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RECREATIONAL VEHICLE CHASSIS Operator’s Manual STI-425-6 A24-00788-000

Recreational Vehicle Chassis Operator's Manual

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Page 1: Recreational Vehicle Chassis Operator's Manual

RECREATIONAL VEHICLECHASSIS

Operator’s ManualSTI-425-6

A24-00788-000

Page 2: Recreational Vehicle Chassis Operator's Manual

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

Freightliner chassis are equipped with various chas-sis and driver controls. The coverage in this manualapplies to all recreational vehicle chassis in generaland everything may not apply specifically to your ve-hicle, due to optional component offerings. Compo-nent coverage specific to the front-engine dieselchassis can be found in Chapter 11. If parts on yourchassis differ from those shown, they may have beeninstalled by the vehicle final-stage manufacturer.

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

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

IMPORTANT: Descriptions and specifications inthis manual were in effect at the time of printing.Freightliner Custom Chassis Corporation re-serves the right to discontinue models and tochange specifications or design at any timewithout notice and without incurring obligation.Descriptions and specifications contained in thispublication provide no warranty, expressed orimplied, and are subject to revisions and edi-tions without notice.

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

Event Data RecorderThis vehicle is equipped with one or more devicesthat record specific vehicle data. The type and

amount of data recorded varies depending on howthe vehicle is equipped (such as the brand of engine,if an air bag is installed, or if the vehicle features acollision avoidance system, etc.).

This vehicle is equipped with an event data recorder(EDR). The main purpose of an EDR is to recorddata in certain crash or near-crash situations, suchas air bag deployment or hitting a road obstacle, thatwill assist in understanding how a vehicle’s systemsperformed. The EDR is designed to record data re-lated to vehicle dynamics and safety systems for ap-proximately 60 seconds. This data can help providea better understanding of the circumstances in whichcrashes and injuries occur. Data recorded includesthe following items:

• how various systems in the vehicle were oper-ating

• engine system information

• how far (if at all) the driver was depressing theaccelerator

• if the driver was depressing the brake pedal

• how fast the vehicle was traveling

NOTE: Data is not recorded by the EDR undernormal driving conditions. Personal data suchas name, gender, age, and crash location arenot recorded. However, other parties such aslaw enforcement could combine the EDR datawith the type of personally identifying data rou-tinely acquired during a crash investigation.

To read data recorded by an EDR, special equipmentis required, and access to the vehicle or the EDR isneeded. In addition to the vehicle manufacturer, otherparties that have the special equipment, such as lawenforcement, can read the information if they haveaccess to the vehicle or the EDR.

Emissions and Fuel EfficiencyComplianceThis vehicle must be regularly inspected and main-tained as indicated in the Recreational Vehicle Chas-sis Maintenance Manual, and in the Pre- and Post-Trip Inspections and Maintenance chapter in thismanual, in order to continue satisfactory performanceand ensure coverage of the vehicle under the manu-facturer’s warranty. Many maintenance procedures

Foreword

STI-425-6 (10/16)A24-00788-000

Printed in U.S.A.

Page 3: Recreational Vehicle Chassis Operator's Manual

ensure that the vehicle and engine continue to com-ply with applicable emissions standards. Mainte-nance procedures, using components engineered tocomply with greenhouse gas emissions and fuel effi-ciency regulations, may be performed by an autho-rized Daimler Trucks North America dealer, an inde-pendent outlet, or the vehicle owner or operator.

The vehicle owner is responsible for determining thesuitability of replacement components to maintaincompliance with federal and local jurisdictional regu-lations. Components including, but not limited to, low-rolling resistance tires are specifically designed andmanufactured to exacting standards for regulatoryfuel efficiency and greenhouse gas emissions compli-ance. It is important that these components are al-ways replaced with components that meet or exceedthe performance of the originally installed compo-nents.

Customer Assistance CenterHaving trouble finding service? Call the CustomerAssistance Center at 1-800-385-4357 or 1-800-FTL-HELP. Call night or day, weekdays or weekends, fordealer referral, vehicle information, or breakdown co-ordination. Our people are knowledgeable, profes-sional, and committed to keeping your vehicle mov-ing.

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

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

To contact NHTSA, you may call the VehicleSafety Hotline toll-free at 1-888-327-4236 (TTY:

1-800-424-9153); go to www.safercar.gov; orwrite to: Administrator, NHTSA, 1200 New JerseyAvenue, SE, Washington, DC 20590. You can alsoobtain other information about motor vehicle safetyfrom www.safercar.gov.

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

For additional road safety information, please visitthe Road Safety website at: www.tc.gc.ca/roadsafety.

© 1997–2016 Daimler Trucks North America LLC. All rights reserved. Daimler Trucks North America LLC is a Daimler

company.

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

Foreword

Page 4: Recreational Vehicle Chassis Operator's Manual

ContentsChapter Page

Introduction, Environmental Concerns and Recommendations,Event Data Recorder, Emissions and Fuel Efficiency Compliance,Customer Assistance Center, Reporting Safety Defects . . . . . . . . . . . . . . . . . . . . Foreword

1 Vehicle Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.12 Lightbar Control Unit (LBCU) Instrument Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.13 Ametek Instrument Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.14 OptiView Instrument Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.15 Instruments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.16 Driver Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.17 Engines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.18 Brake System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.19 Transmissions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.1

10 Steering System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.111 Front-Engine Diesel Chassis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11.112 Pre- and Post-Trip Checklists . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12.113 Pre- and Post-Trip Inspections and Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13.114 Cleaning and Care . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14.115 In an Emergency . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15.116 Towing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16.117 Vehicle Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17.118 Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18.1

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

Page 5: Recreational Vehicle Chassis Operator's Manual

1

Vehicle IdentificationComponent Information Label . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.1Vehicle Identification Number . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.1Emissions Labels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.1

Page 6: Recreational Vehicle Chassis Operator's Manual

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

The component information label lists the manufac-turer, month and year of manufacture, vehicle identifi-cation number (VIN), gross vehicle weight rating(GVWR), front and rear gross axle weight ratings(GAWR), and tire and wheel information. It also indi-cates if the vehicle has been certified as compliantwith Federal Motor Vehicle Safety Standard(FMVSS). See Fig. 1.1.

The tire and rim portion of the component informationlabel certifies suitable tire and rim combinations thatcan be installed on the vehicle for the given grossaxle weight rating. Tires and rims installed on thevehicle at the time of manufacture may have a higherload capacity than that certified by the tire and rimlabel. If the tires and rims currently on the vehiclehave a lower load capacity than that shown on thetire and rim label, then the tires and rims determinethe load limitations on each of the axles.

Incomplete chassis intended for service in the U.S.have an incomplete vehicle certification label at-tached by the final-stage manufacturer. This label willbe attached to the incomplete vehicle document in-cluded with the vehicle, and certifies that the vehicleconforms to all applicable FMVSS regulations in ef-fect on the date of completion.

Vehicle Identification NumberThe chassis vehicle identification number (VIN) isstamped on a metal plate permanently attached tothe vehicle, and the last six digits (designating thechassis serial number) are stamped into the metalframe. See Fig. 1.2. A VIN label is also mounted bythe body builder. Mounting locations vary, to includethe glove box. See Fig. 1.3.

NOTE: Always include the chassis serial num-ber (last six digits of the VIN) when communi-cating to Daimler Trucks North America.

Emissions LabelsAftertreatment System IndicatorsLabelEngines and vehicles manufactured after December31, 2006 and domiciled in the U.S. or Canada arerequired to meet all EPA regulations effective as ofthe vehicle build date, and are equipped with anemission aftertreatment system (ATS). Vehicles do-miciled outside of the U.S. and Canada may nothave aftertreatment equipment, depending upon localstatutory emissions guidelines. See Table 1.1.

A reference label included with the driver’s documen-tation package contains important warning indicatorsin the instrument cluster that pertain to the ATS. SeeFig. 1.4.

It is a violation of U.S. federal law to alter exhaustplumbing, ATS, or other components in any way thatwould bring the engine/vehicle out of compliance with

09/11/2002 f080123

Fig. 1.1, Component Information Label

GAFFNEY, SOUTH CAROLINA, USA4UZA4FVC0TC748531

f080061a04/18/2005

Fig. 1.2, Vehicle Identification Number, Typical

Vehicle Identification

1.1

Page 7: Recreational Vehicle Chassis Operator's Manual

certification requirements [Ref: 42 U.S.C. S7522(a)(3)]. It is the owner’s responsibility to maintain thevehicle so that it conforms to EPA regulations.

Vehicle Emission Control InformationLabelModel year 2013 and later vehicles meet additionalrequirements as specified by federal greenhouse gas

12/04/2001 f080122

Fig. 1.3, Vehicle Identification Number Label, Typical

f080156

EXHAUST AFTERTREATMENT SYSTEM INFORMATION

Switch.

Level 1 Level 3Level 2 Level 4Filter RegenerationRecommended.

Filter is reaching

Bring vehicle tohighway speeds to

Filter Regeneration

Filter is nowreaching maximumcapacity.

To avoid enginederate, bring vehicle

Parked RegenerationRequired − EngineDerate

Filter has reachedmaximum capacity.

Vehicle must beparked, and a Parked

Service Regeneration Required.Engine Derate To Idle Only.

Filter has exceeded maximumcapacity.

Vehicle must be parked, and aService Regeneration must be

(Solid) (Flashing) (Flashing)

CHECKINDICATORLAMP(S)

Indicator LampMessage(s)

Diesel ParticulateFilter Condition

Required Action

capacity.

STOP

allow for an AutomaticRegeneration orperform a Parked

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

Regeneration mustbe performed.Engine will beginderate.

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

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

02/20/2009

WARNING

HEST (High ExhaustSystem Temperature)

Exhaust componentsand exhaust gas are athigh temperature. Whenstationary, keep awayfrom people andflammable materials orvapors.

A regeneration is inprogress.

Flashing

Solid

Regeneration.

Necessary

Fig. 1.4, ATS Indicators

Vehicle Identification

1.2

Page 8: Recreational Vehicle Chassis Operator's Manual

and fuel efficiency regulations (GHG14). Model year2017 and later vehicles meet similar requirements asspecified by GHG17 requirements. These vehiclesare equipped with components that increase fuel effi-ciency and reduce GHG emissions. Componentsmay include, but are not limited to, low-rolling resis-tance tires.

A Vehicle Emission Control Information Label indi-cates compliance with GHG14 regulations. SeeFig. 1.5. It is the owner’s responsibility to maintainthe vehicle so that it conforms to EPA and NHTSA

regulations.

Applicable Emissions System Based on Build Date and EPA RegulationsBuild Date Regulation: Emissions Components

January 1, 2007–December 31,2009

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

January 1, 2010–December 31,2012

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

From March 5, 2012–December31, 2015

GHG14: Aerodynamic and fuel efficiency components including, but not limited to,tires, cab/sleeper side extenders, chassis fairings, bumper, hood, vehicle speedlimiters, and idle reduction timers specifically designed to meet regulatory fuelefficiency and greenhouse gas emissions standards.

From January 1, 2016GHG17: GHG14 components plus OBD16 instrumentation and sensor upgrades, andcomponent technology that meets NHTSA and EPA 2017 fuel efficiency andgreenhouse gas emission standards (GHG17) requirements.

* Cummins, Detroit, and Mercedes-Benz ATD’s are also equipped with a diesel oxidation catalyst to break down pollutants.

Table 1.1, Applicable Emissions System Based on Build Date and EPA Regulations

03/02/2012 f080183

Fig. 1.5, Vehicle Emission Control Information Label

Vehicle Identification

1.3

Page 9: Recreational Vehicle Chassis Operator's Manual

2

Lightbar Control Unit (LBCU)Instrument Panel

Lightbar Control Unit (LBCU) Instrument Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.1

Page 10: Recreational Vehicle Chassis Operator's Manual

Lightbar Control Unit (LBCU)Instrument PanelThe lightbar control unit (LBCU) instrument cluster isa full-featured, individual-gauge cluster with an intelli-gent lightbar (ILB). The individual gauges have lightemitting diode (LED) backlighting. The lightbar con-trol unit receives inputs for the gauges. See Fig. 2.1for a typical instrument gauge panel, and seeFig. 2.2 for the LBCU message center warning lights.See Chapter 5 for detailed warning lamp descrip-tions.

IMPORTANT: The LBCU is capable of determin-ing when input information is lost. The loss ofinput data will be noticeable to the operator bymovement of the gauge to zero. The odometervalue will not be driven to zero if total loss ofvehicle distance data occurs. When data input islost, hyphens (-) will replace the digits in thedata field on the display screen.

NOTE: When the ignition is turned on, all of theindicator lights will illuminate for approximatelythree seconds to allow the operator to perform abulb check.

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

Audible AlarmsDuring start-up, the LBCU will perform a self-test andan audible alarm will sound until the self-test is com-pleted. If any faults are found during the self-test,ERROR will appear on the display screen. Acknowl-edge any alarms before proceeding to the pretripchecklist. The alarm will also sound if any of the fol-lowing conditions occur:

• Air pressure falls below 65 psi (448 kPa).

• Anytime the low air warning light is activated.On the air system, the low air light/audiblealarm will normally come on when the engineis first started, but will go off when the air pres-sure in the air tanks reaches approximately 65to 76 psi (448 to 524 kPa). The parking brakewill not disengage until the air pressure hasreached 65 psi (448 kPa).

• Emergency engine shutdown is activated.

• The parking brake is applied and the transmis-sion is not in neutral.

• The transmission is in neutral or the ignition isoff, and the parking brake is not set and theservice brake is not depressed.

• The turn indicator is active.

• Anytime the ignition is turned off when thepanel lamps are still illuminated.

Emergency ShutdownThe LBCU will shut down if the voltage supply is notwithin the normal operating range of 9 to 16 volts formore than 10 milliseconds (msec). During emergencyshutdown, the gauge pointers will freeze, the displaywill go blank, and the lamps will turn off. When thepower is restored to within the normal operatingrange following an emergency shutdown, the needleswill resynchronize to zero, and the self-test will beperformed before resuming normal operation.

Information CenterThe LBCU is an interactive graphical display that iscapable of displaying text messages and graphics tocommunicate real-time information about the statusand performance of the vehicle to the operator. Thisinformation is organized in a menu-structured format.

Power InitializationWhen the ignition is turned on, the information centerwill illuminate with the Freightliner Custom Chassislogo. If there are no alarms detected from the self-test, the driver checklist is displayed.

Navigating the Menu ScreenNavigate the menu structure using the toggle switch,located in the driver’s area. The "up" arrow of thetoggle switch is yellow. See Fig. 2.3.

Menu StructureThe menu structure is organized around three menuscreens: the ignition off screen, the home screen,and the setup/maintenance/diagnostics screen. Eachof these screens contains lists of the sub-menuscreens that may be accessed by highlighting thedesired sub-menu and clicking the right arrow on thetoggle switch.

Lightbar Control Unit (LBCU) Instrument Panel

2.1

Page 11: Recreational Vehicle Chassis Operator's Manual

18

13

8E

F

0

5

1020

25

30

35

RPMx100

15

RPMx100

ULTR

A LO

W SULFUR DIESEL FUEL ONLY

0

20

40

60 80

100

120

140

25

35 4555

65

75

8505

15

f611060

1

2

3 4

6

7 8

9

10

150

65

00

150

PSI

PSI PSI

10065

100

C0

50

100 H

1 2150

65

00

150

PSI

PSI PSI

10065

100

C0

50

100 H

1 2

STOPCHECKABS

5

09/23/2009

1. Lightbar Control Unit2. Tachometer3. Fuel Gauge4. Diesel Exhaust Fluid (DEF) Gauge

5. Voltmeter6. Speedometer7. Primary Air Gauge

8. Secondary Air Gauge9. Coolant Temperature Gauge10. Oil Pressure Gauge

Fig. 2.1, Typical LBCU Instrument Panel, EPA10 and Newer Engines

f611067

STOPCHECKABS

1 2 3 4 5 6 7 8

9 10 11 12 13 14 15 1609/23/2009

1. Check Engine Warning2. High Exhaust System

Temperature (HEST) Lamp3. Stop Engine Warning4. Dash Driver Display Screen5. ABS Warning

6. Transmission Warning7. Engine Brake Indicator8. Cruise Control Indicator9. Left-Turn Indicator10. Diesel Particulate Filter (DPF)

Lamp

11. Shift Inhibit Indicator12. Headlight High-Beam Indicator13. Parking Brake On Warning14. Low Air Pressure Warning15. Wait to Start Indicator16. Right-Turn Indicator

Fig. 2.2, LBCU Message Center/Warning Lights, EPA10 and Newer Engines

Lightbar Control Unit (LBCU) Instrument Panel

2.2

Page 12: Recreational Vehicle Chassis Operator's Manual

Ignition Off ScreenWhen the ignition is OFF and the headlights are ON,the odometer is displayed. When the ignition is OFFand the generator is ON, the generator hours aredisplayed (if connected by the body builder).

Home Screen

NOTE: Alarm messages have priority over otherdisplay screens. If no alarms are present or allalarms have been acknowledged, the driverchecklist will be displayed.

The following options are found in the menu andsub-menus of the home screen.

• A pretrip inspection checklist that includes 19items and 10 driver-entered options. Onceeach item has been reviewed, click the rightarrow of the toggle switch to place a check bythe item. Click the left arrow to exit the check-list.

• Driver’s Favorite Categories—There are ninecategories that the driver can select from; threecan be viewed at one time. Select the categorydesired by using the up/down toggle switch.Then, click the right arrow of the toggle switchfor three seconds to access the sub-menuswithin each category. Finally, click the leftarrow of the toggle switch to exit.

Setup/Maintenance/Diagnostics ScreenThe setup/maintenance/diagnostics screen is actuallythree different categories for the driver to use. Theyare as follows:

• Setup—Includes set time and date, configurechecklist, select metric/English, set LCD prop-erties.

• Maintenance—Includes engine oil, engine airfilter, engine fuel filter, transmission oil, genera-tor oil, generator fuel filter, generator use time.

• Diagnostics—Includes check gauges, checkicons, check inputs, check outputs, engine di-agnostics, ABS diagnostics, hardware/softwareversion, and software debug display (this menuis used by the gauge manufacturer only).

The following steps are used to make changes withinthe setup/maintenance/diagnostics screen.

1. From the Driver’s Favorite Category menu, holddown the right arrow of the toggle switch for fiveseconds to select the setup/maintenance/diagnostics screen.

2. Press the down arrow on the toggle switch toselect either setup, maintenance, or diagnostics.

3. Press the right arrow on the toggle switch to se-lect the sub-category; "Set Time and Date" forexample.

4. Use the left/right arrows on the toggle switch tochange the information, and the up/down arrowsto move within the sub-category.

5. Once all changes have been made, hold downthe right arrow on the toggle switch.

Menu StructureThe menu structure road map is provided to illustratethe screens that are available in the information cen-ter and the path to specific screens. Refer to theroad maps to set the time and date, view engine di-agnostics, etc. See Fig. 2.4, Fig. 2.5, Fig. 2.6,Fig. 2.7, Fig. 2.8, Fig. 2.9, Fig. 2.10, Fig. 2.11,Fig. 2.12, Fig. 2.13, Fig. 2.14, Fig. 2.15, Fig. 2.16,Fig. 2.17, Fig. 2.18, Fig. 2.19, Fig. 2.20, Fig. 2.21,Fig. 2.22, and Fig. 2.23.

04/19/2005 f610766

Fig. 2.3, Toggle Switch

Lightbar Control Unit (LBCU) Instrument Panel

2.3

Page 13: Recreational Vehicle Chassis Operator's Manual

Checklist MenuPre−Trip Checklist

Check Tow Vehicle

Check an option

Jacks/Air Leveler Up

Favorite Display01/01/00ODOTODAY DIST

Useto return toprevious step

PressPress

Press

Press

Press

Press

PressHold

5 sec

Gen hrsDate & time (mo/day/yr hr:min:sec;month. Day hr:min:sed; hr:min:se)OdometerToday: dist; time; fuel, fuel econ,AVSPD, idle timeLeg: dist; time; fuel,fuel econ,AVSPD,idle timeTrip: dist; time; fuel, fuel econ, AVSPD,idle timeRoad SPD; eng RPM; oil press; instfuel econ; fuel used; eng hrs; engtemp; trbo press; volt)

Format Options

Reset value options onlyapplicable to today dis, leg dist,

trip dist

2:34:2814.4 mi14. 4.mi

Hold

5 sec

Set up maintenanceand diagnose

MAINTENANCEDIAGNOSTICS

SETUPJAN. 1ODOTODAY DIST

2:37:1414.4 mi14. 4.mi

Change format/Information

Reset valueTODAY STARTED 0:00:001/01/2000YES HOLD

RESTART?3sec, NO

Yes

NoSkip checklistmenu

f04071709/26/2006

Fig. 2.4, Favorite Display, LBCU Panel

Lightbar Control Unit (LBCU) Instrument Panel

2.4

Page 14: Recreational Vehicle Chassis Operator's Manual

10/18/2005

Headlights "ON"

OnOff

Ignition

View while headlights ON

OnOff

Headlights

ODO 14.4 mi

Headlights

OnOff

Headlights"OFF"

f040718

Fig. 2.5, View Odometer Value, LBCU Panel

10/18/2005

Generator "ON"

OnOff

Ignition

Shows Generator hours

OnOff

Generator

GEN HRS 0.0

Generator

OnOff

Generator"OFF"

f040719

Fig. 2.6, View Generator Hours, LBCU Panel

02/06/2012 f040720

Favorite Display & Park Brake set01/01/00ODOTODAY DIST

Useto return toprevious step

SetRelease

Park Brake

Press

Press

Hold

3 sec

2:34:2814.4 mi14. 4.mi

Set up, Maintenanceand Diagnostics

MAINTENANCEDIAGNOSTICS

SETUP

Set up Menuto exit

CONFIGURE CHECKLISTSELECT METRIC/ENGLISHSET MISCELLANEOUSSET DISPLAY PROPERTIES

SET TIME AND DATE

Fig. 2.7, Set Up Menu, LBCU Panel

Lightbar Control Unit (LBCU) Instrument Panel

2.5

Page 15: Recreational Vehicle Chassis Operator's Manual

Favorite Display & Park Brake set01/01/00ODOTODAY DIST

Useto return toprevious step

SetRelease

Park Brake

Press

Hold

5 sec

2:34:2814.4 mi14. 4.mi

Set up, Maintenanceand Diagnostics

MAINTENANCEDIAGNOSTICS

SETUP

Set up Menu

CONFIGURE CHECKLISTSELECT METRIC/ENGLISH

SET TIME AND DATE

f040721

Set Time and Date/01/00

Exit withExit with

4:55 24to Saveto Cancel

01

Press

to save

Press

to cancel

Month (1−12)/01/00

Exit withExit with

4:55 24to Saveto Cancel

02

Press

Day (1−31)02/01/00Exit withExit with

4:55 24to Saveto Cancel

01

Press

Year (00−99)01/01/00Exit withExit with

4:55 24to Saveto Cancel

00

Press

Hr (0−23)01/01/00Exit withExit with

4:55 24to Saveto Cancel

4

Press

Min (0−59)01/01/00Exit withExit with

4:55 24to Saveto Cancel

55

Press

Format (AM/PM/24)01/01/00Exit withExit with

4:55 24to Saveto Cancel

24

Pressto change

Pressto change

Pressto change

Pressto change

Pressto change

Pressto change

To save, the cursor must be allthe way to the right

To exit, the cursor must be allthe way to the left Must be left

Press

09/26/2006

Fig. 2.8, Set Time and Date, LBCU Panel

Lightbar Control Unit (LBCU) Instrument Panel

2.6

Page 16: Recreational Vehicle Chassis Operator's Manual

Favorite Display & Park Brake set01/01/00ODOTODAY DIST

Useto return toprevious step

SetRelease

Park Brake

Press

Hold

5 sec

2:34:2814.4 mi14.4.mi

Set up, Maintenanceand Diagnostics

MAINTENANCEDIAGNOSTICS

SETUP

Set up Menu

CONFIGURE CHECKLISTSELECT METRIC/ENGLISH

SET TIME AND DATE

f040722

Configure ChecklistSET TIME AND DATE

SELECT METRIC/ENGLISH

Press

to save

Pressto change

as needed

Press

Hold

5 sec

Press19 times

As many times

Press

Select Items to be displayed in thechecklist menu

Jacks/Air Leveler UpCheck Tow VehicleTire Pressure

Type personal option,characters will appear in

. / 0−9 : ; < = > ?@ A−Z \this order:

a−z !" # $ % & ’ ( ) + , −

Look for empty lines

Pressfor next item

Press toselect

or remove

To add up to 10different and personalized itemsat the end of the list

CONFIGURE CHECKLIST

09/27/2006

Press

to save

Fig. 2.9, Configure Checklist, LBCU Panel

Lightbar Control Unit (LBCU) Instrument Panel

2.7

Page 17: Recreational Vehicle Chassis Operator's Manual

Favorite Display & Park Brake set01/01/00ODOTODAY DIST

Useto return toprevious stepSet

Release

Park Brake

Press

Hold

5 sec

2:34:2814.4 mi14.4.mi

Set up, Maintenanceand Diagnostics

MAINTENANCEDIAGNOSTICS

SETUP

Set up Menu

CONFIGURE CHECKLISTSELECT METRIC/ENGLISH

SET TIME AND DATE

f040725

Set Display Properties line

Press

SELECT METRIC/ENGLISHSET MISCELLANEOUS

Press3 times

SET DISPLAY PROPERTIESSET MISCELLANEOUS

Factory Settings

Dimm w Hdghts OffDimm w Hdghts On

Factory Settings25%25%

Dimm whdlghts on

Increments of 5%from 0% to 95%

Press

changeto

Press

exitto save &

Press

changeto

Press

Press

Dimm whdlghts off

Yes

Factory settings cannot bechanged; they will always be25% for Hdlghts Off and On

09/26/2006

Fig. 2.10, Set Display Properties, LBCU Panel

Lightbar Control Unit (LBCU) Instrument Panel

2.8

Page 18: Recreational Vehicle Chassis Operator's Manual

Favorite Display & Park Brake set01/01/00ODOTODAY DIST

Useto return toprevious stepSet

Release

Park Brake

Press

Hold

5 sec

2:34:2814.4 mi14.4.mi

Set up, Maintenanceand Diagnostics

MAINTENANCEDIAGNOSTICS

SETUP

Maintenance

f040726

Press

ENGINE OIL

ENGINE FUEL FILTERENGINE AIR FILTER

Press

DIAGNOSTICS

SETUPMAINTENANCE

Press

ENGINE OIL

VERIFY SERVICE DONESERV OVERDUE

Press

EVERYVERIFY ENGINE OIL

YES HOLD 3 sec, NOSERVICE DONE

Press

Press

Press

to save

Hold

5 sec

Yes No

Pressto change

CHANGE WITH mi0

SET SERVICE INTERVAL

mi0

This procedure applies for all the options shown in this menu list

03/10/2006

Fig. 2.11, Maintenance Menu, LBCU Panel

Lightbar Control Unit (LBCU) Instrument Panel

2.9

Page 19: Recreational Vehicle Chassis Operator's Manual

Favorite Display & Park Brake set01/01/00ODOTODAY DIST

Useto return toprevious step

SetRelease

Park Brake

Press

Hold

5 sec

2:34:2814.4 mi14.4.mi

Set up, Maintenanceand Diagnostics

MAINTENANCEDIAGNOSTICS

SETUP

Set up Menu

CONFIGURE CHECKLISTSELECT METRIC/ENGLISH

SET TIME AND DATE

Select Metric/EnglishSET TIME AND DATE

Press

to save

Press

change

Press

Select English/Metric Units

Change withExit and save with

CONFIGURE CHECKLISTSELECT METRIC/ENGLISH

to

Presstwice

English

02/06/2012 f040723

Fig. 2.12, Change Units, LBCU Panel

Favorite Display & Park Brake set01/01/00ODOTODAY DIST

Useto return toprevious step

SetRelease

Park Brake

Press

Hold

5 sec

2:34:2814.4 mi14.4.mi

Set up, Maintenanceand Diagnostics

MAINTENANCEDIAGNOSTICS

SETUP

Diagnostics menu

CHECK GAUGES

CHECK INPUTSCHECK ICONS

SETUPMAINTENANCE

Presstwice

DIAGNOSTICS

02/06/2012 f040727

Fig. 2.13, Diagnostics Menu, LBCU Panel

Lightbar Control Unit (LBCU) Instrument Panel

2.10

Page 20: Recreational Vehicle Chassis Operator's Manual

Favorite Display & Park Brake set01/01/00ODOTODAY DIST

Useto return toprevious step

SetRelease

Park Brake

Press

Hold

5 sec

2:34:2814.4 mi14.4.mi

Set up, Maintenanceand Diagnostics

MAINTENANCEDIAGNOSTICS

SETUP

Diagnostics menu

f040728

CHECK GAUGES

CHECK INPUTSCHECK ICONS

SETUPMAINTENANCE

Presstwice

DIAGNOSTICS

Press

to exit

Change values

Speed

Fuel LevelRPM

Air 1

Trans Oil TempAir 2

Battery Voltage

Turbo BoostAmmeter

Appl Air

Eng CoolantSusp Air

Eng Oil Press

50%50%

50%50%

50%50%

50%50%

50%

50%

50%50%

50%

Speed

Fuel LevelRPM 50%

50%

Press

Possible values

While changing the values,gauges should move

Press

09/27/2006

−Speed: 0% (0 mph), 50% (42.5 mph) and 100% (85 mph). −RPM: 0% (0 rpmx100), 50% (17.5 rpmx100) and 100% (35 rpmx100) −Fuel level: 0% (empty), 50% (half) and 100% (full). −Air 1 and Air 2: 0% (0 psi), 50% (75 psi) and 100% (150 psi). −Trans oil temp: 0% (125°F), 50% (237.5°F) and 100% (300°F). −Battery volt: 0% (8V), 50% (13V) and 100% (18V) −Turbo boost: 0% (0 psi), 50% (25 psi) and 100% (50 psi). −Eng coolant: 0% ("C" cold), 50% (half) and 100% ("H" hot). −Eng oil press: 0% (0 psi), 50% (50 psi) and 100% (100 psi). −Ammeter: no gauge shown. −Application air and suspension air: no gauges shown.

270%

Fig. 2.14, Check Gauges and Change Values, LBCU Panel

Lightbar Control Unit (LBCU) Instrument Panel

2.11

Page 21: Recreational Vehicle Chassis Operator's Manual

Favorite Display & Park Brake set01/01/00ODOTODAY DIST

Useto return toprevious step

SetRelease

Park Brake

Press

Hold

5 sec

2:34:2814.4 mi14.4.mi

Set up, Maintenanceand Diagnostics

MAINTENANCEDIAGNOSTICS

SETUP

Diagnostics menu

f040729

CHECK GAUGES

CHECK INPUTS

SETUPMAINTENANCE

Presstwice

DIAGNOSTICS

Press

to exit

Turn On and Off

Press

Press

Press

CHECK ICONS

1st Upper Left

3rd Upper Left2nd Upper Left Off

Off

1st Upper Left

3rd Upper Left2nd Upper Left Off

Off

Press

Press

To selectnext option

Use "Welcome Screen"to locate icons as theyare being lighted

Off

On

03/09/2006

Fig. 2.15, Check Icons and Change Values, LBCU Panel

Lightbar Control Unit (LBCU) Instrument Panel

2.12

Page 22: Recreational Vehicle Chassis Operator's Manual

Favorite Display & Park Brake set01/01/00ODOTODAY DIST

Useto return toprevious step

SetRelease

Park Brake

Press

Hold

5 sec

2:34:2814.4 mi14.4.mi

Set up, Maintenanceand Diagnostics

MAINTENANCEDIAGNOSTICS

SETUP

Diagnostics menu

f040730

CHECK GAUGES

SETUPMAINTENANCE

Presstwice

DIAGNOSTICS

Press

to exit

Press

CHECK ICONSCHECK INPUTS

Presstwice

A03 E Brake 50%D15 Ignition

B12 Audible AlarmC07 Lift Open

C08 Left TurnC04 Tag Axle

D08 Right TurnA05 Brakes Worn

HH/NC

L/NCH/NC

L/NCL/NCL/NC

L

A06 Optional 2A07 Optional 3

B01 Optional 5B08 Optional 6

D04 Optional 8A12 High Beam

D07 High Idle ReqB04 E Brake 100%

L/NCL/NC

L/NCL/NC

L/NCL/NC

H/NCH/NC

B09 Cruise OnC12 Cruise R/A

C10 Spare 1D01 Fuel Level

D12 Pneum ABSB11 Hydraul ABS

LH/NC

105ohmH/NC

0.1V8.4V

A04 Generator

C06 Throttle Dis

C05 Park Brake

C14 Optional 1

L/NC

L/NC

L

L/NC

A08 Optional 4

C11 Optional 7

D11 Service Brake

A09 Water In Fuel

L/NC

L/NC

L/NC

H/NC

C01 Cruise S/D

C13 Brake Fuse S

D10 Rain Sensr

H/NC

14.5V

8.3V

Check inputs

09/26/2006

C16 Spare 2D16 Headlamp Pwr

D14 Battery

OFF

14.3VA01 Panel Light Pwm 0%

8.7V

NOTE: L = Low, H = 12 volt, and NC = not connected.

Fig. 2.16, Check Inputs, LBCU Panel

Lightbar Control Unit (LBCU) Instrument Panel

2.13

Page 23: Recreational Vehicle Chassis Operator's Manual

D6 Vehicle Moving Off

Favorite Display & Park Brake set01/01/00ODOTODAY DIST

Useto return toprevious step

SetRelease

Park Brake

Press

Hold

5 sec

2:34:2814.4 mi14.4.mi

Set up, Maintenanceand Diagnostics

MAINTENANCEDIAGNOSTICS

SETUP

Diagnostics menu

f040731

CHECK ICONS

SETUPMAINTENANCE

Presstwice

DIAGNOSTICS

Press

to exitCHECK INPUTSCHECK OUTPUTS

Press3 times

Check Outputs

C2 Strtr Lock OutC3 Veh Charging Off

Off

D6 Vehicle Moving Off

Turn on and Off

C2 Strtr Lock OutC3 Veh Charging Off

On

Press

Press

PressTo selectnext option

03/09/2006

Fig. 2.17, Check Outputs, LBCU Panel

Lightbar Control Unit (LBCU) Instrument Panel

2.14

Page 24: Recreational Vehicle Chassis Operator's Manual

from Engine Controller

Favorite Display & Park Brake set01/01/00ODOTODAY DIST

Useto return toprevious step

SetRelease

Park Brake

Press

Hold

5 sec

2:34:2814.4 mi14.4.mi

Set up, Maintenanceand Diagnostics

MAINTENANCEDIAGNOSTICS

SETUP

Diagnostics menu

CHECK OUTPUTS

SETUPMAINTENANCE

Presstwice

DIAGNOSTICS

Press

to exit

TRANS DIAGNOSTICS

Press4 times

− ACTIVE ENG FAULTSWait Requesting Faults

Press

ENGINE DIAGNOSTICS

0 ACTIVE ENG FAULTS

02/06/2012 f040732

Fig. 2.18, Engine Diagnostics, LBCU Panel

Useto return toprevious step

Press

Hold

5 sec

Presstwice

Press

to exit

Press

02/06/2012 f040734

from ABS Controller

Favorite Display & Park Brake set01/01/00ODOTODAY DIST

SetRelease

Park Brake2:34:2814.4 mi14.4.mi

Set up, Maintenanceand Diagnostics

MAINTENANCEDIAGNOSTICS

SETUP

Diagnostics menu

SETUPMAINTENANCEDIAGNOSTICS

SW DEBUG DISPLAY

Press6 times

− ACTIVE ABS FAULTSWait Requesting Faults

HARDWARE/SOFTWARE VER

0 ACTIVE ABS FAULTS

ABS DIAGNOSTICS

Fig. 2.19, ABS Diagnostics, LBCU Panel

Lightbar Control Unit (LBCU) Instrument Panel

2.15

Page 25: Recreational Vehicle Chassis Operator's Manual

Useto return toprevious step

Press

Hold

5 sec

Presstwice

Press

to exit

Press

02/06/2012 f040735

Favorite Display & Park Brake set01/01/00ODOTODAY DIST

SetRelease

Park Brake2:34:2814.4 mi14.4.mi

Set up, Maintenanceand Diagnostics

MAINTENANCEDIAGNOSTICS

SETUP

Diagnostics menu

CHECK INTERNAL DATA

SETUPMAINTENANCEDIAGNOSTICS

SW DEBUG DISPLAY

Press7 times

Hardware ver: 0ASoftware ver: 1.08

HARDWARE/SOFTWARE VER

Fig. 2.20, Hardware/Software Menu, LBCU Panel

Useto return toprevious step

Press

Hold

5 sec

Presstwice

Press

to exit

Press

02/06/2012 f040736

Favorite Display & Park Brake set01/01/00ODOTODAY DIST

SetRelease

Park Brake2:34:2814.4 mi14.4.mi

Set up, Maintenanceand Diagnostics

MAINTENANCEDIAGNOSTICS

SETUP

Diagnostics menu

SETUPMAINTENANCEDIAGNOSTICS

ODOMETER DIAGNOSTICSCHECK INTERNAL DATA

Press8 times

0000000000 00000000Display: F9 00000000

SW DEBUG DISPLAY

E 00 5 00

NOTE: This screen is used by the manufacturer only.

Fig. 2.21, Software Debug Display, LBCU Panel

Lightbar Control Unit (LBCU) Instrument Panel

2.16

Page 26: Recreational Vehicle Chassis Operator's Manual

Useto return toprevious step

Press

Hold

5 sec

Presstwice

Press

to exit

Press

02/06/2012 f040738

Favorite Display & Park Brake set01/01/00ODOTODAY DIST

SetRelease

Park Brake2:34:2814.4 mi14.4.mi

Set up, Maintenanceand Diagnostics

MAINTENANCEDIAGNOSTICS

SETUP

Diagnostics menu

SETUPMAINTENANCEDIAGNOSTICS

INPUT OVERRIDE

Press9 times

IP ODOENG ODO

CHECK INTERNAL DATA

DIFF

ODOMETER DIAGNOSTICS

−−−−−−−−−−−−−−−−−−−−−−−−

14.4mi

Fig. 2.22, Odometer Diagnostics, LBCU Panel

Useto return toprevious step

Press

Hold

5 sec

Presstwice

Press

to exit

Press

02/06/2012 f040739

Favorite Display & Park Brake set01/01/00ODOTODAY DIST

SetRelease

Park Brake2:34:2814.4 mi14.4.mi

Set up, Maintenanceand Diagnostics

MAINTENANCEDIAGNOSTICS

SETUP

Diagnostics menu

SETUPMAINTENANCEDIAGNOSTICS

Press10 times

CHECK INTERNAL DATA

C06 Throttle DisD11 Service Brake

B02 Engine Brk 2B04 Engine Brk 1

C01 Cruise S/DC12 Cruise R/A

OffOff

OffOff

Off

C05 Park Brake

D07 High Idle Req

B09 Cruise On Off

Check Input Override

ODOMETER DIAGNOSTICS

Off

Off

Off

INPUT OVERRIDE

Fig. 2.23, Check Input Override, LBCU Panel

Lightbar Control Unit (LBCU) Instrument Panel

2.17

Page 27: Recreational Vehicle Chassis Operator's Manual

3

Ametek Instrument PanelAmetek Instrument Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.1

Page 28: Recreational Vehicle Chassis Operator's Manual

Ametek Instrument PanelThe following information describes a typical instru-ment panel manufactured by Ametek. See Figure 3.1for a typical instrument gauge panel, and see Figure3.2 for the Ametek warning lamps. See Chapter 5 fordetailed warning lamp descriptions.

NOTE: These instrument panels are shown witha standard U.S. speedometer, which showsmiles per hour (mph) more prominently than ki-lometers per hour (km/h).

Message Display CenterThe message display is a graphical, backlit, liquidcrystal display (LCD) that relays information to thevehicle operator. The messages displayed include:

• Odometer

• Trip Odometer 1/Trip Odometer 2

• Chassis Battery Voltage

• Instantaneous Fuel Rate

• Average Fuel Rate

• Gear Attained Status

• Transmission Temperature

• Hour Meter

• Boost Pressure

• Engine Oil Pressure

• Coolant Temperature

• Fuel Level

• Percent Engine Load

• Engine RPM

During normal operation, the LCD displays the odom-eter value and chassis battery voltage on the topline, and driver selected parameters, such as the tripodometer and fuel rate, on the second and thirdlines.

Priority MessagesPriority messages (including warning messages) aredisplayed in the LCD due to various inputs or datamessages. Unless noted otherwise, the priority mes-sage will take over the whole screen, allowing mul-tiple messages to be displayed in five second inter-vals.

Self-TestWhen the ignition is turned on, a required self-testautomatically begins. Gauge needles will reset tozero during the self-test, and then immediately moveto the position dictated by the data received. Duringthis time, the warning lights, alarm (buzzer), anddriver display screen will also perform a self-test.

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

Menu SystemThe menu system is shown on the driver displayscreen once the self-test is finished. The menu sys-tem responds to input from the driver and remainsactive as long as the ignition is on. In order for thedriver to operate the menu system, the ignition mustbe ON, and the park brake must be set (ON). Themain features of the menu system are describedbelow.

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

• Maintenance—shows various maintenance in-tervals such as engine oil, air filter, etc.

• Diagnostics—this is used for setting and read-ing inputs and outputs and checking thegauges. It also shows the hardware and soft-ware version of the instrument panel, and hasmenus to retrieve active error codes from theengine, transmission, and ABS controllers.

NOTE: No lines can be highlighted in the menusystem screen. To get to the sections that canbe highlighted, press the right arrow toggle but-ton and hold it for two seconds. The displayscreen will change and the options shown canthen be highlighted. Once a selection has beenchosen and changes are made, press the rightarrow toggle button to go back to the main mes-sage display screen.

Setup MenuSelect Display UnitsThe set units screen allows the driver to choose be-tween English or metric units of measurement for thedisplayed values. To navigate to the set units screen,see Fig. 3.3, screens H, I, and J.

Ametek Instrument Panel

3.1

Page 29: Recreational Vehicle Chassis Operator's Manual

Startup ScreenThe startup screen selection allows the driver to turnthe startup screen on or off.

LCD ContrastSelect contrast from the menu to set the LCD con-trast. Use the down toggle button to set the contrastto the desired level. To navigate to the contrastscreen, see Fig. 3.3, screen M.

Reset ParametersThe reset parameters screen is included with ve-hicles that have the Allison transmission prognosticsfeature.

Maintenance MenuThe maintenance menu has the following three submenus:

• maintenance intervals

• transmission oil life remaining

• transmission oil filter life monitor

Maintenance IntervalsThe maintenance intervals menu allows the driver toset the change intervals for engine oil and engine airfilter. If the intervals are set to zero, the maintenancewarnings must be disabled.

10/13/2009 f611051

1 2

3

6

8

7 4

5

1. Fuel Gauge2. Speedometer3. Coolant Temperature Gauge4. Toggle Button, Right

5. Toggle Button, Down6. Message Display Center7. Diesel Exhaust Fluid (DEF) Gauge8. Engine Oil Pressure Gauge

Fig. 3.1, Typical Instrument Panel, EPA10 and Newer Engines

Ametek Instrument Panel

3.2

Page 30: Recreational Vehicle Chassis Operator's Manual

Transmission Oil Life RemainingIf transmission prognostics are enabled, this menuindicates how much useful oil life remains.

Transmission Oil Filter Life MonitorIf transmission prognostics are enabled, the trans-mission oil filter life monitor tells the driver if thetransmission oil filter is clogged and in need of repair.A message will appear on the display screen asTRANS OIL FILTER FUNCTIONAL or TRANS OILFILTER CLOGGED.

Diagnostic MenuThe diagnostic menu contains the following items:

• engine faults

• transmission faults

• ABS faults

• check outputs

• odometer diagnostics

• check gauges

• check indicators (warning lamps)

• check LCD

• check binary inputs

• check analog inputs

• check datalink

• hardware/software version

All of the items in the diagnostic menu can be ac-cessed by using the toggle buttons and selecting theauxiliary screens. Then navigate to the diagnosticsub-menu. Some of the more frequently used diag-nostic menus are described further below.

Engine FaultsThis screen displays engine fault codes that are re-ceived from the engine electronic control unit (ECU).To navigate to the engine fault screen, see Fig. 3.4,screen AA.

09/21/2009 f611052

1

2

3 4 5 6 7 8 9 10 11 12 13

14

15

1920

17

18

16

1. Maintenance Warning2. Left-Turn Indicator3. High Exhaust System

Temperature (HEST) Lamp4. Check Engine Warning5. Stop Engine Warning6. Malfunction Indicator Lamp (MIL)7. Engine Brake Indicator

8. Wait to Start Indicator9. ABS Warning10. Shift Inhibit Indicator11. Transmission Warning12. Stop Transmission (hybrid only)13. Diesel Particulate Filter (DPF)

Lamp

14. Right-Turn Indicator15. Fasten Seat Belt Warning16. Air Brake Warning17. Hydraulic Brake System Warning18. Headlight High-Beam Indicator19. Cruise Control Indicator20. Parking Brake On Warning

Fig. 3.2, Warning Lamps, EPA10 and Newer Engines

Ametek Instrument Panel

3.3

Page 31: Recreational Vehicle Chassis Operator's Manual

Transmission FaultsThis screen displays transmission fault codes thatare received from the transmission ECU. To navigateto the transmission fault screen, see Fig. 3.4, screenAB.

ABS DiagnosticsThis screen displays Antilock Brake System (ABS)fault codes that are received from the ABS ECU. Tonavigate to the ABS diagnostic screen, see Fig. 3.4,screen AC.

Check GaugesThe check gauges screen allows the driver to seteach gauge as a percentage of scale (either 0, 50, or100%), as shown in the LCD. To navigate to thecheck gauges screen, see Fig. 3.5, AG screens.

Warning LampThe warning lamp screen allows the driver to testeach warning lamp (not the vehicle load) on and thenoff, displaying the lamp name and status in the LCD.To navigate to the warning lamp screen, seeFig. 3.5, screen AH.

Check LCDSelecting the check LCD screen displays the Freight-liner Custom Chassis Corporation (FCCC) logo innormal and reverse video three times and then re-turns to the menu. To navigate to the check LCDscreen, see Fig. 3.5, screen AI.

Check Binary InputsThe check binary inputs screen displays the pin num-ber and status of each binary input. The toggle but-tons allow the driver to select each binary input. Thisinformation is continuously updated to assist introubleshooting. To navigate to the check binary in-puts screen, see Fig. 3.5, screen AJ.

Check Analog InputsThe check analog inputs screen displays the pinnumber and actual value of each analog input de-fined in the system. The toggle buttons allow thedriver to select each analog input. This information iscontinuously updated to assist in troubleshooting. Tonavigate to the check analog input screen, seeFig. 3.6, screen AK.

Check DatalinkThe check datalink screen allows the driver to viewall devices that communicate on the J1939, J1587,and GMLAN datalinks. To navigate to the check da-talink screen, see Fig. 3.6, screen AL.

Menu NavigationThe menu navigation road maps are provided to il-lustrate the screens that are available in the menusystem. The paths to specific screens are shown,along with instructions for using the toggle buttons tomove from one screen to another. Refer to the roadmaps to change items shown in lines one, two, andthree of the display screen, view the setup screens,diagnostics, etc. See Fig. 3.3, Fig. 3.4, Fig. 3.5,Fig. 3.6, Fig. 3.7, Fig. 3.8, Fig. 3.9, Fig. 3.10,Fig. 3.11, Fig. 3.12, Fig. 3.13, Fig. 3.14, andFig. 3.15.

IMPORTANT: Follow the steps below to changethe three items (also known as favorites) shownin the message display center. The messagedisplay center is referred to as screen C inFig. 3.9.

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

2. Press the down toggle button to select an item tochange. The selected item will now be high-lighted.

3. Press the right toggle button once to enter thefavorites display menu, shown in Fig. 3.9, asscreen D.

4. Use the down toggle button to scroll through theavailable items.

5. Highlight the new item, then press the righttoggle button. The selected item will now appearin the message display center.

Ametek Instrument Panel

3.4

Page 32: Recreational Vehicle Chassis Operator's Manual

SETUP

Down HoldOr (Right & Exit

highlighted)

Down PressCurrent Units =

Metric

Down PressCurrent Units =

English

Current Units =English

Current Units =Metric

Down PressStartup Screen =

Disabled

Down PressStartup Screen =

Enabled

Startup Screen =Enabled

Startup Screen =Disabled

Down PressNot At Min Contrast /

Decrease Contrast

Down PressAt Min Contrast /

Set Contrast to Max

Right PressStartup Screen

highlighted

Right PressSelect Display

Units highlighted

Right PressDisplay Contrast

highlighted

Right PressOr

Down Hold

Right PressOr

Down Hold

Right PressOr

Down Hold

Right PressOr

Down Hold

Right PressOr

Down Hold

Down PressHighlight next

line of list.At middle,wrap to top

Right HoldReset Parameters

Right PressReset Parameters

highlighted

Right PressOr

Down Hold

Right PressOr

Down Hold

AUXILIARYSCREENS

09/23/2009 f040792

Fig. 3.3, Setup Menu Screens

Ametek Instrument Panel

3.5

Page 33: Recreational Vehicle Chassis Operator's Manual

Diagnostics

Note 5:Screen Z scrolls to display the following items: ENGINE FAULTS TRANSMISSION FAULTS ABS FAULTS CHECK OUTPUTS CHECK DATA INPUTS ODOMETER DIAGNOSTICS CHECK GAUGES CHECK WARNING LAMPS CHECK LCD CHECK BINARY INPUTS CHECK ANALOG INPUTS CHECK DATA LINK VERSION INFORMATION EXITThe text DIAGNOSTIC MENU remains fixed on the first line.

Down PressDisplay Next Fault

Down PressDisplay Next Fault

Down PressDisplay Next Fault

Right PressOr

Down Hold

Down PressChange to

Next Output

Right PressOr

Down Hold

Right HoldToggle OutputState Between

Off and On

MenuRight Press

Engine FaultsHighlighted

Right PressTrans FaultsHighlighted

Right PressABS FaultsHighlighted

Right PressCheck Outputs

Highlighted

Menu

(Right & Exithighlighted)

Menu

Right PressOr

Down HoldMenu

Right PressOr

Down HoldMenu

Screens AA,AB,AC Format For J1587

Screen AE For J1587

Down PressHighlight next

line of list.At bottom,wrap to top

Right || Hold DownRight Press

Odometer DiagHighlighted

Menu

09/23/2009 f040795

Fig. 3.4, Diagnostic Menu Screens—Screen 1

Ametek Instrument Panel

3.6

Page 34: Recreational Vehicle Chassis Operator's Manual

Down PressChange to

Next Gauge

Right HoldStep Gauge toNext Position

Right || Hold Down

Down PressChange to

Next Telltale

Right HoldToggle State

BetweenOff and On

Right || Hold Down

Every 1.5 Seconds /Invert Video of

Displayed Image

Right ||9 Seconds Elapsed

|| Hold Down

Down PressChange toNext Input

Right || Hold Down

Right PressCheck Gauges

Highlighted

Right PressWarning Lamps

Highlighted

Right PressCheck LCDHighlighted

Right PressCheck Binary Inputs

Highlighted

Menu

Menu

Menu

Menu

Other Text for Screen AG

09/23/2009 f040796

Fig. 3.5, Diagnostic Menu Screens—Screen 2

Ametek Instrument Panel

3.7

Page 35: Recreational Vehicle Chassis Operator's Manual

02/06/2012 f040797

AUXILIARYSCREENS

SOFTWARE VER: x.yyCONFIG: cccccccHARDWARE VER: z

Right || Hold DownRight Press

Version InformationHighlighted

Menu

Screen AM

Input NamePin pp of 26xx.x Units

Down PressChange toNext Input

Right || Hold Down

ECUs on Data BusJ1939 SA xxJ1939 SA yy

Down PressScroll ScreenDown 1 Line

Right || Hold Down

Right PressCheck Analog Inputs

Highlighted

Right PressCheck Data Link

Highlighted

Menu

Menu

Screen AK

Screen AL

Fig. 3.6, Diagnostic Menu Screens—Screen 3

Ametek Instrument Panel

3.8

Page 36: Recreational Vehicle Chassis Operator's Manual

H*

SELF TEST

DISPLAY MESSAGES

WARNING MESSAGES

Active WarningMessages

No Warnings Active orAll Warnings

Acknowledged

Right HoldPark Brake On

IGNITION ON

IGNITIONOFF

IgnitionOff

Ignition On orHeadlamps On or

Marker Lamps On orPark Brake Off

IgnitionOn

Ignition Off &Headlamps Off &

Marker Lamps Off &Park Brake On

Self TestEnabled

AUXILIARYSCREENS

ACTIVE

Ignition Off &( Headlamps On or

Marker Lamps On orPark Brake Off )

Ignition On

USB Drive Present &Park Brake On &

Vehicle Speed = 0 &Not in Self Test

H*

NORMAL MODE

DOWNLOADMODE

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Fig. 3.7, Ignition On—Normal Mode

Ametek Instrument Panel

3.9

Page 37: Recreational Vehicle Chassis Operator's Manual

SELF TEST

DISPLAY MESSAGES

XXXXXXXXXXXXXXXXXXXXXXXXXXXXXXXXXXXXXXXXXXXXXXXXXXXXXXXXXXXXXXXXXX

XXXXXXXXXXXXXXXXXXXXXXXXXXXXXXXXXXXXXXXXXXXXXXXXXXXXXXXXXXXXXXXXXX

Screen Displayedfor 1.5 Seconds

Screen Displayedfor 1.5 Seconds

Startup Screen Enabled

The Self Test screens display the FCCClogo in normal video (Screen A) and in

reverse video (Screen B)

Startup Screen Disabled

Screen A

Screen B

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Fig. 3.8, Self Test, Ametek Panel

Ametek Instrument Panel

3.10

Page 38: Recreational Vehicle Chassis Operator's Manual

DISPLAY MESSAGES

Selected Line 1 DataSelected Line 2 DataSelected Line 3 Data

Favorites Display MenuAverage Fuel EconomyGear Attained Status

Right Press Highlight First Item in List

Down PressMove to, and Highlight,

Next Item in List

Right PressPut Data For Highlighted ItemIn Display Line CurrentLine

Down HoldMake No Changes

Down Press Highlight CurrentLine

HighlightTimer = 5 sec.

WARNING MESSAGES

AUXILIARY SCREENS

New WarningMessage Active

Right HoldPark Brake On

HighlightTimer = 0

Right Hold Reset Highlighted Item

(if resettable)

Screen C Screen D

11/23/2011 f040790

Fig. 3.9, Display Messages

Ametek Instrument Panel

3.11

Page 39: Recreational Vehicle Chassis Operator's Manual

AUXILIARY SCREENS

SETUP MAINTENANCE DIAGNOSTICS

Down PressHighlight next

line of list.At middle,wrap to top

MAINTENANCE

DIAGNOSTICS

Right PressSetup

highlighted

Right PressDiagnosticshighlighted

Right PressMaintenancehighlighted

SETUP

SETUP.

DISPLAYMESSAGES

Down Hold

TRIP DATARight Press

Trip Datahighlighted

Screen G

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Fig. 3.10, Auxiliary Screens

Ametek Instrument Panel

3.12

Page 40: Recreational Vehicle Chassis Operator's Manual

MAINTENANCE

(Right & Exithighlighted)

Right PressEngine OilHighlighted

Right PressEngine Air Filter

Highlighted

Down PressHighlight next

line of list.At middle,wrap to top

MaintMenu

Down PressDisplay NextValue of Air

Change Distance

Air Change Baseline +Air Change Distance >=

Odometer

Air ChangeDistance = 0

else

Right PressAir Change Distance =

Current DisplayedValue

Right HoldAir ChangeBaseline =Odometer

Right HoldAir ChangeBaseline =Odometer

Right PressOr

Down Hold

Right PressOr

Down Hold

Down PressDisplay NextValue of Oil

Change Distance

Oil Change Baseline +Oil Change Distance >=

Odometer

else

Right PressOil Change Distance =

Current DisplayedValue

Right HoldOil ChangeBaseline =Odometer

Right HoldOil ChangeBaseline =Odometer

Right PressOr

Down Hold

Right PressOr

Down Hold

Oil ChangeDistance = 0

09/23/2009 f040793

Fig. 3.11, Maintenance Menu Screens—Screen 1

Ametek Instrument Panel

3.13

Page 41: Recreational Vehicle Chassis Operator's Manual

02/06/2012 f040794

AUXILIARYSCREENS

Right HoldSend SPN 1584 = 39

Right PressTransmission

Oil LifeHighlighted

Right PressTransmission

Oil FilterHighlighted

Right PressOr

Down Hold

Right PressOr

Down Hold

Right PressOr

Down Hold

MaintMenu

Right HoldSend SPN 1584 = 37

Right PressOr

Down Hold

Fig. 3.12, Maintenance Menu Screens—Screen 2

Ametek Instrument Panel

3.14

Page 42: Recreational Vehicle Chassis Operator's Manual

Trip Data

AUXILIARYSCREENS

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

Trip TimeIdle TimeMax RPMAvg RPMMax SpeedAvg SpeedAvg Fuel EconomyReset AllExit

Right PressReset AllHighlighted

Correct Passcode /Reset Trip

Data

Right Press

Down PressHighlight next

line of list.At bottom,wrap to top

(Right & Exithighlighted)

Wrong Passcode /Down Press

Right Press

09/23/2009 f040798

Fig. 3.13, Trip Data

Ametek Instrument Panel

3.15

Page 43: Recreational Vehicle Chassis Operator's Manual

02/06/2012 f040799

WARNING MESSAGES

DISPLAY MESSAGES

H*

WARNING Warning Message

No WarningMessages in List /

Msg Displayed for 5 Sec. /Display Next Entry in

Warning Message List

Any Button Press

/Display 1st Message

in WarningMessage List

Screen AN

Fig. 3.14, Warning Messages

IGNITION OFF

Park Brake On

Park Brake On

Park Brake Off

IGNITIONON

Headlamps Off &Marker Lamps Off &

Park Brake On

Ignition On

02/06/2012 f040800

Fig. 3.15, Ignition Off (shown when ignition is keyedOFF)

Ametek Instrument Panel

3.16

Page 44: Recreational Vehicle Chassis Operator's Manual

4

OptiView Instrument PanelOptiView™ Instrument Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.1

Page 45: Recreational Vehicle Chassis Operator's Manual

OptiView™ Instrument PanelNOTE: The OptiView instrument panel can becustomized by the body builder. The location ofgauges and icons on the instrument panel mayvary from what is shown here, but the operationof the instrument panel is the same.

The OptiView instrument panel provides the driverwith engine and vehicle information. It is comprisedof standard and optional gauges, an audible alarm, adriver message center, information options (menu-structured format), and warning and indicator lamps(also known as telltales). Warning and indicatorlamps illuminate in red (danger), amber (caution),green (status advisory), or blue (high-beam head-lights active).

See Fig. 4.1 for a typical instrument gauge paneland Fig. 4.2 for the OptiView warning lamps. SeeChapter 5 for detailed warning lamp descriptions.

Ignition SequenceWhen the ignition is turned on, OptiView performs aself-test. Observing the ignition sequence is a goodway to ensure the OptiView panel is functioningproperly.

IMPORTANT: Do not crank the engine until theOptiView self-check is complete.

When the ignition is in the ON position, the followingactions should occur:

• warning and indicator lamps illuminate for ap-proximately three seconds, then are extin-guished;

• seatbelt indicator lamp remains on for an addi-tional five seconds after the other indicatorlamps are extinguished;

• audible alarm sounds until the self-test is com-pleted;

• if any faults are detected, an error messagewill display in the menu area of the instrumentpanel.

When the self-test is complete, all warning lampsand indicators are extinguished.

Audible Alerts

An audible alert sounds during the ignition sequenceuntil the self-test is completed, and whenever one ofthe following conditions exists:

• Air pressure falls below 65 psi (448 kPa).

• Anytime the low air warning lamp is activated.

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1

23 4

5

6

8 79

10

1. Coolant Temperature Gauge2. Primary Air Pressure Gauge3. Tachometer4. Speedometer5. Secondary Air Pressure Gauge

6. Engine Oil Pressure Gauge7. Odometer8. Diesel Exhaust Fluid (DEF) Level

Gauge

9. Menu and Driver Message Area10. Fuel Level Gauge

Fig. 4.1, Typical Instrument Panel, EPA10 and Newer Engines

OptiView Instrument Panel

4.1

Page 46: Recreational Vehicle Chassis Operator's Manual

• During start-up until air pressure in the tanksreaches approximately 70 to 76 psi (483 to 524kPa).

• When the parking brake is engaged. The park-ing brake will not disengage until the air pres-sure has reached 65 psi (448 kPa).

• Emergency engine shutdown is activated.

• The parking brake is applied and the transmis-sion is not in neutral.

• The transmission is in neutral or the ignition isin the OFF position, and the parking brake isnot set and the service brake is not depressed.

• Anytime the ignition is turned OFF and thepanel lamps are still illuminated.

Emergency ShutdownThe instrument panel will shut down if the voltagesupply is not within the normal operating range of 9to 16 volts for more than 10 milliseconds. During

emergency shutdown, the gauge pointers freeze, thedisplay goes blank, and the lamps turn off. Whenpower is restored to within the normal operatingrange following an emergency shutdown, a self-testis performed before resuming normal operation.

Menu StructureThe OptiView instrument panel is an interactivegraphical display that is capable of displaying textmessages and graphics to communicate informationabout the status and performance of the vehicle tothe operator. This information is organized in amenu-structured format around the following menuscreens:

• trip 1

• trip 2

• gauges

• fuel economy

• units

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1

2 3

4

5

6

7

8

9

10

12

11

1314

15

19

16 17 18

25

20 21

22

23

24

1. High Coolant Temperature Warning2. ABS Warning3. Engine Brake Indicator4. Water in Fuel Indicator5. Low Fuel Indicator6. Check Engine Warning7. Stop Engine Warning8. Malfunction Indicator Lamp (MIL)9. Parking Brake On Warning10. Air Brake Warning11. Left-Turn Indicator12. Steerable Tag Axle Warning13. Diesel Particulate Filter (DPF) Lamp

14. High Exhaust System Temperature (HEST) Lamp15. Right-Turn Indicator16. Shift Inhibit Indicator17. Transmission Warning18. Transmission Overheat Warning19. Fasten Seat Belt Warning20. Fog Lamp Indicator21. Low Windshield Washer Fluid Indicator22. Headlight High-Beam Indicator23. Low Oil Pressure Warning24. Low Battery Voltage Warning25. Low Diesel Exhaust Fluid (DEF) Warning

Fig. 4.2, Warning Lamps, EPA10 and Newer Engines

OptiView Instrument Panel

4.2

Page 47: Recreational Vehicle Chassis Operator's Manual

• color settings

• diagnostics

• menu off

The menus appear at the bottom-center of the instru-ment panel as shown in Fig. 4.1. When the instru-ment panel displays a message to the operator, itappears in the menu area.

NOTE: Although cruise control is not a menuitem, the cruise control indicator appears abovethe menu area when activated. See Fig. 4.3 foran example of the cruise control indicator.

Menu NavigationNavigating through the system menus is done withthe buttons on the right side of the steering wheel.See Fig. 4.4. Press the "up" or "down" arrows tohighlight a menu, then press the OK button to enterthe highlighted menu. Press the "back" button to goback to the last menu that was displayed. Press the"home" button to return to the menus in their originalorder.

Trip MenusFrom the main menu, highlight "Trip 1" and press theOK button. The top three items in the TRIP 1 screenappear. See Fig. 4.5. Press the "down" arrow to viewthe bottom three items in the TRIP 1 screen. SeeFig. 4.6. To reset the TRIP 1 information, press andhold the OK button.

The Trip 2 menu functions the same way after high-lighting "Trip 2" and pressing the OK button. SeeFig. 4.7 for the top three items in the TRIP 2 screenand Fig. 4.8 for the bottom three items in the TRIP 2screen. To reset the TRIP 2 information, press andhold the OK button.

Gauge MenusThe driver can choose to display up to three gaugemenus in the menu area if desired. See Fig. 4.9.From the main menu, select "Gauges" and press the

OK button. Use the "down" arrow to highlight one ofthe three currently viewed gauges, then press theOK button and the highlight will flash. Use the "up"

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Fig. 4.3, Cruise Control Indicator

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1

2

3

4

5

1. Home Button2. OK Button3. Up Arrow

4. Back Button5. Down Arrow

Fig. 4.4, Menu Navigation Buttons

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Fig. 4.5, TRIP 1 Top Three Items

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Fig. 4.6, TRIP 1 Bottom Three Items

OptiView Instrument Panel

4.3

Page 48: Recreational Vehicle Chassis Operator's Manual

and "down" arrows to scroll through the availablegauges. Once you have selected the gauge to view,press the OK button again. The highlight stops flash-ing and that gauge is set. Use the same process tochange the other two gauge menus.

Fuel Economy MenuFrom the main menu, select "Fuel Economy" andpress the OK button. See Fig. 4.10, for an exampleof the fuel economy menu.

The blue bar represents the average fuel economyfor this trip since the last reset.

The red bar represents the instantaneous fueleconomy that is reported by the engine.

Press and hold the OK button to reset the distanceto empty value and the average miles per gallon/kilometers per liter.

Units MenuThe units menu allows the driver to choose betweenEnglish or metric units of measurement for the dis-played values. See Fig. 4.11. Changing the unitsonly effects the speedometer, trip 1, trip 2, and fueleconomy. From the main menu, select "Units" andpress the OK button to change the units.

Color Settings MenuThe color settings menu allows the driver to changethe background color that appears in the gauges.From the main menu, select "Color Settings" andpress the OK button. Then select the color—blue,green, or white—using the "up" and "down" arrowsand press the OK button.

Diagnostics MenuFrom the main menu, select "Diagnostics" and pressthe OK button. Three sub-menus appear—Faults,Internal Diagnostics, and System Information.

FaultsThe Faults sub-menu, shown in Fig. 4.12, displaysthe following faults should they occur:

• antilock brake system

• air pressure module

• engine

• instrumentation

• transmission

After selecting "Diagnostics", "Faults" appears in thelist of sub-menus and is highlighted. Press the OKbutton to view any active faults. See Fig. 4.13, for anexample of a fault displayed from the instrumentation

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Fig. 4.7, TRIP 2 Top Three Items

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Fig. 4.8, TRIP 2 Bottom Three Items

09/02/2015 f611303

Fig. 4.9, Gauge Menus

09/02/2015 f611302

Fig. 4.10, Fuel Economy Menu

09/02/2015 f611304

Fig. 4.11, Units Menu

OptiView Instrument Panel

4.4

Page 49: Recreational Vehicle Chassis Operator's Manual

system. When there is no active fault(s), END OFLIST appears in the menu area. See Fig. 4.14.

Internal DiagnosticsThe Internal Diagnostics sub-menu, shown inFig. 4.15, displays internal diagnostic informationwith the current value from the OptiView instrumentpanel. Use the "down" arrow to highlight "InternalDiagnostics", then press the OK button to view theinternal diagnostic information. See Fig. 4.16 andFig. 4.17.

System InformationThe System Information sub-menu shows the currentsoftware version and release date. Use the "down"arrow to highlight "System Information", then pressthe OK button to view the system information. SeeFig. 4.18 and Fig. 4.19.

NOTICEWhen a memory stick with updated software is inthe USB port and the OK button is pressed, theupdater will start programming the OptiView in-strument panel. Do not turn the ignition OFF dur-ing the programming cycle. Damage will occur tothe panel if the power is turned off during theprogramming cycle.

The bottom line of the System Information menu indi-cates the current status of the software updating util-ity. See Fig. 4.19. In this example, the software up-dating utility is idle (not running).

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Fig. 4.12, Faults Sub-Menu

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Fig. 4.13, Active Fault is Displayed

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Fig. 4.14, No Active Fault Exists

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Fig. 4.15, Internal Diagnostics Sub-Menu

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Fig. 4.16, Internal Diagnostic Information Screen 1

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Fig. 4.17, Internal Diagnostic Information Screen 2

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Fig. 4.18, System Information Sub-Menu

09/02/2015 f611309

Fig. 4.19, System Information

OptiView Instrument Panel

4.5

Page 50: Recreational Vehicle Chassis Operator's Manual

5

InstrumentsWarning and Indicator Lamps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.1Speedometer and Tachometer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.5Gauges . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.6Optional Instruments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.8Collision Warning System, Eaton VORAD VS-400 (Stand Alone) . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.8

Page 51: Recreational Vehicle Chassis Operator's Manual

Warning and Indicator LampsThe following information describes the various warn-ing and indicator lamps found in the Lightbar ControlUnit (LBCU), Ametek, and OptiView™ instrument pan-els. See Fig. 5.1 for an example, of the LBCU warn-ing and indicator lamps, Fig. 5.2 for an example ofthe Ametek warning and indicator lamps, andFig. 5.3 for an example of the OptiView warning andindicator lamps.

The instrument cluster has an emergency buzzer thatsounds when serious conditions that require immedi-ate attention occur.

A description of the standard warning and indicatorlamps are listed below.

NOTE: The following descriptions apply to eachinstrument panel where applicable and are listedalphabetically.

ABS WarningThe ABS indicator illuminates when there is a mal-function in the vehicle antilock brake system (ABS).

NOTE: For more information about this indicatorand the ABS system, see Chapter 8.

WARNINGIf the ABS warning lights come on while driving,repair the system immediately to ensure full an-tilock brake capability. Operating the vehiclewhen the ABS needs to be serviced could cause

an accident, possibly resulting in personal injuryor death, or property damage.

Air Brake WarningThe air brake warning lamp activates if the pneu-matic brake system air is low, or if the air suspensionis low.

Auto-Idle

The auto-idle feature will automatically increase theengine rpm when a low system voltage is detectedunder the following conditions:

• The transmission is in Park or Neutral.

• The parking brake is set.

The dash driver display screen will first display AUTOIDLE, meaning the system voltage has droppedbelow 12.2 volts, and the service brake is not on.See Fig. 5.4. The ICU will increase the idle speeduntil the battery voltage reaches 13.4 volts. Acknowl-edge the Auto Idle message by pressing the leftarrow button once on the toggle switch.

After the Auto Idle message is acknowledged theBATTERY LOW VOLTAGE message will display. SeeFig. 5.5. Perform any of the following functions toreturn the engine to normal operation:

• Press the service brake pedal.

• Shift the transmission out of Park or Neutral.

• Release the parking brake.

f611067

STOPCHECKABS

1 2 3 4 5 6 7 8

9 10 11 12 13 14 15 1609/23/2009

1. Check Engine Warning2. High Exhaust System

Temperature (HEST) Lamp3. Stop Engine Warning4. Dash Driver Display Screen5. ABS Warning

6. Transmission Warning7. Engine Brake Indicator8. Cruise Control Indicator9. Left-Turn Indicator10. Diesel Particulate Filter (DPF)

Lamp

11. Shift Inhibit Indicator12. Headlight High-Beam Indicator13. Parking Brake On Warning14. Low Air Pressure Warning15. Wait to Start Indicator16. Right-Turn Indicator

Fig. 5.1, LBCU Warning Lamps, EPA10 and Newer Engines

Instruments

5.1

Page 52: Recreational Vehicle Chassis Operator's Manual

Check Engine WarningThe check engine warning indicator illuminates whencertain faults are detected. If a critical engine condi-tion exists (for example, low oil pressure or highcoolant temperature), the check engine indicator willilluminate to alert the driver to correct the conditionas soon as possible. If the condition gets worse, thestop engine indicator will illuminate. See the Cum-mins Operation and Maintenance Manual for moreinformation.

NOTE: If the check engine indicator illuminatesduring vehicle operation, take the vehicle di-rectly to an authorized Freightliner service facil-ity.

Cruise Control IndicatorThe cruise control indicator illuminates when thecruise control is activated.

Dash Driver Display ScreenThe LBCU’s interactive graphical display communi-cates real-time information about the status and per-formance of the vehicle to the driver.

Diesel Particulate Filter (DPF) LampA solid illumination indicates a regeneration is re-quired. Change to a more challenging duty cycle,such as highway driving, to raise exhaust tempera-tures for at least 20 minutes, or perform a stationaryregeneration. See Parked Regen for details.

A blinking lamp indicates that a stationary regenera-tion is required immediately. An engine derate andshutdown will occur. See Parked Regen for details.

Emergency BuzzerThe emergency buzzer sounds during the ignitionsequence and whenever one of the following condi-tions exists:

09/21/2009 f611052

1

2

3 4 5 6 7 8 9 10 11 12 13

14

15

1920

17

18

16

1. Maintenance Warning2. Left-Turn Indicator3. High Exhaust System

Temperature (HEST) Lamp4. Check Engine Warning5. Stop Engine Warning6. Malfunction Indicator Lamp (MIL)7. Engine Brake Indicator

8. Wait to Start Indicator9. ABS Warning10. Shift Inhibit Indicator11. Transmission Warning12. Stop Transmission (hybrid only)13. Diesel Particulate Filter (DPF)

Lamp

14. Right-Turn Indicator15. Fasten Seat Belt Warning16. Air Brake Warning17. Hydraulic Brake System Warning18. Headlight High-Beam Indicator19. Cruise Control Indicator20. Parking Brake On Warning

Fig. 5.2, Ametek Warning Lamps, EPA10 and Newer Engines

Instruments

5.2

Page 53: Recreational Vehicle Chassis Operator's Manual

• The coolant temperature rises above the pre-set level shown in Table 5.1.

• The engine oil pressure falls below the presetlevel shown in Table 5.2.

• The air pressure falls below the preset level,which is 65 psi (448 kPa).

• The parking brake is set with the vehicle mov-ing at a speed greater than 2 mph (3 km/h).

Engine Brake IndicatorThe engine brake indicator illuminates when the en-gine brake is applied.

Fasten Seat Belt WarningThe fasten seat belts warning indicator illuminates for30 seconds after the ignition switch is turned on.

Fog Lamp IndicatorThe fog lamp indicator illuminates when the foglamps are on.

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1

2 3

4

5

6

7

8

9

10

12

11

1314

15

19

16 17 18

25

20 21

22

23

24

1. High Coolant Temperature Warning2. ABS Warning3. Engine Brake Indicator4. Water in Fuel Indicator5. Low Fuel Indicator6. Check Engine Warning7. Stop Engine Warning8. Malfunction Indicator Lamp (MIL)9. Parking Brake On Warning10. Air Brake Warning11. Left-Turn Indicator12. Steerable Tag Axle Warning13. Diesel Particulate Filter (DPF) Lamp

14. High Exhaust System Temperature (HEST) Lamp15. Right-Turn Indicator16. Shift Inhibit Indicator17. Transmission Warning18. Transmission Overheat Warning19. Fasten Seat Belt Warning20. Fog Lamp Indicator21. Low Windshield Washer Fluid Indicator22. Headlight High-Beam Indicator23. Low Oil Pressure Warning24. Low Battery Voltage Warning25. Low Diesel Exhaust Fluid (DEF) Warning

Fig. 5.3, OptiView Warning Lamps, EPA10 and Newer Engines

02/29/2008 f611001

Fig. 5.4, Auto Idle Message

02/27/2008 f611002

Fig. 5.5, Low Voltage Message

Instruments

5.3

Page 54: Recreational Vehicle Chassis Operator's Manual

Headlight High-Beam IndicatorThe high-beam indicator (sideways beam icon) illumi-nates when the headlight high beams are on.

High Coolant Temperature WarningThe high coolant temperature indicator and emer-gency buzzer activate whenever the coolant tem-perature goes above a preset maximum specified bythe engine manufacturer. See Table 5.1.

Maximum Coolant TemperatureEngine Model °F (°C)

Cummins ISB 220 (104)

Table 5.1, Maximum Coolant Temperature

High Exhaust System Temperature(HEST) LampThe high exhaust system temperature (HEST) lampalerts the operator of high exhaust temperature dur-ing the regen process when the speed is below 5mph (8 km/h), or during a manual regen. The HESTlamp does not signify the need for any kind of ve-hicle or engine service; it only alerts the vehicle op-erator to high exhaust temperatures.

IMPORTANT: Make sure the engine exhaustpipe outlet is not directed at any person, or atany surface or material that will melt, burn, orexplode.

Hydraulic Brake System Warning(Ametek only)The brake system warning lamp illuminates if there isa hydraulic brake system failure, or if the vehicle ispowered and the engine is not running.

Left-Turn IndicatorThe left-turn indicator flashes on and off when theleft-turn signal lights are flashing.

Both turn signal indicators flash when the hazardwarning flasher is turned on.

Low Air Pressure WarningThe low air pressure warning indicator and emer-gency buzzer activate when the engine is turned onif air pressure in the primary or secondary air reser-voir is below 65 to 75 psi (448 to 517 kPa), and re-

main on until air pressure rises above that level inboth reservoirs.

Low Battery Voltage WarningThe low battery voltage warning indicator (batteryicon) illuminates when the battery voltage dropsbelow 12 volts.

Low Diesel Exhaust Fluid (DEF)WarningThe low diesel exhaust fluid (DEF) warning indicatorilluminates when the DEF tank is approximately 10%full. Fill the DEF tank as soon as possible to avoidengine derate (decreased engine power).

Low Fuel IndicatorThe low fuel indicator illuminates when the fuel levelis approximately 1/8 full.

Low Oil Pressure WarningThe low oil pressure warning indicator and emer-gency buzzer activate whenever the engine oil pres-sure goes below the preset minimum specified by theengine manufacturer. See Table 5.2.

Oil Pressure Specifications*†

Engine ModelAt Idle Speed:

psi (kPa)At Rated RPM:

psi (kPa)Cummins ISB 10 (69) 30 (207)* Oil pressures are given with the engine at operating temperature. With

the engine cold, oil pressure may be higher. Individual engines may varyfrom the listed pressures; observe and record pressures when the engineis new to create a guide for checking engine condition.† EPA07 MBE900 engines have an oil pressure switch. When above

minimum pressure, the dash gauge will display the values shown inTable 5.2. If below minimum oil pressure is reached, the dash gauge willread 0 psi.

Table 5.2, Oil Pressure Specifications

Low Windshield Washer FluidIndicatorThe low windshield washer fluid indicator illuminateswhen the washer fluid level is low.

Maintenance Warning (Ametek only)When the maintenance warning lamp illuminates, themessage display center will alert the driver as fol-lows:

Instruments

5.4

Page 55: Recreational Vehicle Chassis Operator's Manual

• Oil Change Required—alerts the driver that theengine has reached the recommended oilchange interval.

• Air Filter Reminder—the air filter requireschecking or replacement.

• Transmission Prognostics Warning—if thetransmission has prognostics enabled.

Malfunction Indicator Lamp (MIL)The malfunction indicator lamp (MIL) indicates anengine emissions-related fault. See the engine op-eration manual for details.

Parking Brake On WarningThe parking brake on indicator activates when theparking brake is engaged.

If the vehicle is moving at a speed of 2 mph (3 km/h)or more, the emergency buzzer will sound until theparking brake is released.

Right-Turn IndicatorThe right-turn indicator flashes on and off when theright-turn signal lights are flashing.

Both turn indicators flash when the hazard warningflasher is turned on.

Shift Inhibit IndicatorThe shift inhibit indicator illuminates when the trans-mission ECU is prohibiting shifting.

Steerable Tag Axle WarningThe steerable tag axle indicator activates when thereis a loss of air pressure at the axle. Air pressure isneeded to lock and unlock the steerable tag axle.See Fig. 5.6.

Stop Engine WarningThe stop engine warning indicator illuminates if amalfunction that could cause engine damage occurs.In most cases, the engine protection warning will illu-minate before the stop engine warning. When thestop engine warning indicator illuminates, immedi-ately park the vehicle in a safe location and shutdown the engine. Continued operation with the stopengine warning indicator illuminated will lead to auto-matic engine shutdown and possible engine damage.

Transmission Overheat WarningThe transmission overheat indicator illuminates whenthe temperature of the transmission fluid goes abovethe preset level set by the transmission manufac-turer.

For more information, see the transmission manufac-turer’s manual provided with the vehicle.

Transmission WarningThe transmission warning indicator will activate dur-ing vehicle operation (not during start-up) if the elec-tronic control unit (ECU) has signaled a diagnosticcode. Diagnostic codes indicate malfunctions intransmission operation. If this indicator stays on con-tinuously during operation, have the transmissionserviced as soon as possible.

Wait to Start IndicatorThe wait-to-start indicator lamp illuminates when theintake heater is active. Wait until the indicator lightgoes off to start the engine.

Water In Fuel IndicatorThe water in fuel indicator notifies the driver the fuelmay contain water. Drain any water collected in thefuel/water separator.

Speedometer and TachometerSpeedometerThe speedometer indicates vehicle speed in milesper hour (mph) or kilometers per hour (km/h). SeeFig. 5.7.

10/22/2015 f611319a

Fig. 5.6, Steerable Tag Axle Indicator

Instruments

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Page 56: Recreational Vehicle Chassis Operator's Manual

Tachometer (Three-in-One Gauge)This gauge serves three functions as follows. SeeFig. 5.8.

• Tachometer—indicates the revolutions per min-ute (rpm) of the engine.

• Fuel Gauge—indicates the amount of fuel inthe fuel tank.

• Voltmeter—indicates the vehicle charging sys-tem voltage when the engine is running, andbattery voltage when the engine is stopped. Bymonitoring the voltmeter, the driver can beaware of potential charging system problemsand have them repaired before the batteriesdischarge enough to create starting difficulties.

The voltmeter shows the voltage of the batterywhen the engine is running. The voltage of afully charged battery is 12.7 to 12.8 volts whenthe engine is stopped. A completely dischargedbattery will produce only about 12.0 volts. Thevoltmeter will indicate lower voltage as the ve-hicle is being started or when electrical devicesin the vehicle are being used.

If the voltmeter shows an undercharged orovercharged condition for an extended period,have the charging system and batterieschecked at a repair facility.

NOTE: Some vehicles may be equipped (by thebody builder) with a battery isolator system anda gel cell battery. On these vehicles, the voltme-

ter measures the average voltage of all the bat-teries when the engine is running. When theengine is stopped, the voltmeter shows the volt-age of the engine-starting batteries.

GaugesSee Fig. 5.9 for an example of the pressure/temperature gauges found in the instrument panel.

0

20

40

60 80

100

120

140

25

35 4555

65

75

8505

15

f61075803/10/2005

Fig. 5.7, Speedometer

0

5

1015 20

25

30

35

RPM

18

13

8E

F

x100

f610762

1

2 3

03/28/2005

1. Tachometer2. Fuel Gauge

3. Voltmeter

Fig. 5.8, Tachometer (Three-In-One Gauge)

150

65

00

150

PSI

f610763

PSI PSI

10065

100

C0

50

100 H

1 2

1 2

3 4

03/28/2005

1. Engine Oil Pressure Gauge2. Coolant Temperature Gauge3. Primary Air Pressure Gauge4. Secondary Air Pressure Gauge

Fig. 5.9, Pressure/Temperature Gauges

Instruments

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Page 57: Recreational Vehicle Chassis Operator's Manual

Pressure/Temperature Gauges (Four-in-One Gauge)Engine Oil Pressure GaugeThe oil pressure gauge should read in the normalrange, from 2 to 80 psi (14 to 552 kPa).

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

Coolant Temperature Gauge

NOTICEA sudden increase in coolant temperature mayindicate engine or cooling system failure. Bringthe vehicle to a safe stop and investigate thecause to prevent further damage. Do not operatethe engine until the cause has been determinedand corrected.

During normal engine operation, the coolant tem-perature gauge should read in the normal range be-tween cold and hot. If the temperature remains belowor exceeds the normal range, inspect the coolingsystem to determine the cause.

Primary and Secondary Air PressureGauges

WARNINGIf air pressure falls below minimum pressure, thebraking ability of the vehicle will be limited. Slowthe vehicle down and bring it to a gradual stop.Do not attempt to move the vehicle until air pres-sure has risen above the minimum level. Movinga vehicle without adequate braking power couldcause an accident resulting in property damage,personal injury, or death.

Air pressure gauges register the pressure in the pri-mary and secondary air systems. Normal pressurewith the engine running is 100 to 120 psi (690 to 827kPa) in both systems.

Air pressure gauges are required on all vehicles withair brakes. A low-air-pressure warning lamp and

buzzer, connected to both the primary and secondarysystems, activate when air pressure in either systemdrops below a minimum pressure of 65 to 75 psi(448 to 517 kPa).

Air Intake Restriction GaugeThe air intake restriction gauge indicates the vacuumon the engine side of the air cleaner. On standardinstallations, it is mounted on the air intake duct inthe engine compartment. See Fig. 5.10. As an optionfor easier viewing, the intake-air restriction indicatorcan be mounted on the dash, usually on the right-hand control panel.

Air intake restriction vacuum is measured in inchesof water (inH2O). For vehicles equipped with agraduated indicator or a restriction gauge on thedash, check the gauge with the engine off. If the yel-low signal stays locked in the red zone once the en-gine is shut down, or is at or above the maximumrestriction value in Table 5.3, the air cleaner elementneeds to be replaced.

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

Air Intake Maximum Restriction Values (inH2O)

Engine Make EPA07 andEPA10 Engines

GHG14 andGHG17 Engines

Cummins 25 25Detroit 22 18

Table 5.3, Air Intake Maximum Restriction Values

PUSH TO RESET

H 0 VACUUM225201510

7

IN H 0 VACUUM2

f09017605/22/97

Fig. 5.10, Air Intake Restriction Indicator

Instruments

5.7

Page 58: Recreational Vehicle Chassis Operator's Manual

Optional InstrumentsOptional instruments are not found on every vehicle.They are stand-alones, not driven by the instrumentcluster, and are usually located on the auxiliary dashpanel.

Turbo Boost GaugeThe turbo boost gauge indicates the boost pressureat the turbocharger, from 0 to 50 psi (0 to 345 kPa).See the Cummins Operation and MaintenanceManual for more information.

Transmission Temperature GaugeThe transmission temperature gauge indicates thetemperature of the transmission oil.

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

Tire Pressure Monitoring System(TPMS)IMPORTANT: Only use temporary resealing orreinflation products that are water soluble andstate that they do not adversely affect the op-eration of the tire pressure sensor(s), if soequipped.

The Tire Pressure Monitoring System (TPMS) con-stantly monitors the pressure and temperature ofeach tire on the vehicle, and provides tire status in-formation to warn the driver about a tire-related prob-lem before it becomes dangerous. Tire sensorsmounted on each wheel measure tire pressure andtemperature every 12 seconds and transmit dataevery 3 to 5 minutes. If a temperature change or tirepressure change of 3 psi (21 kPa) or greater is de-tected, the sensor breaks its regular schedule andtransmits tire data immediately.

For further information on the TPMS, including op-eration, TPMS warnings, and proper tire removal/installation, see the Valor TPMS manual.

Collision Warning System,Eaton VORAD VS-400 (StandAlone)The Eaton VORAD VS-400 is a computerized colli-sion warning system (CWS) that uses forward-looking radar (FLR) to monitor objects ahead, andoptional side-mounted sensors to monitor objectsalongside the vehicle.

The system performs in fog, rain, snow, dust, smoke,and darkness. To be detected, objects must be withinthe radar beam field of view and provide a surfacearea that can reflect back the radar beam.

The front-looking antenna assembly transmits radarsignals to, and receives them back from, objectsahead of the vehicle. This allows the determination ofthe distance, speed, and angle of the target ahead.The system uses this information to warn the driverof potentially dangerous situations.

Optional side sensors also transmit and receive radarsignals, for a distance of 2 to 10 feet (0.5 to 3 me-ters) alongside the vehicle. The side sensor can de-tect unseen objects, moving or stationary, adjacent tothe vehicle.

WARNINGThe Eaton VORAD VS–400 Collision WarningSystem (CWS) is intended solely as an aid for analert and conscientious driver. It is not intendedto be used or relied upon to operate a vehicle.Use the system in conjunction with rearview mir-rors and other instrumentation to safely operatethe vehicle. Operate this vehicle, equipped withthe VS–400 Collision Warning System, in thesame safe manner as if the VS–400 CollisionWarning System were not present.

The VS–400 Collision Warning System is not asubstitute for safe, normal driving procedures,nor will it compensate for any driver impairmentsuch as drugs, alcohol, or fatigue.

The VS–400 Collision Warning System may pro-vide little or no warning of hazards such as pe-destrians, animals, oncoming vehicles, or crosstraffic.

Failure to drive safely and use the system prop-erly could result in personal injury and/or deathand severe property damage.

Instruments

5.8

Page 59: Recreational Vehicle Chassis Operator's Manual

Driver Display UnitThe VORAD system controls are located in the driverinterface unit (DIU). The DIU provides visual andaudio warnings and messages. Menu selections aremade by pressing the up, down, and OK buttons.See Fig. 5.11.

The DIU has the following features:

• An internal speaker for audio warnings.

• Graphic display for visual warnings, menus,and other information.

• User interface keypad for scrolling up, scrollingdown, and selection.

• Ambient light sensor, for auto illumination ad-justment for daytime or night-time display.

• Programmable for driver ID with use of a PIN.

The following lights illuminate on the DIU to indicatea message:

• Red LED—illuminates with the collision alertdisplay.

• Yellow LED—illuminates with headway alertdisplay.

• Orange LED—illuminates when a system fail-ure occurs.

• Blue LED—illuminates when information isavailable.

Immediately after each battery power-on cycle, theDIU initializes by executing self-test routines. During

the initialization time, the screen shown in Fig. 5.12is displayed and all the LED lamps are activated(power-on bulb check) for approximately 3 seconds,along with a power-up tone.

When initialization is complete, the DIU displays theVS-400 system configuration screen. Figure 5.13shows the screens for the VS-400 configured for Col-lision Warning System (CWS) and SmartCruise™,and for CWS only.

05/07/2007 f610919

1

2

3

45

6

7

OK

1. Fault Indicator2. Info Indicator3. Following Distance

Lights

4. Ambient Light Sensor5. Collision Alert Lights6. User Interface Keypad7. Graphic Display

Fig. 5.11, Driver Interface Unit (DIU), VORAD

05/07/2007 f610920

OK

Fig. 5.12, Initialization Screen, VORAD

05/07/2007

VORAD startedCollision WarnSmartCruise

f610921

VORAD startedCollision Warn

A

B

OK

OK

A. Configured for CWS onlyB. Configured for CWS and SmartCruise

Fig. 5.13, System Configuration Screens, VORAD

Instruments

5.9

Page 60: Recreational Vehicle Chassis Operator's Manual

Menu SelectionsIMPORTANT: The display of any menu item isoverridden whenever conditions require an alertwarning, or collision warning, to be displayed.

After initialization, the menu screen is displayed. Inthis screen, the driver may scroll to the desired itemby pressing an arrow button, then pressing the OKbutton to select the item. See Fig. 5.14. If the driverdoes not make a selection within 30 seconds, or thevehicle begins to move, the DIU changes to the sys-tem status display.

The DIU displays menu items when the menu modeis selected. The display of any menu item is overrid-den whenever conditions require an alert warning orcollision warning to be displayed. The menu itemsare listed below.

System Status ScreenSystem status is displayed under normal operatingconditions by scrolling to the "System Status" itemand then pressing the "OK" button. This screenshows the status of each system, indicating if thesystem can operate normally. If a system cannot op-erate normally, the system displays "Failed" besidethe system name rather than "OK". "Failed" means afault is preventing the system from operating and itcan not be used until the fault is corrected or ac-knowledged.

Depending on the VS-400 system installed, one ofthe following screens will appear unless a systemfault is active. Pressing OK exits this menu. SeeFig. 5.15.

Demo (vehicle must be stationary)When the vehicle is stationary, and the demo modeis selected, the DIU will demonstrate the meaning ofall LED and screen displays, including alert mes-sages and sound warnings. The demo screens arescrolled through by pressing the down arrow. Press-ing any other key exits the mode.

VolumeFor configurations with adjustable volume, the mini-mum adjustable volume configuration is 50% of themaximum volume. If the DIU volume is not adjust-able, the display screen shows a grayed bar graphwhenever volume adjustment is selected. After eachignition switch cycle, the volume will default to 100%.

One of the screens in Fig. 5.16 is displayed whenvolume is selected, if conditions do not require thedisplay of headway alerts or warnings.

NOTE: Headway alert tones (yellow LED), andcollision alert tones (red LED), may be sup-pressed when the brake is applied, if the param-eter is configured to do so.

f610922

System Status

VolumeDemo

05/09/2007

OK

Fig. 5.14, Menu Screen, VORAD

05/07/2007 f610923

A

B

Coll ision warnSmartCruise

VORAD statusOKOK

Press OK for Menu

Coll ision warn

VORAD statusOK

Press OK for Menu

OK

OK

A. Status display for CWS and SmartCruiseconfiguration

B. Status display for CWS only configuration

Fig. 5.15, System Status Screens

Instruments

5.10

Page 61: Recreational Vehicle Chassis Operator's Manual

BrightnessThe up and down arrows are used to change thebrightness. This adjustment changes the warningLEDs and graphic display backlight brightness.Pressing the OK button exits this screen. SeeFig. 5.17.

The ambient light sensor reading determines if theDIU is in daytime or nighttime mode. Menu-adjustedbrightness is applied only to the mode the DIU is inat the time of adjustment. The previous brightnesssettings are repeated after each ignition cycle. How-ever, the graphic display and the warning LED bright-

ness range are constrained such that they are al-ways visible regardless of how low the brightness isadjusted in all driving conditions. Pressing the OKbutton exits the menu.

SmartCruise® Headway RangeHeadway range adjustment is only available in theCWS with SmartCruise version of the VS-400 sys-tem, with headway range adjustment enabled. Head-way range adjustment is selected from the mainmenu with the scroll arrow, followed by pressing theOK key to select the screen. Headway range is ad-justable between 3.25 and 2.25 seconds, in 0.25second increments, by pressing the up or down ar-rows. The headway range setting will default to 3.25seconds, after each ignition power cycle.

If the headway adjust screen is selected and head-way range is not enabled, then only the "3.25 sec"screen is displayed. See Fig. 5.18 for the variousheadway range screens.

f610925

A

B

Volume

Volume

OK

OK

05/31/2007

A. Adjustable VolumeB. Non-Adjustable Volume

Fig. 5.16, Volume Display, VORAD

05/07/2007 f610926

Brightness

OK

Fig. 5.17, Brightness Screen, VORAD

05/07/2007 f610927

C

3.25 sec

SmartCruiseRange

A

SmartCruiseRange

2.25 sec

B

3.25 sec

SmartCruiseRange

fixed

OK

OK

OK

A. Minimum headway adjustmentB. Maximum headway adjustmentC. Headway range not enabled

Fig. 5.18, Headway Range Display, VORAD

Instruments

5.11

Page 62: Recreational Vehicle Chassis Operator's Manual

Pressing OK exits the menu.

If the headway range is adjusted to 3 seconds orbelow, and SmartCruise is active, the 3 second colli-sion warning headway alert will not display. All otheralerts are not suppressed.

KM/H MPH ScreenThe up and down arrows are used to select eitherkm/h or mph units for display of SmartCruise setspeed. The previous km/h or mph setting is dis-played at the next ignition cycle. See Fig. 5.19.

Pressing OK exits this menu.

DiagnosticsThe DIU displays fault codes currently active whenthis screen is selected. See Fig. 5.20. The vehiclemust be stationary for the fault codes to display.Contact an authorized Freightliner dealer if faultcodes display.

Forward-Looking-Radar (FLR)Warning SystemIf the VS-400 reads any vehicle speed before theforward-looking-radar has time to warm up, a singletone will sound, and one of the following screens willdisplay. See Fig. 5.21. The FLR may require awarm-up period of up to 5 minutes in extreme coldoutside temperature conditions.

The VS-400 FLR identifies and tracks the nearestobject in the lane of travel. This object is classifiedby the range, and assigned one of the messagesshown in Fig. 5.22, Fig. 5.23, Fig. 5.24, Fig. 5.25,and Fig. 5.26, and described under the followingseven headings.

The alerts given by the VS-400 system are based onthe “headway” to the object ahead, whenever vehiclespeed is 10 mph (16 km/h) or greater.

Object DetectedWhen an object is in the lane of travel, the VS-400system displays the following message and tone.See Fig. 5.22.

• information message: OBJECT DETECTED

• tone sequence: none

05/07/2007 f610928

Speeds will bedisplayed in:

MPHOK

Fig. 5.19, KM/H MPH Selection Display, VORAD

05/07/2007 f610929

DIU DIAGNOSTICSSPN: 00886 FMI:012

OKOK

Fig. 5.20, DIU Diagnostic Display, VORAD

05/07/2007 f610924

A

B

Do not useRadar Warming Up

Radar Warming Up

SmartCruise

Please wait

OK

OK

A. FLR with SmartCruise B. FLR Only

Fig. 5.21, FLR Warm-Up Screens, VORAD

Instruments

5.12

Page 63: Recreational Vehicle Chassis Operator's Manual

3-Second Headway AlertWhen a moving object is in the lane of travel, andthe headway is greater than 2 seconds, up to andincluding 3 seconds, the DIU displays the followingmessage. See Fig. 5.23.

• information message: 3 seconds

• tone sequence: none

2-Second Headway AlertWhen the vehicle is closing on a moving object in thelane of travel, and the headway is greater than 1second, up to and including 2 seconds, the DIU dis-plays the following message and tones. SeeFig. 5.24.

• information message: 2 seconds

• tone sequence: "2-Second closing headwayalert" tones are sounded. (Note: This tone se-quence is not sounded if the brakes areapplied.)

1-Second Headway AlertWhen the vehicle is closing on a moving object in thelane of travel, and the headway is greater than 0.5seconds, up to and including 1 second, the DIU dis-plays the following message and tones. SeeFig. 5.25.

• information message: 1 second

• tone sequence: "1-Second closing headwayalert" tones are sounded. (Note: This tone se-quence is not sounded if the brakes areapplied.)

Collision Alert: 1/2-Second HeadwayWhen the vehicle is closing on a moving object in thelane of travel, and the headway is 0.5 second orless, the DIU displays the following message andtones. See Fig. 5.26.

• information message: COLLISION ALERT

• tone sequence: "1/2-Second closing alert"tones are sounded continuously.

05/07/2007 f610930

Object Detected OK

Fig. 5.22, Object Detected Alert, VORAD

05/07/2007 f610931

3 seconds OK

Fig. 5.23, 3-Second Alert, VORAD

05/07/2007 f610932

seconds2

OK

Fig. 5.24, 2-Second Alert, VORAD

05/07/2007 f610933

sec1

OK

Fig. 5.25, 1-Second Alert, VORAD

Instruments

5.13

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Collision Alert: Slow Moving ObjectSee Fig. 5.26. If the headway to a slow moving ob-ject is 3 seconds or less and the vehicle turn radiusis 750 feet or more, the collision alert message isdisplayed and the "slow moving object tone" issounded, provided:

• the vehicle speed is greater than 35 mph (56km/h);

• the speed of the object is greater than 5 ft (1-1/2 m) per second;

• the object is in the lane of travel, and within220 feet (67 meters) of the vehicle;

• the object speed is less than 80% of the hostvehicle speed.

Collision Alert: Stationary ObjectSee Fig. 5.26. If the headway to a stationary objectis 3 seconds or less, and the vehicle turn radius is750 feet (229 meters) or more, the collision alertmessage is displayed and the "stationary objecttone" is sounded, provided the object is in the lane oftravel, and within 220 feet (67 meters) of the vehicle.

Side Sensor DisplayThe side sensor display is mounted on the A-pillar.See Fig. 5.27. The following lights illuminate.

• The red LED illuminates when an object is de-tected.

• The red LED illuminates and a triple tone issounded, when objects are detected and theturn signal is activated.

• The ambient light sensor determines if the sidesensor display is in daytime or nighttime mode.

The display brightness is automatically ad-justed for daytime or nighttime operation.

• The yellow LED illuminates when no objectsare detected.

• The red and yellow LEDs illuminate togetherwhen there is a fault condition.

Special Road SituationsCertain special road situations may affect the sys-tem’s ability to detect objects. These situations in-clude the effects of curves, dips, and hills which canprovide an unexpected result.

NOTE: A warning may sound when an object isdetected in front of the vehicle even though thedriver intends to turn away or stop before reach-ing the object as follows:

• When an object is detected in a very sharpright- or left-hand turn, the audible alarm willnot sound.

• When approaching a curve, alarms may soundand lights illuminate, because of an object offthe road directly in line with your vehicle. Thiswill not occur when the brakes are applied.

• Elevated obstacles such as overpasses andoverhead signs may be detected, when ap-proaching a roadway descending to a lowerelevation.

• Vehicles cannot be detected on the other sideof a hill. An alarm will not sound until the objectis within the antenna assembly’s field of view.

05/07/2007 f610934

COLLISIONALERT

OK

Fig. 5.26, Collision Alert, VORAD

f61093505/30/2007

1

4

3

2

1. Volume Adjust2. Red LED–Object

detected

3. Ambient light sensor4. Yellow LED–No object

detected

Fig. 5.27, Side Sensor Display, VORAD

Instruments

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Page 65: Recreational Vehicle Chassis Operator's Manual

• On approaching a steep hill, objects above thebeam cannot be detected. Generally, the beamhitting the road surface does not cause analarm.

• The side sensor only detects objects within itsfield of view, next to the tractor. A vehicle far-ther back behind the field of view, will not bedetected.

• The side sensor range is set to detect averagesized vehicles 2 to 10 feet (0.5 to 3 meters)away in the adjacent lane.

• The radar beam will detect near range cut-insof approximately 30 feet (9 meters) or less,depending on the angle of entrance into thelane in front of your vehicle.

WARNINGHeavy rain or water spray at the side sensor maycause both the yellow and red lights on the sidesensor display to illuminate at the same time.Under these conditions the system is temporarilyunable to provide adequate warnings.

Failure to drive safely and use the system prop-erly could result in personal injury and/or deathand severe property damage.

NOTE: A continuous fixed object on the rightside of the vehicle such as a guard rail, wall,tunnel, or bridge may cause the side sensoralert light to stay on.

MaintenanceKeep the antenna assembly and side sensor(s) freeof buildup of mud, dirt, ice, or other debris that mightreduce the system’s range.

Failure Display Mode/Fault CodesThe VS-400 performs internal diagnostics at power-up, then continuously monitors system componentsthereafter.

If a failure is detected, depending on what featuresare affected, the DIU displays a screen similar toFig. 5.28, blinks the orange fault light, and sounds atone. Press the OK button to acknowledge the fault.

After the fault has been acknowledged by the driverpressing the OK button, the DIU will attempt to returnto normal operations. The orange LED is continu-ously illuminated while the fault persists. If the faultdisappears, the VS-400 transmits a message to indi-cate that the fault status has changed to a previouslyactive fault.

In the event the FLR antennae becomes blockedwhile the vehicle is moving (e.g., snow, mud, ice,tampering, etc.), the system sounds a tone and dis-plays the fault screen shown in Fig. 5.29.

Previously active fault codes can be reviewed,tested, and cleared using the Eaton Service Rangerdiagnostic tool. Contact an authorized Freightlinerdealer to review and clear previously active faultcodes. See Table 5.4 for common fault codes.

VORAD Fault CodesDevice SPN FMI Description Notes

DIU/FLR 639 2 One or more required messages missing from datalink —

05/07/2007 f610936

VORAD faultCollision warn FAILED

OK

OK

Fig. 5.28, Fault Display, VORAD

05/07/2007 f610937

VORAD faultRadar Blocked

OK

OK

Fig. 5.29, Antennae Blocked Display, VORAD

Instruments

5.15

Page 66: Recreational Vehicle Chassis Operator's Manual

VORAD Fault CodesDevice SPN FMI Description Notes

DIU/FLR 639 9 No message being received from datalink —DIU/FLR 639 13 Device cannot claim source address on datalink —DIU/FLR 639 19 Messages received with incorrect data or marked as error —FLR 886 7 FLR misaligned —FLR 886 12 FLR internally defective —FLR 886 13 FLR not configured properly —FLR 886 14 FLR blocked —DIU 893 12 DIU internally defective —FLR 898 13 Engine not configured for SmartCruise operation Tested only if SC configuredFLR 898 14 Engine not supported for SmartCruise operation Tested only if SC configured

DIU/FLR 1563 13 VS-400 component detects incompatibility issue withother VS-400 devices —

DIU 1703 3 External right speaker shorted high Tested only if external rightspeaker configured

DIU 1703 4 External right speaker shorted low Tested only if external rightspeaker configured

DIU 1703 5 External right speaker open Tested only if external rightspeaker configured

DIU 1704 3 External left speaker shorted high Tested only if external leftspeaker configured

DIU 1704 4 External left speaker shorted low Tested only if external leftspeaker configured

DIU 1704 5 External left speaker open Tested only if external leftspeaker configured

Table 5.4, VORAD Fault Codes

Instruments

5.16

Page 67: Recreational Vehicle Chassis Operator's Manual

6

Driver ControlsIgnition Switch and Key . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.1Electrical System Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.1Lighting Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.1Windshield Wiper Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.3Cruise Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.4Horn Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.5Powertrain Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.5Braking Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.7Steering Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.7

Page 68: Recreational Vehicle Chassis Operator's Manual

Ignition Switch and KeyThe ignition switch can be turned to four positions:ACCESSORY, OFF, ON, and START. See Fig. 6.1.

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

All of the components that are operable in the OFFposition are operable in the ACCESSORY position.The electric gauges will not operate when the key isin the ACCESSORY position.

Turn the key fully clockwise to the START position tostart the engine. When the engine starts, release thekey.

All electrical systems are operable in the ON posi-tion. The warning lights and the buzzer for low airpressure and low oil pressure operate until minimumpressures are built up.

Electrical System ControlsServicing the electrical system requires special skillsand equipment, and should only be performed by aqualified technician. Take the vehicle to an autho-rized Freightliner dealer when service is needed.

WARNINGDo not attempt to modify, add, splice, or removeelectrical wiring on this vehicle. Doing so could

damage the electrical system and result in a firethat could cause serious personal injury or prop-erty damage.

Battery Disconnect SwitchIMPORTANT: When the batteries are discon-nected (disconnect switch is turned to OFF), thecable to the starter is still hot, as it is not con-nected through the disconnect switch.

Some chassis may be equipped with a battery dis-connect switch that can be used to prevent unwanteddrain from the vehicle battery when the vehicle is notin use or is in storage. It can also rapidly disconnectthe power supply in the event of an emergency.Mounting locations vary. See Fig. 6.2.

Lighting ControlsHeadlight, Panel Light, and Fog LightSwitchesSwitches for the headlights, side marker lights, tail-lights, parking lights, license plate lights, panel lights,and fog lights are located on the dash panel. SeeFig. 6.3. The headlight switch operates as follows:

• Top Position: Headlights and parking lights on.

• Middle Position: Parking lights on.

• Bottom Position: All lights off, except fog lights.

A separate dash panel dimmer switch adjusts dashpanel brightness. Push the top of the switch to in-crease the panel brightness. Push the bottom of theswitch to dim.

07/10/96

1

2

34

f601179

1. Accessory2. Off

3. On4. Start

Fig. 6.1, Ignition Switch

06/15/2010 f545660

Fig. 6.2, Battery Disconnect Switch

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6.1

Page 69: Recreational Vehicle Chassis Operator's Manual

The fog lights are activated by a separate switch.Push the top of the switch to turn the fog lights on.Push the bottom of the switch to turn the fog lightsoff.

High-Beam HeadlightsNOTE: The ignition switch must be on for thehigh beams to work.

To activate the high-beam headlights, pull the multi-function turn signal lever up until a "clicking" sound isheard. See Fig. 6.4. Pull the lever up until it clicksagain to turn the high-beam headlights off. The lowbeams remain on during high beam operation.

When the high-beam headlights are on, a blue lightilluminates on the instrument panel. For vehicles builtfor domicile in the United States, the road lights turnoff when the high beams are activated.

To flash the high beams momentarily, pull the leverup, and release it just before the lever clicks.

Headlight Interrupt (SmartWheel only)To turn the headlights off briefly, press and hold theheadlight interrupt switch on the left switch panel ofthe SmartWheel. See Fig. 6.5 and Fig. 6.6. Theheadlights will remain off only as long as the switchis pressed.

Marker Lamp Interrupt (SmartWheelonly)To flash the marker lamps on or off, press and holdthe marker lamp interrupt switch on the right switchpanel of the SmartWheel. See Fig. 6.5 and Fig. 6.6.The marker lamps will remain on or off only as longas the switch is pressed.

OFF

BRIGHT

DIM

03/24/2015 f611293

A B C

1

2

3

4

6

5

FOGLIGHTS

A. Headlight SwitchB. Brightness Switch

C. Fog Light Switch

1. Headlights and Parking Lights On2. Parking Lights On3. Lights Off4. Dash Panel Brighten5. Dash Panel Dim6. Fog Lights On (push top of switch)

Fig. 6.3, Light Control

CRUISEOFF ON R/A

S

TE

1

2

3

f61095708/14/2012

1. Cruise SET/COAST Button2. Cruise OFF-ON-Resume/Accel Button3. High-Beam Headlights (pull lever up to activate)

Fig. 6.4, Multifunction Turn Signal Switch

f462076

1 2 3

06/28/2007

1. Left Switch Panel2. Horn Pad

3. Right Switch Panel

Fig. 6.5, SmartWheel

Driver Controls

6.2

Page 70: Recreational Vehicle Chassis Operator's Manual

Turn SignalsMoving the multifunction turn signal lever down acti-vates the left turn signal lights; moving it up activatesthe right turn signal lights. See Fig. 6.4 for an ex-ample of the multifunction turn signal lever.

When a turn signal is activated, a green indicatorarrow flashes at the far left or far right of the instru-ment panel.

The lever automatically returns to the neutral position(self-cancels the switch) when the steering wheelreturns to the straight-ahead position after a turn. Tocancel the signal manually, move the lever to theneutral position.

Hazard Warning LightsTo activate the hazard warning lights, pull out thehazard warning light switch located under the multi-function turn signal switch. See Fig. 6.7. When theswitch is pulled out, all of the turn control lights willflash. To cancel the hazard warning lights, move theturn signal switch up or down.

Windshield Wiper ControlsStandard Wiper ControlsOn vehicles equipped with a standard steeringwheel, the windshield wiper control is mounted onthe dash by the body builder. Check with the bodybuilder for operating instructions.

SmartWheel Wiper ControlsNOTE: SmartWheel wiper controls are locatedon the right switch panel. See Fig. 6.5 andFig. 6.6. Activating any wiper switch causes theheadlights to come on. To turn the headlightsoff, turn the ignition off.

Wiper WashPress and hold the wiper wash switch, shown inFig. 6.6, to activate the wiper wash pump. Depend-ing on whether the HI/LOW or variable switch wasselected, the wipers will continue to run in that modewhen the switch is released.

Wiper HI/LOWPress the wiper HI/LOW switch, shown in Fig. 6.6, toactivate the wipers at low speed. Press the switchagain to activate the high speed. Continue pressingthe switch to toggle between high and low speed.

Wiper VariablePress the wiper variable switch, shown in Fig. 6.6, toactivate the wipers for one low-speed wipe. Pressthe switch again within approximately 30 secondsand a second low-speed wipe will occur. The wiper

f462077

A B1

2

3 4

5

6

05/16/2007

A. Left Switch Panel B. Right Switch Panel1. Cruise ON/OFF2. Cruise SET/CANCEL/

RESUME3. Headlight Interrupt

4. Marker Lamp Interrupt5. Wiper Wash/Wiper

OFF/Wiper Variable6. Wiper HI/LOW

Fig. 6.6, SmartWheel Switch Panels

10/26/2005 f462037

1

2

1. Hazard Warning Light Switch2. Turn Signal Lever

Fig. 6.7, Hazard Warning Light Switch Location

Driver Controls

6.3

Page 71: Recreational Vehicle Chassis Operator's Manual

interval is set by the timing between the last twopresses of the switch. Additional presses of theswitch will shorten the interval. The variable modewill cancel if another wiper mode is selected.

Wiper OFFPress the wiper OFF switch, shown in Fig. 6.6, tocancel all wiper operation. Turning the ignition switchto the OFF position has the same effect.

Cruise ControlNOTE: Maximum cruise control speed variesaccording to vehicle specifications, but cannotexceed 75 mph (121 km/h).

Cruise control allows the driver to automatically con-trol the speed of the vehicle above 32 mph (51 km/h). The switches that operate the cruise control sys-tem are located either on the turn signal lever or onthe left switch panel of a SmartWheel steering wheel.

See Fig. 6.4 for turn signal-mounted cruise controlswitches. The OFF-ON-R/A (resume/accelerate)switch allows the driver to turn cruise control on andoff, accelerate while in cruise control, or resumecruise speed. The SET/COAST switch allows thedriver to select the cruise speed or temporarily dis-able the cruise control.

See Fig. 6.5 and Fig. 6.6 for SmartWheel-mountedcruise control switches. The ON/OFF switch turnscruise control on and off. The SET/CANCEL/RESswitch is used to set cruise control speed, acceleratewhile in cruise control, temporarily disengage cruisecontrol, or resume cruise speed.

Turn Signal-Mounted Cruise Control

WARNINGDo not use the cruise control system when driv-ing conditions do not permit maintaining a con-stant speed, such as heavy traffic or on roadsthat are winding, icy, snow covered, slippery, orroads with a loose driving surface. Failure to fol-low this precaution could cause a collision orloss of vehicle control, possibly resulting in per-sonal injury or property damage.

NOTICEDo not shift to neutral (N) when using cruise con-trol. This will cause the engine to overspeed,which can damage the engine.

1. To cruise at a particular speed:

1.1 Move the slide switch on the turn signallever to the ON position.

1.2 Hold the accelerator pedal down until thevehicle reaches the desired speed.

1.3 Press and release the SET/COAST buttonat the end of the turn signal lever.

2. To increase the set speed, move the slide switchon the turn signal lever to the R/A (resume/accelerate) position.

To decrease the set speed, press and hold theSET/COAST button until the desired speed isreached.

3. To disengage the cruise control:

3.1 Depress the brake pedal, or

3.2 Move the slide switch on the turn signallever to the OFF position.

4. If the brake pedal was used to disengage thecruise control, then move the slide switch to theR/A (resume/accelerate) position to resume thepreviously set speed.

NOTE: When pulling a heavy load, climbing avery steep hill, or driving into a strong wind,bring the vehicle up to speed with the accelera-tor pedal and then let the cruise control takeover.

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

5. To operate at high idle using the cruise control:

5.1 Place the shift lever in neutral (N).

5.2 Turn the cruise control on and accelerateto the desired rpm. Press and release theSET button on the turn signal switch.

5.3 Disengage by depressing the brake pedalor turning the cruise control off at the turnsignal switch.

Driver Controls

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Page 72: Recreational Vehicle Chassis Operator's Manual

SmartWheel-Mounted Cruise Control

NOTICEDo not shift to neutral (N) when using cruise con-trol. This will cause the engine to overspeed,which can damage the engine.

1. To cruise at a particular speed:

1.1 Press the ON button on the steeringwheel.

1.2 Hold the accelerator pedal down until thevehicle reaches the desired speed.

1.3 Press the SET button on the steeringwheel.

2. To increase the set speed, accelerate to the de-sired speed, then press the SET button on thesteering wheel.

To decrease the set speed, press and hold theSET button on the steering wheel until the de-sired speed is reached.

3. To disengage the cruise control:

3.1 Depress the brake pedal, or

3.2 Press the OFF button on the steeringwheel.

4. If the brake pedal was used to disengage thecruise control, press the RES button on thesteering wheel to resume the previously setspeed.

NOTE: When pulling a heavy load, climbing avery steep hill, or driving into a strong wind,bring the vehicle up to speed with the accelera-tor pedal and then let the cruise control takeover.

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

5. To operate at high idle using the cruise control:

5.1 Place the shift lever in neutral (N).

5.2 Turn the cruise control on and accelerateto the desired rpm. Press and release theSET button on the steering wheel.

5.3 Disengage by depressing the brake pedalor pressing the OFF button on the steer-ing wheel.

Horn ControlThe button for the horn is located in the center ofsteering wheel. To sound the horn, press the centerof the steering wheel pad. See Fig. 6.8.

Powertrain ControlsAllison Automatic TransmissionsAllison automatic transmissions are controlled by anelectronic control unit (ECU). See Fig. 6.9 andFig. 6.10. See Chapter 9 for complete transmissionoperating instructions.

Tag-Axle Suspension Dump SwitchThe optional tag-axle suspension is a non-liftable,full-time suspension designed to increase the GrossVehicle Weight Rating (GVWR). It is used when therear suspension/axle will be loaded to a weightgreater than 20,000 lb (9072 kg). Under certain con-ditions, air can be exhausted from the air springs toimprove maneuverability or traction on the drive axlevia the tag-axle suspension dump switch.

The tag-axle suspension dump switch is operated bya three-position, dash-mounted rocker switch. SeeFig. 6.11. The manual TAG DUMP mode is activated

f462078a06/28/2007

1

1. Horn Pad

Fig. 6.8, Horn Control, Standard Steering Wheel

Driver Controls

6.5

Page 73: Recreational Vehicle Chassis Operator's Manual

by pressing the top of the rocker switch. The AUTODUMP mode is activated automatically during re-verse gear applications when the rocker switch isplaced in the middle (level) position. When you de-press the bottom of the rocker switch, the tag-axlesuspension dump switch is placed in the OFF (down)position, and the TAG DUMP mode is inactive.

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

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

Tag-Axle Suspension—Dump OnlyIn the TAG DUMP mode, the axle air bags will de-flate when all of the following conditions are met. If

any of these conditions are not met, the tag-axle airbags will fill:

• The tag-axle suspension dump switch is mo-mentarily pressed to toggle the tag-axle controlmodule into the dump mode.

• The vehicle speed is less than 8 mph (13 km/h).

MONITOR

SELECT

R

N

D

MODE

f27015806/22/2007

1

2

3

4

5

6

7

8

9

10

1. Drive (D) Button2. Neutral (N) Button3. Reverse ®) Button4. Select Display5. Select/Monitor Display

Window

6. Monitor Display7. Service Display8. Mode Button9. Upshift Button10. Downshift Button

Fig. 6.9, GEN IV Shift Selector

MONITOR

SELECT

SERVICE

R

N

P

D

MODE

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

!

ARENS CONTROLS

04/02/2003 f270122

1

2

3

4

5

8

12

13

6

14

7

1011

9

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

Window

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

Fig. 6.10, Shift-By-Wire (SBW) Shift Selector

f61074708/05/2004

Fig. 6.11, Tag-Axle Suspension Dump Switch

Driver Controls

6.6

Page 74: Recreational Vehicle Chassis Operator's Manual

• The vehicle is in neutral or a forward gear.

If the vehicle exceeds a speed of 8 mph (13 km/h)while the switch is in the TAG DUMP position, thetag axle suspension dump switch control system willoverride the TAG DUMP mode and the tag suspen-sion air bags will refill.

IMPORTANT: The tag-axle suspension dumpswitch feature must be cycled on and off of theTAG DUMP position if an override event occurswhile the switch is in the TAG DUMP position.

In the AUTO DUMP mode, the axle air bags will de-flate when all of the following conditions are met. Ifany of these conditions are not met, the tag-axle airbags will fill:

• The tag-axle suspension dump switch remainsin the AUTO DUMP mode (reverse maintainedposition).

• The vehicle speed is less than 8 mph (13 km/h).

• The vehicle is in reverse.

Tag-Axle Suspension—Dump and TagWheel SteeringThe tag-axle will be locked in an unsteerable positionwhen any of the following conditions are met:

• The vehicle is in reverse.

• The vehicle speed exceeds 20 mph (32 km/h)while accelerating or exceeds 15 mph (24km/h) while decelerating.

The tag-axle will be unlocked and steerable when allof the following conditions are met:

• The vehicle is in a forward gear.

• The vehicle speed is less than 20 mph (32km/h) while accelerating or less than 15 mph(24 km/h) while decelerating.

Braking ControlParking Brake Control KnobAll pneumatic-braked vehicles are equipped with adiamond-shaped parking brake control knob. SeeFig. 6.12. Pull the knob to apply the parking brake.In air brake systems, before the parking brake canbe released, the air pressure in either brake systemmust be at least 65 psi (448 kPa). See Chapter 8 fordetailed operating instructions.

Steering ControlTRW® ColumnDrive Adjustment Knob

WARNINGThe ColumnDrive system will not steer the ve-hicle by itself. It is only intended to help assistthe driver with steering. The driver must operatethe vehicle the same way they would any othervehicle that does not have this option. Attempt-ing to let the ColumnDrive system operate thevehicle without the full attention of the driver toall road and traffic conditions, could result inproperty damage, severe personal injury, ordeath.

The optional TRW ColumnDrive assists the driver bykeeping the vehicle centered in a variety of condi-tions, such as wind or bumpy sections of highway.Based on the driving conditions detected by the Col-umnDrive sensors, the system helps provide torqueto the steering wheel and avoid the need for suddenjerking motions from the driver.

Along with the automatic adjustments that Column-Drive makes, the driver can also adjust the resis-tance of the steering wheel to their comfort level. Theadjustment knob, shown in Fig. 6.13, has six differ-ent settings. Turning the knob clockwise will increasethe amount of resistance in the steering wheel.

03/30/2010 f421624

Fig. 6.12, Parking Brake Control Knob

Driver Controls

6.7

Page 75: Recreational Vehicle Chassis Operator's Manual

01/19/2012 f611159

Fig. 6.13, ColumnDrive Adjustment Knob

Driver Controls

6.8

Page 76: Recreational Vehicle Chassis Operator's Manual

7

EnginesEngine Starting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.1Engine Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.2Exhaust Brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.3Exhaust Aftertreatment System (ATS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.3Engine Shutdown . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.11

Page 77: Recreational Vehicle Chassis Operator's Manual

Engine StartingThis engine chapter is to serve as a guide for bestpractices only. Each make and model engine mayhave operating characteristics that are unique to thatparticular engine, and will be documented in the en-gine manufacturer’s literature. Always refer to specificinstructions and recommendations from the enginemanufacturer.

NOTE: Before starting the engine, read the ap-plicable instrument panel information (Chap-ter 2, Chapter 3, or Chapter 4). Read Chap-ter 5, Instruments, and Chapter 6, DriverControls. Read the operating instructions in themanufacturer’s engine operation manual beforestarting the engine.

Normal Starting

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

NOTE: Cummins and Detroit engines are run ona dynamometer before being shipped from thefactory. They do not require a break-in period.

IMPORTANT: Special break-in oils are not rec-ommended for new or rebuilt Cummins or De-troit engines.

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

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

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

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

NOTICEIf the engine is equipped with a turbocharger,protect the turbocharger during start-up by notdepressing the accelerator pedal until normal en-gine idle oil pressure registers on the gauge.

1. Before engine start-up, complete the pre- andpost-trip inspections and maintenance proce-dures in Chapter 13.

2. Set the parking brake.

3. Place the transmission in neutral.

4. Turn the key to the ON position and allow thegauge sweep to complete. The audible alert willsound for approximately four seconds.

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

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

NOTICEDo not rev the engine if the oil pressure gaugeindicates no oil pressure. Shut down the engineif oil pressure does not build within approxi-mately ten seconds. Check to determine thecause of the problem. Operating the engine withno oil pressure will damage the engine.

6. Apply load gradually during the warm-up period.

NOTICEIf the oil pressure gauge indicates no oil pres-sure, shut down the engine within approximatelyten seconds to avoid engine damage.

7. Check the oil pressure gauge for any drop in lu-bricating oil pressure or mechanical malfunction

Engines

7.1

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in the lubricating oil system. Minimum oil pres-sure at idle is 7 psi (50 kPa).

Cold-Weather StartingSee the engine manufacturer’s operation manual forstarting aids that are approved for specific engines.

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

Starting After Extended ShutdownBefore engine start-up, complete the pretrip inspec-tions and maintenance procedures in Chapter 13.

NOTICEFailure to eliminate water-diluted lubricating oilmay lead to serious engine damage at startup.

An engine in storage for an extended period of time(over winter, for example) may accumulate water inthe oil pan through normal condensation of moistureon the internal surfaces of the engine. Oil diluted bywater cannot provide adequate bearing protection atstart-up. For this reason, change the engine oil andfilters after extended storage.

Engine OperationNormal Operation

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

Engines produce high horsepower and peak torquecharacteristics at low rpm. Because of this, it is notnecessary to operate the engine at high rpm to de-liver the required horsepower at the wheels. Thesecharacteristics may also result in less shifting andmake shifting at lower rpm (to peak torque) morepractical.

Depending on the vehicle gearing, the posted speedlimit can sometimes allow operation in either of thetop two gears. However, for improved operating effi-ciency (fuel economy and engine life), operate in thetop gear at reduced rpm, rather than in the nextlower gear at the maximum rpm. Cruise at partial

throttle whenever road conditions and speed require-ments permit. This driving technique permits operat-ing within the most economical power range of theengine.

When approaching a hill, accelerate smoothly to startthe upgrade at full power (2000 rpm or higher is rec-ommended), then shift down as desired to maintainthe optimum vehicle speed.

Engines are designed to operate over a wide speedrange. More frequent shifting than necessary doesnot allow proper utilization of this flexibility. The driverwho stays in top gear and uses the wider speedrange will achieve the best fuel economy.

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

The engine is effective as a brake on downhillgrades, but take care not to overspeed the enginegoing downhill. Use a combination of brakes andgears to keep the vehicle under control at all timesand to keep the engine speed below the rated gov-erned rpm.

Cold-Weather OperationSatisfactory performance of a diesel engine operatingin low ambient temperatures requires modification ofthe engine, surrounding equipment, operating prac-tices, and maintenance procedures. The lower thetemperature, the greater the amount of modificationrequired. See the engine manufacturer’s operationmanual for service products approved for use in coldweather engine operation.

If satisfactory engine temperature is not maintained,maintenance costs will increase due to greater en-gine wear. If the engine coolant gets too cold, rawfuel will wash the lubricating oil off the cylinder wallsand dilute the crankcase oil, causing all moving partsof the engine to suffer from poor lubrication.

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

The following points are important to observe whenoperating in cold weather.

• Check for cracks in the battery cases, for cor-rosion of the terminals, and for tightness of thecable clamps at the terminals.

Engines

7.2

Page 79: Recreational Vehicle Chassis Operator's Manual

• Charge the batteries to full capacity. Replacedamaged batteries.

• If equipped, turn off the battery disconnectswitch after the engine is shut down to preventbattery discharge.

• Have the alternator output checked at an au-thorized Freightliner dealer.

• Check the condition and tension of the drivebelts.

• Refer to the engine manufacturer’s operationmanual for recommended heaters, low-viscosity lubricating oils, winter-grade fuels,and approved coolants.

• Periodically check the coolant mix ratio (con-centration of antifreeze in the coolant). Addmore if necessary.

• At temperatures below -4°F (-20°C), a coolantpreheater is recommended.

High-Altitude OperationEngines lose horsepower when operated at high alti-tude because the air is too thin to burn as much fuelas at sea level. Most turbocharged engines are ratedfor higher altitudes than naturally aspirated engines.An engine will have smoky exhaust at high altitudesunless a lower gear is used. Shift gears as neededto avoid excessive exhaust smoke.

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

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

The exhaust brake is activated when the followingconditions are satisfied.

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

2. The accelerator pedal is not depressed.

The Allison transmission provides for optimumretarding by downshifting when the exhaustbrake is selected. When the switch is turned ONand the driver’s foot is removed from the accel-erator pedal, the transmission will immediatelypreselect a lower gear. The transmission thenstarts to downshift through gears to reach thepreselected gear. Downshifting occurs at ahigher speed than is usual when the exhaustbrake is not turned on. This allows the exhaustto provide the maximum retarding power.

Exhaust Aftertreatment System(ATS)Vehicles and/or engines manufactured after Decem-ber 31, 2006 and domiciled in the U.S. or Canadaare required to meet all EPA and NHTSA regulationseffective as of the vehicle build date. Engines manu-factured between January 1, 2007 and December 31,2009 meet EPA07 requirements. Engines manufac-tured between January 1, 2010 and December 31,2012 meet EPA10 requirements.

Model year 2013 and later vehicles meet additionalrequirements as specified by NHTSA and EPA 2014fuel efficiency and greenhouse gas emission stan-dards (GHG14). Model year 2017 and later vehiclesmeet similar requirements as specified by GHG17requirements. These vehicles are equipped withcomponents that increase fuel efficiency and reduceGHG emissions.

IMPORTANT: Depending on local jurisdictionalguidelines, vehicles that are domiciled outside ofthe U.S. and Canada may not have emissionsaftertreatment systems (ATS) that are compliantwith EPA regulations.

NOTICEFollow these guidelines for engines that complywith EPA07 or newer regulations, or damage mayoccur to the aftertreatment device (ATD) and thewarranty may be compromised.

• Use ultralow-sulfur diesel with 15 ppm sulfurcontent or less.

• Do not use fuel blended with used engine lubeoil or kerosene.

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• Engine lube oil must have a sulfated ash levelless than 1.0 wt %; currently referred to asCJ-4 oil.

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

IMPORTANT: See the engine manufacturer’soperation manual for complete details and op-eration of the ATS.

EPA07 EnginesEngines built between January 1, 2007 and Decem-ber 31, 2009 are required to meet EPA07 guidelinesfor reduced exhaust emissions of particulate matterand nitrogen oxides (NOx). NOx is limited to justover 1 gram per brake horsepower hour (g/bhp-hr),and particulate matter cannot exceed 0.01 g/bhp-hr.

The EPA07 ATS varies according to engine manufac-turer and vehicle configuration, but the exhaust muf-fler is replaced by an aftertreatment device (ATD).Inside the ATD, the exhaust first passes over the die-sel oxidation catalyst (DOC), then passes throughthe diesel particulate filter (DPF), which traps sootparticles. The soot is burned to ash during a processcalled regeneration (regen).

EPA10 and Newer EnginesThe EPA mandates that all engines built after De-cember 31, 2009 must reduce the level of emissionsexhausted by the engine to the following levels:

• Nitrogen Oxides (NOx) – 0.2 g/bhp-hr

• Particulate Matter (PM) – .01 g/bhp-hr

To meet EPA guidelines, engines that are compliantwith EPA10 and newer regulations use an ATS thathas, in addition to a DOC/DPF device like that usedin an EPA07 ATD, a Selective Catalytic Reduction(SCR) device to reduce NOx downstream of the en-gine.

After exhaust gases leave the engine, they flow intothe ATS. First they flow into a two-part ATD, com-prised of a diesel oxidation catalyst (DOC), and adiesel particulate filter (DPF). The DPF traps sootparticles, then exhaust heat converts the soot to ashin the DPF, in a process called regeneration (regen).The harder an engine works, the better it disposes of

soot. Passive regen occurs when the engine is run-ning under load and regen occurs without input. Ifthe engine isn’t running hot enough, the electroniccontrols may initiate an active regen, whereby extrafuel is injected into the exhaust stream before thediesel particulate filter, to superheat the soot trappedin the filter and reduce it to ash. Both types of regenoccur without driver input.

WARNINGActive regeneration can occur automatically any-time the vehicle is moving. The exhaust gas tem-perature could reach 1500°F (816°C), which is hotenough to cause a fire, heat damage to objectsor materials, or personal injury to persons nearthe exhaust outlet.

The exhaust temperature can remain high evenafter the vehicle has stopped. When stopping thevehicle shortly after an automatic regen, ensurethe exhaust outlets are directed away from struc-tures, trees, vegetation, flammable materials, andanything else that may be damaged or injured byexposure to high heat.

Operating at reduced engine load will allow soot toaccumulate in the DPF. When this occurs, the DPFlamp illuminates, indicating that a regen must be per-formed, and the driver must either bring the vehicleup to highway speed to increase the load, or parkthe vehicle and initiate a parked regen. See ParkedRegen, later in this chapter for instructions.

After the exhaust stream passes through the ATD, itflows through another canister housing the SCR de-vice. A controlled quantity of diesel exhaust fluid(DEF) is injected into the exhaust stream, where heatconverts it to ammonia (NH3) gas. This mixture flowsthrough the SCR device, where the ammonia gasreacts with the NOx in the exhaust, to produce harm-less nitrogen (N2) and water vapor (H2O), which thenexits out of the tailpipe.

ATS Warning LampsWarning lamps in the driver’s message center alertthe driver of situations with the ATS.

• An illuminated DPF lamp indicates a regen isneeded. See Fig. 7.1.

• A slow, 10-second flashing of the high exhaustsystem temperature (HEST) lamp alerts thedriver that a parked regen is in progress, butthe exhaust temperatures are still relativelycool. It also indicates that the high-idle speed

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is being controlled by the engine software, notthe driver. See Fig. 7.2.

• A steadily illuminated HEST lamp alerts theoperator of high exhaust temperatures whenvehicle speed is below 5 mph (8 km/h) while itis performing an automatic regen, and during aparked regen.

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

Parked Regen

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

Before initiating a parked regeneration, make cer-tain the exhaust outlets are directed away fromstructures, trees, vegetation, flammable materi-

als, and anything else that may be damaged orinjured by prolonged exposure to high heat.

A reference label is included with the driver’s docu-mentation package initially in the glove box, that ex-plains the ATS warnings, and actions required toavoid further engine protection sequences. SeeFig. 7.3.

IMPORTANT: The vehicle can have two differentways to initiate a parked regen, depending onthe body builder. If there is not a regen switchon the dash, go to the Shorting Plug section.

The regen switch, located on the dash, is used toinitiate a parked regen of the aftertreatment device.See Fig. 7.4.

NOTE: The DPF lamp must be illuminated be-fore the regen switch will initiate a parkedregen.

To initiate a parked regeneration, perform the follow-ing steps.

1. Park the vehicle away from all combustible andflammable materials. Chock the tires. Start andwarm the engine until the coolant temperature isat least 150°F (66°C).

2. Set the parking brake. If the parking brake wasalready set, it must be released, then set again.

For manual transmissions, fully depress theclutch pedal, put the transmission in neutral, thenrelease the pedal.

If the vehicle has a two-pedal automated trans-mission, shift it into gear, then back to neutral.

IMPORTANT: The driver must remain with thevehicle during the entire regen cycle.

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

4. The regen cycle will finish after 20 to 60 minutes,at which time engine idle speed will drop to nor-mal and the vehicle can be driven normally. TheHEST lamp may be illuminated, but will go outwhen the vehicle speed exceeds 5 mph (8 km/h),or the system has cooled to normal operatingtemperature.

5. To stop a parked regen at any time during theprocess, engage the clutch, brake, or acceleratorpedal, or turn off the engine.

09/25/2006 f610815a

Fig. 7.1, Diesel Particulate Filter (DPF) Lamp

09/25/2006 f610816a

Fig. 7.2, High Exhaust System Temperature (HEST)Lamp

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Shorting Plug

NOTE: The DPF lamp must be illuminated be-fore the shorting plug will initiate a parkedregen.

The shorting plug is used to initiate a parked regenof the ATD. The shorting plug is located under thedash, next to the steering column. Mounting locationsvary. See Fig. 7.5.

To initiate a parked regeneration, perform the follow-ing steps.

1. Park the vehicle away from all combustible andflammable materials. Chock the tires. Start andwarm the engine until the coolant temperature isat least 150°F (66°C).

2. Set the parking brake. If the parking brake wasalready set, it must be released, then set again.

f080147

EXHAUST AFTERTREATMENT SYSTEM INFORMATION

Switch.

Level 1 Level 3Level 2 Level 4Filter RegenerationRecommended

Filter is reaching

Bring vehicle tohighway speeds to

Filter RegenerationNecessary

Filter is nowreaching maximumcapacity.

To avoid enginederate bring vehicle

Parked RegenerationRequired − EngineDerate

Filter has reachedmaximum capacity.

Vehicle must beparked and a Parked

Parked Regeneration Required −Engine Shut Down

Filter has exceededmaximum capacity

Vehicle must be parked and aParked Regeneration or Service

(Solid) (Flashing) (Flashing)

CHECK CHECK

(Flashing)

INDICATORLAMP(S)

Indicator LampMessage(s)

Diesel ParticulateFilter Condition

Required Action

capacity. .

STOP

See Engine Operator’s Manual for complete Regeneration Instructions.

allow for an AutomaticRegeneration orperform a ParkedRegeneration.

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

Regeneration mustbe performed −engine will beginderate.

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

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

06/29/2009

24−01583−000B

WARNING

HEST (High ExhaustSystem Temperature)

Exhaust Componentsand exhaust gas areat high temperature. When stationary, keepaway from people andflammable materialsor vapors.

A regeneration is inprogress.

Flashing

Solid

Fig. 7.3, Exhaust-Aftertreatment Warnings Reference Label

f61119906/19/2012

Fig. 7.4, Regen Switch

f54520702/11/2009

1

2

3

1. Primary Lock2. Secondary "Red" Lock

3. Plug

Fig. 7.5, Shorting Plug

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For manual transmissions, fully depress theclutch pedal, put the transmission in neutral, thenrelease the pedal.

If the vehicle has a two-pedal automated trans-mission, shift it into gear, then back to neutral.

IMPORTANT: The driver must remain with thevehicle during the entire regen cycle.

3. Disconnect the shorting plug, as follows.

3.1 Slide the secondary red lock away fromthe white cover. See Fig. 7.5, Ref. 2.

3.2 Push the primary lock in. See Fig. 7.5,Ref. 1.

3.3 Pull the plug apart. See Fig. 7.5, Ref. 3.

4. Wait four seconds.

5. Connect the shorting plug.

6. Engine rpm will rise, and initiate the regen pro-cess.

7. The regen cycle will finish after 20 to 60 minutes,at which time engine idle speed will drop to nor-mal and the vehicle can be driven normally. TheHEST lamp may be illuminated, but will go outwhen the vehicle speed exceeds 5 mph (8 km/h),or the system has cooled to normal operatingtemperature. The DPF light will shut off.

8. To stop a parked regen at any time during theprocess, engage the clutch, service brake, oraccelerator pedal, or turn off the engine.

DPF MaintenanceEventually ash will accumulate in the DPF and thefilter will require servicing. DPF servicing must beperformed by an authorized technician, following theengine manufacturer’s instructions. A record must bemaintained for warranty purposes, that includes:

• date of cleaning or replacement;

• vehicle mileage;

• particulate filter part number and serial number.

Diesel Exhaust Fluid and Tank,EPA10 and Newer EnginesDiesel Exhaust FluidDiesel exhaust fluid (DEF) is used in the ATS tolower NOx in the exhaust stream. DEF is colorlessand close to odorless (it may have a slightly pungentodor similar to ammonia). It is nontoxic, nonflam-

mable, and biodegradable. It is mildly corrosive toaluminum, but does not affect the strength or struc-ture of the aluminum.

White crystals may be noticeable around compo-nents that come into contact with DEF. The crystalsare easily removed with water.

DEF consumption varies depending on ambient con-ditions and vehicle application.

Freezing ConditionsDEF freezes to slush at around 12°F (-11°C). It is notdamaged or destroyed if frozen, and is fully usablewhen thawed. The DEF in the tank is allowed tofreeze while a vehicle is non-operational. At start-up,normal operation of the vehicle is not inhibited if theDEF is frozen; an immersion heater with engine cool-ant flowing through it warms the DEF once the en-gine is running, allowing the SCR system to operate.

Pre-2013 DEF supply lines are electrically-heatedand are purged when the engine is shut down; com-plete purging of the DEF lines requires approximatelyfive minutes after the engine is shut down.

DEF supply lines with engine model year 2013 andnewer are designed to survive freezing conditionswhile containing DEF, so purging is not required.

DEF TankEngines that are compliant with EPA10 and newerregulations are equipped with a DEF tank locatedforward of the ATS. See Fig. 7.6. The DEF tank hasa 19 mm filler neck inlet that prevents the hose froma diesel outlet from being inserted, and has a bluecap for easy identification.

The DEF tank will require filling a minimum of ap-proximately every second diesel refuel depending onthe DEF tank capacity. 10-, 13-, and 15-gallon tankcapacities are available. DEF consumption is ap-proximately 2% of fuel consumption, dependent onvehicle operation. For every 50 gallons of diesel fuelconsumed, approximately 1 gallon of DEF will beconsumed.

Some vehicles are equipped with a remote DEF fill-port. If so equipped, the remote port is directly oppo-site the DEF tank on the other side of the vehicle,and has a blue cap over the fill-port. See Fig. 7.7.

Fuel/DEF GaugeThe fuel and DEF levels are measured in a multipur-pose fuel/DEF/voltmeter gauge. See Fig. 7.8.

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Fuel level is indicated at the top of the gauge. Belowthe fuel level, a low fuel warning lamp illuminatesamber when the fuel level drops below 1/8th of thecapacity.

The DEF lightbar indicates the level in the DEF tankas follows.

• Four bars illuminated green—Between 75%and 100% full

• Three bars illuminated green—Between 50%and 75% full

• Two bars illuminated green—Between 25%and 50% full

• One bar illuminated green—Between approxi-mately 10% and 25% full

• One bar illuminated amber—DEF very low, re-fill DEF

• One bar flashing red—DEF empty, refill DEF

LBCU DEF Warnings and Engine Limits

IMPORTANT: Ignoring the DEF warning lightsand not refilling the DEF tank will result in lim-ited engine power with a speed limit of 5 mph (8km/h) eventually being applied. See the enginemanufacturer’s operation and maintenancemanual for further information.

DEF Level—Initial WarningWhen the DEF level becomes low, the followingwarning strongly encourages the driver to refill theDEF tank. See Fig. 7.9.

• One bar of the DEF-level lightbar illuminatesamber.

The DEF tank must be filled to cancel the warningsequence.

DEF LowWhen the DEF level reads low, the following warn-ings are activated. See Fig. 7.10.

• A LOW DEF message appears on the LBCUdriver display screen.

• One bar of the DEF-level lightbar flashes red.

• The CHECK engine lamp (amber) illuminates.

Engine performance is limited, with progressivelyharsher engine power limits applied.

The DEF tank must be filled to cancel the warningsequence.

DEF EmptyWhen the DEF tank registers empty, the followingwarnings are activated. See Fig. 7.10.

• A VERY LOW DEF message appears on theLBCU driver display screen.

• One bar of the DEF-level lightbar flashes red.

• The CHECK engine lamp illuminates.

Engine performance is limited, with progressivelyharsher engine power limits applied.

The DEF tank must be filled to cancel the warningsequence.

06/28/2012 f490471

1 2

3

1. ATS2. DEF Tank

3. DEF Gauge (optional)

Fig. 7.6, DEF Tank With Optional DEF Gauge

f49051605/20/2016

Fig. 7.7, Remote DEF Fill-Port

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DEF Level Empty and IgnoredIf the empty warning is ignored and the DEF is notrefilled, the red STOP engine lamp illuminates in ad-dition to the CHECK engine warning lamp. A 5 mph(8 km/h) speed limit is applied after the next engineshutdown or while parked and idling. See Fig. 7.11.

DEF Quality or SCR Tampering

NOTICEOnce contaminated DEF has been detected in theSCR system, the vehicle must be taken to an au-thorized service center to check the SCR systemfor damage, and to deactivate the warning lightand engine limits.

If contaminated DEF or tampering is detected, theSCR system activates a POOR DEF QUALITY mes-sage on the LBCU driver display screen and engineperformance is limited with progressively harsher en-gine power limits applied. If the fault is not corrected,the CHECK engine lamp illuminates, then the STOPengine lamp illuminates and a 5 mph (8 km/h) speed

09/21/2009 f611061

18

13

8E

F

0

5

1020

25

30

35

RPMx100

15

RPMx100

ULTR

A LO

W SULFUR DIESEL FUEL ONLY

18

13

8E

F

0

5

1020

25

30

35

RPMx100

15

RPMx100

ULTR

A LO

W SULFUR DIESEL FUEL ONLY

18

13

8E

F

0

5

1020

25

30

35

RPMx100

15

RPMx100

ULTR

A LO

W SULFUR DIESEL FUEL ONLY

A B C

A. 1 to 4 lamps steady green in DEF lightbar, DEF level indicators.B. 1 lamp steady amber in DEF lightbar, DEF very low.C. 1 lamp flashing red in DEF lightbar, DEF empty.

Fig. 7.8, Fuel/DEF/Voltmeter Gauge

A09/21/2009 f611062

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

Fig. 7.9, DEF Level Initial Warning

A09/21/2009 f611063

NOTE: Engine power is limited.A. DEF-Level Lightbar (1 bar flashing red)

Fig. 7.10, DEF Level Low and Empty Warnings

A09/21/2009 f611064

NOTE: The STOP engine and CHECK engine lampsilluminate, engine power is limited, speed limit of 5 mph(8 km/h).A. DEF-Level Lightbar (1 bar flashing red)

Fig. 7.11, DEF Empty and Ignored Warning

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limit is applied after the next engine shutdown, orwhile parked and idling. See Fig. 7.11.

Ametek DEF Warnings and Engine Limits

IMPORTANT: Ignoring the DEF warning lightsand not refilling the DEF tank will result in lim-ited engine power with a speed limit of 5 mph (8km/h) eventually being applied. See the enginemanufacturer’s operation and maintenancemanual for further information.

DEF Level Low—Initial and CriticalWarningsWhen the DEF level reads low the following warningsstrongly encourage the driver to refill the DEF tank.See Fig. 7.12.

• The DEF warning lamp illuminates constantly(initial warning).

• The DEF warning lamp flashes (critical warn-ing).

• DEF-level lightbar illuminates solid amber.

DEF EmptyWhen the DEF level reads empty, the following warn-ings are activated. See Fig. 7.13.

• One bar of the DEF-level lightbar flashes red.

• The DEF warning lamp flashes.

• The CHECK engine lamp illuminates.

Engine performance is limited, with progressivelyharsher engine power limits applied.

The DEF tank must be filled to cancel the warningsequence.

DEF Level Empty and IgnoredIf the empty warning is ignored and the DEF is notrefilled, the red STOP engine lamp illuminates in ad-dition to the DEF warning lamp and the CHECK en-gine warning lamp. See Fig. 7.14.

If the DEF tank is not refilled, a 5 mph (8 km/h)speed limit will be applied after the next engine shut-down, or while parked and idling.

DEF Quality or SCR Tampering

NOTICEOnce contaminated DEF has been detected in theSCR system, the vehicle must be taken to an au-thorized service center to check the SCR systemfor damage, and to deactivate the warning lightand engine limits.

If contaminated DEF or tampering is detected, theDEF warning light flashes, and engine performanceis limited with progressively harsher engine powerlimits applied. If the fault is not corrected, the

A

B10/13/2009 f611056

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

Fig. 7.12, DEF Level Low Initial and Critical Warnings

10/13/2009 f611057

A

B

NOTE: Engine performance is limited.A. DEF Warning Lamp (flashing amber)B. DEF-Level Lightbar (1 bar flashing red)

Fig. 7.13, DEF Empty Warning

A

B11/18/2010 f611059bB

NOTE: The STOP engine, CHECK engine, and DEFlamps illuminate, engine power is limited, speed limit of5 mph (8 km/h).A. DEF Warning Lamp (flashing amber)B. DEF-Level Lightbar (1 bar flashing red)

Fig. 7.14, DEF Empty and Ignored Warning

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CHECK engine lamp illuminates, then the STOP en-gine lamp illuminates and a 5 mph (8 km/h) speedlimit will be applied after the next engine shutdown,or while parked and idling. See Fig. 7.14.

OptiView™ DEF Warnings and EngineLimits

NOTE: The OptiView instrument panel has aDEF gauge that contains a low DEF warninglamp, which activates when the DEF tank needsto be refilled. Along with the DEF warning lampactivation, warning statements appear in thecenter of the OptiView panel.

DEF Level Low—Initial and CriticalWarningsWhen the DEF level reads low the following warningsstrongly encourage the driver to refill the DEF tank.

• The DEF warning lamp illuminates constantly(initial warning).

• The DEF warning lamp flashes (critical warn-ing).

• A "LOW DEF" message appears in the centerof the instrument panel.

• A brief audible alert will notify the driver.

The DEF tank must be filled to cancel the warningsequence.

DEF Level Very LowWhen the DEF level reads very low, the followingwarnings are activated.

• The DEF warning lamp flashes.

• A "VERY LOW DEF" message appears in thecenter of the instrument panel.

• A brief audible alert will notify the driver.

The DEF tank must be filled to cancel the warningsequence.

DEF EmptyWhen the DEF level reads empty, the following warn-ings are activated.

• The DEF warning lamp flashes.

• The CHECK engine lamp illuminates.

Engine performance is limited, with progressivelyharsher engine power limits applied.

The DEF tank must be filled to cancel the warningsequence.

DEF Level Empty and IgnoredIf the empty warning is ignored and the DEF is notrefilled, the red STOP engine lamp illuminates in ad-dition to the DEF warning lamp and the CHECK en-gine warning lamp.

If the DEF tank is not refilled, a 5 mph (8 km/h)speed limit will be applied after the next engine shut-down, or while parked and idling.

DEF Quality or SCR Tampering

NOTICEOnce contaminated DEF has been detected in theSCR system, the vehicle must be taken to an au-thorized service center to check the SCR systemfor damage, and to deactivate the warning lightand engine limits.

If contaminated DEF or tampering is detected, theDEF warning light flashes, and engine performanceis limited with progressively harsher engine powerlimits applied. If the fault is not corrected, theCHECK engine lamp illuminates, then the STOP en-gine lamp illuminates and a 5 mph (8 km/h) speedlimit will be applied after the next engine shutdown,or while parked and idling.

Engine Shutdown

NOTICEExcept in an emergency, do not shut down theengine when the coolant temperature is above194°F (90°C). To do so could damage the engine.

1. With the vehicle stopped, place the transmissionin the neutral (N) position and set the parkingbrake.

2. It is important to idle an engine for 3 to 5 min-utes before shutting it down. This allows the lu-bricating oil and the coolant to carry heat awayfrom the combustion chambers, bearings, shafts,and seals.

IMPORTANT: Long periods of idling are notgood for an engine because the combustionchamber temperatures drop so low that the fuelmay not burn completely. This will cause carbon

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to clog the piston rings and may result in stuckvalves.

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

4. Turn the ignition key to the OFF position andshut down the engine.

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8

Brake SystemAir Brake System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.1Antilock Braking System (ABS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.2

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Air Brake SystemGeneral Information

WARNINGFreightliner Custom Chassis Corporation (FCCC)neither recommends nor approves connecting atrailer or other towed vehicle’s braking systemdirectly to the vehicle braking system. FCCC alsoneither recommends nor approves tapping intothe vehicle air brake system nor operating atowed vehicle or trailer’s braking system bymeans of the vehicle braking system. Failure toobserve this warning could result in personal in-jury or death, or substantial property damage.

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

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

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

Air Brake System With External Fill (Schrader)Valve

Before a vehicle with insufficient brake system airpressure can be moved, the parking brake must bereleased by applying an external air source. Firstblock the wheels, then turn the ignition switch to theON position, then fill the appropriate system air res-ervoir using the Schrader valve on the inlet side ofthe air dryer. The parking brake will not release untilair pressure reaches 65 psi (448 kPa). The low airbuzzer will sound until air pressure reaches 65 to 73psi (448 to 503 kPa) with the ignition switch in theON position.

IMPORTANT: If the air pressure in the brakingsystem drops back below 38 to 42 psi (262 to290 kPa) the parking brake will reengage.

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

Allow time for the air compressor to build up a mini-mum of 95 psi (655 kPa) pressure in both the pri-mary and secondary systems. Monitor the air pres-sure system by observing the dual system airpressure gauges and the low-air-pressure warninglight and buzzer. The warning light and buzzer shutoff when the pressure in both systems reaches 65 to73 psi (448 to 503 kPa).

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

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

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

The yellow diamond-shaped knob on the controlpanel actuates the parking brake valve. See Fig. 8.1.Pull the knob to apply the parking brake.

WARNINGIf the vehicle is equipped with an air suspensionsystem, do not move the vehicle with the air sus-pension deflated. Doing so could result in a loss

Brake System

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Page 91: Recreational Vehicle Chassis Operator's Manual

of vehicle control, possibly causing personal in-jury and property damage.

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

If the brakes are wet, drive the vehicle in low (L)or 1st gear and lightly apply the brakes to heatand dry them. Allow hot brakes to cool beforeusing the spring parking brakes. Always chockthe tires.

Brake Burnishing (new vehicle)IMPORTANT: Check the brake system and en-sure that it is in proper operating condition be-fore attempting the brake burnishing procedure.

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

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

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

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

4. Next, drive the vehicle 5 to 7 miles (8 to 11 km)allowing the brakes to cool, and then come to astop.

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

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

Automatic Slack Adjusters

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

Automatic slack adjusters should never be manuallyadjusted except during routine maintenance of thefoundation brakes (e.g., replacing shoes), duringslack adjuster installation, or in an emergency situa-tion.

When the brake pushrod stroke exceeds the legalbrake adjustment limit on a vehicle, there is likely amechanical problem with the foundation brake com-ponents or the adjuster is improperly installed.

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

Antilock Braking System (ABS)Meritor WABCO® ABS

WARNINGAlthough the ABS improves vehicle control dur-ing emergency braking situations, the driver stillhas the responsibility to change driving stylesdepending on existing traffic and road condi-tions. Failure to change driving styles to accom-modate existing traffic and road conditions couldcause an accident, possibly resulting in personalinjury or death, or property damage.

The Meritor WABCO ABS is an electronic wheelspeed monitoring and control system that works withthe air brake system. ABS passively monitors vehicle

03/30/2010 f421624

Fig. 8.1, Parking Brake Control Knob

Brake System

8.2

Page 92: Recreational Vehicle Chassis Operator's Manual

wheel speed at all times, but controls wheel speedduring an emergency or reduced-traction stop. Innormal braking applications, the standard air brakesystem is in effect.

IMPORTANT: For proper ABS operation, do notmismatch tire sizes among any of the tires onthe vehicle. Mismatching tire sizes could resultin a reduced braking force, leading to longerstopping distances and cause an ABS event toregister on the electronic control unit (ECU).

WARNINGAn accumulation of road salt, dirt, and debris onthe ABS tone wheels and sensors can cause theABS warning light to illuminate. If the ABS lightilluminates while driving, have the ABS serviced.Operating the vehicle when the ABS needs to beserviced could cause an accident, possibly re-sulting in personal injury or death, or propertydamage.

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

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

The Meritor WABCO ABS combines one front-axlecontrol channel with the rear axle (four sensor sys-tem) to form one control circuit. For example, thesensor and solenoid control valve at the left-frontaxle form a control circuit with the sensor and sole-noid valve on the right-rear axle. If, during vehicleoperation, the safety circuit senses a failure in anypart of the ABS (a sensor, solenoid control valve, wir-ing connections, short circuit, etc.), the ABS warninglight illuminates and the control circuit where the fail-ure occurred is switched to normal braking action.The remaining control circuit will retain the ABS ef-fect. Even if the ABS is partially or completely inop-erative, normal braking ability is maintained. An ex-ception would be if a solenoid control valve (orcombination solenoid control valve) is damaged and

inoperative. As these components are an integralpart of the air brake system, normal braking may beimpaired or inoperative.

WARNINGIf any of the ABS warning lights do not work asdescribed above or illuminates while driving, re-pair the ABS immediately to ensure full antilockbraking capability. Operating the vehicle whenthe ABS needs to be serviced could cause an ac-cident, possibly resulting in personal injury ordeath, or property damage.

During emergency or reduced-traction stops, fullydepress the brake pedal until the vehicle comes to asafe stop; do not pump the brake pedal. With thebrake pedal fully depressed, the ABS will control allwheels to provide steering control and a reducedbraking distance.

Brake System

8.3

Page 93: Recreational Vehicle Chassis Operator's Manual

9

TransmissionsDriving Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.1Allison Automatic Transmissions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.1

Page 94: Recreational Vehicle Chassis Operator's Manual

Driving PrecautionsThe vehicle operator should use care when acceler-ating or downshifting on slippery road surfaces. Sud-den acceleration or engine braking, caused by shift-ing to a lower gear range, can result in a loss ofvehicle control. This is very important on snow- orice-covered roads. See Chapter 8 for information onbrake operation.

If the vehicle is stuck in sand or mud, do not attemptto pull the vehicle out under its own power. Requestprofessional towing assistance.

NOTICEDo not attempt to rock the vehicle. If rocking thevehicle is necessary, even at low speeds, it maycause engine overheating, axle damage, trans-mission damage or failure, or tire damage.

Do not coast the vehicle in neutral. Severe trans-mission damage may result and the vehicle willnot have the benefit of engine braking.

WARNINGTo reduce the risk of personal injury, beforegoing down a steep or long grade, reduce speedand down shift the treansmission. Do not holdthe brake pedal down too long or too often whilegoing down a steep or long grade. This couldcause the brakes to overheat, reducing their ef-fectiveness. As a result, the vehicle will not slowdown at the usual rate. Failure to take thesesteps could result in the loss of vehicle control.

To avoid skidding on slippery roads, do not downshiftinto "1" (Low) at speeds above 20 mph (32 km/h).

On slippery surfaces, avoid quick movements of thesteering wheel. Decrease your speed and allow forextra stopping distance required by these conditions.

Avoid driving through flooded areas unless you aresure the water is no higher than the bottom of thewheel rims. Drive through slowly. Allow adequatestopping distance since wet brakes do not grip well.After driving through water, gently apply the brakesseveral times while the vehicle is moving slowly, todry the brakes.

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

Allison AutomaticTransmissions

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

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

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

2500/3000/4000 MH ModelsGeneral Information2500, 3000, and 4000 MH series automatic transmis-sions have six forward speeds and one Reverse ®)speed. These transmissions have electronic shiftcontrols that can be programmed to allow the use ofdifferent numbers of geared speeds. See Fig. 9.1.For instance the transmission can be programmed tooperate as a 4-speed, 5-speed, or 6-speed unit inthe "primary" shift mode. If needed, a "secondary"shift mode can be programmed to provide anothershift configuration to optimize vehicle use under dif-ferent operating conditions. To activate a secondaryshift mode, or other special function programmed intothe electronic control unit (ECU), depress the Modebutton. A label just above the Mode button identifiesthe special function.

The 3000 and 4000 MH series transmissionsystems are designed to warn the driver oftransmission malfunctions. The driver of a ve-hicle equipped with these transmissions shouldknow the extent of the warning system in orderto safely operate the vehicle. See Chapter 5 forinformation on the warning system.

Transmissions

9.1

Page 95: Recreational Vehicle Chassis Operator's Manual

Operation1. Start the engine.

2. Use Reverse ®) to back the vehicle. Completelystop the vehicle before shifting from a forwardgear to Reverse ®) or from Reverse ®) to a for-ward gear. There is only one Reverse ®) gear.

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

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

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

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

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

See the Allison Transmission Owner’s Manualformore information on 3000 and 4000 MH trans-mission operation.

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

2100/2500 Models (Arens SBW)General InformationThe Arens shift-by-wire (SBW) push-button shift se-lector is part of an electronic shift control systemused with Allison series 2100/2500 5-speed auto-matic transmissions. An electronic actuator ismounted to the transmission.

The 2100/2500 series transmissions have a parkpawl and the SBW selector has a Park (P) position.See Fig. 9.2.

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

Calibrating Arens SBWIf the vehicle shuts down in gear and will not start,check the two 10-amp fuses. Then check to see ifeither one or two Ns appear on the transmissionshifter and the vehicle will not start. To reset thetransmission shifter, turn the ignition to the "ON" po-sition. On the transmission shifter, go through thefollowing sequence of N-R-N-D-N. This should resetthe shifter and allow the vehicle to start.

Transmission Operation1. At the top left side of the selector, is the select

display. On the left side of the display window,an LED character indicates which gear has beenselected.

MONITOR

SELECT

R

N

D

MODE

f27015806/22/2007

1

2

3

4

5

6

7

8

9

10

NOTE: The number displayed in the Digital Display win-dow is the highest forward range available in the se-lected position. Visually check to confirm the range se-lected. If the display is flashing, the shift is inhibited.1. Drive (D) Button2. Neutral (N) Button3. Reverse ®) Button4. Select Display5. Select/Monitor Display Window6. Monitor Display7. Service Display8. Mode Button9. Upshift Button10. Downshift Button

Fig. 9.1, GEN IV Shift Selector

Transmissions

9.2

Page 96: Recreational Vehicle Chassis Operator's Manual

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

WARNINGIf the Park (P) position is selected and the letterP does not appear on the monitor side of the dis-play window, the parking brake must be set. Oth-erwise the vehicle could move unexpectedly andcause an accident, possibly resulting in personalinjury and property damage.

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

3. The Park (P) button shifts the transmission toNeutral (N) and engages the park pawl. WhenPark (P) is selected, the monitor side of the dis-play window will show a letter P.

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

IMPORTANT: If the ignition switch is turned tothe OFF position before selecting Park (P), abuzzer will sound and the monitor display willshow the gear that is currently engaged. SelectPark (P) to turn off the buzzer and the display.Also, with the engine not running (ignition switchin the ON position and park pawl not engaged),a buzzer will sound and the monitor display willshow an N for Neutral (N). Select Park (P) toturn off the buzzer and the display.

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

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

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

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

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

MONITOR

SELECT

SERVICE

R

N

P

D

MODE

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

!

ARENS CONTROLS

04/02/2003 f270122

1

2

3

4

5

8

12

13

6

14

7

1011

9

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

Window

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

Fig. 9.2, SBW Shift Selector (2100/2500 series)

Transmissions

9.3

Page 97: Recreational Vehicle Chassis Operator's Manual

11 as progressively lower gears are manuallyselected.

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

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

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

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

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

IMPORTANT: An illuminated service display mayindicate a loss of safety back-up systems. Useextra care when shifting to ensure that thetransmission is operating properly.

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

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

Transmissions

9.4

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10

Steering SystemPower Steering System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.1Steering Column Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.1

Page 99: Recreational Vehicle Chassis Operator's Manual

Power Steering SystemNOTE: When there is no load on the vehicleand the front tires are pointed straight ahead,the steering wheel spokes should be at the 9and 3 o’clock positions or within 10 degrees toeither side. See Fig. 10.1.

The body builder is responsible for centering thesteering wheel.

Steering Column AdjustmentTRW Tilt/Telescope Steering Column

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

To tilt the steering column, press down on the footpedal (located below the steering wheel) to releasethe steering column lock. Adjust the column to thedesired position. Release the foot pedal to lock thesteering column in place. To telescope the steeringcolumn, lift up the lever on the steering column. Pullthe steering wheel upward or push it downward untilit is at the desired height. Release the lever to lockthe steering column in place. See Fig. 10.2.

NOTE: For safety, the steering column is lockedat all times unless the foot pedal is depressedor if the lever is engaged.

f462089

10°

10°

10°

10°

1 2

06/28/2007

1. 9 o’Clock 2. 3 o’Clock

Fig. 10.1, Steering Wheel Centered

f462091

A

1

08/14/2007

B2

A. Telescope B. Tilt1. Foot Pedal 2. Lever

Fig. 10.2, TRW Tilt/Telescope Steering Column (typical)

Steering System

10.1

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11

Front-Engine Diesel ChassisInstrumentation Control Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11.1Exhaust Aftertreatment System (ATS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11.10Allison Automatic Transmissions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11.17Hydraulic Brake System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11.19

Page 101: Recreational Vehicle Chassis Operator's Manual

Instrumentation Control UnitFigure 11.1 shows a typical set of instruments forvehicles equipped with the MC Recreational Vehicleinstrument cluster (ICU3-M2).

The MC Recreational Vehicle instrument cluster is anupdated version of the basic electronic dashboard(ICU-3). It can accept information from the datalinkand sensors installed on the vehicle, and sends thatinformation to electronic gauges.

The instrument cluster has the capability to drive in-dependent stand-alone gauges such as those in-stalled on the auxiliary dash panel. Figure 11.2shows a typical dash.

Dash Message CenterThe dash message center houses all of the standardand optional warning and indicator lights. Warningmessages and diagnostic fault codes will appear inthe driver display screen.

Ignition SequenceWhen the ignition is turned on, all the electronicgauges complete a full sweep of their dials, thewarning and indicator lights light up, and the buzzersounds for 3 seconds. See Fig. 11.3 for the ignitionsequence.

The following lamps illuminate during the ignition se-quence:

• fasten seat belt warning

• low battery voltage warning

• high coolant temperature warning

8 f611083

1 2 4 5

7

9

3

10

11

11/09/2009

6

1. Engine Oil Pressure Gauge2. Dash Message Center3. Headlight High-Beam Indicator4. Dash Driver Display Screen5. Fuel Level Gauge

6. Diesel Exhaust Fluid (DEF) Gauge7. Primary Air Pressure Gauge8. Mode/Reset Switch9. Secondary Air Pressure Gauge

10. Speedometer11. Tachometer (optional)12. Transmission Temperature Gauge13. Coolant Temperature Gauge

Fig. 11.1, Gauge Layout (typical, U.S.), EPA10 and Newer Engines

Front-Engine Diesel Chassis

11.1

Page 102: Recreational Vehicle Chassis Operator's Manual

• low engine oil pressure warning

• parking brake on indicator

• all engine indicator/warning lights, includingcheck engine and engine protection

NOTE: While the engine and ABS warning lightsilluminate during the ignition sequence, they arenot controlled by the instrument cluster but bytheir own system ECU (electronic control unit).

When the ignition switch has been turned on, theICU performs a self-test, looking for active faults.During the first half of the self-test, all segments ofthe display will illuminate as follows.

• First line (odometer): "888888.8"

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

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

• Fourth line: "ENGINE"

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

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

If however, the instrument cluster has received activefault codes from the other devices, it displays themone after the other until the parking brake is re-leased, or the ignition switch is turned off. Once theparking brake is released, the dash message centerdisplays the odometer again.

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

If the fault requires immediate attention, the engineprotection system will activate. In most cases, thecheck engine lamp will also illuminate.

Some examples include:

5

4

f610578

1

23

10/11/2001

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

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

4. Auxiliary Dash Panel5. Climate Control Panel

Fig. 11.2, Dash Panel Layout (typical)

Front-Engine Diesel Chassis

11.2

Page 103: Recreational Vehicle Chassis Operator's Manual

• high coolant temperature

• low coolant level

• low engine oil pressure

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

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

IMPORTANT: If the legend SERVICE ENGINEappears on the driver display screen while oper-ating the vehicle, bring the vehicle to an autho-rized Freightliner service facility when conve-nient.

OdometerThe odometer is a seven-digit display with a decimalpoint, until the vehicle has traveled 999,999.9 milesor kilometers (km). At one million miles (km), theodometer resets itself to "1000000", without the deci-mal point, and can continue up to 9,999,999. Theodometer only displays significant figures (no leadingzeros).

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

Mode/Reset SwitchThe mode/reset switch is located on the right side ofthe instrument cluster. See Fig. 11.4. The mode/resetswitch is used to scroll through the displays on themessage display screen, and to reset the trip dis-tance and trip hours values to zero.

POWER ON

PARK BRAKE

IGNITION ON

HEADLIGHTS ON

RELEASE PARK BRAKE

f040420b10/24/2001

RELEASED − MOVING

FAULT CODESCREEN

IF NO FAULTSWERE DETECTED

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

IF FAULT DETECTED

ICU PERFORMS SELF−TEST:

888888.8

ABS 136

ODOMETERSCREEN

123456.7

12.3 VOLTS

123456.7

12.3 VOLTS

MI

MI

TRIP MI KM HOURS38.8 VOLTS SERVICE

ENGINE

Fig. 11.3, Ignition Sequence

09/25/99

PUSH− MODE HOLD− RESET

f610340

Fig. 11.4, Mode/Reset Switch

Front-Engine Diesel Chassis

11.3

Page 104: Recreational Vehicle Chassis Operator's Manual

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

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

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

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

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

To reset trip miles and/or trip hours to zero,press the mode/reset switch for 1 second orlonger. To toggle between MI (miles) or KM(kilometers), press the mode/reset switch whilein the SELECT screen.

Warning and Indicator LampsThere can be up to 27 warning and indicator lamps(telltales) installed in the dash message center. SeeFig. 11.5.

The instrument cluster has an emergency buzzer thatsounds when serious conditions that require immedi-ate attention occur.

A description of the standard warning and indicatorlamps are listed below.

Check Engine WarningThe check engine warning indicator illuminates whencertain faults are detected. If a critical engine condi-tion exists (for example, low oil pressure or highcoolant temperature), the check engine indicator willilluminate to alert the driver to correct the conditionas soon as possible. If the condition gets worse, thestop engine indicator will illuminate.

NOTE: If the check engine indicator illuminatesduring vehicle operation, take the vehicle di-rectly to an authorized Freightliner service facil-ity.

Stop Engine WarningThe stop engine warning indicator illuminates whenthe protection system available for the engine hasbeen activated. On some engines, the engine elec-tronic control unit (ECU) will derate the engine, allow-ing it to run, but at lower rpm and slower vehiclespeed. The vehicle may be driven to a safe location.

The engine ECU will derate the engine. The drivermust safely bring the vehicle to a stop on the side ofthe road.

NOTICEBecause operating the engine when the stop en-gine indicator is illuminated can lead to severeengine damage, the driver must move the vehicleto a safe location as quickly as possible.

To restart the engine turn the ignition switch to OFF,leave it there a few seconds, and turn the switch toSTART.

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

07/08/2011

OPT

ABS ABSCHECK STOP

f611066

1 2 3 4

8 9 1014 15

5 6

11 12 1320 211817

7

OPTOPTOPTOPTOPTOPTOPTOPT

16 19

1. Optional Indicator2. Check Engine Warning3. Stop Engine Warning4. Malfunction Indicator Lamp (MIL)5. ABS Warning6. Transmission Overheat Warning7. Trailer ABS Indicator (not used)8. Low Oil Pressure Warning9. High Coolant Temperature Warning10. Fasten Seat Belt Warning11. Parking Brake On Warning12. Diesel Particulate Filter (DPF) Lamp13. High Exhaust System Temperature (HEST) Lamp14. Left-Turn Indicator15. Low Battery Voltage Warning16. Water In Fuel Indicator17. Dash Driver Display Screen18. Headlight High-Beam Indicator19. Cruise Control Indicator20. Low Air Pressure Warning21. Right-Turn Signal Arrow

Fig. 11.5, Warning and Indicator Lights, EPA10 andNewer Engines

Front-Engine Diesel Chassis

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Malfunction Indicator Lamp (MIL)The malfunction indicator lamp (MIL) indicates anengine emissions-related fault. See the engine op-eration manual for details.

ABS WarningThe ABS indicator illuminates when there is a mal-function in the vehicle antilock brake system (ABS).

NOTE: For more information about this indicatorand the ABS system, see Chapter 8.

Transmission Overheat WarningThe transmission overheat indicator illuminates whenthe temperature of the transmission fluid goes abovethe preset level set by the transmission manufac-turer.

For more information, see the transmission manufac-turer’s manual provided with the vehicle.

Low Oil Pressure WarningThe low oil pressure warning indicator and emer-gency buzzer activate whenever the engine oil pres-sure goes below the preset minimum specified by theengine manufacturer. See Table 11.1.

Oil Pressure Specifications*†

Engine ModelAt Idle Speed:

psi (kPa)At Rated RPM:

psi (kPa)Cummins ISB 10 (69) 30 (207)* Oil pressures are given with the engine at operating temperature. With

the engine cold, oil pressure may be higher. Individual engines may varyfrom the listed pressures; observe and record pressures when the engineis new to create a guide for checking engine condition.† EPA07 MBE900 engines have an oil pressure switch. When above

minimum pressure, the dash gauge will display the values shown inTable 11.1. If below minimum oil pressure is reached, the dash gaugewill read 0 psi.

Table 11.1, Oil Pressure Specifications

High Coolant Temperature WarningThe high coolant temperature indicator and emer-gency buzzer activate whenever the coolant tem-perature goes above a preset maximum specified bythe engine manufacturer. See Table 11.2.

Maximum Coolant TemperatureEngine Model °F (°C)

Cummins ISB 220 (104)

Table 11.2, Maximum Coolant Temperature

Fasten Seat Belt WarningThe fasten seat belts warning indicator illuminates for15 seconds after the ignition switch is turned on.

Parking Brake On WarningThe parking brake on indicator activates when theparking brake is engaged.

If the vehicle is moving at a speed of 2 mph (3 km/h)or more, the emergency buzzer will sound until theparking brake is released.

Diesel Particulate Filter (DPF) LampA solid illumination indicates a regeneration is re-quired. Change to a more challenging duty cycle,such as highway driving, to raise exhaust tempera-tures for at least 20 minutes, or perform a stationaryregeneration. See Parked Regen for details.

A blinking lamp indicates that a stationary regenera-tion is required immediately. An engine derate andshutdown will occur. See Parked Regen for details.

High Exhaust System Temperature(HEST) LampA slow (10-second) flash, indicates a regeneration isin progress, and the driver is not controlling the en-gine idle speed.

A solid illumination indicates potentially hazardousexhaust temperatures at the outlet of the tail pipe ifspeed is below 5 mph (8 km/h). It does not signifythe need for service; it only alerts the vehicle opera-tor of high exhaust temperatures. See the engineoperation manual for details.

IMPORTANT: Make sure the engine exhaustpipe outlet is not directed at any person, or atany surface or material that will melt, burn, orexplode.

Left-Turn IndicatorThe left-turn indicator flashes on and off when theleft-turn signal lights are flashing.

Both turn signal indicators flash when the hazardwarning flasher is turned on.

Low Battery Voltage WarningThe low battery voltage warning indicator (batteryicon) illuminates when the battery voltage dropsbelow 12 volts.

Front-Engine Diesel Chassis

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Water In Fuel IndicatorThe water in fuel indicator notifies the driver the fuelmay contain water. Drain any water collected in thefuel/water separator.

Headlight High-Beam IndicatorThe high-beam indicator (sideways beam icon) illumi-nates when the headlight high beams are on.

Cruise Control IndicatorThe cruise control indicator illuminates when thecruise control is activated.

Low Air Pressure WarningThe low air pressure warning indicator and emer-gency buzzer activate when the engine is turned onif air pressure in the primary or secondary air reser-voir is below 65 to 75 psi (448 to 517 kPa), and re-main on until air pressure rises above that level inboth reservoirs.

Right-Turn IndicatorThe right-turn indicator flashes on and off when theright-turn signal lights are flashing.

Both turn indicators flash when the hazard warningflasher is turned on.

Emergency BuzzerThe emergency buzzer sounds during the ignitionsequence and whenever one of the following condi-tions exists:

• The engine oil pressure falls below the presetlevel shown in Table 11.1.

• The coolant temperature rises above the pre-set level shown in Table 11.2.

• The air pressure falls below the preset level,which is 65 psi (448 kPa).

• The parking brake is set with the vehicle mov-ing at a speed greater than 2 mph (3 km/h).

Optional Warning and IndicatorLampsA description of some commonly used optional warn-ing and indicator lamps are listed below.

Air Filter IndicatorThe air filter indicator (AIR FILTER legend) illumi-nates when the air cleaner filter element is clogged.If the air filter indicator light is steadily illuminated forany period of time, check the air intake restrictiongauge. If the yellow signal stays locked in the redzone once the engine is shut down, or is at or abovethe maximum restriction value in Table 11.3, replacethe air cleaner element.

IMPORTANT: Never attempt to clean the air fil-ter.

Air Intake Maximum Restriction Values (inH2O)

Engine Make EPA07 andEPA10 Engines

GHG14 andGHG17 Engines

Cummins 25 25Detroit 22 18

Table 11.3, Air Intake Maximum Restriction Values

Alternator No Charge IndicatorThe alternator no charge indicator (NO CHARGE leg-end) illuminates when the alternator is not chargingproperly.

Speedometer and TachometerSpeedometerThree kinds of speedometer faces are available. TheU.S. version of the speedometer registers speed inboth miles per hour (mph) and kilometers per hour(km/h), with mph in larger numbers. See Fig. 11.6.

The NAFTA version (not shown) of the speedometerface reverses this arrangement, with km/h in larger

10/09/2001

0

5

10

1520

30

RPM5

15

2535

4555

65

75

85

MPHkm/h

25

X100

30

5070

90

130

110

10

1 2f610527

1. Tachometer 2. Speedometer

Fig. 11.6, Speedometer and Tachometer

Front-Engine Diesel Chassis

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numbers. The metric-only version (not shown) showskm/h exclusively.

TachometerThe tachometer indicates engine speed in revolutionsper minute (rpm) and serves as a guide for shiftingthe transmission and keeping the engine in the ap-propriate rpm range. See Fig. 11.6. For low idle andrated rpm, see the engine identification plate.

GaugesCoolant Temperature Gauge

NOTICEA sudden increase in coolant temperature mayindicate engine or cooling system failure. Bringthe vehicle to a safe stop and investigate thecause to prevent further damage. Do not operatethe engine until the cause has been determinedand corrected.

During normal engine operation, the coolant tem-perature gauge should read 175 to 195°F (79 to91°C). See Fig. 11.7. If the temperature remainsbelow 160°F (71°C) or exceeds the maximum tem-perature shown in Table 11.2, inspect the coolingsystem to determine the cause. See the vehicleworkshop manual for troubleshooting and repairprocedures.

The coolant temperature gauge is mission-critical.See Fig. 11.7. If the coolant temperature rises abovethe preset levels shown in Table 11.2, first, the checkengine light will illuminate, and, if the condition doesnot improve, the engine protection light will also illu-minate and the buzzer will sound. At this point, the

engine will derate or shut down, depending on thetype of engine protection system installed.

Engine Oil Pressure Gauge

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

The engine oil pressure gauge is mission-critical.See Fig. 11.8. If the engine oil pressure falls belowthe preset levels shown in Table 11.1, first, the checkengine light will illuminate, and, if the condition doesnot improve, the engine protection light will also illu-minate and the buzzer will sound. At this point, theengine will derate or shut down, depending on thetype of engine protection system installed.

Fuel Level GaugeThe fuel level gauge indicates the level of fuel in thefuel tank(s). See Fig. 11.9. For more detailed infor-mation on the fuel gauge used with EPA10 andnewer engines, see Diesel Exhaust Fluid and Tank,EPA10 and Newer Engines. One fuel gauge is stan-dard. If equipped with a second (optional) fuel gauge,each fuel tank level is indicated on a separategauge.

Transmission Fluid Temperature GaugeThe transmission fluid temperature gauge is optional.

During normal operation, the transmission fluid tem-perature gauge reading should not exceed 250°F(121°C) at the sump. See Fig. 11.10.

10/09/2001 f610565

WATER

100

150 200

250

Fig. 11.7, Coolant Temperature Gauge

10/09/2001

0 100

50

PSI

OIL

f610528

Fig. 11.8, Engine Oil Pressure Gauge

Front-Engine Diesel Chassis

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NOTICEA sudden increase in transmission fluid tempera-ture that is not caused by a load increase mayindicate mechanical failure. Bring the vehicle to asafe stop and investigate the cause to preventfurther damage. Do not operate the vehicle untilthe cause has been determined and corrected.

NOTE: Under heavy loads, such as when climb-ing steep grades, temperatures may climbabove those given here for limited periods.

VoltmeterThe voltmeter is a digital readout located on the bot-tom line of the driver display screen whenever theignition switch is turned on.

It indicates the vehicle charging system voltage whenthe engine is running and the battery voltage whenthe engine is stopped. By monitoring the voltmeter,the driver can be aware of potential charging systemproblems and have them fixed before the batteriesdischarge enough to create starting difficulties.

The voltmeter will normally show approximately 13.7to 14.1 volts when the engine is running. The voltageof a fully charged battery is 12.7 to 12.8 volts whenthe engine is stopped. Battery voltage under 12.0volts is considered a low battery, and a completelydischarged battery will produce only about 11.0 volts.The voltmeter will indicate lower voltage as the ve-hicle is being started or when electrical devices inthe vehicle are being used.

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

Optional InstrumentsOptional instruments are not found on every vehicle.They are stand-alones, not driven by the instrumentcluster, and are usually located on the auxiliary dashpanel. They are listed here in alphabetical order, tomake the information easier to find.

AmmeterThe ammeter measures current flowing to and fromthe battery. See Fig. 11.11. When the batteries arebeing charged, the meter needle moves to the plusside of the gauge; when the batteries are being dis-charged, the needle moves to the minus side. A con-sistent negative reading when the engine is runningindicates a possible problem with the chargingsystem.

Axle Oil Temperature Gauge, Rear

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

During normal operation, the rear axle oil tempera-ture gauge should read between 160 and 220°F (71and 104°C) for Detroit™ and Meritor™ drive axles.See Fig. 11.12.

09/17/2009 f611048

Fig. 11.9, Fuel Gauge, EPA10 and Newer Engines

10/30/2001 f610600

TRANS

125 350

F

275200

Fig. 11.10, Transmission Fluid Temperature Gauge

Front-Engine Diesel Chassis

11.8

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

Digital ClockThe digital clock has black characters on a con-stantly backlighted green display, with a brightnessthat automatically adjusts for day or night. The clockhas a 24-hour alarm, with a three-minute snooze fea-ture. See Fig. 11.13.

1. To set the time of day:

1.1 Push the Run/Set (lower) switch to theright (TIME-SET position).

NOTE: When the hour setting is for a timebetween noon and midnight, the small lettersPM will appear in the lower left corner of the

display; no PM display indicates an AM set-ting.

1.2 Advance the hour setting to the correctnumber by pushing and releasing the hourbutton as many times as needed. Or if thebutton is pressed and held in for longerthan 2 seconds, the numbers will continueto advance until the button is released.

1.3 Advance the minute setting by repeatedlypushing, or pushing and holding the min-ute button as needed.

1.4 Push the Run/Set switch to the middle(RUN) position.

2. To set the alarm time:

2.1 Push the Run/Set switch to the left(ALARM-SET position).

2.2 Set the alarm time by using the same pro-cedure that you used to set the time ofday; remember to set the hour for A.M.(no letters in the corner of the display), orP.M. as desired.

2.3 Return the Run/Set switch to the middle(RUN) position; the readout will return tothe time-of-day setting.

3. To operate the alarm:

3.1 With the alarm time set, push the alarm(upper) switch to the left. An alarm "wave"symbol and the letters AL will appear inthe upper left corner of the display whenthe alarm is on.

10/10/2001 f610573

Fig. 11.11, Ammeter

10/10/2001 f610571

Fig. 11.12, Axle Oil Temperature Gauge

10/11/2001 f610576

Fig. 11.13, Digital Clock

Front-Engine Diesel Chassis

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3.2 When the displayed time of day coincideswith the alarm time, the alarm will sound.If the SNOOZ button is not pushed or thealarm switch is not moved, the alarm willautomatically stop sounding after 1 minuteand will not sound again for 24 hours.

3.3 If desired, press the SNOOZ button whilethe alarm is sounding to shut the alarm offfor 3 minutes. The alarm symbol will flashin the display when the button is pushedand will continue to flash until the alarmswitch is moved or the alarm has soundedfor one minute. The snooze procedure canbe done as many times as desired.

3.4 Move the alarm switch to the right whenyou wish to shut off or cancel the alarm;the alarm symbol will disappear.

Air Intake Restriction GaugeThe intake-air restriction indicator measures thevacuum on the engine side of the air cleaner at theair cleaner outlet. See Fig. 11.14. On standard instal-lations, it is mounted on the intake air piping in theengine compartment.

Air intake restriction vacuum is measured in inchesof water (inH2O). For vehicles equipped with a gradu-ated indicator or a restriction gauge on the dash,check the gauge with the engine off. If the yellowsignal stays locked in the red zone once the engineis shut down, or is at or above the maximum restric-

tion value in Table 11.3, replace the air cleaner ele-ment.

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

PyrometerA pyrometer can be installed on the exhaust pipeand registers the exhaust temperature near the tur-bocharger. See Fig. 11.15. Maximum exhaust tem-peratures are listed in Table 11.4.

Variations in engine load can cause exhaust tem-peratures to vary. If the pyrometer reading showsthat exhaust temperature exceeds normal, reducefuel to the engine until the exhaust temperature isreduced. Shift to a lower gear if the engine isoverloaded.

Maximum Exhaust TemperatureEngine Model °F (°C)

Cummins ISB 1290 (700)

Table 11.4, Maximum Exhaust Temperature

Turbocharger Boost Pressure GaugeA turbocharger boost pressure gauge measures thepressure in the intake manifold, in excess of atmos-pheric pressure, being created by the turbocharger.See Fig. 11.16.

Exhaust Aftertreatment System(ATS)Vehicles and/or engines manufactured after Decem-ber 31, 2006 and domiciled in the U.S. or Canada

10/10/2001 f610568

Fig. 11.14, Air Intake Restriction Gauge

10/10/2001 f610570

Fig. 11.15, Pyrometer

Front-Engine Diesel Chassis

11.10

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are required to meet all EPA and NHTSA regulationseffective as of the vehicle build date. Engines manu-factured between January 1, 2007 and December 31,2009 meet EPA07 requirements. Engines manufac-tured between January 1, 2010 and December 31,2012 meet EPA10 requirements.

Model year 2013 and later vehicles meet additionalrequirements as specified by NHTSA and EPA 2014fuel efficiency and greenhouse gas emission stan-dards (GHG14). Model year 2017 and later vehiclesmeet similar requirements as specified by GHG17requirements. These vehicles are equipped withcomponents that increase fuel efficiency and reduceGHG emissions.

IMPORTANT: Depending on local jurisdictionalguidelines, vehicles that are domiciled outside ofthe U.S. and Canada may not have emissionsaftertreatment systems (ATS) that are compliantwith EPA regulations.

NOTICEFollow these guidelines for engines that complywith EPA07 or newer regulations, or damage mayoccur to the aftertreatment device (ATD) and thewarranty may be compromised.

• Use ultralow-sulfur diesel with 15 ppm sulfurcontent or less.

• Do not use fuel blended with used engine lubeoil or kerosene.

• Engine lube oil must have a sulfated ash levelless than 1.0 wt %; currently referred to asCJ-4 oil.

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

IMPORTANT: See the engine manufacturer’soperation manual for complete details and op-eration of the ATS.

EPA07 EnginesEngines built between January 1, 2007 and Decem-ber 31, 2009 are required to meet EPA07 guidelinesfor reduced exhaust emissions of particulate matterand nitrogen oxides (NOx). NOx is limited to justover 1 gram per brake horsepower hour (g/bhp-hr),and particulate matter cannot exceed 0.01 g/bhp-hr.

The EPA07 ATS varies according to engine manufac-turer and vehicle configuration, but the exhaust muf-fler is replaced by an aftertreatment device (ATD).Inside the ATD, the exhaust first passes over the die-sel oxidation catalyst (DOC), then passes throughthe diesel particulate filter (DPF), which traps sootparticles. The soot is burned to ash during a processcalled regeneration (regen).

EPA10 and Newer EnginesThe EPA mandates that all engines built after De-cember 31, 2009 must reduce the level of emissionsexhausted by the engine to the following levels:

• Nitrogen Oxides (NOx) – 0.2 g/bhp-hr

• Particulate Matter (PM) – .01 g/bhp-hr

To meet EPA guidelines, engines that are compliantwith EPA10 and newer regulations use an ATS thathas, in addition to a DOC/DPF device like that usedin an EPA07 ATD, a Selective Catalytic Reduction(SCR) device to reduce NOx downstream of the en-gine.

After exhaust gases leave the engine, they flow intothe ATS. First they flow into a two-part ATD, com-prised of a diesel oxidation catalyst (DOC), and adiesel particulate filter (DPF). The DPF traps sootparticles, then exhaust heat converts the soot to ashin the DPF, in a process called regeneration (regen).The harder an engine works, the better it disposes ofsoot. Passive regen occurs when the engine is run-ning under load and regen occurs without input. Ifthe engine isn’t running hot enough, the electronic

10/10/2001 f610574

Fig. 11.16, Turbo Boost Pressure Gauge

Front-Engine Diesel Chassis

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Page 112: Recreational Vehicle Chassis Operator's Manual

controls may initiate an active regen, whereby extrafuel is injected into the exhaust stream before thediesel particulate filter, to superheat the soot trappedin the filter and reduce it to ash. Both types of regenoccur without driver input.

WARNINGActive regeneration can occur automatically any-time the vehicle is moving. The exhaust gas tem-perature could reach 1500°F (816°C), which is hotenough to cause a fire, heat damage to objectsor materials, or personal injury to persons nearthe exhaust outlet.

The exhaust temperature can remain high evenafter the vehicle has stopped. When stopping thevehicle shortly after an automatic regen, ensurethe exhaust outlets are directed away from struc-tures, trees, vegetation, flammable materials, andanything else that may be damaged or injured byexposure to high heat.

Operating at reduced engine load will allow soot toaccumulate in the DPF. When this occurs, the DPFlamp illuminates, indicating that a regen must be per-formed, and the driver must either bring the vehicleup to highway speed to increase the load, or parkthe vehicle and initiate a parked regen. See ParkedRegen, later in this chapter for instructions.

After the exhaust stream passes through the ATD, itflows through another canister housing the SCR de-vice. A controlled quantity of diesel exhaust fluid(DEF) is injected into the exhaust stream, where heatconverts it to ammonia (NH 3) gas. This mixtureflows through the SCR device, where the ammoniagas reacts with the NOx in the exhaust, to produceharmless nitrogen (N 2) and water vapor (H 2O),which then exits out of the tailpipe.

ATS Warning LampsWarning lamps in the driver’s message center alertthe driver of situations with the ATS.

• An illuminated DPF lamp indicates a regen isneeded. See Fig. 11.17.

• A slow, 10-second flashing of the high exhaustsystem temperature (HEST) lamp alerts thedriver that a parked regen is in progress, butthe exhaust temperatures are still relativelycool. It also indicates that the high-idle speedis being controlled by the engine software, notthe driver. See Fig. 11.18.

• A steadily illuminated HEST lamp alerts theoperator of high exhaust temperatures whenvehicle speed is below 5 mph (8 km/h) while itis performing an automatic regen, and during aparked regen.

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

Parked Regen

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

Before initiating a parked regeneration, make cer-tain the exhaust outlets are directed away fromstructures, trees, vegetation, flammable materi-als, and anything else that may be damaged orinjured by prolonged exposure to high heat.

09/25/2006 f610815a

Fig. 11.17, Diesel Particulate Filter (DPF) Lamp

09/25/2006 f610816a

Fig. 11.18, High Exhaust System Temperature (HEST)Lamp

Front-Engine Diesel Chassis

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A reference label is included with the driver’s docu-mentation package initially in the glove box, that ex-plains the ATS warnings, and actions required toavoid further engine protection sequences. SeeFig. 11.19.

IMPORTANT: The vehicle can have two differentways to initiate a parked regen, depending onthe body builder. If there is not a regen switchon the dash, go to the Shorting Plug section.

The regen switch, located on the dash, is used toinitiate a parked regen of the aftertreatment device.See Fig. 11.20.

NOTE: The DPF lamp must be illuminated be-fore the regen switch will initiate a parkedregen.

To initiate a parked regeneration, perform the follow-

ing steps.

1. Park the vehicle away from all combustible andflammable materials. Chock the tires. Start andwarm the engine until the coolant temperature isat least 150°F (66°C).

2. Set the parking brake. If the parking brake wasalready set, it must be released, then set again.

For manual transmissions, fully depress theclutch pedal, put the transmission in neutral, thenrelease the pedal.

If the vehicle has a two-pedal automated trans-mission, shift it into gear, then back to neutral.

IMPORTANT: The driver must remain with thevehicle during the entire regen cycle.

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

4. The regen cycle will finish after 20 to 60 minutes,at which time engine idle speed will drop to nor-mal and the vehicle can be driven normally. The

f080147

EXHAUST AFTERTREATMENT SYSTEM INFORMATION

Switch.

Level 1 Level 3Level 2 Level 4Filter RegenerationRecommended

Filter is reaching

Bring vehicle tohighway speeds to

Filter RegenerationNecessary

Filter is nowreaching maximumcapacity.

To avoid enginederate bring vehicle

Parked RegenerationRequired − EngineDerate

Filter has reachedmaximum capacity.

Vehicle must beparked and a Parked

Parked Regeneration Required −Engine Shut Down

Filter has exceededmaximum capacity

Vehicle must be parked and aParked Regeneration or Service

(Solid) (Flashing) (Flashing)

CHECK CHECK

(Flashing)

INDICATORLAMP(S)

Indicator LampMessage(s)

Diesel ParticulateFilter Condition

Required Action

capacity. .

STOP

See Engine Operator’s Manual for complete Regeneration Instructions.

allow for an AutomaticRegeneration orperform a ParkedRegeneration.

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

Regeneration mustbe performed −engine will beginderate.

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

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

06/29/2009

24−01583−000B

WARNING

HEST (High ExhaustSystem Temperature)

Exhaust Componentsand exhaust gas areat high temperature. When stationary, keepaway from people andflammable materialsor vapors.

A regeneration is inprogress.

Flashing

Solid

Fig. 11.19, Exhaust-Aftertreatment Warnings Reference Label

f61119906/19/2012

Fig. 11.20, Regen Switch

Front-Engine Diesel Chassis

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HEST lamp may be illuminated, but will go outwhen the vehicle speed exceeds 5 mph (8 km/h),or the system has cooled to normal operatingtemperature.

5. To stop a parked regen at any time during theprocess, engage the clutch, brake, or acceleratorpedal, or turn off the engine.

Shorting Plug

NOTE: The DPF lamp must be illuminated be-fore the shorting plug will initiate a parkedregen.

The shorting plug is used to initiate a parked regenof the ATD. The shorting plug is located under thedash, next to the steering column. Mounting locationsvary. See Fig. 11.21.

To initiate a parked regeneration, perform the follow-ing steps.

1. Park the vehicle away from all combustible andflammable materials. Chock the tires. Start andwarm the engine until the coolant temperature isat least 150°F (66°C).

2. Set the parking brake. If the parking brake wasalready set, it must be released, then set again.

For manual transmissions, fully depress theclutch pedal, put the transmission in neutral, thenrelease the pedal.

If the vehicle has a two-pedal automated trans-mission, shift it into gear, then back to neutral.

IMPORTANT: The driver must remain with thevehicle during the entire regen cycle.

3. Disconnect the shorting plug, as follows.

3.1 Slide the secondary red lock away fromthe white cover. See Fig. 11.21, Ref. 2.

3.2 Push the primary lock in. See Fig. 11.21,Ref. 1.

3.3 Pull the plug apart. See Fig. 11.21, Ref. 3.

4. Wait four seconds.

5. Connect the shorting plug.

6. Engine rpm will rise, and initiate the regen pro-cess.

7. The regen cycle will finish after 20 to 60 minutes,at which time engine idle speed will drop to nor-mal and the vehicle can be driven normally. TheHEST lamp may be illuminated, but will go outwhen the vehicle speed exceeds 5 mph (8 km/h),or the system has cooled to normal operatingtemperature. The DPF light will shut off.

8. To stop a parked regen at any time during theprocess, engage the clutch, service brake, oraccelerator pedal, or turn off the engine.

DPF MaintenanceEventually ash will accumulate in the DPF and thefilter will require servicing. DPF servicing must beperformed by an authorized technician, following theengine manufacturer’s instructions. A record must bemaintained for warranty purposes, that includes:

• date of cleaning or replacement;

• vehicle mileage;

• particulate filter part number and serial number.

Diesel Exhaust Fluid and Tank,EPA10 and Newer EnginesDiesel Exhaust FluidDiesel exhaust fluid (DEF) is used in the ATS tolower NOx in the exhaust stream. DEF is colorlessand close to odorless (it may have a slightly pungentodor similar to ammonia). It is nontoxic, nonflam-mable, and biodegradable. It is mildly corrosive toaluminum, but does not affect the strength or struc-ture of the aluminum.

f54520702/11/2009

1

2

3

1. Primary Lock2. Secondary "Red" Lock

3. Plug

Fig. 11.21, Shorting Plug

Front-Engine Diesel Chassis

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White crystals may be noticeable around compo-nents that come into contact with DEF. The crystalsare easily removed with water.

DEF consumption varies depending on ambient con-ditions and vehicle application.

Freezing ConditionsDEF freezes to slush at around 12°F (-11°C). It is notdamaged or destroyed if frozen, and is fully usablewhen thawed. The DEF in the tank is allowed tofreeze while a vehicle is non-operational. At start-up,normal operation of the vehicle is not inhibited if theDEF is frozen; an immersion heater with engine cool-ant flowing through it warms the DEF once the en-gine is running, allowing the SCR system to operate.

Pre-2013 DEF supply lines are electrically-heatedand are purged when the engine is shut down; com-plete purging of the DEF lines requires approximatelyfive minutes after the engine is shut down.

DEF supply lines with engine model year 2013 andnewer are designed to survive freezing conditionswhile containing DEF, so purging is not required.

DEF TankEngines that are compliant with EPA10 and newerregulations are equipped with a DEF tank locatedforward of the ATS. See Fig. 11.22. The DEF tankhas a 19 mm filler neck inlet that prevents the hosefrom a diesel outlet from being inserted, and has ablue cap for easy identification.

The DEF tank has a 10-gallon capacity and will re-quire filling a minimum of approximately every sec-

ond diesel refuel. DEF consumption is approximately2% of fuel consumption, dependent on vehicle opera-tion. For every 50 gallons of diesel fuel consumed,approximately 1 gallon of DEF will be consumed.

Fuel/DEF GaugeThe fuel and DEF levels are measured in a dual pur-pose fuel/DEF gauge. See Fig. 11.23.

Fuel level is indicated at the top of the gauge. Belowthe fuel level, a low fuel warning lamp illuminatesamber when the fuel level drops below 1/8th of thecapacity.

The lower portion of the gauge has a DEF warninglamp that illuminates when the DEF tank is nearempty, and a DEF lightbar that indicates the level inthe DEF tank as follows.

• Four bars illuminated green—Between 75%and 100% full

• Three bars illuminated green—Between 50%and 75% full

• Two bars illuminated green—Between 25%and 50% full

• One bar illuminated green—Between approxi-mately 10% and 25% full

• One bar illuminated amber—DEF very low, re-fill DEF

• One bar flashing red—DEF empty, refill DEF

DEF Warnings and Engine LimitsIMPORTANT: Ignoring the DEF warning lightsand not refilling the DEF will result in limited en-gine power with a speed limit of 5 mph (8 km/h)eventually being applied. See the Cummins Op-eration and Maintenance Manual for further in-formation.

DEF Level Low—Initial and CriticalWarningsWhen the DEF level reads low the following warningsstrongly encourage the driver to refill the DEF tank.See Fig. 11.24.

• The DEF warning lamp illuminates constantly(initial warning).

• The DEF warning lamp flashes (critical warn-ing).

• DEF-level lightbar illuminates solid amber.

06/28/2012 f490471

1 2

3

1. ATS2. DEF Tank

3. DEF Gauge (optional)

Fig. 11.22, DEF Tank With Optional DEF Gauge

Front-Engine Diesel Chassis

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DEF EmptyWhen the DEF level reads empty, the followinglamps notify the driver. See Fig. 11.25.

• One bar of the DEF-level indicator flashes red.

• The DEF warning lamp flashes amber.

• The CHECK engine lamp illuminates.

Engine performance is limited, with progressivelyharsher engine power limits applied.

The DEF tank must be filled to cancel the warningsequence.

DEF Level Empty and IgnoredIf the empty warning is ignored and the DEF is notrefilled, the red STOP engine lamp illuminates in ad-

dition to the DEF warning lamp and the CHECK en-gine warning lamp. See Fig. 11.26.

If the DEF tank is not refilled, a 5 mph (8 km/h)speed limit will be applied after the next engine shut-down, or while parked and idling.

DEF Quality or SCR Tampering

NOTICEOnce contaminated DEF or tampering has beendetected in the SCR system, the vehicle must betaken to an authorized service center to checkthe SCR system for damage, and to deactivatethe warning light and engine limits.

11/08/2010 f611037

B

1/2ULTRA LOW SULFURDIESEL FUEL ONLY

E F

DEF

FE

1/2ULTRA LOW SULFURDIESEL FUEL ONLY

E F

DEF

FE

1/2ULTRA LOW SULFURDIESEL FUEL ONLY

E F

DEF

FE

A C

1 2

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

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

1. Low Fuel Warning Lamp (amber at 1/8 tank of fuel) 2. Low DEF Warning Lamp

Fig. 11.23, Fuel/DEF Gauge

A

B

07/09/2009 f470537

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

Fig. 11.24, DEF Level Low Initial and Critical Warnings

A

B

07/09/2009 f470538

NOTE: Engine power is limited.A. DEF Warning Lamp (flashing amber)B. DEF-Level Lightbar (1 bar flashing red)

Fig. 11.25, DEF Empty Warning

Front-Engine Diesel Chassis

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If contaminated DEF or tampering is detected, theDEF warning light flashes, and engine power is lim-ited with progressively harsher limits applied. If thefault is not corrected, the STOP engine light illumi-nates and a 5 mph (8 km/h) speed limit is appliedafter the next engine shutdown, or while parked andidling. See Fig. 11.26.

Allison AutomaticTransmissions

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

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

1000/2100/2200/2350 MH ModelsGeneral InformationThe Arens shift-by-wire (SBW) push-button shift se-lector is part of an electronic shift control systemused with Allison series 1000/2100/2200/23505-speed automatic transmissions. An electronic ac-tuator is mounted on the transmission.

The 1000/2200/2350 series transmission has a parkpawl and the SBW selector has a Park (P) position.The 2100 series transmission has a park brake (Pb)button. See Fig. 11.27 and Fig. 11.28.

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

Transmission Operation1. At the top left side of the selector, is the select

display. On the left side of the display window,an LED character indicates which gear has beenselected.

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

A

B

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NOTE: The STOP engine, CHECK engine, and DEFlamps illuminate, engine power is limited, speed limit of5 mph (8 km/h).A. DEF Warning Lamp (flashing amber)B. DEF-Level Lightbar (1 bar flashing red)

Fig. 11.26, DEF Empty and Ignored Warning

MONITOR

SELECT

SERVICE

R

N

P

D

MODE

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

!

ARENS CONTROLS

04/02/2003 f270122

1

2

3

4

5

8

12

13

6

14

7

1011

9

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

Window

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

Fig. 11.27, SBW Shift Selector (1000/2200/2350 series)

Front-Engine Diesel Chassis

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

NOTE: Only the 1000/2200/2350 MH modeltransmissions have a park pawl and a Park (P)button.

3. The Park (P) button shifts the transmission toNeutral (N) and engages the park pawl. WhenPark (P) is selected, the monitor side of the dis-play window will show a letter P.

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

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

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

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

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

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

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

MONITOR

SELECT

SERVICE

R

N

Pb

D

MODE

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

!

ARENS CONTROLS

f270122a

1

2

3

4

5

8

12

13

6

14

7

1011

9

10/25/2005

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

Button6. Select Display7. Select/Monitor Display

Window

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

Fig. 11.28, SBW Pushbutton Shift Selector with ParkBrake (Pb) Button (2100 series)

Front-Engine Diesel Chassis

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

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

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

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

NOTICETo prevent transmission and axle damage, makesure the automatic transmission is in high rangewhen performing an axle shift with the vehiclemoving.

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

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

Hydraulic Brake SystemGeneral InformationThe hydraulic brake system includes a powerbooster, master cylinder, reservoir, hydraulic lines, abrake rotor on each wheel hub, and a brake caliperand pad assembly at each rotor. See Fig. 11.29.

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

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

The master cylinder controls braking power to thefront and rear brakes. The Bendix Hydro-Max®power booster is attached to the rear of the mastercylinder and is connected to the power steering sys-tem (which provides pressurized power steeringfluid). An electrically powered "reserve" pump oper-ates if there is inadequate fluid flow from the powersteering pump to the power booster. The brake sys-tem warning light comes on if there is a problemwithin the system. Bring the vehicle to a safe stopand correct the problem before continuing operationof the vehicle.

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

07/31/2015 f460513b

A

B

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

Fig. 11.29, Hydraulic Brake Reservoir

Front-Engine Diesel Chassis

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applications, the standard hydraulic brake system isin effect.

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

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

The electronic control unit also has a safety circuitthat constantly monitors the wheel sensors, brakepressure modulator, and the electrical circuitry. Thedash warning light (ABS) comes on after the ignitionis switched on. Once the vehicle moves faster thanabout 4 mph (6 km/h), the warning light goes outonly if all the vehicle’s ABS components are working.

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

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

During emergency or reduced-traction stops,fully depress the brake pedal until the vehiclecomes to a safe stop; do not pump the brakepedal. With the brake pedal fully depressed, theABS system will control all wheels to providesteering control and a reduced braking distance.

Although the ABS system improves vehicle controlduring emergency braking situations, the driver stillhas the responsibility to change driving styles de-pending on the existing traffic and road conditions.For example, the ABS system cannot prevent an ac-cident if the driver is speeding or following tooclosely on slippery road surfaces.

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

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

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

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

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

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

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

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

• Shifting directly from "Pb" to "N" does not re-lease the parking brake. "Pb" must be de-pressed, then a drive gear must be selected to

Front-Engine Diesel Chassis

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release the parking brake. The "BRAKE" warn-ing light will flash and a chime will sound whenthis procedure is performed.

Front-Engine Diesel Chassis

11.21

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12

Pre- and Post-TripChecklists

Pretrip and Post-Trip General Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12.1Daily Pretrip Inspection and Maintenance Checklist . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12.1Weekly Post-Trip Inspection and Maintenance Checklist . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12.3Monthly Post-Trip Inspection and Maintenance Checklist . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12.3

Page 123: Recreational Vehicle Chassis Operator's Manual

Pretrip and Post-Trip GeneralInformationRegulations in both Canada and the United Statesclearly indicate that it is the driver’s responsibility toperform an inspection and ensure the complete road-worthiness of a vehicle before placing it into servicefor the day.

IMPORTANT: The pre- and post-trip checklists,and inspections and maintenance proceduresdetailed in this chapter, are not all-inclusive.Also refer to other component and body manu-facturers’ instructions for specific inspection andmaintenance instructions.

Use the pretrip inspection checklist to ensure thatvehicle components are in good working conditionbefore each trip. Use the weekly and monthly post-trip inspection checklists to note any items that re-quire attention before the next trip. A driver that isfamiliar with the vehicle, and drives it regularly, canperform the daily inspections, then add the weeklyand monthly post-trip inspections as scheduled. If thedriver does not operate the vehicle on a consistentbasis, all three of the inspection procedures shouldbe performed before the trip.

Pre- and post-trip inspections cannot be donequickly. However, careful inspections save time byeliminating stops later to adjust items overlooked orforgotten.

Numbers in parentheses within each of the checklistsreference the corresponding detailed instructionsfound under "Daily (D), Weekly (W), or Monthly (M)Procedures" in Chapter 13.

If any system or component does not pass this in-spection, it must be corrected before operating thevehicle. Whenever equipment requires adjustment,replacement, repair, addition of lubricants, or achange of lubricants, take the vehicle to an autho-rized Freightliner dealer for assistance.

Daily Pretrip Inspection andMaintenance ChecklistIMPORTANT: Before performing any of thesechecks, apply the parking brake and chock thetires.

For the daily pretrip inspection and maintenancechecklist see Table 12.1.

Pre- and Post-Trip Checklists

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Procedure Performed(check off)

Daily Pretrip Inspections/ChecksProcedureReference

_______ Drain manually drained air reservoirs (that are not equipped with automatic drainvalves) D1

Check _______ windshield washer reservoir fluid D2Inspect _______ wheel seal and hub cap (for leakage) –Check _______ surge tank coolant level D3Check _______ radiator and charge air cooler D4Inspect _______ engine and chassis wiring D5Inspect _______ air intake system D6Inspect _______ intake-air restriction indicator mounted on air intake D6Check _______ engine oil level D7Check _______ power steering fluid level D8Check _______ fuel tank(s), fuel lines, and connections D9Check _______ fuel level D10Inspect _______ fuel/water separator D11Check _______ front and rear suspension components D12Check _______ headlights, mirrors, and window glass, and windshield wipers D13Check _______ doors (open without difficulty and close securely) –

_______ Adjust driver’s seat, then align rearview and downview mirrors –Check _______ dash-mounted intake-air restriction indicator D6Check _______ oil- and air-pressure warning systems D14Check _______ instrument panel warning lights D15Check _______ ICU fault codes (front-engine diesel chassis) D15Check _______ horn, windshield wipers, and windshield washer D16Inspect _______ heater, defroster, and optional mirror heat controls D17Check _______ panel lights and interior lights D18Check _______ exterior lights and reflectors D19Check _______ tire pressure D20Check _______ tire condition D20Check _______ rims and wheels D21Check _______ automatic transmission fluid level D22Inspect _______ air brake chambers and pushrods D23Inspect _______ air brake lines D24Inspect _______ slack adjusters D25Inspect _______ air brake system operation D26Check _______ frame rails (missing bolts), crossmembers (bent or loose) –Check _______ Bendix Hydro-Max® brake booster (front-engine diesel chassis) D27

Check _______ mud flaps (aren’t damaged, at least 10 inches above the ground, and bracketsare secure) –

Check _______ exhaust system (mounted securely, connected tightly, no signs of leaks such assoot trails) –

_______ Remove chocks and test service brakes D28

Inspector___________________________________________________ Date ________________

Table 12.1, Daily Pretrip Inspection and Maintenance Checklist

Pre- and Post-Trip Checklists

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Weekly Post-Trip Inspectionand Maintenance ChecklistBefore performing any of these checks, applythe parking brake and chock the tires.

For the weekly post-trip inspection and maintenancechecklist see Table 12.2.

Procedure Performed(check off)

Weekly Post-Trip Inspections/ChecksProcedureReference

_______ Manually drain air reservoirs that are equipped with automatic drain valves —Inspect _______ batteries and battery cables W1Check _______ wheel bearing lubricant level W2Inspect _______ steering components W3Check _______ drive belt condition W4

Inspector___________________________________________________ Date ________________

Table 12.2, Weekly Post-Trip Inspection and Maintenance Checklist

Monthly Post-Trip Inspectionand Maintenance ChecklistBefore performing any of these checks, applythe parking brake and chock the tires.

For the monthly post-trip inspection and maintenancechecklist see Table 12.3.

Procedure Performed(check off)

Monthly Post-Trip Inspections/ChecksProcedureReference

_______ Clean the battery terminals M1Inspect _______ radiator hoses and heater hoses M2

Check _______ fluid level in the hydraulic clutch reservoir (if applicable, and if necessary, fill withDOT 3 brake fluid) —

Check _______ steering wheel play M3Check _______ outer surfaces of the body (for visible surface breaks and damage) —Check _______ hood tilt damper (attached at both ends) —Inspect _______ brake lining wear M4Inspect _______ driveshaft —Inspect _______ (and lubricate if needed) Meritor Roller Pins; inspect the brake shoes M5

Inspector___________________________________________________ Date ________________

Table 12.3, Monthly Post-Trip Inspection and Maintenance Checklist

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13

Pre- and Post-TripInspections and

MaintenanceSafety Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13.1Daily Pretrip Inspection and Maintenance Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13.1Weekly Post-Trip Inspection and Maintenance Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13.12Monthly Post-Trip Inspection and Maintenance Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13.13

Page 127: Recreational Vehicle Chassis Operator's Manual

Safety Precautions

DANGERWhen working on the vehicle, shut down the en-gine, set the parking brake, and chock the tires.Before working under the vehicle, always placejack stands under the frame rails to ensure thevehicle can not drop. Failure to follow thesesteps could result in serious personal injury ordeath.

Daily Pretrip Inspection andMaintenance ProceduresWhenever equipment requires adjustment, replace-ment, and/or repair, take your vehicle to an autho-rized Freightliner dealer for assistance.

1. Drain manually drained brake system air reser-voirs.

Water and oil normally enter the air reservoir inthe form of vapor because of the heat generatedduring compression. After the water and oil con-dense, drain the resulting emulsion as follows:

1.1 Open the wet tank valve. The drain cockor lanyard is located on the forward end ofthe supply air reservoir, which is con-nected directly to the air compressor.Block the valve open.

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

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

1.2 Exhaust the remaining air and moisturefrom the system by opening the draincocks on the bottoms of the remaining airreservoirs, or pull the lanyard(s) until theair is exhausted.

1.3 Water and oil emulsion often form pocketsthat will not drain while compressed air isin the reservoirs. Because of these pock-ets, leave the valves blocked open duringthe first part of the pretrip inspection.

1.4 If the drained water is cloudy or oily, itmay indicate a problem with the compres-sor. If oil is allowed to contaminate the airdryer, it will not remove the water from theair brake system, which could adverselyaffect braking.

2. Check the fluid level in the windshield washerreservoir.

Add washer fluid as needed.

WARNINGWasher fluids may be flammable and poisonous.Do not expose washer fluid to an open flame orany burning material, such as a cigarette. Alwayscomply with the washer fluid manufacturer’s rec-ommended safety precautions.

3. Check the coolant level in the surge tank.

See Fig. 13.1. If the coolant is low, add a 50/50mixture of water and antifreeze. Refer to the en-gine manufacturer’s service literature for ap-proved coolants. Fill the surge tank with coolantto the MAX line when the tank is cool. If thesurge tank was empty, start the engine after re-filling and check the level again when the engineis at operating temperature.

05/31/2007 f200705

Fig. 13.1, Surge Tank Fill Cap

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

4. Inspect the radiator and charge air cooler.

4.1 Inspect the radiator and charge air coolerfor clogged fins. Use compressed air orwater directed from the fan side of thecore to backflush any material restrictingairflow.

4.2 Inspect the radiator and charge air coolerfor damage and accumulated debris.Straighten bent or damaged fins to permitairflow across all areas of the cores.

NOTE: When traveling through areas of highinsect concentration, it may be necessary toclean the exterior of the radiator or thecharge air cooler core as often as every 200miles (320 km).

4.3 Also inspect and clean the condenser. Ifclogged, the condenser can restrict airflowthrough the radiator.

4.4 Check the radiator for leaks. If leaks arefound, have the radiator repaired or re-placed. Take the vehicle to an authorizedFreightliner dealer for assistance.

5. Inspect the engine and chassis wiring.

Check for loose wiring, chafed insulation, anddamaged or loose hold-down clamps. Tightenloose wires or hold-down clamps; replace dam-aged wiring or clamps.

6. Inspect the air intake system for leaks or dam-age.

NOTICEFailure to maintain a sealed air intake systemcould allow the entry of dirt and contaminantsinto the engine. This could adversely affect en-gine performance and result in engine damage.

6.1 Check the intake-air restriction indicator todetermine if the air cleaner needs to bechanged. See Fig. 13.2.

6.2 If the yellow signal stays locked in the redzone once the engine is shut down, or isat or above the maximum restriction value

in Table 13.1, replace the air cleaner ele-ment. Take the vehicle to an authorizedFreightliner dealer for assistance.

Air Intake Maximum Restriction Values (inH2O)

Engine Make EPA07 andEPA10 Engines

GHG14 andGHG17 Engines

Cummins 25 25Detroit 22 18

Table 13.1, Air Intake Maximum Restriction Values

NOTE: After replacing the filter element,reset the restriction indicator by pressing therubber reset button.

6.3 Inspect the air cleaner, and replace itwhen it becomes clogged or dirty.

6.4 Check the engine air intake piping fromthe air cleaner to the engine intake. In-spect the piping for loose connections,cracks, torn or collapsed hoses, punc-tures, and other damage. Tighten looseconnections, and have damaged compo-nents replaced. Make sure the piping sys-tem is airtight so that all intake air passesthrough the air cleaner. Engine damagecan occur if the air intake system is notproperly maintained.

7. Check the engine oil level.

PUSH TO RESET

H 0 VACUUM225201510

7

IN H 0 VACUUM2

f09017605/22/97

Fig. 13.2, Air Restriction Indicator

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NOTICEOperating the engine with the oil level below theminimum fill (or "add") mark or above the maxi-mum fill (or "full") mark could result in enginedamage.

7.1 Park the vehicle on a level surface. Allowseveral minutes for the oil to drain backinto the oil pan to ensure an accuratereading.

NOTE: Follow the engine manufacturer’sguidelines for engine shutdown time require-ments prior to checking the oil level.

7.2 Pull out the dipstick and clean it with apaper towel or cloth, then push the dip-stick back in all the way. Remove it again,keeping the tip down, and check the oillevel.

7.3 If the oil is below the cross-hatched area,or the add mark, at the tip of the dipstick,add at least one quart (liter) of the recom-mended oil. See Fig. 13.3.

For diesel engines that comply withEPA07 or newer regulations, use CJ-4engine oil with less than 1% sulfated ash.

NOTICEFailure to use the recommended oil can result inengine or aftertreatment component damage andwill void the warranty.

8. Check the fluid level in the steering system hy-draulic fluid reservoir. See Fig. 13.4.

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

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

9. Inspect the fuel tanks, fuel lines, and connectionsfor leaks.

Replace leaking fuel tanks; repair or replace anymechanisms, lines, or connections that are leak-ing. Take the vehicle to an authorized Freightlinerdealer for assistance.

10. Check the fuel level in the fuel tank(s). To keepcondensation to a minimum, fuel tanks should befilled at the end of each day. Federal regulationsprohibit filling a fuel tank to more than 95 percentof its liquid capacity. Select the proper grade offuel as specified by the engine manufacturer.

WARNINGNever fill fuel tanks to more than 95 percent oftheir liquid capacity. This could make them morelikely to rupture from impact possibly causingfire and resulting in serious personal injury anddeath by burning. Do not mix gasoline or alcoholwith diesel fuel. This mixture could cause an ex-plosion, possibly resulting in serious personalinjury or death. Do not fill the fuel tanks in thepresence of sparks, open flames, or intense heat.These could ignite the fuel, possibly causing se-vere burns.

IMPORTANT: Use ultralow-sulfur diesel (ULSD)fuel with 15 ppm sulfur content or less, basedon ASTM D2622 test procedure. Failure to useultralow-sulfur diesel fuels may void the war-ranty on emission components.

NOTICEWater in the fuel/water separator will appear asbeads. With the engine off, drain the separator

10/26/2012 f012203

FULL ADD 2 QT

Fig. 13.3, Oil Dipstick

MAX

Min

04/10/97 f461177

Fig. 13.4, Steering System Hydraulic Fluid Reservoir

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only enough to remove the water; about two tea-spoons at a time. Do not drain the separatorcompletely or it will be necessary to prime thefuel system before the vehicle may be startedagain.

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

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

11.1 Shut off the engine.

11.2 Remove the fuel cap.

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

11.4 Close the drain and install the fuel cap.

11.5 Run the engine and check for leaks.

12. Inspect the front and rear suspension compo-nents, including springs, spring hangers, shocks,and suspension brackets.

12.1 Check for broken spring leaves, looseU-bolts, cracks in the suspensionbrackets, and loose fasteners in the springhangers and shackles.

12.2 Inspect the shock absorbers for loose fas-teners and leaks.

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

12.4 On vehicles with air suspensions, checkfor leaks. Check air suspension compo-nents for cuts and bulges.

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

13. Clean the windshield, side, and rear windowswith a long-handled or telescoping window clean-ing device and standard cleaning solutions.Stand only on the ground, on a stepladder, or anelevated walkway. The vehicle entry/exit stepsand handholds are not designed for this purpose.The tires, fenders, engine, and other under-hoodcomponents do not have adequate gripping sur-faces and handholds.

Check the condition of the windshield wiper armsand blades.

Be sure the windshield wiper blades are ten-sioned against the windshield.

Inspect the wiper blades for damage and deterio-rated rubber.

Replace the wiper arms if the wiper blades arenot tensioned against the windshield.

Replace damaged or deteriorated wiper blades.

WARNINGWhen cleaning windshields and windows, alwaysstand on the ground or on a secure ladder orplatform. Use a long-handled window cleaner. Donot use the cab steps, tires, fenders, fuel tanks,engine, or under-hood components to access thewindshield or windows. Doing so could cause afall and result in an injury.

Replace wiper arms and blades when necessaryto maintain good visibility. Poor visibility couldinterfere with the driver’s ability to control thevehicle, possibly resulting in serious personalinjury or death.

14. Check the oil- and air-pressure warning systems.

When the engine is started, oil- and air-pressurewarnings will come on until the oil and air pres-sure rise above a preset minimum. After startingthe engine, make sure the oil- and air-pressurewarning systems are operating and that thebuzzer stops sounding when the preset minimumis reached.

14.1 If the warning systems do not come onwhen the ignition is turned on, have thesystems repaired.

14.2 If the air pressure in both systems isabove the preset minimum when the en-gine is started, test the low air pressurewarning system by repeatedly pumping

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the brake pedal to lower the pressure tobelow this range, or until the warning sys-tem comes on.

NOTE: The air pressure in both the primaryand secondary air reservoir systems mustbe above 65 psi (448 kPa) on most vehicles.

15. Check the instrument panel warning lights. Dur-ing the ignition sequence, if any warning lightsremain on, see Chapter 5 for detailed instruc-tions on warning lights.

For Front-Engine Diesel Chassis, check the in-strumentation control unit (ICU) for fault codes.

During the ignition sequence, if an active fault isdetected in any device that is connected to thedatalink, the message display screen will showthe active fault codes, one after the other untilthe parking brake is released or the ignitionswitch is turned off. See Chapter 11 for detailedoperating instructions for the ICU.

16. Make sure that the horn, windshield wipers, andwindshield washers are operating properly.These devices must be in good working order forsafe vehicle operation.

16.1 Make sure that the horn works. If a horn isnot working, have it repaired before tripdeparture.

16.2 Check the wiper and washer control onthe multifunction turn signal switch. If thewipers and/or washers are not working,have them repaired before trip departure.

17. During cold weather; make sure the heater, de-froster, and optional mirror heat controls are op-erating properly. If so equipped, turn on the mir-ror heat switch and make sure the system isworking.

18. Check the operation of all the panel lights andinterior lights.

Turn on the headlights, dash lights, and four-wayflashers and leave them on. If any of the gaugebulbs, the dome light bulbs, or the right- and left-turn indicator bulbs are not working, replacethem.

19. Make sure all the exterior lights are workingproperly. Check that all the lights and reflectorsare clean.

19.1 Check that the brake lights, taillights,headlights, parking lights, turn signals,road lights (if so equipped), and frontclearance lights are working properly andare clean.

19.2 Test the high and low beams of the head-lights.

19.3 Replace the light bulbs or sealed beamunits that are not working. Refer to thebody builder book for light bulb replace-ment.

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

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

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

20.1 Check the inflation pressures of the tiresbefore each trip, using an accurate tirepressure gauge. See Fig. 13.5. Check tirepressures when the tires are cool. Themaximum inflation pressure for each tire isprovided on the outer wall of the tire. In-flate the tires to the applicable pressures,if needed. Be sure that valve stem capsare used on every tire, and that they arescrewed on finger-tight.

See either the Michelin Recreational Ve-hicle Tire Guide or Goodyear ServiceManual for correct tire inflation pressuresfor the vehicle load.

Overinflation gives the treaded surface ofthe tire a convex shape. See Fig. 13.6.This causes premature tire wear in themiddle part of the tire since this section isprimarily in contact with the road.

Underinflation gives the tread surface aconcave shape. See Fig. 13.6. Thiscauses excessive tire wear on the outer

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edges of the tire since those edges areprimarily in contact with the road.

WARNINGDo not operate the vehicle with underinflated oroverinflated tires. Incorrect inflation can stressthe tires and make the tires and rims more sus-ceptible to damage, possibly leading to rim ortire failure and loss of vehicle control, resultingin serious personal injury or death.

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

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

IMPORTANT: Low-rolling resistance (LRR)tires minimize wasted energy as a tire rolls,thereby decreasing rolling effort and improv-ing fuel efficiency. If tire replacement is nec-essary, replacement tires must meet or ex-ceed the rolling resistance of the originallyinstalled tires in order to maintain compli-ance with greenhouse gas and fuel effi-ciency regulations (GHG14).

Contact your tire manufacturer/supplier todetermine the rolling resistance of the origi-nally installed tires. Visit www.epa.gov/smartway for additional information and re-sources.

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

IMPORTANT: Only use temporary resealingor reinflation products that are water solubleand state that they do not adversely affectthe operation of the tire pressure sensor(s),if so equipped.

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

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

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

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

WARNINGOn vehicles equipped with ZF independent frontsuspension (IFS) and ZF SB 7000 front air disc

f40006111/03/94

Fig. 13.5, Checking Tire Pressures

A B C11/03/94 f400062a

A. Tire correctly inflatedB. Tire overinflated

C. Tire underinflated

Fig. 13.6, Checking Tire Inflation

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

21. Check the wheel nuts for indications of loose-ness. Examine each wheel component.

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

Examine the wheel assembly components (in-cluding studs and nuts) for cracks or other dam-age.

WARNINGHave any worn or damaged wheel componentsreplaced by a qualified person using the wheelmanufacturer’s instructions and the wheel indus-try’s standard safety precautions and equipment.Otherwise a vehicle or workshop accident couldoccur, possibly resulting in serious personal in-jury or death.

22. Check the fluid level in the automatic transmis-sion. See Fig. 13.7 and Fig. 13.8.

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

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

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

22.3 Wipe the dipstick clean and check thefluid level. A safe operating level is anylevel within the HOT run (upper) band onthe dipstick. See Fig. 13.9.

22.4 If the fluid is not within this range, add ordrain fluid as needed to bring the level tothe top of the HOT run band. SeeTable 13.2 for fluid types and capacities.

Transmission Lubricant CapacitiesSeries Refill Capacity*†

1000, 2000 16.0 (15.1)3000, 4000 MH 17.5 (16.5)* Quantities listed are approximate. Add the recommended amount offluid as listed under refill capacity, then perform a "hot check" and addfluid as needed. Do not overfill.† Some Allison 3000 MH transmissions have a deeper oil sump than

other models. These models require 3 additional quarts (2.8 L) of auto-matic transmission fluid (ATF).

Table 13.2, Transmission Lubricant Capacities

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

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

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

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f350162a

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1. Coolant Reservoir2. Transmission Fluid Dipstick3. Hydraulic Reservoir

Fig. 13.7, Transmission Fluid Level Check

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

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

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

23. Inspect the air brake components including thebrake chamber pushrod, air reservoirs, and airlines.

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

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

f544667

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1. Coolant Reservoir2. Engine Oil Fill

3. Engine Oil Dipstick4. Transmission Fluid Dipstick

5. Hydraulic Fluid Reservoir

Fig. 13.8, Transmission Fluid Level Check (front-engine diesel chassis)

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A

B

f270002a

A. Cold Run Band B. Hot Run Band

Fig. 13.9, Automatic Transmission Dipstick Markings

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

If there is a leak, the hose should be replaced.Take your vehicle to an authorized Freightlinerdealer for assistance.

Look for worn clevis pins on brake chamberpushrods and missing or damaged cotter pins onthe brake chamber pushrods clevis pins. Replaceworn clevis pins and install new cotter pins ifnecessary.

Visually inspect the piston rod engagement withthe clevis. At least 7 threads of engagement arerequired; there should be 1 inch (25 mm) ofclearance from the centerline of the clevis pinhole to the end of the piston rod. See Fig. 13.10.Take your vehicle to an authorized Freightlinerdealer for assistance.

See if the chamber piston rod is in line with theslack adjuster. Misalignment can cause the pis-ton rod to rub on the non-pressure chamber andcause a dragging brake. Take your vehicle to anauthorized Freightliner dealer for assistance.

Visually inspect the exterior surfaces of thechamber for damage. Make sure that breatherholes in the non-pressure section(s) are openand free of debris. Take your vehicle to an autho-rized Freightliner dealer for assistance.

Inspect the air lines as follows.

23.1 Check the clearance between the hoses,exhaust manifold, and turbocharger, orother hot spots. Excessive heat will causethe material in the hoses to deterioraterapidly or become brittle. Provide at least6 inches (152 mm) of clearance. Moreclearance is recommended if the hose islocated above the heat source.

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

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

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

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

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

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

23.7 Check the bend radii of all hoses. SeeFig. 13.11. The minimum bend radius of ahose is that bend which the hose will with-stand without experiencing damagingstresses or kinking. For minimum bendradius values, take your vehicle to an au-thorized Freightliner dealer for assistance.

When a rubber hose bend does not meetminimum radius requirements, the outsidemay appear smooth even if the inner tube

f420225a

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

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

4. Cotter Pin5. Clevis Pin

Fig. 13.10, Piston Rod Engagement With the Clevis

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is kinked. Reroute the hose or replace itwith one of adequate length if the bendradius is not within minimumspecifications.

23.8 Check straight hose installations (thosehoses that do not bend along their rout-ing). Pressure changes can cause a hoseto lengthen up to 2 percent, or shorten upto 4 percent. A 100-inch (2540-mm) lengthof hose, for example, can contract to 96inches (2440 mm). If the hose has noslack when it is exhausted of air, replace itwith one of adequate length to avoid apossible blow-off from the fitting duringvehicle operation.

23.9 Check for kinked or twisted hoses. A 7percent twist in the hose can reduce itslife by up to 90 percent. Also, a twistedhose under pressure tends to untwist. Thiscould cause it to loosen the fitting. Recon-nect hoses that are twisted.

24. Inspect the air brake lines.

24.1 Check the clearance between the hosesand the exhaust manifold or other hotspots. Excessive heat will cause materialin hoses to deteriorate rapidly or becomebrittle. Provide at least 6 inches (152 mm)of clearance. More clearance is recom-mended if the hose is located above theheat source.

24.2 Check for kinks, dents, or swelling of thehoses. If damaged, have the hose re-placed with the same size and type.

NOTE: Do not route the hose on top of any-thing likely to be stepped on.

24.3 Check for damage to hoses located nearmoving parts, such as drivelines, kingpins,suspensions, and axles. If moving partsare catching or pinching the lines, correctas needed.

24.4 Check for hose damage caused by abra-sion. If abraded, have the hose replaced.Check for the cause of abrasion, such asloose or damaged hose clamps. Have theclamps repaired or replaced as needed.

24.5 Observe the hose cover condition, espe-cially hoses exposed to water splash andice. If dried out or ragged (the wire isshowing through the cover), have thehose(s) replaced.

24.6 Inspect the air tubing, especially tubingmade of nylon. In cold weather, nylon tub-ing is sensitive to damage, such as nicksor cuts. Have nicked or cut tubing re-placed, even if it is not leaking.

NOTE: The front brake lines flex continu-ously in vehicle operation, so they requirespecial examination. Give particular attentionto the areas near where they connect to thefront air brake chambers.

24.7 This inspection requires two people, onein the driver’s seat, and another to inspectthe brake line connections at the wheels.

Both wheel air lines must be inspectedwith the emergency brake set, engineidling, air pressure at 80 to 90 psi (550 to620 kPa), and the brake pedal held down.

24.8 Turn the wheels to full lock in one direc-tion and inspect both air lines where theyconnect to the air chambers, then turn thewheels to full lock in the other directionand inspect both lines. If a hose is leak-ing, have it replaced.

IMPORTANT: ABS-equipped vehicles operat-ing in regions where especially corrosive iceremoval chemicals are used may experiencehigher than normal rotor corrosion. Tonerings should be routinely inspected for corro-sion. Severe corrosion of the integral ABStone ring may cause the ABS warning lampin the dash to illuminate due to false wheelspeed readings. If the ABS warning lampilluminates at any time other than at vehicle

11/03/94 f420329aA

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

Fig. 13.11, Bend Radius

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start-up, have the problem repaired immedi-ately.

25. Inspect the slack adjusters.

Inspect the slack adjuster for any signs of dam-age. If damaged, have the slack adjuster re-placed.

Inspect the slack adjuster boot for cuts or tears.If the boot is damaged, have it replaced. Takeyour vehicle to an authorized Freightliner dealerfor assistance. See Fig. 13.12.

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

26. Check the air brake system for proper operation.

26.1 Check the air governor cut-in and cut-outpressures as follows:

Run the engine at fast idle. The air gover-nor should cut out the air compressor atapproximately 120 psi (827 kPa). With theengine idling, apply the brake pedal sev-eral times. The air governor should cut in

the air compressor at approximately 100psi (689 kPa). If the air governor does notcut in and cut out as described above, itmust be adjusted to these specifications. Ifthe air governor cannot be adjusted orrepaired, replace it before operating thevehicle.

26.2 Check the air pressure buildup time asfollows:

With the air system fully charged to 120psi (827 kPa), make one full brake appli-cation and note the air pressure readingon the gauge. Continue to reduce the airpressure by moderate brake applicationsto a maximum of 90 psi (620 kPa), thenrun the engine at governed rpm. If thetime required to raise the air pressure to120 psi (827 kPa) (from the pressurenoted after one brake application) is morethan 30 seconds, eliminate any leaks orreplace the air compressor before operat-ing the vehicle.

26.3 Check the air pressure reserve as follows:

With the air system fully charged to 120psi (827 kPa), stop the engine and notethe air pressure. Then make one full brakeapplication and observe the pressuredrop. If it drops more than 25 psi (172kPa), all areas of leakage must be elimi-nated before operating the vehicle.

26.4 Check the air leakage in the system asfollows:

With the parking brake (spring brake) ap-plied, the transmission out of gear, andthe tires chocked, charge the air systemuntil cut-out pressure of 120 psi (827 kPa)is reached.

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

Charge the air system until cut-out pres-sure of 120 psi (827 kPa) is reached. Withthe parking brakes released and the ser-vice brake applied, shut down the engine,wait one minute and note the air pressuregauge reading. Observe the air pressuredrop in psi (kPa) per minute.

f42139806/17/2003

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1. 7/16-inch Adjusting Nut2. Grease Fitting3. Boot4. Link5. Brake Chamber Piston Rod6. Clevis7. 1/2-inch Clevis Pin8. 1/4-inch Clevis Pin9. Grease Relief Opening10. Slack Adjuster Spline

Fig. 13.12, Gunite Automatic Slack Adjuster

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If leakage exceeds the limits shown inTable 13.3, repair all areas of leakage be-fore driving the vehicle.

Maximum Air Leakage Per MinuteBrakes Released Brakes Applied

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

Table 13.3, Maximum Allowable Service BrakeLeakage

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

27.1 With the ignition off, depress the brakepedal and listen for the back-up motor toengage. The operator should also feel thepedal force relieve and the pedal shoulddepress easily.

27.2 With the engine running, and the parkingbrake released; operator is to ensure thatthe BRAKE warning indicator light is noton. This is a dual indicator, and indicatesthat the parking brake is set, and warns ifthere is a Hydro-Max failure conditionother than loss of back-up motor power.

28. Test the service brakes.

When starting to move the vehicle and beforepicking up speed, test the brakes with the footpedal and parking brake control valve (yellowknob) to be sure they will bring the vehicle to asafe stop.

Weekly Post-Trip Inspectionand Maintenance Procedures1. Inspect the batteries and battery cables.

Access the batteries. Be sure the battery hold-down is secure. If it is loose, tighten the hold-down bolts; if it is broken, replace it.

Remove any corrosion from the hold-down andthe top of the battery. Use diluted ammonia or asoda solution to neutralize the acid present, thenrinse off the ammonia or soda solution with cleanwater.

If the battery posts or cable terminals are cor-roded, disconnect the terminals from the posts.Clean them with a soda solution and a wirebrush. After cleaning, connect the terminals tothe battery posts, then apply a thin coat of di-

electric grease to the posts and terminals to helpretard corrosion.

2. Check the level of the wheel bearing lubricant inthe hub cap at each end of the front axle. SeeFig. 13.13.

If needed, fill the hubs to the level indicated onthe hub cap. See Chapter 18 for recommendedlubricants.

IMPORTANT: Before removing the fill plug, al-ways clean the hub cap and plug.

3. Examine the steering components.

See Fig. 13.14. If repairs are needed, take yourvehicle to an authorized Freightliner dealer forassistance.

3.1 Check the mounting bolts and pitman armnut, for tightness.

3.2 Check the drag link nuts for missing cotterpins.

3.3 Inspect the steering drive shaft and steer-ing linkage for excessive looseness, orother damage.

3.4 Tighten loose nuts and have damagedparts replaced as needed.

4. Check the condition of the drive belt.

f330247b

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A. Hub Cavity Full1. Fill Plug/Magnetic Drain2. Drain Plug

Fig. 13.13, Oil-Filled Hub Cap

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Look for signs of wear (frayed edges) and dam-age (breaks or cracks). If a belt is worn or dam-aged, have the belt replaced. Take your vehicleto an authorized Freightliner dealer for assis-tance.

Monthly Post-Trip Inspectionand Maintenance Procedures1. Clean the batteries.

1.1 Remove any corrosion from the hold-downand the top of the battery. Use a soda so-lution to neutralize the acid present, thenrinse off the soda solution with cleanwater.

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

1.2 If the battery posts or cable terminals arecorroded, disconnect the terminals fromthe posts. Clean them with a soda solutionand a wire brush. After cleaning, connectthe terminals to the battery posts, then

apply a thin coat of petroleum jelly to theposts and terminals to help retard corro-sion.

WARNINGBattery posts, terminals, and related accessoriescontain lead and lead compounds, chemicalsknown to the State of California to cause cancerand reproductive harm. To prevent possible per-sonal injury, always wash your hands after han-dling battery parts and related accessories.

2. Inspect the radiator and heater hoses, includingthe clamps and support brackets.

2.1 Make sure the radiator inlet and outlethoses are pliable and are not cracking orballooning. Replace hoses that show signsof cracking, weakening, or ballooning.

2.2 Make sure the heater hoses are pliableand are not cracking or ballooning. Re-place hoses that show signs of cracking,weakening, or ballooning.

2.3 Tighten the hose clamps as necessary,but do not overtighten, as hose life can beadversely affected.

2.4 Be sure the hose support brackets aresecurely fastened. Make sure the hosesare not located near sources of wear,abrasion, or high heat.

IMPORTANT: Replace all hoses, includingheater hoses, at the same time. Service-typeknitted or braided yarn-reinforced neoprenehose is acceptable. Silicone hoses havingan extended service life can be substitutedfor the reinforced neoprene type. Contactyour local Freightliner dealer for assistance.

3. Check the steering wheel for excessive play. SeeFig. 13.15.

3.1 With the front tires straight ahead, turn thesteering wheel until motion is observed atthe front wheels. Hold the steering wheelin this position.

3.2 Align a reference mark on a ruler, thenslowly turn the steering wheel in the oppo-site direction until motion is again detectedat the wheels.

11/15/2000 f461825

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

Fig. 13.14, TRW Steering Gear Installation

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3.3 Determine the lash (free play) at the rim ofthe steering wheel. Excessive lash existsif steering wheel movement exceeds 2-1/4inches (57 mm) with an 18 inch (450 mm)steering wheel.

See local/federal regulations for accept-able ranges of lash.

4. Check the brake lining wear on all vehicles, in-cluding those with automatic slack adjusters.Proper brake operation is dependent on periodicmaintenance and inspection of the brake linings.

4.1 Check that brake linings are free of oil andgrease.

4.2 Inspect the thickness of the brake linings.If the axle assembly is equipped with adust shield or backing plate, remove theinspection plugs. If any brake linings areworn to less than approximately 1/4 inch(6.4 mm) at the thinnest point, have thelinings replaced on all brake assemblieson that axle. Take your vehicle to an au-thorized Freightliner dealer for assistance.

4.3 Check the brake drums for wear andcracks.

4.4 Check that the inspection plugs in the dustshields or backing plates, if so equipped,are installed.

5. Inspect brake shoe components and performMeritor Roller Pin lubricating, if needed, as fol-lows. See Fig. 13.16.

5.1 Check the anchor pins, rollers and bush-ing for lubricant and excessive debris.

5.2 If the parts are damaged in any way, re-place them.

5.3 While the brake is disassembled duringinspection, apply anchor pin grease withBentone thickeners, NLGI grade 1, Meritorspecification 0-616-A, 0-617-B or equiva-lent. See Fig. 13.16 for brake lubricationareas.

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A. Lash Area

Fig. 13.15, Measuring Lash at the Steering Wheel

f43049907/11/2008

B

C

B

A

A. Anchor Pins — lubricate grease fittings.B. Shoe Rollers— lubricate where pins touch the brake

shoes.C. Bushing — lubricate grease fittings.

Fig. 13.16, Meritor Roller Pin Lubrication Areas

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14

Cleaning and CareWashing and Polishing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14.1Wheel Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14.1Care of Chrome Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14.1Dashboard and Instrument Panel Care . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14.1

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Washing and PolishingTo protect the finish of your new vehicle, follow theseguidelines carefully:

• During the first 30 days, rinse your vehicle fre-quently with water. If the vehicle is dirty, use amild liquid soap. Do not use detergent.

• During the first 30 days, do not use anythingabrasive on your vehicle. Brushes, chemicals,and cleaners may scratch the finish.

• During the first 120 days, do not wax yourvehicle.

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

• Avoid washing your vehicle in the hot sun. Al-ways use water. After the vehicle is completelywashed, dry it with a towel or chamois.

• Do not dust painted surfaces with a dry cloth,as this will scratch the paint.

• Do not remove ice or snow from a painted sur-face with a scraper of any sort.

• To prevent damage to the finish, wax it regu-larly. If the finish has become dull, before wax-ing, remove oxidized paint using a cleaner spe-cifically designed for this purpose. Remove allroad tar and tree sap before waxing. Freight-liner recommends that a quality brand ofcleaner or cleaner-polish and polishing wax beused.

• Do not let diesel fuel or antifreeze stand on apainted surface. If either should occur, rinsethe surface off with water.

• To prevent corrosion, have any nicks or otherdamage on the finish touched up as soon aspossible.

• Park your vehicle in a sheltered area wheneverpossible.

Wheel CleaningAccuride® Machined and PolishedAluminum WheelsRegular cleaning of Accuride machined or polishedaluminum wheels is recommended to keep the wheelfinish bright and shiny. The use of an aluminumwheel polish or carnauba wax will protect the pol-ished wheel surfaces, will help prevent corrosion and

pitting on the aluminum wheel surfaces caused fromnatural environmental contamination, and will makefuture cleaning and polishing easier.

1. Rinse the wheel with high-pressure water to re-move any debris, grit, or dirt particles.

2. Use a 100% cotton cloth dipped in a mild soapsolution to help remove built up dirt and grease.

3. Rinse the remaining soap residue from thewheel.

4. Dry the wheel thoroughly with a 100% cottoncloth.

5. Use metal cleaner/polish that is compatible withaluminum to remove spots and stains from thesurfaces of the wheel as necessary.

6. Apply carnauba wax to the visible wheel sur-faces. Carnauba wax should be reapplied on aregular basis to maintain the wheel luster.

Care of Chrome PartsTo prevent rust, keep chrome parts clean and pro-tected at all times. This is especially important duringwinter driving and in coastal areas where there isexposure to salt air.

When cleaning chrome parts, use clean water and asoft cloth or sponge. A mild detergent may also beused.

Sponge gently, then rinse. If necessary, use a non-abrasive chrome cleaner to remove stubborn rust orother material. Do not use steel wool.

To help protect the chrome after cleaning, apply acoat of polishing wax to the surface. Never use waxon parts that are exposed to high heat, such as ex-haust pipes.

Dashboard and InstrumentPanel Care

NOTICEWhen cleaning the dashboard, instrument panel,or gauge lens covers, do not use Armor-All Pro-tectant®, STP Son-of-a-Gun®, window cleaner, orother equivalent treatments. These cleaners con-tain vinyl plasticizers which can cause stresscrazing in the interior plastic panels and can re-sult in cracking of the panels. Some cleaners canalso have an adverse effect on the clear plastic

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of instrument panels and gauge lens covers, re-sulting in a foggy or cloudy appearance. Thistype of damage is not covered by vehicle war-ranty.

To clean the dashboard, instrument panel, and gaugelens covers, use a cloth dampened with warm soapywater. Make certain to wring the cloth out well beforecleaning, as excess water will damage the electricalcomponents.

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15

In an EmergencyFreightliner Help . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15.1Hazard Warning Lights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15.1Towing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15.1Emergency Starting With Jumper Cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15.1Changing a Flat Tire . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15.3Running Out of Fuel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15.3

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

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

TowingSee Chapter 16 for towing information.

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

WARNINGBatteries release explosive gas. Do not smokewhen working around batteries. Put out all flamesand remove all sources of sparks or intense heatin the vicinity of the battery. Do not allow the ve-hicles to touch each other. Do not lean over thebatteries when making connections, and keep allother persons away from the batteries. Failure tofollow these precautions could lead to severepersonal injury as a result of an explosion oracid burns.

NOTICEMake sure that both starting systems are thesame voltage. Electronic devices on both ve-hicles can be damaged when connected to a ve-hicle with a different operating voltage.

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

IMPORTANT: Do not attempt to jump start adamaged battery.

2. Open the battery door (location will vary) to ac-cess the batteries. Slide the battery tray out.

NOTICEAlways connect the batteries and jumper cablescorrectly (positive-to-positive and negative-to-negative). Connecting a charging device back-wards (positive-to-negative) can severely damagethe vehicle electrical content and cause non-warrantable failures.

3. Connect the positive (+) jumper cable to thepositive terminal on the discharged battery. SeeFig. 15.1.

4. Connect the other end of the positive jumpercable to the positive terminal on the booster bat-tery providing the charge.

WARNINGDo the next step exactly as instructed and do notallow the clamps of one cable to touch theclamps of the other cable. Otherwise, a sparkcould occur near a battery, possibly resulting insevere personal injury from explosion or acidburns.

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

6. Connect the other end of the negative jumpercable to the negative ground stud on the vehiclerequiring the jump start.

7. Start the engine of the vehicle providing the jumpstart and let the engine run for a few minutes tocharge the batteries of the other vehicle.

NOTICEDo not crank the engine for more than 30 sec-onds at a time during any of the following proce-dures. Wait two minutes after each try to allowthe starter to cool. Failure to do so could causestarter damage.

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

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

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WARNINGDo the next step exactly as instructed and do notallow the clamps of one cable to touch theclamps of the other cable. Otherwise, a sparkcould occur near a battery, possibly resulting insevere personal injury from explosion or acidburns.

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

11. Disconnect the negative jumper cable from thebooster battery.

12. Disconnect the positive cable from the boosterbattery.

13. Disconnect the other end of the positive jumpercable from the jump started vehicle.

14. Slide the battery tray back into position and closethe battery door.

01/07/2011 f545725

1

2

3

4

A

C

EB

D

−−

+

+

+

+

+

+

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

A. Discharged BatteryB. Negative Ground Stud

C. Positive Jumper CableD. Negative Jumper Cable

E. Booster Battery

1. 1st Connection: Positive Jumper Cable to Discharged Battery2. 2nd Connection: Positive Jumper Cable to Booster Battery3. 3rd Connection: Negative Jumper Cable to Booster Battery4. 4th Connection: Negative Jumper Cable to Negative Ground Stud (discharged battery)

Fig. 15.1, Jumper Connections (three battery system shown for clarity)

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Changing a Flat Tire

DANGERWhen working on the vehicle, shut down the en-gine, set the parking brake, and chock the tires.Before working under the vehicle, always placejack stands under the frame rails to ensure thevehicle can not drop. Failure to follow thesesteps could result in serious personal injury ordeath.

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

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

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

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

3. Turn on the hazard warning lights.

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

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

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

NOTE: The jacking point for the front and rearwheels is directly under the axle. See Fig. 15.2and Fig. 15.3 for correct jack placement.

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

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

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

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

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

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

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

13. After operating the vehicle for 50 to 100 miles(80 to 161 km), retighten the nuts. Tighten thewheel nuts to the correct torque specifications inthe proper tightening sequences. See Group 40of the Recreational Vehicle Chassis MaintenanceManual for instructions.

Running Out of Fuel

WARNINGDiesel fuel is flammable. When you approach avehicle and the smell of diesel fuel is present,immediately shut off all engines and ignitionsources. Avoid causing sparks and stay awayfrom arcing switches and equipment. Extinguishcigarettes, pilot lights, flames, or other sourcesof ignition in the area and adjacent areas. Imme-diately provide extra ventilation to the area. Donot start the vehicle or any other type of equip-ment until the fuel leak is corrected and the areacleared of fuel. Failure to perform these actionscould lead to the ignition of the fuel, which couldcause personal injury or death, or severe prop-erty damage.

If the vehicle runs out of fuel, try to stop the vehicleon a level location away from traffic. Add at least 2gallons (8 liters) of fuel to the fuel tank in order torestart the engine. If the vehicle is not level, up to 6gallons (22 liters) of fuel may be required. Prolongedengine cranking may be required to pump fuel fromthe fuel tank to the engine before the engine willstart.

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

If the vehicle will not start by cranking the engine, thefuel system may need to be primed. See the appli-cable engine manufacturer’s operation and mainte-nance manual.

11/10/2009 f3302591 12

1. Proper Jack Placement Location(s) 2. Incorrect Jack Placement Location

Fig. 15.2, Jack Placement for ZF IFS

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07/30/2014 f321182a

1

1

1

11

2

1. Incorrect Jack Placement2. Correct Jack Placement

Fig. 15.3, Jack Placement for V-Ride

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16

TowingTowing the Vehicle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16.1Towing With the Vehicle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16.2

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

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

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

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

1. Set the parking brake on the tow vehicle.

2. Chock the tires of the tow vehicle.

3. Set the parking brake on the disabled vehicle.

4. Chock the tires of the disabled vehicle.

5. Underneath the disabled vehicle, at the transmis-sion, remove the access hole plug at the rear ofthe SBW actuator. See Fig. 16.1.

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

7. Replace the access hole plug.

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

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

Front Towing Hookup1. Disconnect the battery ground cable.

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

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

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

3. Attach the towing device.

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

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

WARNINGBefore releasing the parking brakes, make theconnection to the towing vehicle or chock thetires on the disabled vehicle. Failure to do so

f270124

12

3

05/16/2003

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

Fig. 16.1, SBW Actuator (at transmission)

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could result in hazardous conditions because thevehicle could suddenly roll and injury couldoccur.

6. Release the parking brake.

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

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

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

2. Disconnect the battery ground cable.

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

3. Attach the towing device.

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

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

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

Towing With the Vehicle

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

The towing vehicle’s brake system is rated foroperation at the Gross Vehicle Weight Rating(GVWR) and does not include the towed weight.Separate functional brake systems and chocksmust be used for safe control and parking oftowed vehicles and trailers weighing more than1500 lbs (681 kg).

Do not tow unbraked vehicles if the combinedweight of both vehicles is more than the sum ofthe Gross Axle Weight Ratings (GAWR) of thetowing vehicle. Otherwise brake capacity will beinadequate, which could result in personal injuryor death.

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

1. Never load the vehicle over the Gross VehicleWeight Rating (GVWR). Considerable damage tothe drivetrain may result if the vehicle is over itsGVWR. Check the GVWR safety compliance cer-tification label (provided by the final manufac-turer) to find the GVWR.

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

3. Subtract the GVW (which is the actual weight ofthe vehicle alone) from the GCWR (which is the

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total weight this vehicle can safely pull) to deter-mine the acceptable weight this vehicle can tow.

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

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

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

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

7-Pin ConnectorThe following information lists the amperage (amp)load limits for each of the connections in the 7-pinconnector. See Fig. 16.2 for an example of the 7-pinconnector.

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

• RH Stop/Turn — 20 amp

• Back Up Lamps — 10 amp

• LH Stop/Turn — 20 amp

• Running Lamps — 20 amp

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

• Ground [–] — for all

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

NOTICEAlways disconnect the battery and the engineelectronic control module (ECM) before weldinganything to the chassis frame.

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

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

Hitch RatingA standard hitch has two ratings depending on themode of operation; see Table 16.1.

• Weight Carrying—Requires a draw bar andhitch ball. The draw bar supports all of the ver-tical tongue load of the trailer.

• Weight Distributing—Requires an aftermarketweight distributing system, consisting of a drawbar, hitch ball, spring bars, and snap-upbrackets. The vertical tongue load of the traileris distributed between the truck and the trailerby this system.

IMPORTANT: The towing vehicle’s brake systemis rated for operation at the GVWR and does

02/02/2005 f544573

ELECTRIC BRAKESRH STOP/TURN

BACKUP LAMPSLH STOP/TURN

RUNNING LAMPS

Fig. 16.2, 7-Pin Connector

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not include the towed weight. Separate func-tional brake systems and wheel chocks must beused for safe driving control and parking oftowed vehicles or trailers weighing more than1500 lbs (681 kg).

The maximum vehicle weight rating and towingcapacities are based on the powertrain andchassis equipment options specified on yourvehicle. Table 16.1 defines the maximum ve-hicle and trailer weight ratings according to thevehicle transmission options. The actual vehicleweight and towing capacities of your vehiclemay be less due to the chassis and OEM equip-ment combinations specified by the final stagemanufacturer (body builder). Refer to the manu-facturer’s certification labels for actual vehicleweight ratings.

Trailers

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

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

WARNINGDo not exceed the GVWR or the GAWR specifiedon the certification label. Table 16.1 lists themaximum GVWR and GAWR for recreational ve-hicle chassis. Towing trailers beyond the maxi-mum recommended gross trailer weight exceedsthe limit of the vehicle and could result in enginedamage, transmission damage, structural dam-age, or loss of vehicle control. Failure to observe

this warning could result in severe injury ordeath, or substantial property damage.

Parking With A TrailerPark the vehicle on a flat surface. Chock the tires asfollows:

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

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

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

4. Apply the park brake.

5. Depending on the series of transmission, selecteither Neutral (N) or Park (P) on the gear shiftselector.

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

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

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

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Trailer Weight Ratings*

ChassisModel

AllisonTransmission

MaximumGVWR lbs (kg)

MaximumGCWR lbs (kg)

Hitch TypeMaximum Gross

Trailer Weight lbs (kg)

XC, MC

1000 MH 22,000 (9988) 26,000 (11 804)Weight Carrying 10,000 (4540)

Weight Distributing 12,000 (5448)

2100 MH 26,000 (11 804) 30,000 (13 620)Weight Carrying 10,000 (4540)

Weight Distributing 12,000 (5448)

2200 MH 26,000 (11 804) 26,000 (11 804)Weight Carrying 10,000 (4540)

Weight Distributing 12,000 (5448)

2350 MH 30,000 (13 620) 30,000 (13 620)Weight Carrying 10,000 (4540)

Weight Distributing 12,000 (5448)

2500 MH 33,000 (14 982) 33,000 (14 982)Weight Carrying 10,000 (4540)

Weight Distributing 12,000 (5448)

2550 MH 30,000 (13 620) 30,000 (13 620)Weight Carrying 10,000 (4540)

Weight Distributing 12,000 (5448)

XC3000 MH * *

Weight Carrying 15,000 (6810)Weight Distributing 16,000 (7264)

4000 MH * *Weight Carrying 15,000 (6810)

Weight Distributing 16,000 (7264)* Values shown are the maximum for each model. Actual vehicle weight and tow ratings may be less, depending on the chassis and body manufacturer’s

equipment options. Refer to the manufacturer’s certification labels for the actual vehicle weight ratings.

Table 16.1, Trailer Weight Ratings

• Allow considerably more room for stoppingwhen the trailer is attached. If you have amanual brake controller, "lead" with the trailerbrakes (if so equipped) when approaching astop, if possible. Trailer brakes are also handyfor correcting trailer side-sway. Just touch themfor a moment without using your vehicle brakesand the trailer should settle down and tracksteadily again.

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

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

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

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

as the added weight of the trailer can dramati-cally decrease the acceleration of the towingvehicle.

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

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

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

• When possible, do not park on a grade with atrailer. However, when this is necessary, applythe service brakes and hold while someoneelse places chocks under the trailer’s wheels.

To start out when parked on a grade, apply theservice brake pedal and with the vehicle eitherin Neutral (N) or Park (P), start the engine.Shift the transmission into gear and release theparking brake. Then release the brake pedaland move the vehicle uphill to free the chocks.

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Apply the brake pedal while another personretrieves the chocks.

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17

Vehicle StoragePreparation for Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17.1Removal from Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17.1

Page 158: Recreational Vehicle Chassis Operator's Manual

Preparation for StorageWhen storing your recreational vehicle for an ex-tended period of time (60 days or more), the follow-ing steps should be taken to give it maximum protec-tion. Note the date and mileage on the vehicle whenit is placed in storage.

• Fill the fuel tank and add a high-quality fuelstabilizer to the fuel. Never store the vehiclewith a partially full tank of fuel.

• Change the engine oil and filter. Used oil doesnot provide adequate protection.

• The cooling system was originally protectedwith antifreeze to –34°F (–37°C). If colder tem-peratures are expected, adjust the mixture. Ifthe coolant has been in the vehicle for fiveyears or 100,000 miles (160 900 km), flush thecooling system and fill it with an appropriatemixture of antifreeze and water, making surethat the coolant contains a rust inhibitor.

• If it has been more than 18 months or 24,000miles (38 616 km) since the transmission wasserviced, change the transmission fluid andfilter.

• Service the fuel filters.

• Run the engine until it is fully warmed up.

• Operate the air conditioning.

• If possible, store the vehicle in a dry, well ven-tilated area, protected from sunlight.

• Check the tires for damage and set the tirepressure to maximum as indicated on the side-wall of the tire. Clean the tires using a mildsoap that would be used to clean the vehicle.

• If possible, raise the vehicle onto safetystands. Do not store the vehicle on hydraulicleveling jacks. Hydraulic jacks will bleed pres-sure over time, lowering the coach back ontothe tires.

• Cover the tires to protect them from heat andsunlight.

• If possible, release the parking brake.

• Remove and clean the battery. Always discon-nect the negative cable first, then the positivecable. Store the battery in a cool, dry placeand keep it charged.

• Lubricate all grease fittings on the chassis anddrivetrain.

• Cover all engine and transmission openingswith moisture-resistant tape.

Removal from StorageFollow these steps when the recreational vehicle isremoved from storage.

• Remove the covers from the tires and thor-oughly inspect the tires for damage. Inflatethem to the correct pressure for the actualweight on the tires. Consult the Michelin orGoodyear manual included with your chassisfor correct tire pressure. Weigh the vehicle ifyou do not know how much it weighs.

• Check for fluid leaks. Repair as necessary.

• Check the engine oil level. Add oil if needed.

• Check the coolant level in the reservoir andradiator. Add coolant if needed.

• Check the hydraulic fluid level in the reservoir.Add fluid if needed.

• Check the engine belts for wear, damage, orcracking.

• Check the engine fan for damage.

• Check the fuel/water separator. If it is empty,prime the fuel system. For priming instructions,see the Cummins Operation and MaintenanceManual.

• Check the engine compartment for nesting ani-mals. Check for leaks and damage to thehoses and wiring.

• Check the rear axle lubricant level.

• Lubricate all grease fittings on the chassis anddrivetrain.

• Check the charge level of the battery. Cleanthe ends of the battery cables. If the batteriesneed to be replaced, install a clean and fullycharged battery. Always connect the positivecable first, then connect the negative cable.Coat the battery terminals and connectors witha dielectric protectant sealant.

• If the vehicle was stored on safety stands,lower the vehicle at this time and set the park-ing brake.

• Turn the ignition to the RUN position. Verifythat the fuel gauge and voltmeter are workingcorrectly.

Vehicle Storage

17.1

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• Run the engine until it is warm, then checkagain for fluid leaks.

• Check the transmission fluid level using thecold check method in the Allison Operator’sManual.

• Check all exterior lights and replace as neces-sary.

Vehicle Storage

17.2

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18

SpecificationsTorque Charts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18.1Conversion Charts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18.4Fluids and Lubricants . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18.5Electric Service Center . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18.6Fuse/Relay/Circuit Breaker Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18.7

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Torque ChartsTorque Values for U.S. Customary Thread Fasteners With Lubricated* or Plated Threads†

ThreadDiameter—

Pitch

Regular Hex FlangedGrade 5

BoltGrade 5 or

B NutGrade 8 or

8.2 BoltGrade 8 or

C NutGrade 5

BoltGrade B

NutGrade 8 or

8.2 BoltGrade G

NutTorque: lbf·ft (N·m) Torque: lbf·ft (N·m) Torque: lbf·ft (N·m) Torque: lbf·ft (N·m)

f230002 f230003 f230004 f230005 f230006 f230007 f230008 f230009

1/4–20 7 (9) 8 (11) 6 (8) 10 (14)1/4–28 8 (11) 9 (12) 7 (9) 12 (16)

5/16–18 15 (20) 16 (22) 13 (18) 21 (28)5/16–24 16 (22) 17 (23) 14 (19) 23 (31)3/8–16 26 (35) 28 (38) 23 (31) 37 (50)3/8–24 30 (41) 32 (43) 25 (34) 42 (57)

7/16–14 42 (57) 45 (61) 35 (47) 60 (81)7/16–20 47 (64) 50 (68) 40 (54) 66 (89)1/2–13 64 (87) 68 (92) 55 (75) 91 (123)1/2–20 72 (98) 77 (104) 65 (88) 102 (138)

9/16–12 92 (125) 98 (133) 80 (108) 130 (176)9/16–18 103 (140) 110 (149) 90 (122) 146 (198)

5/8–11 128 (173) 136 (184) 110 (149) 180 (244)5/8–18 145 (197) 154 (209) 130 (176) 204 (277)3/4–10 226 (306) 241 (327) 200 (271) 320 (434)3/4–16 253 (343) 269 (365) 220 (298) 357 (484)7/8–9 365 (495) 388 (526) 320 (434) 515 (698)

7/8–14 402 (545) 427 (579) 350 (475) 568 (770)1–8 — 582 (789) — —

1–12 — 637 (863) — —1–14 — 652 (884) — —

* Freightliner recommends that all plated and unplated fasteners be coated with oil before installation.† Use these torque values if either the bolt or nut is lubricated or plated (zinc-phosphate conversion-coated, cadmium-plated, or waxed, Geomet 321XL

coated, or waxed).

Table 18.1, Torque Values for U.S. Customary Thread Fasteners With Lubricated or Plated Threads

Specifications

18.1

Page 162: Recreational Vehicle Chassis Operator's Manual

Torque Values for U.S. Customary Thread Fasteners With Dry (Unlubricated)* Plain (Unplated) Threads†

ThreadDiameter—

Pitch

Regular Hex Flanged

Grade 5 BoltGrade 5 or B

NutGrade 8 or 8.2

BoltGrade 8 or C

NutGrade 8 or 8.2

BoltGrade G Nut

Torque: lbf·ft (N·m) Torque: lbf·ft (N·m) Torque: lbf·ft (N·m)

f230002 f230003 f230004 f230005 f230008 f230009

1/4–20 8 (11) 10 (14) —1/4–28 9 (12) 12 (16) —

5/16–18 15 (20) 22 (30) 22 (30)5/16–24 17 (23) 25 (34) —3/8–16 28 (38) 40 (54) 40 (54)3/8–24 31 (42) 45 (61) —

7/16–14 45 (61) 65 (88) 65 (88)7/16–20 50 (68) 70 (95) —1/2–13 70 (95) 95 (129) 95 (129)1/2–20 75 (102) 110 (149) —

9/16–12 100 (136) 140 (190) 140 (190)9/16–18 110 (149) 155 (210) —

5/8–11 135 (183) 190 (258) 190 (258)5/8–18 155 (210) 215 (292) —3/4–10 240 (325) 340 (461) 340 (461)3/4–16 270 (366) 380 (515) —7/8–9 385 (522) 540 (732) —

7/8–14 425 (576) 600 (813) —1–8 580 (786) 820 (1112) —

1–12 635 (861) 900 (1220) —1–14 650 (881) 915 (1241) —

* Threads may have residual oil, but will be dry to the touch.† Male and female threads (bolt and nut) must both be unlubricated and unplated. If either is plated or lubricated, use Table 18.3. Freightliner recommends

that all plated and unplated fasteners be coated with oil before installation.

Table 18.2, Torque Values for U.S. Customary Thread Fasteners With Dry (Unlubricated) Plain (Unplated) Threads

Specifications

18.2

Page 163: Recreational Vehicle Chassis Operator's Manual

Torque Values for Metric Thread Fasteners With Lubricated* or Plated Threads†

ThreadDiameter—

Pitch

Class 8.8 Bolt Class 8 Nut Class 10.9 Bolt Class 10 Nut

Torque: lbf·ft (N·m) Torque: lbf·ft (N·m)

f230010

8.8

f230011

8

f230012

10.9

f230013

10

M6 5 (7) 7 (9)M8 12 (16) 17 (23)M8 x 1 13 (18) 18 (24)M10 24 (33) 34 (46)M10 x 1.25 27 (37) 38 (52)M12 42 (57) 60 (81)M12 x 1.5 43 (58) 62 (84)M14 66 (89) 95 (129)M14 x 1.5 72 (98) 103 (140)M16 103 (140) 148 (201)M16 x 1.5 110 (149) 157 (213)M18 147 (199) 203 (275)M18 x 1.5 165 (224) 229 (310)M20 208 (282) 288 (390)M20 x 1.5 213 (313) 320 (434)M22 283 (384) 392 (531)M22 x 1.5 315 (427) 431 (584)M24 360 (488) 498 (675)M24 x 2 392 (531) 542 (735)M27 527 (715) 729 (988)M27 x 2 569 (771) 788 (1068)M30 715 (969) 990 (1342)M30 x 2 792 (1074) 1096 (1486)* Freightliner recommends that all plated and unplated fasteners be coated with oil before installation.† Use these torque values if either the bolt or nut is lubricated or plated (zinc-phosphate conversion-coated,

cadmium-plated, or waxed, Geomet 321XL coated, or waxed).

Table 18.3, Torque Values for Metric Thread Fasteners With Lubricated or PlatedThreads

Specifications

18.3

Page 164: Recreational Vehicle Chassis Operator's Manual

Conversion ChartsWhen You Know U.S.

CustomaryMultiply

ByTo Get Metric

When YouKnow Metric

MultiplyBy

To Get U.S. Customary

Lengthinches (in) 25.4 millimeters (mm) 0.03937 inches (in)inches (in) 2.54 centimeters (cm) 0.3937 inches (in)feet (ft) 0.3048 meters (m) 3.281 feet (ft)yards (yd) 0.9144 meters (m) 1.094 yards (yd)miles (mi) 1.609 kilometers (km) 0.6215 miles (mi)Areasquare inches (in2) 645.16 square millimeters (mm2) 0.00155 square inches (in2)square inches (in2) 6.452 square centimeters (cm2) 0.155 square inches (in2)square feet (ft2) 0.0929 square meters (m2) 10.764 square feet (ft2)Volumecubic inches (in3) 16387.0 cubic millimeter (mm3) 0.000061 cubic inches (in3)cubic inches (in3) 16.387 cubic centimeters (cm3) 0.06102 cubic inches (in3)cubic inches (in3) 0.01639 liters (L) 61.024 cubic inches (in3)fluid ounces (fl oz) 29.54 milliliters (mL) 0.03381 fluid ounces (fl oz)pints (pt) 0.47318 liters (L) 2.1134 pints (pt)quarts (qt) 0.94635 liters (L) 1.0567 quarts (qt)gallons (gal) 3.7854 liters (L) 0.2642 gallons (gal)cubic feet (ft3) 28.317 liters (L) 0.03531 cubic feet (ft3)cubic feet (ft3) 0.02832 cubic meters (m3) 35.315 cubic feet (ft3)Weight/Forceounces (av) (oz) 28.35 grams (g) 0.03527 ounces (av) (oz)pounds (av) (lb) 0.454 kilograms (kg) 2.205 pounds (av) (lb)U.S. tons (t) 907.18 kilograms (kg) 0.001102 U.S. tons (t)U.S. tons (t) 0.90718 metric tons (t) 1.1023 U.S. tons (t)Torque/Work Forceinch–pounds (lbf·in) 11.298 Newton–centimeters (N·cm) 0.08851 inch–pounds (lbf·in)foot–pounds (lbf·ft) 1.3558 Newton–meters (N·m) 0.7376 foot–pounds (lbf·ft)Pressure/Vacuuminches of mercury (inHg) 3.37685 kilo Pascals (kPa) 0.29613 inches of mercury (inHg)pounds per square inch (psi) 6.895 kilo Pascals (kPa) 0.14503 pounds per square inch (psi)

Table 18.4, Metric/U.S. Customary Conversion

When You Know SubtractThen

Divide ByTo Get

When YouKnow

MultiplyBy

ThenAdd

To Get

degrees Fahrenheit (°F) 32 1.8 degrees Celsius (°C) 1.8 32 degrees Fahrenheit (°F)

Table 18.5, Temperature Conversion

Specifications

18.4

Page 165: Recreational Vehicle Chassis Operator's Manual

Fluids and LubricantsIn the engine cooling system use 50 percent waterand 50 percent corrosion-inhibiting antifreeze to pro-tect the engine to –34°F (–37°C) year round.

Coolant Capacities*

Engine Make Coolant Volume: qt (L)Cummins 12 (11)* The total coolant volume is dependent on the number and location of optional passenger heaters.

Table 18.6, Coolant Capacities

Approved CoolantsRefer to the engine manufacturer’s service literature for approved coolant.

Table 18.7, Approved Coolants

Approved Allison Transmission Lubricants*

TES-295 Approval Number Company Product Brand NameAN-051005 ExxonMobil Lubricants and Petroleum Specialties Company Mobil Delvac Synthetic ATFAN-011001 Castrol Heavy Duty Lubricants TranSyndAN-031002 BP Autran Syn 295AN-031003 Cognis Corporation Emgard 2805AN-031004 International Truck & Engine Company Fleetrite Synthetic ATFAN-071006 John Deere & Company HD SynTran

* To check the latest Allison approved fluids, go to www.allisontransmission.com. Lubricants listed in order of preference. Do not mix types of oil.

Table 18.8, Approved Allison Transmission Lubricants

Allison Transmission Lubricant CapacitiesTransmission Model Fill Capacity:* qt (L)

1000/2000 Series (standard sump) 14.8 (14)1000/2000 Series (shallow sump) 12.7 (12)2100/2200/2500 Series (shallow sump) 13 (12)3000 Series (4 inch) 29 (27)3000 Series (2 inch) 26 (25)* Quantities listed are approximate. Add the recommended amount of fluid as listed under fill capacity. Do not overfill.

Table 18.9, Allison Transmission Lubricant Capacities

Specifications

18.5

Page 166: Recreational Vehicle Chassis Operator's Manual

Approved Driveline LubricantsLubricant andSpecification

Lubricant Brands

Universal joint, slipjoint, and splinegrease must meetArvinMeritorSpecification O–634–B(NLGI Grade No. 2,Lithium 12-HydroxyStearate withMolybdenum Disulfide)

Phillips Petroleum Philube MW–EP2 GreaseExxon 5160Amalie All Purpose Grease withMoly–L1–2MShell Super Duty Special FFMarathon Maralube Molycode529Shell Moly Poly GreaseKendall L424 GreaseAmoco Super Chassis GreaseFord Specification M1C–75B orpart number C1AZ 19590

Table 18.10, Approved Driveline Lubricants

Approved Power Steering FluidsFluid Type* Approved Fluid*

Automatic Transmission FluidDexron® III or equivalentDexron® II

* Fill the power steering reservoir only with approved clean fluid. Do notmix fluid types. Wear eye protection when changing the fluid and filter.

Table 18.11, Approved Power Steering Fluids

Freightliner Drive Axle Lubricant CapacityDifferential/Hubs Capacity: qt (L)

Differential Only 5.8 (5.5)Differential and Hubs 7.4 (7.0)

Table 18.12, Freightliner Drive Axle LubricantCapacity

Meritor Drive Axle Lubricant CapacityAxle Model Capacity: pt (L)*RS-15-120 16 (7.6)RS-17-145 33.6 (15.9)RS-19-145 34.4 (16.3)RS-21-145 32 (15.1)RS-23-160 42 (19.9)RS-23-165 42 (19.9)

* Quantities listed are approximate and include 1 pint (0.5 L) for eachwheel end and with the drive pinion at 3 degrees.

Table 18.13, Meritor Drive Axle Lubricant Capacity

Electric Service CenterThe information under this heading is to help familiar-ize the driver with the basic electrical system. Servic-ing the electrical system should be done only byqualified technicians. Special skills and equipmentare required. Take your vehicle to an authorizedFreightliner service facility for repairs. The Recre-ational Vehicle chassis uses multiple electrical com-ponents (and fuel and hydraulic filters). Each compo-nent is mounted in varying locations on the chassis.If equipped with an Arens service center, it ismounted in one specific location, and that mountinglocation will vary. See Fig. 18.1. See Table 18.14,Table 18.15, and Table 18.16 for connectorinformation.

Connector 1Connector Position Description

1A ECU-IGN

07/05/2007

1 2 3

4 5 6f545107

1. Connector 4, Power Input A2. Connector 4, Power Input B3. Connector 4, Power Input C4. Connector 3, 8 Positions5. Connector 1, 16 Positions6. Connector 2, 12 Positions

Fig. 18.1, Arens Controls

Specifications

18.6

Page 167: Recreational Vehicle Chassis Operator's Manual

Connector 1Connector Position Description

1B FAN-SIG1C FAN NO1D EXTRA1E ECM BATT1F SPARE1G SPARE NC1H DIAG PWR1J FAN NC1K FAN RTN1L MBE ECM BATT1M HYD FAN MOD1N SPARE COM1P IGN1R SPARE NO1S SPARE SIG

Table 18.14, Connector 1

Connector 2Connector Position Description

2A IGN SW START2B TCM BATT2C TCM BATT2D L TURN SIG2E REV LPS SIG2F REV LPS OUT2G GND2H START OUT2J NEU START SIG2K TCM2L MARKER SIG2M R TURN SIG

Table 18.15, Connector 2

Connector 3Connector Position Description

3A REV TOW3B EXTRA3C EXTRA3D EXTRA3E R TURN OUT3F MARKER OUT3G L TURN OUT3H IGN OUT TOW

Table 18.16, Connector 3

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

Fuse/Relay/Circuit BreakerIdentification (front-engine dieselchassis)The electrical system has five separate power distri-bution modules (PDMs) containing both fuses andrelays. An optional tow power PDM is also available.See Fig. 18.2 and Fig. 18.3. The PDMs are mountedin two places:

• Two inside the cab area, typically at the baseof the steering column.

• Three outside, typically mounted to the right ofthe operator’s station.

Fuse/Relay/Circuit BreakerIdentificationThe electrical system has a box that contains bothfuses and relays. The box is mounted in varying lo-cations (typically in the cab under the dash) depend-ing on the design of the chassis. The fuses and relayboxes shown vary depending on chassis options.See Fig. 18.4, Fig. 18.5, Fig. 18.6, and Fig. 18.7.

Specifications

18.7

Page 168: Recreational Vehicle Chassis Operator's Manual

07/05/2007 f545105Ref. Dia.: 24−01514

Fig. 18.2, Cab PDMs (inside cab)

07/05/2007 f545106Ref. Dia.: 24−01565

Fig. 18.3, Chassis and Optional Tow Power PDMs(chassis mounted)

Specifications

18.8

Page 169: Recreational Vehicle Chassis Operator's Manual

07/06/2007 f545104Ref. Dia.: 24−01483

Fig. 18.4, Fuse/Relay (typical install)

Specifications

18.9

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07/06/2007 f545108Ref. Dia.: 24−01483

Fig. 18.5, Fuse/Relay (typical install)

Specifications

18.10

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07/06/2007 f545109Ref. Dia.: 24−01483

Fig. 18.6, Fuse/Relay (typical install)

Specifications

18.11

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07/06/2007 f545110Ref. Dia.: 24−01483

Fig. 18.7, Fuse/Relay (typical install)

Specifications

18.12

Page 173: Recreational Vehicle Chassis Operator's Manual

Subject Page

AAir Brake System . . . . . . . . . . . . . . . . . . . . . . . . . 8.1

Automatic Slack Adjusters . . . . . . . . . . . . . . . . . 8.2Brake Burnishing (new

vehicle) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.2General Information . . . . . . . . . . . . . . . . . . . . . 8.1Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.1

Allison Automatic Transmissions . . . . . . . . . . . . . 11.171000/2100/2200/2350 MH

Models . . . . . . . . . . . . . . . . . . . . . . . . . . . 11.172100/2500 Models (Arens

SBW) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.22500/3000/4000 MH Models . . . . . . . . . . . . . . . 9.1

Ametek Instrument Panel . . . . . . . . . . . . . . . . . . . 3.1Menu Navigation . . . . . . . . . . . . . . . . . . . . . . . 3.4Menu System . . . . . . . . . . . . . . . . . . . . . . . . . 3.1Message Display Center . . . . . . . . . . . . . . . . . . 3.1Priority Messages . . . . . . . . . . . . . . . . . . . . . . 3.1Self-Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.1

Antilock Braking System (ABS) . . . . . . . . . . . . . . . . 8.2Meritor WABCO® ABS . . . . . . . . . . . . . . . . . . . 8.2

BBraking Control . . . . . . . . . . . . . . . . . . . . . . . . . . 6.7

Parking Brake Control Knob . . . . . . . . . . . . . . . 6.7

CCare of Chrome Parts . . . . . . . . . . . . . . . . . . . . . 14.1Changing a Flat Tire . . . . . . . . . . . . . . . . . . . . . . 15.3Collision Warning System,

Eaton VORAD VS-400 (StandAlone) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.8Driver Display Unit . . . . . . . . . . . . . . . . . . . . . . 5.9Failure Display Mode/Fault

Codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.15Forward-Looking-Radar

(FLR) Warning System . . . . . . . . . . . . . . . . . 5.12Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . 5.15Menu Selections . . . . . . . . . . . . . . . . . . . . . . 5.10Side Sensor Display . . . . . . . . . . . . . . . . . . . . 5.14Special Road Situations . . . . . . . . . . . . . . . . . 5.14

Component Information Label . . . . . . . . . . . . . . . . 1.1Conversion Charts . . . . . . . . . . . . . . . . . . . . . . . 18.4Cruise Control . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.4

SmartWheel-Mounted CruiseControl . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.5

Turn Signal-Mounted CruiseControl . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.4

Subject Page

DDaily Pretrip Inspection and

Maintenance Checklist . . . . . . . . . . . . . . . . . . . 12.1Daily Pretrip Inspection and

Maintenance Procedures . . . . . . . . . . . . . . . . . . 13.1Dashboard and Instrument

Panel Care . . . . . . . . . . . . . . . . . . . . . . . . . . . 14.1Driving Precautions . . . . . . . . . . . . . . . . . . . . . . . 9.1

EElectric Service Center . . . . . . . . . . . . . . . . . . . . 18.6Electrical System Controls . . . . . . . . . . . . . . . . . . . 6.1

Battery Disconnect Switch . . . . . . . . . . . . . . . . . 6.1Emergency Starting With

Jumper Cables . . . . . . . . . . . . . . . . . . . . . . . . 15.1Emissions Labels . . . . . . . . . . . . . . . . . . . . . . . . . 1.1

Aftertreatment SystemIndicators Label . . . . . . . . . . . . . . . . . . . . . . 1.1

Vehicle Emission ControlInformation Label . . . . . . . . . . . . . . . . . . . . . 1.2

Engine Operation . . . . . . . . . . . . . . . . . . . . . . . . . 7.2Cold-Weather Operation . . . . . . . . . . . . . . . . . . 7.2High-Altitude Operation . . . . . . . . . . . . . . . . . . . 7.3Normal Operation . . . . . . . . . . . . . . . . . . . . . . 7.2

Engine Shutdown . . . . . . . . . . . . . . . . . . . . . . . . 7.11Engine Starting . . . . . . . . . . . . . . . . . . . . . . . . . . 7.1

Cold-Weather Starting . . . . . . . . . . . . . . . . . . . 7.2Normal Starting . . . . . . . . . . . . . . . . . . . . . . . . 7.1Starting After Extended

Shutdown . . . . . . . . . . . . . . . . . . . . . . . . . . 7.2Exhaust Aftertreatment System

(ATS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11.10DEF Warnings and Engine

Limits . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11.15Diesel Exhaust Fluid and

Tank, EPA10 and NewerEngines . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.7

EPA07 Engines . . . . . . . . . . . . . . . . . . . . . . . . 7.4EPA10 and Newer Engines . . . . . . . . . . . . . . . . 7.4Fuel/DEF Gauge . . . . . . . . . . . . . . . . . . . . . 11.15

Exhaust Brake . . . . . . . . . . . . . . . . . . . . . . . . . . 7.3

FFluids and Lubricants . . . . . . . . . . . . . . . . . . . . . 18.5Freightliner Help . . . . . . . . . . . . . . . . . . . . . . . . 15.1Fuse/Relay/Circuit Breaker

Identification . . . . . . . . . . . . . . . . . . . . . . . . . . 18.7Fuse/Relay/Circuit Breaker

Identification (front-enginediesel chassis) . . . . . . . . . . . . . . . . . . . . . . 18.7

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Fuse/Relay/Circuit BreakerIdentification . . . . . . . . . . . . . . . . . . . . . . . . 18.7

GGauges . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.6

Air Intake Restriction Gauge . . . . . . . . . . . . . . . 5.7Pressure/Temperature

Gauges (Four-in-OneGauge) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.7

HHazard Warning Lights . . . . . . . . . . . . . . . . . . . . 15.1Horn Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.5Hydraulic Brake System . . . . . . . . . . . . . . . . . . . 11.19

Auto-Apply Parking BrakeOperation . . . . . . . . . . . . . . . . . . . . . . . . . 11.20

General Information . . . . . . . . . . . . . . . . . . . 11.19Meritor WABCO® Antilock

Braking System (ABS),Hydraulic Brake Systems . . . . . . . . . . . . . . . 11.19

IIgnition Switch and Key . . . . . . . . . . . . . . . . . . . . 6.1Instrumentation Control Unit . . . . . . . . . . . . . . . . . 11.1

Dash Message Center . . . . . . . . . . . . . . . . . . . 11.1Gauges . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11.7Ignition Sequence . . . . . . . . . . . . . . . . . . . . . . 11.1Mode/Reset Switch . . . . . . . . . . . . . . . . . . . . . 11.3Odometer . . . . . . . . . . . . . . . . . . . . . . . . . . . 11.3Optional Instruments . . . . . . . . . . . . . . . . . . . . 11.8Optional Warning and

Indicator Lamps . . . . . . . . . . . . . . . . . . . . . . 11.6Speedometer and

Tachometer . . . . . . . . . . . . . . . . . . . . . . . . . 11.6Warning and Indicator

Lamps . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11.4

LLightbar Control Unit (LBCU)

Instrument Panel . . . . . . . . . . . . . . . . . . . . . . . . 2.1Audible Alarms . . . . . . . . . . . . . . . . . . . . . . . . 2.1Emergency Shutdown . . . . . . . . . . . . . . . . . . . . 2.1Information Center . . . . . . . . . . . . . . . . . . . . . . 2.1Menu Structure . . . . . . . . . . . . . . . . . . . . . . . . 2.3

Lighting Controls . . . . . . . . . . . . . . . . . . . . . . . . . 6.1Hazard Warning Lights . . . . . . . . . . . . . . . . . . . 6.3Headlight Interrupt

(SmartWheel only) . . . . . . . . . . . . . . . . . . . . . 6.2Headlight, Panel Light, and

Fog Light Switches . . . . . . . . . . . . . . . . . . . . 6.1

Subject Page

High-Beam Headlights . . . . . . . . . . . . . . . . . . . 6.2Marker Lamp Interrupt

(SmartWheel only) . . . . . . . . . . . . . . . . . . . . . 6.2Turn Signals . . . . . . . . . . . . . . . . . . . . . . . . . . 6.3

MMonthly Post-Trip Inspection

and Maintenance Checklist . . . . . . . . . . . . . . . . 12.3Monthly Post-Trip Inspection

and Maintenance Procedures . . . . . . . . . . . . . . 13.13

OOptional Instruments . . . . . . . . . . . . . . . . . . . . . . 5.8

Tire Pressure MonitoringSystem (TPMS) . . . . . . . . . . . . . . . . . . . . . . . 5.8

Transmission TemperatureGauge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.8

Turbo Boost Gauge . . . . . . . . . . . . . . . . . . . . . 5.8OptiView™ Instrument Panel . . . . . . . . . . . . . . . . . 4.1

Audible Alerts . . . . . . . . . . . . . . . . . . . . . . . . . 4.1Emergency Shutdown . . . . . . . . . . . . . . . . . . . . 4.2Ignition Sequence . . . . . . . . . . . . . . . . . . . . . . 4.1Menu Structure . . . . . . . . . . . . . . . . . . . . . . . . 4.2

PPower Steering System . . . . . . . . . . . . . . . . . . . . 10.1Powertrain Controls . . . . . . . . . . . . . . . . . . . . . . . 6.5

Allison AutomaticTransmissions . . . . . . . . . . . . . . . . . . . . . . . . 6.5

Tag-Axle Suspension DumpSwitch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.5

Preparation for Storage . . . . . . . . . . . . . . . . . . . . 17.1Pretrip and Post-Trip General

Information . . . . . . . . . . . . . . . . . . . . . . . . . . . 12.1

RRemoval from Storage . . . . . . . . . . . . . . . . . . . . 17.1Running Out of Fuel . . . . . . . . . . . . . . . . . . . . . . 15.3

SSafety Precautions . . . . . . . . . . . . . . . . . . . . . . . 13.1Speedometer and Tachometer . . . . . . . . . . . . . . . . 5.5

Speedometer . . . . . . . . . . . . . . . . . . . . . . . . . 5.5Tachometer (Three-in-One

Gauge) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.6Steering Column Adjustment . . . . . . . . . . . . . . . . 10.1

TRW Tilt/Telescope SteeringColumn . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.1

Steering Control . . . . . . . . . . . . . . . . . . . . . . . . . 6.7

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TRW® ColumnDriveAdjustment Knob . . . . . . . . . . . . . . . . . . . . . . 6.7

TTorque Charts . . . . . . . . . . . . . . . . . . . . . . . . . . 18.1Towing the Vehicle . . . . . . . . . . . . . . . . . . . . . . . 16.1

Front Towing Hookup . . . . . . . . . . . . . . . . . . . 16.1Rear Towing Hookup . . . . . . . . . . . . . . . . . . . 16.2Removing the Transmission

from the Park (P) Position . . . . . . . . . . . . . . . 16.1Towing With the Vehicle . . . . . . . . . . . . . . . . . . . 16.2

7-Pin Connector . . . . . . . . . . . . . . . . . . . . . . . 16.3General Information . . . . . . . . . . . . . . . . . . . . 16.2Hitches . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16.3Trailers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16.4

Towing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15.1

VVehicle Identification Number . . . . . . . . . . . . . . . . . 1.1

WWarning and Indicator Lamps . . . . . . . . . . . . . . . . . 5.1

ABS Warning . . . . . . . . . . . . . . . . . . . . . . . . . 5.1Air Brake Warning . . . . . . . . . . . . . . . . . . . . . . 5.1Auto-Idle . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.1Check Engine Warning . . . . . . . . . . . . . . . . . . . 5.2Cruise Control Indicator . . . . . . . . . . . . . . . . . . 5.2Dash Driver Display Screen . . . . . . . . . . . . . . . . 5.2Diesel Particulate Filter

(DPF) Lamp . . . . . . . . . . . . . . . . . . . . . . . . . 5.2Emergency Buzzer . . . . . . . . . . . . . . . . . . . . . . 5.2Engine Brake Indicator . . . . . . . . . . . . . . . . . . . 5.3Fasten Seat Belt Warning . . . . . . . . . . . . . . . . . 5.3Fog Lamp Indicator . . . . . . . . . . . . . . . . . . . . . 5.3Headlight High-Beam

Indicator . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.4High Coolant Temperature

Warning . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.4High Exhaust System

Temperature (HEST) Lamp . . . . . . . . . . . . . . . 5.4Hydraulic Brake System

Warning (Ametek only) . . . . . . . . . . . . . . . . . . 5.4Left-Turn Indicator . . . . . . . . . . . . . . . . . . . . . . 5.4Low Air Pressure Warning . . . . . . . . . . . . . . . . . 5.4Low Battery Voltage Warning . . . . . . . . . . . . . . . 5.4Low Diesel Exhaust Fluid

(DEF) Warning . . . . . . . . . . . . . . . . . . . . . . . 5.4Low Fuel Indicator . . . . . . . . . . . . . . . . . . . . . . 5.4Low Oil Pressure Warning . . . . . . . . . . . . . . . . . 5.4

Subject Page

Low Windshield WasherFluid Indicator . . . . . . . . . . . . . . . . . . . . . . . . 5.4

Maintenance Warning(Ametek only) . . . . . . . . . . . . . . . . . . . . . . . . 5.4

Malfunction Indicator Lamp(MIL) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.5

Parking Brake On Warning . . . . . . . . . . . . . . . . 5.5Right-Turn Indicator . . . . . . . . . . . . . . . . . . . . . 5.5Shift Inhibit Indicator . . . . . . . . . . . . . . . . . . . . . 5.5Steerable Tag Axle Warning . . . . . . . . . . . . . . . . 5.5Stop Engine Warning . . . . . . . . . . . . . . . . . . . . 5.5Transmission Overheat

Warning . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.5Transmission Warning . . . . . . . . . . . . . . . . . . . 5.5Wait to Start Indicator . . . . . . . . . . . . . . . . . . . . 5.5Water In Fuel Indicator . . . . . . . . . . . . . . . . . . . 5.5

Washing and Polishing . . . . . . . . . . . . . . . . . . . . 14.1Weekly Post-Trip Inspection

and Maintenance Checklist . . . . . . . . . . . . . . . . 12.3Weekly Post-Trip Inspection

and Maintenance Procedures . . . . . . . . . . . . . . 13.12Wheel Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . 14.1

Accuride® Machined andPolished Aluminum Wheels . . . . . . . . . . . . . . 14.1

Windshield Wiper Controls . . . . . . . . . . . . . . . . . . . 6.3SmartWheel Wiper Controls . . . . . . . . . . . . . . . . 6.3Standard Wiper Controls . . . . . . . . . . . . . . . . . . 6.3

Index

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