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freightliner S2 Operator's Manual

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S2 CHASSIS
Operator's Manual
STI-479-6
A24-01453-000

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Summary of Contents for freightliner S2

  • Page 1 S2 CHASSIS Operator’s Manual STI-479-6 A24-01453-000...
  • Page 2 This vehicle must be regularly inspected and main- when disposing of materials. tained as indicated in the S2 Chassis Maintenance Manual, and in the Pre- and Post-Trip Inspections Event Data Recorder and Maintenance chapter in this manual, in order to...
  • Page 3 However, NHTSA cannot become involved in individual problems between you, your dealer, or Freightliner Custom Chassis Corporation. To contact NHTSA, you may call the Vehicle Safety Hotline toll-free at 1-888-327-4236 (TTY: 1-800-424-9153);...

  • Page 4: Table Of Contents

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

  • Page 5: Vehicle Identification

    Vehicle Identification Component Information Label ............1.1 Vehicle Identification Number .
  • Page 6 Vehicle Identification Component Information Label tire and rim label, then the tires and rims determine the load limitations on each of the axles. NOTE: Labels shown in this chapter are ex- Incomplete chassis intended for service in the U.S. amples only. Actual specifications may vary from have an incomplete vehicle certification label at- vehicle to vehicle.
  • Page 7 Vehicle Identification in the instrument cluster that pertain to the ATS. See It is a violation of U.S. federal law to alter exhaust Fig. 1.4. plumbing, ATS, or other components in any way that 12/04/2001 f080122 Fig. 1.3, Vehicle Identification Number Label, Typical EXHAUST AFTERTREATMENT SYSTEM INFORMATION WARNING INDICATOR...
  • Page 8 Vehicle Identification would bring the engine/vehicle out of compliance with A Vehicle Emission Control Information Label indi- certification requirements [Ref: 42 U.S.C. S7522(a) cates compliance with GHG14 regulations. See (3)]. It is the owner’s responsibility to maintain the Fig. 1.5. It is the owner’s responsibility to maintain vehicle so that it conforms to EPA regulations.

  • Page 9: Vehicle Access

    Vehicle Access Battery Access ..............2.1 Hood Opening and Closing .
  • Page 10 Vehicle Access Battery Access or the vehicle may not start, and permanent bat- tery damage could occur. Battery Compartment The battery compartment is located behind the driver’s area, attached to the frame rail. To open the battery access door, insert and turn the key, then pull the access door open.
  • Page 11 Vehicle Access NOTICE Do not let the hood free-fall to the fully open po- sition. To do so could damage the hood or hood straps. Standing in front of the hood, tilt the rear of the hood upward until it reaches the over-center po- sition (45-degrees from vertical).

  • Page 12: Instruments

    Instruments Instrumentation Control Unit ............3.1 Warning and Indicator Lights .

  • Page 13: Instrumentation Control Unit

    Instruments Instrumentation Control Unit The S2 Chassis instrument clusters have the capabil- ity to drive independent stand-alone gauges such as those installed on the auxiliary dash panel. Figure Figure 3.1 Fig. 3.2 show a typical set of instru- shows a typical dash.
  • Page 14 Instruments CHECK STOP BRAKE FUEL F° WATER PUSH− MODE HOLD− RESET F° km/h X100 TRANS 10/26/2006 f610837b 1. Engine Oil Pressure Gauge 5. Fuel Level Gauge 9. Speedometer (U.S. version) 2. Dash Message Center 6. Primary Air Pressure Gauge 10. Tachometer (optional) 3.
  • Page 15 Instruments 07/31/2006 f831703 NOTE: Instruments and controls, and their locations, may vary from those shown. 1. Left-Hand Window Outlet 4. Windshield Defrost Outlets 7. HVAC Cover 2. Instrumentation Control Unit 5. Right-Hand Dash Outlet 8. Climate Control Panel (ICU3) 6. Right-Hand Window Outlet 9.
  • Page 16 NOTE: If active faults are present, take the ve- operating the vehicle, bring the vehicle to an hicle as soon as possible to an authorized authorized Freightliner service facility when Freightliner service facility. convenient. If the fault is mission-critical, that is, if it is a serious...

  • Page 17: Warning And Indicator Lights

    NOTE: If the check engine light illuminates dur- sition is left blank. ing vehicle operation, take the vehicle directly to The instrument cluster has an emergency buzzer that an authorized Freightliner service facility. sounds when mission-critical conditions occur.
  • Page 18 Instruments vehicle speed. The vehicle may be driven to a safe location. The engine ECU will derate the engine. The driver must safely bring the vehicle to a stop on the side of the road. CHECK STOP BRAKE NOTICE Because operating the engine when the red stop engine light is illuminated can lead to severe en- gine damage, the driver must move the vehicle to 09/28/2006...
  • Page 19 Instruments Diesel Particulate Filter (DPF) Lamp Oil Pressure Specifications Pressure at Pressure at Solid illumination indicates a regeneration is required. Engine Model Idle RPM Rated RPM Change to a more challenging duty cycle, such as Mercedes-Benz 50 psi (345 highway driving, to raise exhaust temperatures for at 50 psi (345 kPa) †...
  • Page 20 Instruments completely or it will be necessary to prime the Emergency Buzzer fuel system before the vehicle can be started The emergency buzzer sounds during the ignition again. sequence and whenever one of the following condi- tions exists: WARNING • The engine oil pressure falls below the preset Diesel fuel is flammable and can ignite if exposed level shown in...

  • Page 21: Speedometer And Tachometer

    Instruments Check Transmission Indicator (diesel engine only) NOTE: Although it appears in the row of op- tional indicator lights, the check transmission indicator is a standard indicator light. The check transmission indicator light, shown in km/h Fig. 3.8, notifies the driver of three things. The indi- X100 cator light has a solid illumination and any of the fol- lowing items could be the cause for activating the...
  • Page 22 160°F (71°C), or exceeds the maximum tem- perature shown in Table 3.2, inspect the cooling sys- ULTRA LOW SULFUR tem to determine the cause. See Group 20 of the S2 DIESEL FUEL ONLY Chassis Workshop Manual. F° 08/21/2009 f611045 1.

  • Page 23: Optional Instruments

    Instruments FUEL 10/09/2001 f610566 Fig. 3.13, Fuel Level Gauge the 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. Moving a vehicle without adequate braking power could cause an accident resulting in property damage, personal injury, or death.
  • Page 24 Instruments for easier viewing, the intake-air restriction indicator can be mounted on the dash, usually on the right- hand control panel. 10/10/2001 f610573 Fig. 3.16, Ammeter Axle Oil Temperature Gauge, Rear NOTICE A sudden increase in oil temperature that is not 10/10/2001 f610568 caused by a load increase may indicate mechani-...
  • Page 25 Instruments Under heavy loads, such as when climbing steep Push the Run/Set switch to the left grades, temperatures up to a maximum of 250°F (ALARM-SET position). (121°C) are not unusual. Set the alarm time by using the same pro- cedure used to set the time of day; re- Digital Clock member to set the hour for AM (no letters in the corner of the display), or PM as de-...
  • Page 26 Instruments • 180 to 225°F (82 to 107°C) for Cummins ISB NOTICE engines • 177 to 203°F (81 to 95°C) for Mercedes-Benz A sudden increase in transmission fluid tempera- MBE900 engines ture that is not caused by a load increase may indicate mechanical failure.

  • Page 27: Controls

    Controls Ignition Switch and Key ............4.1 Lighting Controls .

  • Page 28: Ignition Switch And Key

    Controls • Ignition Switch and Key Rocker switches can be pressed up or down to perform a function. Certain rocker switches are guarded to prevent them from being switched The ignition switch has four positions: ACCESSORY, on or off accidentally. OFF, ON, and START.

  • Page 29: Multifunction Turn Signal Switch

    Controls Daytime Running Lights Switching on the ignition and releasing the parking brakes automatically activates the daytime running lights, if so equipped. The daytime running lights will operate until the parking brakes are applied or the headlights are turned on. NOTE: Daytime running lights are standard on all Canadian vehicles.
  • Page 30 Controls marked on the dial by lines of increasing length, and two steady speed settings, LO and HI. Rotating the control dial forward (in a counterclock- wise direction) turns the wipers on. If they are al- ready on, rotating the handle further forward in- creases the speed of the wipers through the various delay settings, and to the LO and HI settings.

  • Page 31: Aftertreatment System (Ats) Regen Switch

    Controls Aftertreatment System (ATS) Regen Switch NOTE: Some alternative fueled vehicles are not equipped with a regeneration (regen) switch. A regen switch, located on the dash, allows the driver to control three states. See Fig. 4.9. These include: • request regeneration •...

  • Page 32: Powertrain Controls

    Controls NOTICE If equipped with a manual transmission, do not attempt to shift gears without using the clutch pedal when the cruise control is engaged. Failure to follow this precaution will result in a temporar- ily uncontrolled increase in engine speed; trans- mission damage and gear stripping could result.
  • Page 33 Controls • The Set/Resume Switch—this three-position The fast idle system can be used to increase engine paddle switch bears the legend RES/ACC idle speed whenever the following conditions are above the paddle and SET/CST below the met. paddle. • The brake pedal is not pressed. To cruise at a particular speed, do these steps: •...
  • Page 34 Controls 11/28/2001 f610589 Fig. 4.13, Exhaust Brake Switch When the transmission is in D (drive), the vehicle will operate in 4th and 5th gear as needed. To shift down into a lower gear, pull the lower half of the T-handle selector up.

  • Page 35: Braking Controls

    Fig. 4.16, Differential Lock Switch traction control (ATC), an amber wheel spin indicator light (WHEEL SPIN legend). See Fig. 4.18. Take the vehicle to an authorized Freightliner See the brake system operating instructions in Chap- dealer as soon as possible. ter 13 for more information about ABS.

  • Page 36: Cab Features

    Cab Features Windows ............... . 5.1 Mirrors .

  • Page 37: Windows

    Cab Features Windows Mirrors Standard windows operate mechanically using a The standard outside mirrors are mounted on the hand crank. door frame. There is a primary rear view mirror and a convex mirror. Power windows are optional, and can be installed on one side or both sides.

  • Page 38: Seats

    Cab Features the area adjacent to the right side of the cab. See Unless otherwise noted, all seat adjustments should Fig. 5.5. be made while seated and before the engine is started. Due to the high degree of adjustability found in high- back air suspension seats, it is possible to set the seat back recline adjustment and the seat slide ad- justment in such a combination that the seat back...
  • Page 39 Cab Features This adjustment is either mechanical or air con- trolled, depending on the make and model of the seat. See Fig. 5.7. 10/05/2001 f910484 A. Backrest Tilt B. Seat Cushion Tilt Fig. 5.8, Cushion Tilt Adjustments 10/05/2001 f910483 A. Lumbar Support B.
  • Page 40 Cab Features Bostrom Seat Seat Cushion Tilt Seat Slide Adjustment Rotate the seat cushion tilt knob to increase or de- crease seat cushion tilt. Move the seat slide and isolator lever, shown in Fig. 5.10, to the left and hold it there to slide the Backrest Tilt seat forward or backward to the desired position.
  • Page 41 Cab Features 10/08/2001 f910487 1. Seat Slide Lever 2. Seat Cushion Tilt Adjustment 3. Ride Height Knob 4. Lumbar Support Lever 5. Backrest Lever Fig. 5.12, Sears Low Profile Seat f910445 11/14/2000 1. Backrest Tilt Knob Lumbar Support 2. Lumbar Support Switch 3.

  • Page 42: Seat Belts And Tether Belts

    Seat belt assemblies are designed to secure persons in the vehicle to help reduce the chance of injury or the amount of injury resulting from accidents or sud- den stops. For this reason, Freightliner Custom 10/09/2001 f910486 Chassis Corporation (FCCC) urges that the driver NOTE: Armrests are optional.
  • Page 43 Cab Features IMPORTANT: Seat belts have a finite life which worn by one person at a time. In case of an acci- dent or sudden stop, personal injury or death may be much shorter than the life of the vehicle. could result from misuse.
  • Page 44 Cab Features position. See Fig. 5.16. To activate the latch, lean forward until you hear a click. This will allow for approximately 1 inch (2.5 cm) of slack be- tween your chest and the shoulder harness. Once engaged, the latch will allow you to lean forward about 5 inches (13 cm) without having to reset the latch.

  • Page 45: Cab Amenities

    Cab Features head console. See Fig. 5.20. The overhead storage bin is often removed and replaced with a CB radio. Two map holders with netted openings are located overhead, one on either side of the overhead con- sole. 11/02/95 f910144 Fig.
  • Page 46 Cab Features 10/08/2001 f680027 1. Overhead Storage Bin 2. Overhead Console 3. Map Holder Netting Fig. 5.20, Overhead Storage 5.10...

  • Page 47: Electrical Systems

    Electrical Systems Electrical System General Information ..........6.1 Power Distribution Modules .
  • Page 48 Electrical Systems Electrical System General Information The S2 Chassis uses an electrical system where multiple electrical signals are carried along a simpli- fied set of wires, reducing the size of wiring bundles. There are significantly fewer wires overall, meaning less chance of damage, shorts, and other problems.
  • Page 49 Electrical Systems Main PDM Fuse Identification Description Fuse Spare — Hydraulic Pump and RLY (if equipped with hydraulic brakes) Spare — Spare — Table 6.1, Main PDM Fuse Identification 12/19/2003 f544381 1. Battery Power Mega Fuse 1 3. Engine Harness (green) 5.

  • Page 50: Heater, Ventilating, And Air Conditioner (Hvac)

    Heater, Ventilating, and Air Conditioner (HVAC) Climate Control Panel ............. 7.1...
  • Page 51 Heater, Ventilating, and Air Conditioner (HVAC) Climate Control Panel lets, the defrost (windshield) outlets, or a combination of these outlets. Nine air selection modes are avail- able on a system without air conditioning. See The climate control panel controls the HVAC for the Fig.
  • Page 52 Heater, Ventilating, and Air Conditioner (HVAC) 06/18/2003 f831453a 1. Fan Switch 3. Temperature Control Switch 5. Recirculation Indicator 2. Air Selection Switch 4. Recirculation Button Fig. 7.2, Climate Control Panel With Air Conditioning 06/18/2003 f831462 06/17/2003 f831455 A. Air Conditioning Modes 1.
  • Page 53 Heater, Ventilating, and Air Conditioner (HVAC) Defrost Mode: Directs all airflow through the wise) for hot air. There are 21 positions on the tem- defrost outlets. perature control switch ranging from full cool air to full hot air. Air Selection Switch With Air Fresh Air Mode Conditioning Air Conditioning Face Mode: Directs all airflow...
  • Page 54 It will be necessary to cycle the fan switch off, and then on, to reset the motor. If the problem appears repeatedly, take the vehicle to an authorized Freightliner dealer for repairs.

  • Page 55: Engines

    Engines Engine Starting ..............8.1 Engine Operation .
  • Page 56 Engines Engine Starting IMPORTANT: On vehicles equipped with an in- take air preheater, the INTAKE HEATER indica- For cold-weather starting, refer to the Cummins or tor stays on for a minimum of two seconds, re- Mercedes-Benz engine manufacturer’s operator’s gardless of coolant temperature. Wait until the manual, as applicable, for detailed instructions.
  • Page 57 Engines Starting After Extended Shutdown or the air intake, and cause engine overspeed. Be es- pecially cautious of low-lying or closed-in areas, and Oil Change always check for signs that flammable vapors may be present. NOTE: An engine in storage for an extended period of time (over winter, for example) may DANGER accumulate water in the oil pan.
  • Page 58 Engines Depending on the vehicle gearing, the posted NOTICE speed limit can sometimes allow operation in ei- ther of the top two gears; however, for improved Continuous operation below 140°F (60°C), above operating efficiency (fuel economy and engine 212°F (100°C), or with the oil pressure below 10 life), operate in the top gear at reduced rpm psi (69 kPa), can damage the engine.
  • Page 59 Engines Voltage-Based Auto High Idle gines. The extreme heat can cause bearings to seize or oil seals to leak. Place the shift lever in Neutral (N) or Park (P) NOTE: Long periods of idling are not good for and set the parking brake. an engine because the combustion chamber The idle rpm will automatically increase when the temperatures drop so low that the fuel may not...

  • Page 60: Exhaust Aftertreatment Systems

    Exhaust Aftertreatment Systems Aftertreatment System, EPA10 and Newer Engines ........9.1 Diesel Exhaust Fluid and Tank, EPA10 and Newer Engines .
  • Page 61 Exhaust Aftertreatment Systems • Aftertreatment System, EPA10 Engine lube oil must have a sulfated ash level less than 1.0 wt %; currently referred and Newer Engines to as CJ-4 oil. • Use only certified diesel exhaust fluid (DEF) Engines manufactured between January 1, 2010 and in the DEF tank.
  • Page 62 Exhaust Aftertreatment Systems Operating at reduced engine load will allow soot to accumulate in the DPF. When this occurs, the DPF lamp illuminates, indicating that a regen must be per- formed, and the driver must either bring the vehicle up to highway speed to increase the load, or park the vehicle and initiate a parked regen.
  • Page 63 Exhaust Aftertreatment Systems A reference label is included with the driver’s docu- (because the engine software is signaling for a mentation package initially in the glove box, that ex- parked regen). plains the ATS warnings, and actions required to The regen-inhibit switch (optional when available) avoid further engine protection sequences.
  • Page 64 Exhaust Aftertreatment Systems 07/30/2009 f610944 Fig. 9.5, Regen Inhibit Switch (optional when available) For manual transmissions, fully depress the clutch pedal, put the transmission in neutral, then 02/11/2009 f545207 release the pedal. 1. Primary Lock 3. Plug If the vehicle has a two-pedal automated trans- 2.
  • Page 65 The DEF tank will require filling a minimum of ap- • proximately every second diesel refuel depending on vehicle mileage; the DEF tank capacity. The S2 Chassis has an 11.5- • particulate filter part number and serial number. gallon tank capacity. DEF consumption is approxi-...
  • Page 66 Exhaust Aftertreatment Systems ULTRA LOW SULFUR ULTRA LOW SULFUR ULTRA LOW SULFUR DIESEL FUEL ONLY DIESEL FUEL ONLY DIESEL FUEL ONLY 11/08/2010 f611037 A. Green bars—DEF level indicators. C. One bar flashing red—DEF empty, refill DEF. B. One bar illuminated amber—DEF very low, refill DEF. 1.
  • Page 67 Exhaust Aftertreatment Systems after the next engine shutdown, or while parked and idling. See Fig. 9.10. EPA07 Aftertreatment System (ATS) All on-road diesel engines built after December 31, 2006, (EPA07 engines) must meet strict new guide- lines for reduced exhaust emissions of particulate matter and nitrogen oxides (NOx).
  • Page 68 Exhaust Aftertreatment Systems the DPF, which traps soot particles. If exhaust tem- A steadily illuminated HEST lamp alerts the operator perature is high enough, the trapped soot is reduced of high exhaust temperature during the regeneration to ash in a process called passive regeneration process, if vehicle speed is below 5 mph (8 km/h).
  • Page 69 Exhaust Aftertreatment Systems NOTE: The regen switch can start a regen only when at least one of two conditions exists: ei- ther the DPF lamp is lit, or the engine software calls for it. If neither of those conditions exist, the regen switch cannot cause a regen to hap- pen.
  • Page 70 Exhaust Aftertreatment Systems then the Check Engine lamp will flash for 30 sec- onds, before the engine shuts down. 9.10...

  • Page 71: Transmission

    Transmission Driving Precautions ............. . 10.1 Allison On-Highway Transmissions .

  • Page 72: Driving Precautions

    Transmission Driving Precautions When driving on icy or graveled surfaces, reduce speed. Avoid sharp turning maneuvers. The vehicle operator should use care when acceler- Allison On-Highway ating or downshifting on slippery road surfaces. Sud- den acceleration or engine braking, caused by shift- Transmissions ing to a lower gear range, can result in a loss of vehicle control.
  • Page 73 Transmission Chock the rear tires and take any other steps necessary to keep the vehicle from moving. Range Inhibit Indicator, 2000 Series A RANGE INHIBIT indicator is a standard feature of the 2000 series transmissions. The RANGE INHIBIT indicator comes on to alert the driver that transmis- sion operation is being inhibited and that the range shifts being requested by the driver may not occur.
  • Page 74 Transmission PB (Auto-Apply Parking Brake, optional selected. However, during downhill operation, the transmission may upshift to the next higher range, if on 2000 Series) the engine is exceeding its governed speed in the The auto-apply parking brake places the transmis- lower range.
  • Page 75 Transmission WARNING Do not coast in neutral. Coasting in neutral can cause an accident, possibly resulting in severe personal injury or death. Do not let the vehicle coast in neutral. If the vehicle is allowed to coast in neutral, the engine brake will not work and the driver could lose control of the ve- hicle.
  • Page 76 Transmission Mode Button WARNING The MODE button starts a specialized input or output function that has been previously programmed into When going downhill, use a combination of the ECU or TCM. Pressing the MODE button downshifting, braking, and other retarding de- changes transmission operation for a specific func- vices to control vehicle speed and the engine’s tion.

  • Page 77: Eaton® Fuller® Straight-Shift Transmissions

    Transmission NOTE: During normal operation, an illuminated shifting is desired and less gear reduction is accept- able. mode indicator LED signifies the specialized mode operation is in use. Operation, Straight-Shift To enter diagnostics mode, first park the vehicle and Always use first gear when starting to move the apply the parking brake.

  • Page 78: Clutches

    Transmission On synchronized models, depress the Clutches are designed for specific vehicle applica- clutch pedal and move the shift lever to tions and loads. These limitations should not be ex- the next lower gear. ceeded. On unsynchronized models, depress the Riding the Clutch Pedal clutch pedal and move the shift lever to neutral.
  • Page 79 Reporting erratic clutch operation as soon as pos- Some clutches have an internal adjustment. See the sible will give maintenance personnel a chance to applicable section in Group 25 of the S2 Chassis inspect the clutch components. Workshop Manual for clutch adjustment procedures and specifications.

  • Page 80: Drive Axles

    Drive Axles ™ ™ Drive Axles, Detroit and Meritor ..........11.1...
  • Page 81 30 seconds, the lock mechanism may not be fully engaged/disengaged. Bring the vehicle to an autho- IMPORTANT: The differential lock rocker switch rized Freightliner service facility for testing. is guarded to prevent unintentional switch acti- vation. If the light emitting diode (LED) in the...
  • Page 82 Drive Axles NOTICE The differential lock should be engaged when the vehicle is stopped or moving at a low, constant speed and the wheels are not spinning, slipping, or losing traction. Engagement at high speed or power can damage the axle(s). Do not permit rear wheels to spin freely for more than ten seconds when traction is lost.

  • Page 83: Steering System

    Steering System Steering Controls ..............12.1...
  • Page 84 9 o’clock and 3 o’clock posi- tions, or within 10 degrees to either side as shown in Fig. 12.1. See Group 46 of the S2 Chassis Work- shop Manual for steering adjustment procedures. 11/14/2001 f461922 10°...

  • Page 85: Hydraulic And Air Brake Systems

    Hydraulic and Air Brake Systems Dual Air Brake System ............13.1 Air Brake Operation .

  • Page 86: Dual Air Brake System

    Hydraulic and Air Brake Systems Dual Air Brake System A dual air brake system consists of two independent air brake systems that use a single set of brake con- trols. Each system has its own reservoir, plumbing, and brake chambers. The primary air system oper- ates the service brakes on the rear axle;...
  • Page 87 Hydraulic and Air Brake Systems Check to see that the wheel chair lift is in the Bring the vehicle to a safe stop and have stowed position. the air system repaired before continuing. Confirm that the wheel chair lift switch is in the During normal brake stops, depress the service OFF position.

  • Page 88: Bosch Hydraulic Pin Slide Brakes

    Hydraulic and Air Brake Systems IMPORTANT: Before caging the parking brakes, Operation make the connection to a towing vehicle or Before driving the vehicle, secure all loose items in chock the tires. the vehicle so that they will not fly forward during a After correcting the brake system problem, uncage full brake application.

  • Page 89: Meritor Wabco Pneumatic Antilock Braking System (Abs)

    Hydraulic and Air Brake Systems 05/24/2012 f420477a A. Fill level for brake fluid. Fig. 13.2, Master Cylinder Reservoir Meritor WABCO Pneumatic sized tires could result in a reduced braking force, leading to longer stopping distances. Antilock Braking System (ABS) During emergency or reduced traction stops, fully Pneumatic ABS is an electronic wheel speed moni- depress the brake pedal until the vehicle comes to a toring and control system that works with the air...

  • Page 90: Exhaust Brake

    Hydraulic and Air Brake Systems the ATC system automatically limits wheel spin dur- NOTICE ing reduced-traction situations. In normal braking ap- plications, the standard air brake system is in effect. Do not turn the differential lock switch on while During reduced-traction situations, the ATC solenoid the WHEEL SPIN indicator light is on.
  • Page 91 Hydraulic and Air Brake Systems switch is on, an amber light emitting diode (LED) illu- follow this precaution could result in a loss of minates inside the switch. When the panel lights are vehicle control and possible personal injury or on, the EXHST BRK legend is backlit in green.

  • Page 92: Engine Brake

    Hydraulic and Air Brake Systems When the panel lights are on, the Hi-Lo icon is back- NOTICE lit in amber on the three-position switch. On both the three-position switch and the two-position switch, the Do not allow the engine to exceed its governed ENG BRK legend is backlit in green when the panel speed, or serious engine damage could result.

  • Page 93: Pre- And Post-Trip Checklists

    Pre- and Post-Trip Checklists Pretrip and Post-Trip General Information ..........14.1 Daily Pretrip Inspection and Maintenance Checklist .

  • Page 94: Pretrip And Post-Trip General Information

    Whenever equipment requires adjustment, replacement, repair, addition of lubricants, or a change of lubricants, see the S2 Chassis Workshop Manual for procedures and specifications, or take the vehicle to an authorized Freightliner dealer.
  • Page 95 Pre- and Post-Trip Checklists Procedure Performed Procedure Daily Pretrip Inspections/Checks (check off) Reference Drain manually drained air reservoirs (that are not equipped with automatic drain _______ valves) Check _______ windshield washer reservoir fluid Inspect _______ wheel seal and hub cap (for leakage) —...

  • Page 96: Weekly Post-Trip Inspection And Maintenance Checklist

    Pre- and Post-Trip Checklists Weekly Post-Trip Inspection For the weekly post-trip inspection and maintenance checklist see Table 14.2. and Maintenance Checklist IMPORTANT: Before performing any of these checks, apply the parking brake and chock the tires. Procedure Performed Procedure Weekly Post-Trip Inspections/Checks (check off) Reference _______...

  • Page 97: Pre- And Post-Trip Inspections And Maintenance

    Pre- and Post-Trip Inspections and Maintenance Safety Precautions ............. . . 15.1 Daily Pretrip Inspection and Maintenance Procedures .

  • Page 98: Safety Precautions

    Do not expose washer fluid to an open flame or Whenever equipment requires adjustment, replace- any burning material, such as a cigarette. Always ment, and/or repair, see the S2 Chassis Workshop comply with the washer fluid manufacturer’s rec- Manual for procedures and specifications. Specific ommended safety precautions.
  • Page 99 † 275110 NOTICE Freightliner-approved antifreeze must meet one of the following condi- tions: A. Ethylene glycol solution that meets GM 6038–M Engineering Standards. B. Ethylene glycol solution that has less than 0.1% anhydrous Failure to maintain a sealed air intake system sodium metasilicate and meets either GM 1825–M or GM 1899–M Engi-...
  • Page 100 Pre- and Post-Trip Inspections and Maintenance Park the vehicle on a level surface. Allow several minutes for the oil to drain back into the oil pan to ensure an accurate reading. NOTE: For diesel engines, follow the engine manufacturer’s guidelines for engine shut- down time requirements prior to checking the oil level.
  • Page 101 If equipped with a fuel/water separator, check for For repair and/or replacement procedures, water. see Group 47 of the S2 Chassis Work- Drain any water found. Check the fuel/water shop Manual, or take the vehicle to an separator for leaks and contaminants.
  • Page 102 Pre- and Post-Trip Inspections and Maintenance Replace the wiper arms if the wiper blades are not tensioned against the windshield. Replace damaged or deteriorated wiper blades. WARNING When cleaning windshields and windows, always stand on the ground or on a secure ladder or platform.
  • Page 103 Pre- and Post-Trip Inspections and Maintenance the parking brake is released or the ignition switch is turned off. See Chapter 3 for detailed operating instructions for the ICU. Make sure that the horn, windshield wipers, and windshield washers are operating properly. These devices must be in good working order for safe vehicle operation.
  • Page 104 (GHG14). age. Contact your tire manufacturer/supplier to deter- See Group 33 or Group 35 of the S2 mine the rolling resistance of the originally in- Chassis Workshop Manual for service pro- stalled tires. Visit www.epa.gov/smartway...
  • Page 105 Pre- and Post-Trip Inspections and Maintenance 02/09/95 f400001 Fig. 15.9, Worn Stud Holes wheel nut torque can break studs, damage threads, and crack discs in the stud hole area. Use the recommended torque values and follow the proper tightening sequence. NOTE: Vehicles operating under severe or ad- verse conditions should be checked more fre- quently.
  • Page 106 If dried out or ragged (the wire or liner brake. See Group 42 of the S2 Chassis is showing through the cover), have the Workshop Manual.
  • Page 107 Pre- and Post-Trip Inspections and Maintenance 23.6 Inspect the air tubing, especially tubing made of nylon. In cold weather, nylon tub- ing is sensitive to damage, such as nicks or 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 require special examination.

  • Page 108: Weekly Post-Trip Inspection And Maintenance Procedures

    Pre- and Post-Trip Inspections and Maintenance With the air system fully charged to 120 Maximum Allowable Service Brake Leakage psi (827 kPa), make one full brake appli- Maximum Air Leakage Per Minute cation and note the air pressure reading Brakes Released Brakes Applied on the gauge.
  • Page 109 If needed, fill the hubs to the level indicated on have the belt replaced, following the instructions the hub cap. See Chapter 19, for recommended in Group 01 of the S2 Chassis Workshop lubricants. Manual. IMPORTANT: Before removing the fill plug, al- ways clean the hub cap and plug.

  • Page 110: Monthly Post-Trip Inspection And Maintenance Procedures

    To prevent possible per- extended service life can be substituted for the sonal injury, always wash your hands after han- reinforced neoprene type. See the Freightliner dling battery parts and related accessories. Service Parts Catalog or contact your Freight- Clean the batteries.
  • Page 111 1/4 inch (6.4 mm) at the thinnest point, have the linings replaced on all brake assemblies on that axle. See Group 42 of the S2 Chassis Workshop Manual for lining re- placement instructions and camshaft end- play inspection.

  • Page 112: Cleaning And Care

    Cleaning and Care Washing and Polishing ............16.1 Care of Fiberglass Parts .
  • Page 113 Cleaning and Care Washing and Polishing Care of Fiberglass Parts Wash unpainted fiberglass air fairings and shields NOTICE monthly with a mild detergent, such as dishwashing liquid. Avoid strong alkaline cleansers. When pressure washing the vehicle or leaving Apply a wax specifically designed for fiberglass. the hood open when parked outdoors and sub- ject to rain, cover the air cleaner inlet with a plas- Care of Chrome Parts...
  • Page 114 Cleaning and Care crazing in the interior plastic panels and can re- Tars, Asphalts, and Creosote sult in cracking of the panels. Some cleaners can Tars, asphalts, and creosote stain vinyl after pro- also have an adverse effect on the clear plastic longed contact.
  • Page 115 Cleaning and Care Miscellaneous stain. Dab repeatedly with clear, cool water, and blot dry. If stains do not respond to any of the treatments de- scribed above, it is sometimes helpful to expose the vinyl to direct sunlight for up to 30 hours. Mustard, ball point ink, certain shoe polishes, and dyes often bleach out in direct sunlight, leaving the vinyl undam- aged.

  • Page 116: In An Emergency

    In an Emergency Hazard Warning Lights ............17.1 Emergency Starting With Jumper Cables .

  • Page 117: Hazard Warning Lights

    In an Emergency Hazard Warning Lights personal injury as a result of an explosion or acid burns. The hazard warning light switch is part of the multi- function turn signal switch. It is a red rocker switch NOTICE located on the top of the multifunction switch module. Fig.
  • Page 118 In an Emergency − − − − − − 01/07/2011 f545725 Disconnect jumper cables in the REVERSE order that they were connected. A. Discharged Battery C. Positive Jumper Cable E. Booster Battery B. Negative Ground Stud D. Negative Jumper Cable 1.

  • Page 119: Towing

    In an Emergency Start the engine of the vehicle providing the jump IMPORTANT: When it is necessary to tow the start and let the engine run for a few minutes to vehicle, make sure the instructions below are charge the batteries of the other vehicle. closely followed to prevent damage to the ve- hicle.

  • Page 120: Running Out Of Fuel

    In an Emergency Connect the clearance lights, taillights, and sig- See the engine manufacturer’s manual for in- nal lights. Connect any special towing lights re- structions to prime the fuel system. quired by local regulations. If further assistance is needed, call the Freight- liner Customer Assistance Center at 1-800-385- WARNING 4357 or 1-800-FTL-HELP.

  • Page 121: Fire Extinguisher

    In a star pattern, tighten the nuts evenly until snug. See Group 40 of the S2 Workshop Manual for wheel tightening patterns and torque specifications. Lower the vehicle until the wheel touches the ground.

  • Page 122: Headlight Aiming

    Headlight Aiming Preliminary Checks ............. . . 18.1 Checking Headlight Aim .
  • Page 123 Headlight Aiming Mark the vertical distances found in step 2 on Preliminary Checks the screen or wall, directly in front of the head- lights. These marks represent the desired loca- Before checking or adjusting the headlight aim, do tions of each headlight bulb center in the follow- the following: ing steps.
  • Page 124 Headlight Aiming 10/15/2012 f545850g A. Measure the distance from the ground to the center of each headlight bulb. B. Mark where the center of each headlight projection should appear. 1. Screen or Wall 3. Center of Left-Hand Headlight Projection 2. Center of Right-Hand Headlight Projection Fig.
  • Page 125 Headlight Aiming 11/05/2002 f544235 NOTE: The right-hand side headlight bucket is shown. The left-hand side is opposite. 1. Horizontal (inboard) Adjusting Knob 2. Vertical (outboard) Adjusting Knob Fig. 18.4, Headlight Adjusting Knobs Vertical Low-Beam Headlight Variation Limits Distance Between Ground Desired Variation ( Fig.

  • Page 126: Propane Fuel System

    Propane Fuel System General Information ............. . 19.1 Ignition Switch and Key .

  • Page 127: General Information

    Propane Fuel System General Information with a minimum of 90% propane and a maximum of 5% propylene. This grade of propane is 100 plus oc- tane and provides proper performance and emissions CAUTION control, which the fuel system is designed to deliver. The engine is designed to operate properly on a The propane fuel system requires special tools to wide variety of liquid propane gas (LPG) blends...

  • Page 128: Engine Operation

    Propane Fuel System In the OFF position, the key slot is vertical; the key Moving a vehicle with the starter and/or using the can be inserted and removed only in this position. starter to bump the engine for maintenance pro- The following can be operated in the OFF position cedures is strictly prohibited.

  • Page 129: T-Handle Shifter

    The auto-apply parking brake places the transmis- T-Handle Shifter sion in neutral and applies the parking brake. The S2 propane chassis is equipped with an Allison R (Reverse) 2300 or 2350 Series transmission. A T-handle shift control is used by the driver to select the transmis- Reverse is used to back the vehicle.

  • Page 130: Propane Refueling

    Propane Fuel System N (Neutral) NOTE: To have the transmission select these ranges automatically, leave the selector lever in The neutral position places the transmission in neu- D (drive). tral. When neutral is selected, the vehicle service brakes, parking brake, or emergency brake must be Propane Refueling applied.
  • Page 131 Propane Fuel System other serious injuries. Keep sparks and flames Ensure that there are no open flames or ignition away from propane. Do not smoke near propane sources in the area. or when refueling the vehicle. Turn the fuel tank cap counterclockwise and re- Propane is stored in the fuel tank under high move it.

  • Page 132: Ametek Instrument Panel

    Propane Fuel System Open the 80% bleeder valve only if required. per hour (mph) more prominently than kilome- CleanFuel USA does not recommend using the ters per hour (km/h). bleeder valve. Use of the valve in a low emission fuel station is prohibited. Message Display Center Open the valve on the refueling nozzle.
  • Page 133 Propane Fuel System 12/05/2012 f611202 1. Tachometer 5. Primary Air Pressure Gauge 8. Dash Driver Display Screen 2. Dash Message Center 6. Secondary Air Pressure Gauge 9. Toggle Button, Down 3. Speedometer 7. Coolant Temperature Gauge 10. Toggle Button, Right 4.
  • Page 134 Propane Fuel System gauges. It also shows the hardware and soft- filter. If the intervals are set to zero, the maintenance ware version of the instrument panel, and has warnings must be disabled. menus to retrieve active error codes from the Transmission Oil Life Remaining engine, transmission, and ABS controllers.
  • Page 135 Propane Fuel System SETUP Right Press Down Hold Current Units = English Down Press Down Press Current Units = Current Units = English Metric Current Units = Right Press Metric Right Press Select Display Units highlighted Down Hold Right Press Down Hold Startup Screen = Enabled...

  • Page 136: Warning And Indicator Lights

    Propane Fuel System Transmission Faults Check Datalink This screen displays transmission fault codes that The check datalink screen allows the driver to view are received from the transmission ECU. To navigate all devices that communicate on the J1939, J1587, to the transmission fault screen, see Fig.
  • Page 137 Propane Fuel System Diagnostics Screens AA,AB,AC Format For J1587 Down Press Note 5: Display Next Fault Screen Z scrolls to display the following items: ENGINE FAULTS TRANSMISSION FAULTS Right Press Right Press ABS FAULTS Engine Faults Menu CHECK OUTPUTS Highlighted Down Hold CHECK DATA INPUTS ODOMETER DIAGNOSTICS...
  • Page 138 Propane Fuel System Other Text for Screen AG Down Press Change to Next Gauge Right Press Check Gauges Right || Hold Down Menu Highlighted Right Hold Step Gauge to Next Position Down Press Change to Next Telltale Right Press Menu Warning Lamps Right || Hold Down Highlighted...
  • Page 139 At this point, the vehicle is unsafe to drive and to the engine. should be transported to an authorized Freightliner The red stop engine warning light illuminates to indi- service facility. cate that the protection system available for the en-...
  • Page 140 Propane Fuel System Ignition On or Headlamps On or Marker Lamps On or Park Brake Off ACTIVE Ignition Off & IGNITION ( Headlamps On or Marker Lamps On or Park Brake Off ) Ignition On Ignition Ignition IGNITION ON NORMAL MODE SELF TEST Self Test Enabled...
  • Page 141 Propane Fuel System SELF TEST The Self Test screens display the FCCC logo in normal video (Screen A) and in reverse video (Screen B) Startup Screen Enabled Screen A XXXXXXXXXXXXXXXXXXXXXX XXXXXXXXXXXXXXXXXXXXXX XXXXXXXXXXXXXXXXXXXXXX Screen Displayed for 1.5 Seconds Startup Screen Disabled Screen B XXXXXXXXXXXXXXXXXXXXXX XXXXXXXXXXXXXXXXXXXXXX...
  • Page 142 Propane Fuel System DISPLAY MESSAGES Right Hold Reset Highlighted Item Down Hold (if resettable) Make No Changes Screen D Screen C Right Press Selected Line 1 Data Favorites Display Menu Selected Line 2 Data Highlight First Item in List Average Fuel Economy Selected Line 3 Data Gear Attained Status Right Press...
  • Page 143 Propane Fuel System AUXILIARY SCREENS Right Press Setup SETUP highlighted SETUP. Right Press Maintenance MAINTENANCE highlighted Screen G SETUP MAINTENANCE DIAGNOSTICS Down Press Right Press Highlight next Diagnostics DIAGNOSTICS line of list. highlighted At middle, wrap to top Down Hold Right Press TRIP DATA Trip Data...
  • Page 144 Propane Fuel System MAINTENANCE Maint Menu Right Press Down Hold Down Press (Right & Exit Highlight next highlighted) line of list. Right Hold At middle, Oil Change Baseline + Oil Change wrap to top Oil Change Distance >= Baseline = Odometer Odometer Right Press...

  • Page 145: Speedometer And Tachometer

    244° (118°C) the emergency buzzer propriate rpm range. See Fig. 19.19. and stop engine light will turn off. NOTE: The check engine light will remain on until the vehicle is inspected at an authorized Freightliner service facility. 19.19...

  • Page 146: Standard Instruments

    Propane Fuel System Trip Data Down Press Highlight next line of list. At bottom, Right Press wrap to top Right Press Correct Passcode / Reset All Reset Trip Highlighted Data (Right & Exit highlighted) Down Press Wrong Passcode / Note 6: Screen AO scrolls to display the following items: Trip Time...

  • Page 147: Grade Brake

    Propane Fuel System WARNING MESSAGES Msg Displayed for 5 Sec. / Display Next Entry in Warning Message List Display 1 Message in Warning Message List Screen AN WARNING Any Button Press Warning Message No Warning Messages in List / DISPLAY MESSAGES 02/06/2012 f040799...
  • Page 148 Propane Fuel System IGNITION OFF Park Brake Off Park Brake On Park Brake On Headlamps Off & Ignition On Marker Lamps Off & Park Brake On IGNITION 02/06/2012 f040800 Fig. 19.17, Ignition Off (shown when ignition is keyed OFF) transmission. It should not be confused with ex- haust brake or engine brake.
  • Page 149 Propane Fuel System 10 11 12 13 10/30/2012 f611201 1. Maintenance Warning Light 8. Headlight High-Beam Indicator 14. Check Transmission Indicator 2. Left-Turn Signal Arrow 9. Wait to Start Warning 15. Stop Transmission Indicator 3. Check Engine Indicator 10. Hydraulic Brake System Warning 16.
  • Page 150 Propane Fuel System 10/01/2013 f611219 1. Low-Level Warning Light Fig. 19.20, Fuel Level Gauge 09/18/2013 f611218 1. Primary Air Pressure Gauge 3. Low Secondary Air Pressure Warning Light 2. Low Primary Air Pressure Warning Light 4. Secondary Air Pressure Gauge Fig.
  • Page 151 Propane Fuel System 09/18/2013 f611220 1. High Coolant Temperature Warning Light Fig. 19.22, Coolant Temperature Gauge 09/20/2013 f261458 Fig. 19.23, Grade Brake Switch 19.25...

  • Page 152: Specifications

    Specifications Torque Charts ..............20.1 Conversion Charts .

  • Page 153: Torque Charts

    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).
  • Page 154 Male and female threads (bolt and nut) must both be unlubricated and unplated. If either is plated or lubricated, use Table 20.3. Freightliner recommends that all plated and unplated fasteners be coated with oil before installation. Table 20.2, Torque Values for U.S. Customary Thread Fasteners With Dry (Unlubricated) Plain (Unplated) Threads...
  • Page 155 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).

  • Page 156: Conversion Charts

    Specifications Conversion Charts When You Know U.S. Multiply When You Multiply To Get Metric To Get U.S. Customary Customary Know Metric Length inches (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...

  • Page 157: Fluids And Lubricants

    Specifications Fluids and Lubricants Table 20.6 for fluid and lubricant specifications. Fluid and Lubricant Specifications Component Recommended Fluid or Lubricant Front Axle Spindle Pins, Tie Rods, Drag Link, Multipurpose Grease Lithium 12- Hydroxy Stearate NLGI No. 2; for Intermediate Steering Shaft, Front Brake and temperatures below 0°F (–18°C), use MIL-G-10924B Pedal Shafts, Slip Spline and Universal Joints Hydraulic Brake Master Cylinder...

  • Page 158: Bulb Replacement

    Specifications Bulb Replacement Table 20.8 for bulb replacement information. Replacement Bulb Part Numbers Description Part Number Headlight, Low Beam WEE 9006 Headlight, High Beam WEE 9005 Front Turn Signal Light WEE 3157 Front Fender Marker Light WEE 194 Table 20.8, Replacement Bulb Part Numbers 20.6...

  • Page 159: Index

    Index Subject Page Subject Page Cup Holders ......5.9 Care of Chrome Parts ..... 16.1 Adjusting Headlight Aim .
  • Page 160 Index Subject Page Subject Page General Information, Closing the Hood ..... . . 2.2 Straight-Shift ......10.6 Tilting the Hood .
  • Page 161 Index Subject Page Subject Page Fuel/Diesel Exhaust Fluid (DEF) Gauge ..... . . 3.10 Optional Instruments ..... . 3.11 Primary and Secondary Air Pressure Gauges .
  • Page 162 Index Subject Page Check Transmission Indicator ......19.16 Cruise Control Indicator ....3.8 Diesel Particulate Filter (DPF) Lamp .

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