute.
Valve Knobs
If leakage exceeds the limits shown in
45.3 Check the air pressure reserve. With the air Table 11.6, repair all areas of leakage be-
system fully charged to 125 psi (862 kPa), fore driving the vehicle.
stop the engine and note the air pressure.
Then make one full brake application and
observe the pressure drop. If it drops more

11.32
Pretrip Inspection and Daily Maintenance
Maximum Allowable Service Brake Air Leakage The trailer air supply valve knob must pop
out immediately and the tractor and trailer
Service Brakes spring parking brakes must both apply.
Maximum Allowable
Description Air Leakage in psi With a fully charged air system of 125 psi
(kPa) Per Minute (862 kPa), push in the parking brake control
valve knob. The tractor spring parking
Released Applied
brakes should release. Push the trailer air
Truck or Tractor Only 2 (14) 3 (21) supply valve knob in.
Truck or Tractor w/Single Trailer 3 (21) 4 (28)
Truck or Tractor w/Two Trailers 5 (35) 6 (42) With the trailer air system charged to 125
psi (862 kPa), the trailer brakes (spring park-
Table 11.6, Maximum Allowable Service Brake Air ing brakes, if equipped, or service brakes)
Leakage should release.
Pull the trailer air supply valve knob out. The
trailer brakes should apply.
WARNING
NOTE: For trailers not equipped with spring park-
Before operating the vehicle, be sure that the spring ing brakes, the trailer service brakes automatically
parking brakes on the tractor and the spring park- apply when the trailer air supply valve knob pops
ing (or service) brakes on the trailer pass the above out.
tests. Otherwise an unexpected parking brake appli-
cation could occur, causing some loss of vehicle 46. When starting to move the vehicle and before pick-
control and possibly resulting in serious personal ing up speed, test the brakes with the brake pedal
injury. and parking brake control valve to be sure they will
bring the vehicle to a safe stop.
45.5 On vehicles with a trailer air brake hookup,
check the spring parking brake system by If the vehicle has hydraulic brakes, depress the
pushing in the trailer air supply valve knob, brake pedal, release the parking brake, and check
and releasing the trailer parking brakes. Pull that the brake system warning light goes off. If the
the parking brake control valve knob out.

11.33
 Pretrip Inspection and Daily Maintenance
warning light remains on after releasing the parking
brake, correct the problem before driving off.
47. Pull the parking brake control valve knob or apply
the hand brake with the vehicle on a 20 percent
grade. If the parking brakes do not hold the vehicle,
repair the parking brake system.

11.34
 12

Cab Appearance
Cab Washing and Polishing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12.1
Care of Fiberglass Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12.1
Care of Chrome Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12.1
Dashboard Care . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12.2
Vinyl Upholstery Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12.2
Velour Upholstery Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12.4
Cab Appearance
Cab Washing and Polishing and tree sap before waxing. Sterling recommends
that a quality brand of cleaner or cleaner-polish
To protect the finish of your new vehicle, follow these and polishing wax be used.
guidelines carefully: • Do not let diesel fuel or antifreeze stand on a
• During the first 30 days, rinse your vehicle fre- painted surface. If either should occur, rinse the
quently with water. If the vehicle is dirty, use a surface off with water.
mild liquid soap. Do not use detergent. • To prevent rust, have any nicks or other damage
• During the first 30 days, do not use anything on the finish touched up as soon as possible.
abrasive on your vehicle. Brushes, chemicals, • Park your vehicle in a sheltered area whenever
and cleaners may scratch the finish. possible.
• During the first 120 days, do not wax your ve-
hicle. Care of Fiberglass Parts
To extend the life of your vehicle’s finish, follow these
Wash unpainted fiberglass air fairings and shields
guidelines:
monthly with a mild detergent, such as dishwashing liq-
• Avoid washing your vehicle in the hot sun. Al- uid. Avoid strong alkaline cleansers.
ways use water. After the cab is completely
Apply a wax specifically designed for fiberglass.
washed, dry it with a towel or chamois.
• Do not dust painted surfaces with a dry cloth, as Care of Chrome Parts
this will scratch the paint.
• Do not remove ice or snow from a painted sur- To prevent rust, keep chrome parts clean and protected
face with a scraper of any sort. at all times. This is especially important during winter
driving and in coastal areas where there is exposure to
• To prevent damage to the finish, wax it regularly. salt air.
If the finish has become dull, before waxing, re-
move oxidized paint using a cleaner specifically When cleaning chrome parts, use clean water and a
designed for this purpose. Remove all road tar soft cloth or sponge. A mild detergent may also be
used.

12.1
 Cab Appearance
Sponge gently, then rinse. If necessary, use a nonabra- recommended cleaning procedures. Waxing or refinish-
sive chrome cleaner to remove stubborn rust or other ing improves soil resistance and cleanability for all vi-
material. Do not use steel wool. nyls. Any hard wax, such as that used on automobiles,
may be used.
To help protect the chrome after cleaning, apply a coat
of polishing wax to the surface. Never use wax on parts
that are exposed to high heat, such as exhaust pipes. Ordinary Dirt
Wash the upholstery with warm water and mild soap,
Dashboard Care such as saddle or oil soap. Apply soapy water to a
large area and allow to soak for a few minutes, then rub
Periodically wipe the dashboard with a water-dampened briskly with a cloth to remove the dirt. This can be re-
cloth. A mild detergent can be used, but avoid using peated several times as necessary.
strong detergents.
If dirt is deeply imbedded, use a soft bristle brush after
applying the soap.
CAUTION If dirt is extremely difficult to remove, wall-washing
Do not use Armor-All Protectant®, STP Son-of-a- preparations normally found around the home can be
Gun®, or other equivalent treatments. These clean- used. Powdered cleaners, such as those used for sinks
ers contain vinyl plasticizers which can cause and tiles, are abrasive and must be used with caution
stress crazing in the interior plastic panels which as they can scratch the vinyl or give it a permanent dull
can result in cracking of the panels. appearance.

Chewing Gum
Vinyl Upholstery Cleaning
Harden the gum with an ice cube wrapped in a plastic
To prevent soiling, frequent vacuuming or light brushing bag, then scrape it off with a dull knife. Any remaining
to remove dust and dirt is recommended. Harsh clean- traces of gum can be removed with an all-purpose light
ing agents can cause permanent damage to vinyl up- oil (peanut butter will also work) and wiped off.
holstery. To preserve the upholstery and prevent dam-
age, carefully review the following sections for

12.2
Cab Appearance
Tars, Asphalts, and Creosote Nail Polish and Nail Polish Remover
Tars, asphalts, and creosote stain vinyl after prolonged Prolonged contact with these substances causes per-
contact. They should be wiped off immediately and the manent damage to vinyl. Careful blotting immediately
area carefully cleaned, using a cloth dampened with after contact minimizes damage. Do not spread the liq-
naphtha. uid during removal.

Paint, Shoe Heel Marks Shoe Polish

Paint should be removed immediately. Do not use paint Most shoe polishes contain dyes which penetrate vinyl
remover or liquid-type brush cleaner on vinyl. An un- and stain it permanently. Shoe polish should be wiped
printed cloth, dampened with naphtha or turpentine may off as quickly as possible using naphtha or lighter fluid.
be used. Use care to prevent contact with parts of the If staining occurs, try the procedure used for sulfide
upholstery that are not vinyl. stains.

Sulfide Stains Ball Point Ink

Sulfide compounds, such as those found in eggs and Ball point ink can sometimes be removed if rubbed im-
some canned goods, can stain after prolonged contact mediately with a damp cloth, using water or rubbing al-
with vinyl. These stains can be removed by placing a cohol. If this does not work, try the procedure used for
clean, unprinted piece of cloth over the spotted area sulfide stains.
and pouring a liberal amount of 6 percent hydrogen per-
oxide onto the cloth. Allow the saturated cloth to remain Miscellaneous
on the spot for 30 to 60 minutes. For stubborn spots,
allow the hydrogen-peroxide saturated cloth to remain If stains do not respond to any of the treatments de-
on the area overnight. Use caution to prevent the solu- scribed above, it is sometimes helpful to expose the
tion from seeping into the seams or it will weaken the vinyl to direct sunlight for up to 30 hours. Mustard, ball
cotton thread. point ink, certain shoe polishes, and dyes often bleach
out in direct sunlight leaving the vinyl undamaged.

12.3
 Cab Appearance
Velour Upholstery Cleaning Chewing Gum or Wax
To prevent soiling, frequent vacuuming or light brushing Harden the gum or wax with an ice cube wrapped in a
to remove dust and dirt is recommended. Spot clean plastic bag, then scrape it off with a dull knife. Excess
with a mild solvent or an upholstery shampoo, or the wax can be absorbed by placing a thick white blotter
foam from a mild detergent. When using a solvent or a over the wax and heating with a warm (not hot) iron.
dry-cleaning product, follow the instructions carefully Remove the remainder by using the procedure for
and clean only in a well-ventilated area. Avoid any prod- grease and oil-based stains.
uct that contains carbon tetrachloride or other toxic ma-
terials. With either method, pretest a small area before Mildew
proceeding. Use a professional upholstery cleaning ser-
vice when extensive cleaning is needed. Brush the dry fabric with a soft brush. Sponge with de-
tergent, and blot. If the fabric is colorfast, dilute a tea-
spoon of bleach in one quart (one liter) of cool water.
Grease and Oil-Based Stains Apply with a swab, directly on the mildew stain. Dab
Dampen a small absorbent cloth with dry-cleaning sol- repeatedly with clear, cool water, and blot dry.
vent 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 cir-
cular motions. Pat and blot as dry as possible. Repeat if
necessary before drying thoroughly.

12.4
 13

In an Emergency
Hazard Warning Lights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13.1
Fire Extinguisher . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13.1
Emergency Kit, Optional . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13.1
Emergency Starting With Jumper Cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13.1
Towing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13.3
Fire in the Cab . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13.6
In an Emergency
Hazard Warning Lights stances such as fuel. An explosion or fire could oc-
cur causing serious personal injury.
The hazard warning lights switch is located either on
the turn signal lever or on top of the steering column.
Press the switch to turn on the hazard warning lights.
Emergency Starting With
Press the switch again to turn off the hazard warning Jumper Cables
lights.
When using jumper cables, use the following instruc-
tions.
Fire Extinguisher
A fire extinguisher is located in the cab by the driver’s WARNING
door.
Batteries release explosive gas. Do not smoke when
working around batteries. Put out all flames and re-
Emergency Kit, Optional move all sources of sparks or intense heat in the
An optional emergency kit is located in the cab. The kit vicinity of the battery. Do not allow the vehicles to
includes one or more of the following: a first aid kit, a touch each other. Do not lean over the batteries
reflective vest, a triangular reflector, and a flare kit. when making connections, and keep all other per-
sons away from the batteries. Failure to follow
If there is an emergency while driving, cautiously pull off these precautions could lead to severe personal in-
the road. Turn on the hazard warning lights. Place the jury as a result of an explosion or acid burns.
flares and reflector along the side of the road to alert
other drivers that an emergency situation exists.
CAUTION
WARNING Make sure both starting systems have the same
voltage outputs, and avoid making sparks. Other-
Use extreme care when placing flares in emergency wise the vehicle charging systems could be se-
situations that involve exposure to flammable sub- verely damaged. Also, do not attempt to charge iso-
lated, deep-cycle batteries with jumper cables.

13.1
 In an Emergency
Follow the manufacturer’s instructions when charg- of the other cable. Otherwise, a spark could occur
ing deep-cycle batteries. near a battery, possibly resulting in severe personal
injury from explosion and acid burns.
On vehicles equipped with optional jump-start posts,
attach the positive cable clamp to the positive post in- 3. Connect one end of the second jumper cable to the
stead of to the battery, and attach the negative cable negative terminal of the booster battery and con-
clamp to the negative post. nect the other end to the negative jump-start post
or the starter ground lug. The starter ground lug
(Fig. 13.1) is the best location. Do not use the
CAUTION frame rail or the engine block as a ground.
Connecting the jumper cables to the vehicle frame NOTE: It may be easier to access the starter
rail or to the engine block can cause severe dam- ground lug by routing the jumper cable underneath
age to the engine wiring. the vehicle. If the starter ground lug is not acces-
On vehicles without jump-start posts, the positive cable sible, connect to the negative battery post of the
clamp can be attached to the starter positive lug termi- discharged battery.
nal.
1. Apply the parking brakes and turn off the lights and WARNING
all other electrical loads.
On vehicles with Mercedes-Benz AGS transmis-
2. Connect an end of one jumper cable to the positive sions, make sure the current gear indicator displays
terminal of the booster battery (or jump-start post if "N" before starting the vehicle. If the transmision
equipped) and connect the other end of the cable starts in gear, it could cause an accident resulting
to the positive terminal of the discharged battery (or in death, serious personal injury, or property dam-
jump-start post if equipped). age.
4. Start the engine of the vehicle with the booster bat-
WARNING teries and let the engine run a few minutes to
charge the batteries of the other vehicle.
Do the next step exactly as instructed and do not
allow the clamps of one cable to touch the clamps

13.2
In an Emergency
2 WARNING
3 Do the next step exactly as instructed and do not
allow the clamps of one cable to touch the clamps
of the other cable. Otherwise, a spark could occur
near a battery, possibly resulting in severe personal
4 injury from explosion and acid burns.
7. Disconnect the grounded cable from the vehicle,
then disconnect the other end of the cable from the
negative terminal of the booster battery.
8. Disconnect the remaining cable from the newly
1 charged battery or jump-start post first, then discon-
nect the other end.
01/06/99 f150965
1.
2.
Starter Motor
Solenoid
Towing
3. Solenoid Positive Lug Terminal When it is necessary to tow the vehicle, make sure the
4. Ground Lug instructions below are closely followed to prevent dam-
age to the vehicle.
Fig. 13.1, Delco Remy 42-MT Starter

5. Attempt to start the engine of the vehicle with the WARNING

batteries receiving the charge. Do not operate the
starter longer than 30 seconds, and wait at least Do not tow an unbraked vehicle if the combined
two minutes between starting attempts to allow the weight of both vehicles is more than the sum of the
starter to cool. gross axle weight ratings (GAWR) of the towing ve-
6. When the engine starts, let it idle a few minutes. hicle. Otherwise brake capacity will be inadequate,
which could result in personal injury or death.

13.3
 In an Emergency
Front Towing Hookup CAUTION
1. Disconnect the battery ground cables.
Failure to protect the frame rails from the chains
could cause damage, leading to eventual frame fail-
CAUTION ure.
Failure to remove the axle shafts when towing the 4. On dual-drive axles, if the vehicle is to be lifted and
vehicle with the rear wheels on the ground could towed, chain the forward rear-axle assembly to the
result in damage to the transmission and other vehicle frame. Use protection to keep the chains
parts. from damaging the frame.
2. Remove both drive axle shafts. On dual-drive axles, 5. Remove the bumper extension and chrome bumper
if the vehicle is to be lifted and towed, remove only if equipped. Remove the bumper fairing if equipped.
the rearmost drive axle shafts.
6. On vehicles equipped with an air fairing, adjust the
On vehicles equipped with an air fairing, remove trim tab to the lowest position.
both the forward and rearmost drive axle shafts if
there is insufficient towing clearance. 7. Attach the towing device. Due to the many vari-
ables that exist in towing, positioning the lifting and
3. Cover the ends of the hubs with metal plates or towing device is the sole responsibility of the
plywood cut to fit the axle opening, and drilled to fit towing-vehicle operator.
the axle shaft studs. This prevents lubricant from
leaking out and will keep contaminants from getting 8. On vehicles equipped with an air fairing, measure
into and damaging the wheel bearings and axle the distance from the ground to the bumper, or from
lubricant. the ground to a frame bracket.
9. Lift the vehicle and secure the safety chains. If ex-
tra towing clearance is needed, remove the front
wheels.

13.4
In an Emergency
WARNING Rear Towing Hookup
Failure to lower the vehicle could result in the air CAUTION
fairing striking an overhead obstruction, such as a
bridge or overpass, and causing vehicle damage or Using a rear towing hookup on a vehicle equipped
personal injury. with a roof fairing could cause damage to the cab
structure.
10. On vehicles equipped with an air fairing, repeat the
measurement taken in step 8. The difference be- 1. Place the front tires straight forward and secure the
tween the two measurements must not exceed 14 steering wheel in this position.
inches (36 cm). If necessary, lower the vehicle.
2. Disconnect the battery ground cables.
11. Connect the clearance lights, taillights, and signal
lights. Connect any special towing lights required by
local regulations.
CAUTION
Failure to protect the frame rails from the chains
WARNING could cause damage, leading to eventual frame fail-
ure.
Failure to chock the tires or connect the tow truck’s
air brake system before releasing the spring park- 3. On dual-drive axles, using protection to keep the
ing brakes could allow the disabled vehicle to sud- chains from damaging the vehicle frame, chain the
denly roll. This could cause property damage or forward-rear drive axle to the frame.
personal injury. 4. Attach the towing device. Due to the many vari-
12. Chock the tires on the disabled vehicle and connect ables that exist in towing, positioning the lifting and
the towing vehicle’s air brake system to the vehicle towing device is the sole responsibility of the
being towed. Then, release the spring parking towing-vehicle operator.
brakes and remove the chocks. 5. Lift the vehicle and secure the safety chains. If ex-
tra clearance is needed, remove the bumper exten-
sion if equipped.

13.5
 In an Emergency
6. Connect the clearance lights, taillights, and signal
lights. Also connect any special towing lights re-
quired by local regulations.

Fire in the Cab

The incidence of fire in medium-duty trucks is rare, ac-
cording 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 despite this, most materials will burn.
The cab of this vehicle contains urethane foam, which
is of concern in this respect.

WARNING
Urethane foam is flammable! Do not allow any
flames, sparks, or other heat sources such as ciga-
rettes or light bulbs to contact urethane foam. Ure-
thane foam in contact with such heat sources could
cause a serious, rapid fire, which could result in
death, severe burns, or gas poisoning, as well as
damage to the vehicle.

In Case of a Cab Fire

As quickly as possible, bring the vehicle to a safe stop,
apply the parking brake, turn off the ignition, and get out
of the vehicle.

13.6
Index
Subject Page Subject Page Subject Page
A C Care of Chrome Parts . . . . . . . . . 12.1
Care of Fiberglass Parts . . . . . . . 12.1
Air Brake System . . . . . . . . . . . . 6.2 Cab Door Locks and Handles . . . . . 3.1
Clutches . . . . . . . . . . . . . . . . . 7.22
Automatic Slack Adjusters . . . . . 6.8 Cab Entry and Exit . . . . . . . . . . . 3.2
Clutch Adjustments . . . . . . . . . 7.25
General Information . . . . . . . . . 6.2 Entering the Driver’s Side When
There are Two Cab Access Clutch Operation . . . . . . . . . . 7.23
Meritor™ WABCO® Antilock
Steps . . . . . . . . . . . . . . . . 3.2 General Information . . . . . . . . 7.22
Braking System (ABS), Air
Brake Systems . . . . . . . . . . . 6.5 Entering the Driver’s Side When Lubrication . . . . . . . . . . . . . . 7.25
Operation . . . . . . . . . . . . . . . 6.3 There is One Cab Access Cold Weather Operation . . . . . . . . 7.12
Step . . . . . . . . . . . . . . . . . 3.5 Caterpillar . . . . . . . . . . . . . . 7.13
Air Conditioning, Optional . . . . . . . . 4.3
Entering the Passenger’s Side Cummins . . . . . . . . . . . . . . 7.14
Allison AT/MT Series Transmissions . 8.37 When There are Two Cab
Allison AT 500 Series . . . . . . . 8.37 Mercedes-Benz . . . . . . . . . . . 7.12
Access Steps . . . . . . . . . . . 3.4
Allison MT 600 Models . . . . . . 8.38 Cold Weather Starting . . . . . . . . . . 7.5
Entering the Passenger’s Side
Allison MD Series Transmissions . . 8.33 When There is One Cab Caterpillar . . . . . . . . . . . . . . . 7.5
Operating Instructions, MD Access Step . . . . . . . . . . . . 3.5 Cummins . . . . . . . . . . . . . . . 7.6
Series . . . . . . . . . . . . . . . 8.33 Exiting the Driver’s Side When Mercedes-Benz . . . . . . . . . . . 7.5
Safety Precautions . . . . . . . . . 8.33 There are Two Cab Access Controls . . . . . . . . . . . . . . . . . . 2.1
Steps . . . . . . . . . . . . . . . . 3.4
Allison On-Highway Transmissions . 8.28 ABS Diagnostic Switch, Optional . 2.12
Exiting the Driver’s Side When
Operating Instructions, On- Automatic Transmission Controls . 2.15
There is One Cab Access
Highway Transmissions . . . . . 8.30 Axle Lock Switch, Optional . . . . 2.11
Step . . . . . . . . . . . . . . . . . 3.5
Range Inhibit Indicator, 2000 Cruise Control . . . . . . . . . . . 2.13
Exiting the Passenger’s Side
and 2400 Series . . . . . . . . . 8.30 Daytime Running Lights,
When There are Two Cab
Safety Precautions, On-Highway Access Steps . . . . . . . . . . . 3.5 Optional . . . . . . . . . . . . . . . 2.4
Transmissions . . . . . . . . . . 8.28 Engine Brake Switch, Optional . . 2.11
Exiting the Passenger’s Side
When There is One Cab Exhaust Brake Switch, Optional . 2.11
B Access Step . . . . . . . . . . . . 3.6 Headlight and Parking Light
Cab Washing and Polishing . . . . . . 12.1 Switch . . . . . . . . . . . . . . . . 2.3
Back-of-Cab Grab Handles, Steps,
and Deck Plate . . . . . . . . . . . . 3.15 Canadian Motor Vehicle Safety Heated Mirror Switch, Optional . . 2.10
Standard (CMVSS) Labels . . . . . . 1.2

I-1
 Index
Subject Page Subject Page Subject Page
Heater and Air-Conditioner D General Information, UltraShift
Controls . . . . . . . . . . . . . . . 2.8 ASW . . . . . . . . . . . . . . . . . 8.8
Dashboard Care . . . . . . . . . . . . 12.2
Horn . . . . . . . . . . . . . . . . . . 2.8 Operation, UltraShift ASW . . . . . 8.8
Defogging and Defrosting Using
Hot Posts . . . . . . . . . . . . . . . 2.9 Ultrashift Diagnostics . . . . . . . 8.16
Fresh Air . . . . . . . . . . . . . . . . 4.2
Ignition Switch and Key . . . . . . . 2.1 Emergency Kit, Optional . . . . . . . . 13.1
Door Windows . . . . . . . . . . . . . . 3.1
Instrument and Control Panel Emergency Starting With Jumper
Dimmer Switch . . . . . . . . . . . 2.5 Cables . . . . . . . . . . . . . . . . . 13.1
Lighted Mirrors, Optional . . . . . . 2.5 E Engine Braking System, Optional . . 7.22
Manual Transmission Controls . . 2.15 Eaton Fuller AutoShift Automated Mercedes-Benz Engine Brake/
Marker Blink Switch . . . . . . . . . 2.4 Transmissions . . . . . . . . . . . . . 8.3 Constant Throttle Valves . . . . 7.22
Message Display Screen . . . . . 2.16 General Information, AutoShift . . . 8.3 Engine Break-In . . . . . . . . . . . . . 7.6
Mode/Reset Switch, Optional . . . 2.10 Operation, SmartShift With Caterpillar . . . . . . . . . . . . . . . 7.7
Parking Brake Control Valve and Eaton Fuller AutoShift . . . . . . . 8.4 Cummins . . . . . . . . . . . . . . . 7.7
Trailer Air Supply Valve . . . . . . 2.9 Eaton Fuller Deep-Reduction Mercedes-Benz . . . . . . . . . . . 7.6
Power Lock Switch, Optional . . . . 2.1 Transmissions . . . . . . . . . . . . 8.23 Engine Operation . . . . . . . . . . . . 7.7
Power Mirror Switch, Optional . . . 2.3 General Information, Deep Caterpillar . . . . . . . . . . . . . . . 7.9
Reduction . . . . . . . . . . . . . 8.23
Power Window Switch, Optional . . 2.1 Cummins . . . . . . . . . . . . . . . 7.11
Operation, Deep Reduction . . . . 8.23
Tilt or Tilt and Telescoping Mercedes-Benz . . . . . . . . . . . 7.8
Steering Wheel, Optional . . . . . 2.7 Eaton Fuller Range-Shift
Transmissions . . . . . . . . . . . . 8.19 Engine Shutdown . . . . . . . . . . . . 7.15
Traction in Mud or Snow Switch, Caterpillar . . . . . . . . . . . . . . 7.16
Optional . . . . . . . . . . . . . . 2.12 General Information, Range-
Shift . . . . . . . . . . . . . . . . 8.19 Cummins . . . . . . . . . . . . . . 7.17
Trailer Brake Hand Control Mercedes-Benz . . . . . . . . . . . 7.15
Valve Lever . . . . . . . . . . . . . 2.8 Operation, Range-Shift . . . . . . 8.21
Eaton Fuller Straight-Shift Engine Starting . . . . . . . . . . . . . . 7.1
Turn Signal Lever, Signal-Stat . . . 2.6
Transmissions . . . . . . . . . . . . 8.17 Caterpillar . . . . . . . . . . . . . . . 7.3
Turn Signal Lever, United
Technologies . . . . . . . . . . . . 2.5 General Information, Straight- Cummins . . . . . . . . . . . . . . . 7.4
Shift . . . . . . . . . . . . . . . . 8.18 Mercedes-Benz . . . . . . . . . . . 7.2
Wheel Lock Switch, Optional . . . 2.10
Operation, Straight-Shift . . . . . . 8.19 Pre-Start . . . . . . . . . . . . . . . 7.1
Eaton Fuller UltraShift™ . . . . . . . . . 8.8 Starting Precautions, All Engines . 7.2

I-2
Index
Subject Page Subject Page Subject Page
EPA Vehicle Noise Emission Heating . . . . . . . . . . . . . . . . . . 4.2 Forward and Rear Axle Oil
Control Label . . . . . . . . . . . . . . 1.3 High Altitude Operation . . . . . . . . 7.18 Temperature Gauges, Optional . 2.28
Exhaust Braking System, Optional . . 7.18 Holland Fifth Wheels . . . . . . . . . . 10.1 Fuel Gauge . . . . . . . . . . . . . 2.27
General Information . . . . . . . . 7.18 3500 Series Stationary Models . . 10.1 Intake Air Restriction Indicator,
Pacbrake® Exhaust Brake . . . . . 7.20 Fifth Wheel Locking Operation . . 10.2 Dash Mounted, Optional . . . . 2.29
Exterior Switches . . . . . . . . . . . . 2.31 Hood Tilting . . . . . . . . . . . . . . . . 3.6 Intake Air Restriction Indicator . . 2.29
Battery Shutoff Switch, Optional . 2.31 To Return the Hood . . . . . . . . 3.14 Primary and Secondary Air
Pressure Gauges . . . . . . . . 2.26
To Tilt the Hood . . . . . . . . . . . 3.6
F HVAC General Information . . . . . . . 4.1
Speedometer . . . . . . . . . . . .
Tachometer, Optional . . . . . . .
2.24
2.24
Federal Motor Vehicle Safety Hydraulic Brake System . . . . . . . . 6.9
Transmission Oil Temperature
Standard (FMVSS) Labels . . . . . . 1.1 General Information . . . . . . . . . 6.9
Gauge, Optional . . . . . . . . . 2.27
Fire Extinguisher . . . . . . . . . . . . 13.1 Meritor™ WABCO® Antilock
Voltage Reading . . . . . . . . . . 2.25
Fire in the Cab . . . . . . . . . . . . . 13.6 Braking System (ABS),
Hydraulic Brake Systems . . . . 6.10
In Case of a Cab Fire . . . . . . . 13.6
Fontaine® Fifth Wheels . . . . . . . . 10.4
Operation . . . . . . . . . . . . . . 6.10 M
6000/7000 Series No-Slack® II Mercedes-Benz Automated
Stationary Models . . . . . . . . 10.4 I Transmissions . . . . . . . . . . . . 8.41
Fifth Wheel Lock Mechanism for AGS Diagnostics . . . . . . . . . . 8.49
Instrument and Control Panel . . . . . 2.1
Trailer Kingpin . . . . . . . . . . 10.5 General Information, AGS . . . . . 8.41
Instrumentation Control Unit, Level I . 2.16
Fifth Wheel Locking Operation . . 10.6 Operation, AGS . . . . . . . . . . . 8.42
Level I ICU Ignition Sequence . . 2.20
Freightliner SmartShift Shift Control . . 8.1 Mercedes-Benz Manual
Mode/Reset Switch . . . . . . . . 2.22 Transmissions . . . . . . . . . . . . 8.26
Fresh Air . . . . . . . . . . . . . . . . . 4.4
Warning and Indicator Lights . . . 2.16 Meritor™ Axle Lock Operation . . . . . 9.3
Fuse, Relay, and Circuit Breaker
Instruments . . . . . . . . . . . . . . . 2.24
Identification . . . . . . . . . . . . . . 3.6 Meritor™ Drive Axles With Wheel
Application Air Pressure Gauge, Lock . . . . . . . . . . . . . . . . . . . 9.1
Optional . . . . . . . . . . . . . . 2.29
Meritor™ Tandem Drive Axles With
H Coolant Temperature Gauge . . . 2.25 Axle Lock . . . . . . . . . . . . . . . . 9.2
Hazard Warning Lights . . . . . . . . 13.1 Engine Oil Pressure Gauge . . . . 2.24 Meritor™ Wheel Lock Operation . . . . 9.1

I-3
 Index
Subject Page Subject Page Subject Page
N Power Steering System . . . . . . . 6.1 Shoe Polish . . . . . . . . . . . . . 12.3
Sulfide Stains . . . . . . . . . . . . 12.3
NGI Instrument Cluster, Optional . . . 2.31
Instruments . . . . . . . . . . . . . 2.31 T Tars, Asphalts, and Creosote . . . 12.3
Light Bar . . . . . . . . . . . . . . . 2.31 Tire and Rim Labels . . . . . . . . . . . 1.3
Message Center . . . . . . . . . . 2.32 Towing . . . . . . . . . . . . . . . . . . 13.3
Mode and Set Buttons . . . . . . . 2.33 Front Towing Hookup . . . . . . . 13.4
Rear Towing Hookup . . . . . . . . 13.5
P TTC Manual Transmissions . . . . . . 8.27
General Information, TTC . . . . . 8.27
Pretrip Inspection and Daily
Maintenance Procedures . . . . . . 11.3 Operation, TTC . . . . . . . . . . . 8.27
Pretrip Inspection Checklist . . . . . . 11.1
V
S Vehicle Specification Decal . . . . . . . 1.1
Seat Belts and Tether Belts . . . . . . 5.6 Velour Upholstery Cleaning . . . . . . 12.4
General Information . . . . . . . . . 5.6 Chewing Gum or Wax . . . . . . . 12.4
Seat Belt Operation . . . . . . . . . 5.6 Grease and Oil-Based Stains . . . 12.4
Seats . . . . . . . . . . . . . . . . . . . 5.1 Mildew . . . . . . . . . . . . . . . . 12.4
Bostrom Talladega™ 915 Seat . . . 5.5 Sugar and Water-Based Stains . . 12.4
General Information . . . . . . . . . 5.1 Vinyl Upholstery Cleaning . . . . . . . 12.2
National 2000 Series Seat . . . . . 5.3 Ball Point Ink . . . . . . . . . . . . 12.3
National Nonsuspended Seat . . . 5.3 Chewing Gum . . . . . . . . . . . . 12.2
Two-Passenger Bench Seat . . . . 5.6 Miscellaneous . . . . . . . . . . . . 12.3
Starting After an Extended Nail Polish and Nail Polish
Shutdown or Oil Change . . . . . . . 7.6 Remover . . . . . . . . . . . . . 12.3
Steering System . . . . . . . . . . . . . 6.1 Ordinary Dirt . . . . . . . . . . . . 12.2
General Information . . . . . . . . . 6.1 Paint, Shoe Heel Marks . . . . . . 12.3

I-4