freightliner Columbia Manual
freightliner Columbia Manual

freightliner Columbia Manual

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Table of Contents

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Introduction
This manual provides information needed to operate
and understand the vehicle and its components.
More detailed information is contained in the Owner's
Warranty Information for North America booklet, and
in the vehicle's workshop and maintenance manuals.
Custom-built Freightliner vehicles are equipped with
various chassis and cab components. Not all of the
information contained in this manual applies to every
vehicle. For details about components in your ve-
hicle, refer to the chassis specification pages in-
cluded in all new vehicles and to the vehicle specifi-
cation decal, located inside the vehicle.
For your reference, keep this manual in the vehicle
at all times.
IMPORTANT: Descriptions and specifications in this
manual were in effect at the time of printing. Freight-
liner Trucks reserves the right to discontinue models
and to change specifications or design at any time
without notice and without incurring obligation. De-
scriptions and specifications contained in this publi-
cation provide no warranty, expressed or implied,
and are subject to revisions and editions without no-
tice.
Environmental Concerns and
Recommendations
Whenever you see instructions in this manual to dis-
card materials, you should first attempt to reclaim
and recycle them. To preserve our environment, fol-
low appropriate environmental rules and regulations
when disposing of materials.
Event Data Recorder
This vehicle is equipped with one or more devices
that record specific vehicle data. The type and
amount of data recorded varies depending on how
the vehicle is equipped (such as the brand of engine,
if an air bag is installed, or if the vehicle features a
collision avoidance system, etc.).
Customer Assistance Center
Having trouble finding service? Call the Customer
Assistance Center at 1-800-385-4357 or 1-800-FTL-
HELP. Call night or day, weekdays or weekends, for
dealer referral, vehicle information, breakdown coor-
dination, or Fleetpack assistance. Our people are
knowledgeable, professional, and committed to fol-
lowing through to help you keep your truck moving.

Reporting Safety Defects

If you believe that your vehicle has a defect which
could cause a crash or could cause injury or
death, you should immediately inform the National
Highway Traffic Safety Administration (NHTSA) in
addition to notifying Daimler Trucks North America
LLC.
If the NHTSA receives similar complaints, it may
open an investigation, and if it finds that a safety
defect exists in a group of vehicles, it may order a
recall and remedy campaign. However, NHTSA
cannot become involved in individual problems
between you, your dealer, or Daimler Trucks North
America LLC.
To contact NHTSA, you may call the Vehicle
Safety Hotline toll-free at 1-888-327-4236 (TTY:
1-800-424-9153); go to www.safercar.gov; or
write to: Administrator, NHTSA, 1200 New Jersey
Avenue, SE, Washington, DC 20590. You can also
obtain other information about motor vehicle safety
from www.safercar.gov.
Canadian customers who wish to report a safety-
related defect to Transport Canada, Defect Investi-
gations and Recalls, may telephone the toll-free
hotline 1-800-333-0510, or contact Transport
Canada by mail at: Transport Canada, ASFAD,
Place de Ville Tower C, 330 Sparks Street,
Ottawa, Ontario, Canada K1A 0N5.
For additional road safety information, please visit
the Road Safety website at:
roadsafety.
Foreword
www.tc.gc.ca/
STI-405-2 (10/11)
A24-01034-000
Printed in U.S.A.

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Summary of Contents for freightliner Columbia

  • Page 1: Reporting Safety Defects

    If you believe that your vehicle has a defect which in the vehicle’s workshop and maintenance manuals. could cause a crash or could cause injury or Custom-built Freightliner vehicles are equipped with death, you should immediately inform the National various chassis and cab components. Not all of the...
  • Page 2 Foreword © 2001–2011 Daimler Trucks North America LLC. All rights reserved. Daimler Trucks North America LLC is a Daimler company. No part of this publication, in whole or part, may be translated, reproduced, stored in a retrieval system, or transmitted in any form by any means, electronic, mechanical, photocopying, recording, or otherwise, without the prior written per- mission of Daimler Trucks North America LLC.
  • Page 3: Table Of Contents

    Contents Chapter Page Introduction, Environmental Concerns and Recommendations, Event Data Recorder, Customer Assistance Center, Reporting Safety Defects ........... . . Foreword Vehicle Identification .
  • Page 4 Vehicle Identification Vehicle Specification Decal ............1.1 Federal Motor Vehicle Safety Standard (FMVSS) Labels .
  • Page 5: Vehicle Identification

    Vehicle Identification Vehicle Specification Decal The vehicle specification decal lists the vehicle model, identification number, and major component models. It also recaps the major assemblies and in- stallations shown on the chassis specification sheet. 11/21/96 f080053 One copy of the specification decal is attached to the 1.
  • Page 6: Canadian Motor Vehicle Safety Standard (Cmvss) Labels

    Fig. 1.7, Vehicle Noise Emission Control Label 3. Gross Axle Weight Ratings: developed by considering each component in an axle system — IMPORTANT: Certain Freightliner incomplete including suspension, axle, wheels, and tires — and vehicles may be produced with incomplete noise...
  • Page 7 Vehicle Identification EXHAUST AFTERTREATMENT SYSTEM INFORMATION WARNING INDICATOR STOP CHECK CHECK LAMP(S) (Solid) (Flashing) (Flashing) (Flashing) Level 1 Level 2 Level 3 Level 4 Indicator Lamp Filter Regeneration Filter Regeneration Parked Regeneration Parked Regeneration Required − HEST (High Exhaust Message(s) Recommended Necessary Required −...
  • Page 8 Instruments and Controls Identification Instrument and Control Panel ............2.1 Instrumentation Control Unit 4 (ICU4 and ICU4-2) .
  • Page 9: Instruments And Controls Identification

    Instruments and Controls Identification Instrument and Control Panel Engine Protection—Warning and CHECK STOP Shutdown Process WARNING 03/20/2008 f611000 When the red STOP engine or engine protection 1. Stop Engine Override Switch light illuminates, most engines are programmed 2. Amber Check Engine Warning Lamp to shut down automatically within 30 seconds.
  • Page 10 Instruments and Controls Identification Warning and Indicator Lights Indicates an undesirable engine condition is detected or Check Engine Lamp (amber) recorded. If the condition gets worse, the stop engine or CHECK engine protection light will illuminate. Indicates a serious fault that requires the engine shut down immediately.
  • Page 11 Instruments and Controls Identification Warning and Indicator Lights High-Beam Indicator (blue) Indicates the headlights are on high beam. Activates with a buzzer when air pressure in the primary or Low Air Pressure Warning Lamp secondary air reservoir falls below 64 to 76 psi (440 to 525 (red) kPa).
  • Page 12 Instruments and Controls Identification WATER X 100 AXLE FUEL VOLTS km/h TRANS AXLE TURBO PYRO 04/01/2004 f610706 1. Engine Oil Pressure Gauge 6. Turbo Boost Air Pressure Gauge 12. Secondary Air Pressure Gauge 2. Engine Coolant Temperature 7. Dash Message Center 13.
  • Page 13 Instruments and Controls Identification CHECK STOP 09/05/2006 f610817 1. Left-Turn Signal 7. Message Display Screen 14. Low Air System Pressure Warning 2. Check Engine Indicator 8. Mode/Reset Switch 15. High-Beam Indicator 3. Optional Indicator 9. Tractor ABS Indicator 16. Parking/Emergency Brake 4.
  • Page 14 Instruments and Controls Identification Go to the Diagnostic Default Odometer and Engine Display Hold Display Screen Screens figure. Push Push Go to the Diagnostic Hold To Reset Trip Miles Hold and Engine Display Screens figure. Push Push Hold To Reset Trip Hours Push Hold Push...
  • Page 15 HOURS appears on the screen, service hours are enabled. Either service Figure 2.7 shows the instrument panel for Columbia miles or hours can be enabled, but not both. If ser- vehicles equipped with the ICU3 and ICU3 ’07. The...
  • Page 16 Instruments and Controls Identification • low air pressure • low oil pressure • high coolant temperature FUEL • the parking brake is applied and the vehicle is moving at a speed of at least 2 mph (3 km/h) F° WATER ICU3/ICU3 ’07 Ignition Sequence F°...
  • Page 17 Instruments and Controls Identification 11/10/2006 f610231a 1. Stop Engine Warning 11. Engine Protection Warning 19. Parking Brake On Warning 2. Engine Fan On Indicator (optional) (optional) 20. Recirculated Air Indicator 3. Do Not Shift Indicator (optional) 12. No Charge Indicator (optional) (optional) 4.
  • Page 18: Mode/Reset Switch

    Instruments and Controls Identification POWER ON HEADLIGHTS ON IGNITION ON 888888.8 ICU INITIALIZES ODOMETER ELECTRONIC GAUGE NEEDLES SCREEN SWEEP, WARNING/INDICATOR LIGHTS COME ON, BUZZER SOUNDS IF NO FAULTS IF FAULT DETECTED WERE DETECTED ABS 136 123456.7 FAULT CODE 12.3 VOLTS SCREEN PARK BRAKE RELEASED −...
  • Page 19: Instrumentation Control Unit 2L (Icu2L)

    Instruments and Controls Identification 123456.7 CLEAr Default Odometer Hold Clear Defaults Dispay Screen 12.3 VOLTS Push Push 123456.7 123456.7 To Dispay Total Engine Miles TRIP Hold To Reset Trip Miles EC = Engine Control 12.3 VOLTS Push Push 123456.7 123456.7 To Dispay Total Engine Hours TRIP HOURS...
  • Page 20: Instruments

    Instruments and Controls Identification The following lights illuminate during the ignition se- quence: • Fasten Seat Belt Warning • Low Battery Voltage Warning • High Coolant Temperature Warning • Low Engine Oil Pressure Warning 17 18 19 16 • Low Air Pressure Warning 06/26/98 f601458 •...
  • Page 21 Instruments and Controls Identification POWER ON HEADLIGHTS ON IGNITION ON 123456 ODOMETER ICU PERFORMS SELFTEST: SCREEN ELECTRONIC GAUGE NEEDLES SWEEP, WARNING/INDICATOR LIGHTS COME ON, BUZZER SOUNDS IF NO FAULTS IF FAULT DETECTED WERE DETECTED A/C 190 FAULT CODE 123456 SCREEN PARK BRAKE RELEASED −...
  • Page 22 Table 2.2, inspect the cooling sys- charging system problems and have them fixed be- tem to determine the cause. See the Columbia ® fore the batteries discharge enough to create starting Workshop Manual for troubleshooting and repair pro- difficulties.
  • Page 23: Fuel Gauge

    Instruments and Controls Identification the engine is stopped. A completely discharged bat- Primary and Secondary Air Pressure tery will produce only about 12.0 volts. The voltmeter Gauges will indicate lower voltage as the vehicle is being started or when electrical devices in the vehicle are Air pressure gauges register the pressure in the pri- being used.
  • Page 24: Transmissions

    Instruments and Controls Identification (121°C) for Eaton ® Fuller ® transmissions. See vice inH O , in Table 2.4, the air cleaner needs to be Fig. 2.17. replaced. NOTE: Rain or snow can wet the filter and CAUTION cause a higher than normal reading temporarily. A sudden increase in oil temperature that is not Intake-Air Restriction Indicator caused by a load increase may indicate mechani-...
  • Page 25: Controls

    Instruments and Controls Identification needle moves to the minus side. A consistent nega- Set the alarm time by using the same pro- tive reading when the engine is running indicates a cedure that you used to set the time of possible problem with the charging system.
  • Page 26: Cruise Control

    Instruments and Controls Identification heater, and electric or diesel-fired engine-coolant pre- heaters can be operated in the off position (regard- less of whether the key is inserted). In the ACCESSORY position, the key is turned coun- terclockwise. The auxiliary (bunk) fan, windshield fan(s), radio or stereo system, mirror heat, ether start system, air dryer, backup lights, and all of the electri- cal systems that are operable in the off position are...
  • Page 27: Instruments And Controls Identification

    Instruments and Controls Identification To disengage the cruise control: Momentarily flip the paddle switch on the instrument control panel down to SET/ Depress the brake pedal or clutch pedal. CST. or —Press the lower half of the SPD CNTL or —Push the SET button on the transmis- rocker switch on the instrument control sion shift knob.
  • Page 28 Instruments and Controls Identification oil temperature. If such a condition occurs, the yellow sage center or the Driver Message Center, on the A Check Engine light on the dash will illuminate. If the panel. See Fig. 2.21. See Fig. 2.22 for the dash problem gets bad enough to cause possible engine label detail.
  • Page 29 Instruments and Controls Identification NOTE: When the system is in the thermostat mode, it is also in the engine mode. It will continue to operate in the engine mode even if the thermostat mode is turned off. M O D E With the system in the engine mode, set °...
  • Page 30 Instruments and Controls Identification To shut down Optimized Idle completely, either turn off the ignition or use the drive away feature. The drive away feature allows the use of all the DDEC features. Use the drive away feature as follows: If the engine is running: Release the park- ing brakes or put the transmission in gear.
  • Page 31: California Engine Idle Limiting

    Instruments and Controls Identification • the operator (accelerator pedal position, engine time in top gear), and critical incidents (such as de- brake switch, etc.); tailed diagnostic data records and hard braking events). DDEC Data can be downloaded using • other electronic control units (for example, the DDEC Reports software to produce reports.
  • Page 32 Instruments and Controls Identification Vehicles equipped with antilock braking systems tially damaging conditions are detected. See "Engine (ABS) have the ability to turn the engine brake off if Protection—Warning and Shutdown Process" at the a wheel-slip condition is detected. The engine brake beginning of this chapter, for more information.
  • Page 33: Power Mirrors

    Instruments and Controls Identification seat to prevent damage to the seat and the cab inte- Parking Brake Control Valve and rior. Trailer Air Supply Valve All adjustment controls for a suspension seat are lo- The yellow diamond-shaped knob operates the park- cated on the seat base.
  • Page 34: Cigarette Lighter

    Instruments and Controls Identification Mirror Heat Switch, Optional Turn Signal Lever One or both outside door mirrors can be heated to The turn signal lever is mounted on the steering col- keep them defrosted. When the mirror heat (MIRR umn. See Fig.
  • Page 35 If so equipped, the transmission range control valve and splitter valve are attached to the gearshift knob. Transmission shift pattern labels are located inside the cab. For control of the automated mechanical transmissions, use the Freightliner SmartShift ™ Transmission Shift Control mounted on the steering column. See...
  • Page 36: Rear Axles

    Instruments and Controls Identification 10/02/2006 f610848 Fig. 2.33, Request/Inhibit Regen Switch The style and function of switch will vary with the en- 06/03/99 f270065 gine make and model. See the engine operation 1. Upshift (in manual mode, pull upward) manual for operation details. 2.
  • Page 37 Instruments and Controls Identification Interaxle Differential Lockout Control Valve Switch CAUTION The interaxle lock should only be engaged when the vehicle is moving slowly at low throttle. En- gagement at high speed or power can damage the axle(s). The interaxle lock, standard on all dual-drive ve- 9/07/95 f310489 hicles, is driver-actuated by means of a LOCK/...
  • Page 38: Windshield Wiper/Washer Controls

    Instruments and Controls Identification lights, if equipped. The daytime running lights will CAUTION operate until the parking brakes are applied or the headlights are turned on. Never exhaust air from the suspension while driving. When the air is exhausted, the suspen- Headlight Dimmer sion will not absorb road shocks and could be damaged.
  • Page 39 Instruments and Controls Identification For vehicles built to operate in Canada, the marker lights must be on before the road lights can be turned on. Utility Light Switch, Optional Utility lights can be swivel-mounted on top of the cab, mounted on the intake/exhaust support, or flush- mounted in the back of the cab or sleeper box.
  • Page 40 Instruments and Controls Identification 06/10/98 f601053 Fig. 2.41, Passenger’s Footwell Courtesy Light Bunk Reading Light Switches, Optional— SleeperCabs Only Bunk reading lights are high-intensity reading lights for use when reading in the bunk. They are located on the bunk control panel for each bunk. To turn on 09/29/95 f541139 the bunk reading lights, press the rocker switch on...
  • Page 41: Collision Warning System (Cws), Eaton Vorad Evt-300, Optional

    Instruments and Controls Identification predetermined cab and sleeper circuits. These cir- while driving, repair the ABS system immedi- cuits will remain off until the LVD measures 13.0 ately to ensure full antilock braking capability. volts applied to the system, which can be done by Vehicles with ABS may also have automatic traction starting the engine.
  • Page 42: Evt–300 Driver Display Unit

    Instruments and Controls Identification objects ahead. This allows the determination of the tional driver’s identification card. Alert and indicator distance to, relative speed of, and angle to the target lights advise of multiple warning levels, system of vehicles and objects ahead. The system uses this power, system failure, and if so configured, failure of information to warn the driver of potentially danger- the driver to enter the identification card.
  • Page 43 Instruments and Controls Identification FAIL VOLUME ALERTS RANGE EATON VORAD T E C H N O L O G I E S 10/15/98 f610258 1. Red System Failure Indicator Light 7. Ambient Light Sensor 2. Green Power ON/Driver’s Card Status Indicator Light 8.
  • Page 44 Instruments and Controls Identification two- to three-second following interval behind A failure of the optional side sensor(s) will cause another vehicle in the same lane. If you are a continuous red light on the side sensor display within a two-second following interval and closing to appear.
  • Page 45 Instruments and Controls Identification EVT–300 Special Road Situations ther back, behind the field of view, will not be detected. • WARNING The side sensor range is set to detect average sized vehicles, 2 to 10 feet (0.5 to 3 meters) away, in the adjacent lane.
  • Page 46: Lane Guidance System, Optional

    Instruments and Controls Identification EVT–300 Maintenance and Position the DDU range knob to the left to blink active fault codes and to the right to blink inac- Diagnostics tive codes. Keep the antenna assembly and side sensor(s) Fault codes can only be reviewed, tested, and free of a buildup of mud, dirt, ice, or other debris cleared by using a Pro-Link ®...
  • Page 47: Roll Stability Control

    Instruments and Controls Identification • driver. The system may not indicate lane depar- Weather conditions such as snow, heavy rain, tures under certain conditions. Read carefully the ice, or standing water. information in this manual to understand the cir- • Damaged, worn, or faded lane markings.
  • Page 48 Instruments and Controls Identification A decal (Fig. 2.48) on the auxiliary dash panel and an amber-colored dash indicator light (Fig. 2.49) indi- cate that the vehicle is equipped with the Roll Stabil- ity Control system. The dash indicator light illumi- nates whenever the Roll Stability Control system intervenes.
  • Page 49: Vehicle Access

    Vehicle Access Ignition and Lock Key ............. . 3.1 Cab Door Locks and Handles .
  • Page 50: Ignition And Lock Key

    Vehicle Access Ignition and Lock Key One key operates the ignition switch and all of the door locks. IMPORTANT: Each key is numbered. Record the number so, if needed, a duplicate key can be made. Cab Door Locks and Handles To unlock the driver’s door from outside the cab, in- sert the key in the lockset and turn it one-quarter turn clockwise...
  • Page 51: Entering The Driver's Side

    Vehicle Access Be careful not to get hands or feet tangled in Exiting the Driver’s Side (Fig. 3.3) hoses or other back-of-cab equipment. Careless- Exit the cab from the driver’s side as follows: ness could cause a person to trip and fall, with possible injury.
  • Page 52: Door Windows

    Vehicle Access Grasp the grab handle at the aft edge of the Circuit Breaker/Relay Panel door opening with your left hand. The circuit breaker/relay panel is located in front of Grasp the handle on the door (Fig. 3.4) with your the passenger’s seat under the top cover of the in- right hand.
  • Page 53: Baggage Compartment Doors

    Vehicle Access IMPORTANT: The sleeper doors are two-stage touch any part of the exhaust system, or severe burns could occur. latching. When closing the doors, ensure that they are completely latched to prevent wind When trailer air and electrical connections cannot be noise and water intrusion.
  • Page 54: Battery Box Cover

    Remove the air fairing panel. See Group onto, or leaving, the back-of-cab area. 60 of the Columbia ® Workshop Manual for instruc- tions. If no air fairing panel is installed, remove the Always maintain three-point contact with the step plate.
  • Page 55: Dash Storage Bin

    Fig. 3.8, Glove Boxes and Overhead Storage Cup Holders Overhead Lights The Columbia vehicle features two cup holders above the ash tray and waste bin on the center Above both the driver’s and the passenger’s seats panel.
  • Page 56: Footwell Lights

    Vehicle Access Footwell Lights There are optional red lights mounted underneath the dash on the driver’s and the passenger’s sides of the vehicle. These lights are activated by a rocker switch on the lower dash panel next to the climate control switches.
  • Page 57: Heater And Air Conditioner

    Heater and Air Conditioner Constant Discharge Temperature Control ..........4.1 Cab Climate Control Panel .
  • Page 58: Constant Discharge Temperature Control

    Heater and Air Conditioner Constant Discharge NOTE: When the fan switch on the cab climate control panel is off and the sleeper air condi- Temperature Control tioner is on, the cab fan will operate at low speed even though the cab fan switch is in the The cab heater and air conditioner system is a Con- off position.
  • Page 59 Heater and Air Conditioner Defrost Mode: Directs all airflow through the defrost outlets. The air conditioner automatically turns on in this mode. The recirculation button will not work in this mode. Temperature Control Switch The temperature control switch is used to select the desired temperature.
  • Page 60: Sleeper Climate Control Panel

    Heater and Air Conditioner Recirculation mode is on. If the fan speed or temperature setting on the sleeper climate control panel is adjusted when The recirculation mode limits the amount of outside the bunk override mode is on, the bunk override air entering the cab.
  • Page 61: Parked Hvac

    Heater and Air Conditioner Overview The Bergstrom NITE (No Idle Thermal Environment) parked, or no-idle, air conditioning system is a com- pact, electrically powered, 3000-BTU system. It is designed to provide a means of air conditioning to the sleeper area without having the engine running. It is completely self-contained, and runs on 12-volt deep-cycle batteries.
  • Page 62: Air Outlets

    Heater and Air Conditioner outlet vents for the A/C and heater units are clear. Blocked vents will hamper the operation of the unit. The control panel for the parked A/C and heater is located on the back wall of the sleeper near the left side.
  • Page 63: Seats And Seat Belts

    Seats and Seat Belts Seats ................5.1 Seat Belts and Tether Belts .
  • Page 64: Seats

    Seats and Seat Belts Seats Seat Adjustment The following is a description of adjustments that can General Information be made to various Freightliner-installed seats. Not all seats have all of the adjustments listed below. Unless otherwise noted, all seat adjustments should Fig. 5.1.
  • Page 65 Seats and Seat Belts Height Adjustment: The entire seat moves up or down when adjusting the height. The adjustment is either manually or air controlled, depending on the make of the seat. Bottom Cushion Angle or Fore and Aft Bottom Cushion Height: This feature enables the occu- pant to raise or lower the front or back of the bottom cushion.
  • Page 66 6. Fore and Aft Adjustment and Isolator Lever 5. Lumbar Support Switch 7. Lumbar Support Knob (non-LSO models) 6. Height Adjustment Switch Fig. 5.4, Freightliner/Bostrom Seat Adjustment Controls Fig. 5.3, EzyRider Seat Adjustment Controls (Vehicles Built on or After November 28, 2005) Weight and Height Adjustment...
  • Page 67: National 2000 Series Seat

    Seats and Seat Belts Lumbar Support Height Adjustment To increase lumbar support on LSO models, press To raise or lower the height of the seat, use the the plus sign on the lumbar support switch. To de- height adjustment switch on the side of the seat. crease lumbar support on LSO models, press the Fore and Aft Seat Adjustment minus sign on the switch.
  • Page 68: Seat Belt Operation

    Seats and Seat Belts Inspect the seat belts and tether belts (if so WARNING equipped). Check the web for fraying, cuts, extreme dirt and Always use the vehicle’s seat belt system when dust, or for severe fading from exposure to sun- operating the vehicle.
  • Page 69: In An Emergency

    Seats and Seat Belts 01/06/95 f910048a A. 1 Inch (2.5 cm) Maximum 01/18/95 f910004a Fig. 5.8, Adjusting Shoulder Harness Clearance Fig. 5.6, Fastening the Three-Point Belt 08/09/2010 f910634 A. Correct—Belt is centered on your shoulder and chest, away from your face and neck. B.
  • Page 70: Sleeper Compartment Restraints

    Seats and Seat Belts on your shoulder and chest, away from your face and neck. See Fig. 5.7. To unbuckle the three-point seat belt, press the release button on the buckle; see Fig. 5.10. NOTE: Make sure the three-point seat belt is completely retracted when it is not in use.
  • Page 71: Supplemental Restraint System, Optional

    Seats and Seat Belts Supplemental Restraint System, Optional The supplemental restraint system can consist of an air bag and SPACE system, or an air bag only sys- tem. Your vehicle may or may not have a supple- mental restraint system. Air Bag, Optional 01/06/95 f910068a...
  • Page 72: Space System, Optional

    Seats and Seat Belts connector from the system will disable the WARNING safety shunt and could cause unintentional deployment. Consider undeployed air bags to be dangerous • Allow deployed air bag systems to cool and capable of deploying at any time. Do not at- after deployment.
  • Page 73 Seats and Seat Belts 09/03/97 f910172 1. Pretensioning Cable Tether 2. SPACE Module 07/29/97 f910235 3. Suspension Seat 4. Gas Cylinder A. Seat Tether Without the SPACE System 5. Sensor Bracket B. Seat Belt Assembly B-Pillar Components 1. Height Adjuster 5.
  • Page 74 Seats and Seat Belts Do not attempt to service or to disassemble the SPACE module. The SPACE module cannot be serviced. Doing so could result in severe bodily injury or death. Although the air bag/SPACE system components will not likely explode, self-deploy, or produce shrapnel, take care when it is necessary to re- place or perform work around the air bag/SPACE system components.
  • Page 75: Steering And Brake Systems

    Steering and Brake Systems Steering System ..............6.1 Brake System .
  • Page 76: Steering System

    Driving the vehicle without the power-assist fea- spokes should be centered, ±10 degrees, as shown ture of the steering system requires much greater 6.1. See Group 46 of the Columbia ® Work- Fig.
  • Page 77: Brake System Operation

    Steering and Brake Systems Before driving your vehicle, allow time for the air After correcting the brake system problem, uncage compressor to build up a minimum of 100 psi (689 the spring parking brakes before resuming normal kPa) pressure in both the primary and secondary vehicle operation.
  • Page 78 Steering and Brake Systems 03/10/99 f610291 1. Trailer Air Supply Valve Knob 9/26/95 f461056 2. Parking Brake Valve Knob 1. Turn Signal Lever 2. Trailer Brake Hand Control Valve Fig. 6.3, Brake Valve Knobs 3. Hazard Warning Light Tab vice brakes are wet. To do so could damage the Fig.
  • Page 79 Steering and Brake Systems After the ignition switch is turned on, the tractor CAUTION warning light (TRACTOR ABS) and, if equipped with Automatic Traction Control, the wheel spin (WHEEL Never apply the service and spring parking SPIN) indicator light come on for about three sec- brakes simultaneously.
  • Page 80 Steering and Brake Systems During emergency or reduced-traction stops, fully as driver brake demand, wheel speed, and vehicle depress the brake pedal until the vehicle comes to a load is gathered by a network of electronic sensing safe stop; do not pump the brake pedal. With the devices (including load sensors, and signal generat- brake pedal fully depressed, the ABS system will ing tone wheels and sensors located in the wheel...
  • Page 81: Automatic Slack Adjusters

    Steering and Brake Systems do not switch off after three seconds, the system should be checked. NOTE: If there is no bulb check and no dis- played fault, most likely the brake pedal is par- tially depressed, either by the driver or by some- thing holding the pedal down.
  • Page 82: Engines And Clutches

    Engines and Clutches EPA07 Aftertreatment System (ATS) ..........7.1 DD15 Heavy-Duty Engine .
  • Page 83: Index

    Engines and Clutches EPA07 Aftertreatment System vehicle is driven normally under load; the driver is not even aware that it is happening. The harder an (ATS) EPA07 engine works, the better it disposes of soot, as the exhaust heat alone is enough to burn the soot On-road diesel engines built after December 31, to ash.
  • Page 84 Engines and Clutches high idle speed is being controlled by the engine Fig. 7.2. A DPF lamp blinking at the same time as a software, not the driver. steadily illuminated yellow Check Engine lamp, indi- cates that a parked regen must be performed imme- A steadily illuminated high temperature (HEST) lamp diately, or an engine derate will occur.
  • Page 85: Dd15 Heavy-Duty Engine

    Engines and Clutches 09/25/2006 f610814a 07/30/2009 f610944 Fig. 7.4, Malfunction Indicator Lamp (MIL) Fig. 7.6, Regen-Inhibit Switch Engine Protection An engine protection system monitors all engine sen- sors and electronic components, and recognizes sys- tem malfunctions. If a critical fault is detected, an amber Check Engine warning lamp and a red Stop Engine lamp illuminate.
  • Page 86 Engines and Clutches • low oil pressure The DD15 engine provides horsepower through 2100 rpm, but fuel economy is not as efficient above 1800 • auxiliary shutdown rpm. If you decide to drive at lower rpm for improved fuel economy, don’t let different engine noises throw Stop Engine Override Switch you off guard.
  • Page 87 Engines and Clutches use of the vehicle brakes will cause them to heat CAUTION up, reducing their stopping ability. This condi- tion, referred to as “brake fade”, may result in NEVER use ether as a starting aid on a DD HD loss of braking, which could lead to loss of con- engine.
  • Page 88: Engine Starting-Cat, Cummins, Dde S60, M-B

    Engines and Clutches NOTE: On single trailers or combinations, a light If a vehicle does not start on the first attempt, make sure that the engine has completely air application of the trailer brakes may be desir- stopped rotating before reapplying the starter able to help keep the trailer stretched out.
  • Page 89 Engines and Clutches If the engine does not start after 30 sec- CAUTION onds of cranking, turn the ignition switch off. Protect the turbocharger during the start-up by NOTE: Some starters are equipped with op- not opening the throttle or accelerating the en- tional overcrank protection.
  • Page 90: Cold-Weather Starting

    Engines and Clutches IMPORTANT: If the engine won’t start, check the sweep of their dials, the warning and indicator lights light up, and the buzzer sounds for three main engine power fuses. The fuses are located seconds. along the main engine electrical harness on the left frame rail, near the batteries.
  • Page 91: Starting After Extended Shutdown Or Oil Change-Cat, Cummins, Dde S60, M-B

    Engines and Clutches its use, handling, and storage. Many starting flu- Mercedes-Benz ids are in capsules or pressure cans, and im- proper usage can be dangerous. CAUTION Do not attempt to use any type of vapor- Never attempt to start any Mercedes-Benz elec- compound start system near heat or open flame.
  • Page 92: Engine Break-In-Cat, Cummins, Dde S60, M-B

    Engines and Clutches Check the turbocharger for signs of oil or ex- Engine Operation—CAT, haust leaks. Correct any problems before starting Cummins, DDE S60, M-B the engine. Safety and Environmental Check the engine mounting bolts for tightness. Retighten them if necessary. Considerations Make sure the battery cable connections are clean and tight.
  • Page 93 Engines and Clutches General Information See the manufacturer’s engine operation manual for specific reccomendations for your engine. Operate the engine at low load when the engine is first started. After normal oil pressure is reached and the temperature gauge needle be- (16) (32) (48)
  • Page 94 Engines and Clutches the engine when downshifting too soon or miss- rpm. However, during engine braking only, a ing the full use of a gear by downshifting too higher rpm can be used to increase retarding late. The shift points of any vehicle can be deter- power, if necessary.
  • Page 95: Cold-Weather Operation-Cat, Cummins, Dde S60, M-B

    Engines and Clutches Cold-Weather Operation—CAT, Check for cracks in the battery cases, for corro- sion of the terminals, and for tightness of the Cummins, DDE S60, M-B cable clamps at the terminals. Charge the batteries to full capacity. Replace any Satisfactory performance of a diesel engine operating battery that is unable to hold full charge or is in low ambient temperatures requires modification of...
  • Page 96: Dde S

    Engines and Clutches temperatures below –10°F (–23°C), consult your Arctic specifications refer to the design of material Caterpillar dealer for recommendations. and specifications of components necessary for sat- isfactory engine operation in extremely low tempera- When customer parameters include cold-mode tures to –65°F (–54°C).
  • Page 97: High-Altitude Operation-Cat, Cummins, Dde S60, M-B

    If the engine is to be operated in arctic tem- Engines lose horsepower when operated at high alti- peratures, consult the nearest Freightliner tude because the air is too thin to burn as much fuel dealer or an authorized Detroit Diesel engine as at sea level.
  • Page 98: Engine Braking Systems-Cat, Cummins, Dde S60, M-B

    Engines and Clutches accelerated wear of the engine components. Ex- Allow the engine to run at idle for four to five cessive temperatures in the turbocharger center- minutes. This allows the engine to cool and the housing will cause oil coking problems. Follow turbocharger to slow down.
  • Page 99 "Control speed" is the speed at which the engine throttle pedals. If it fails to activate, take the ve- brake performs 100 percent of the required downhill hicle to an authorized Freightliner dealer for ser- braking, resulting in a constant speed of descent. vice.
  • Page 100: Turbo Brake (Mbe4000 Only)

    Engines and Clutches To obtain maximum retarding, maintain the top perature of the oil at full engine power or full governed speed of the engine through appropri- BrakeSaver capacity, but not both at the same ate selection of gears when the engine brake is time.
  • Page 101: Exhaust Brake System-Cat, Cummins, Dde S60, M-B

    Engines and Clutches Constant-Throttle Engine Brake pedals, allows the driver to make maximum use of the exhaust brake in off-highway and mountain driv- (MBE4000 only) ing as well as in traffic or high-speed highway driv- ing. The standard engine braking system is the constant- throttle system combined with an exhaust flap.
  • Page 102: Clutches

    Notify your Depending on the grade and vehicle load, you Freightliner dealer of the problem. may or may not feel the retarding force acting against your body when the brake is applied.
  • Page 103 Engines and Clutches Gear Shifting Techniques Slightly depressing the clutch pedal while driving is damaging to the clutch, because partial clutch en- Shift into the next higher gear when the vehicle gagement causes slippage and heat. Resting your speed allows the transmission input shaft speed to foot on the clutch pedal will also put a constant thrust match the flywheel speed when engaging the clutch.
  • Page 104: Clutch Maintenance

    Clutches have an internal adjustment and external The clutch pedal free travel should be checked and ® linkage adjustment. See Group 25 of the Columbia commented on daily in the driver’s report. Workshop Manual for clutch adjustment procedures and specifications.
  • Page 105 Engines and Clutches CAUTION Failure to lubricate the release bearing and link- age as recommended could result in release bearing and clutch damage. 7.23...
  • Page 106 Transmissions Freightliner SmartShift Shift Control ..........8.1 Eaton Fuller AutoShift Automated Transmissions .
  • Page 107: Freightliner Smartshift Shift Control

    Transmissions Freightliner SmartShift Shift Control General Information, SmartShift ™ The SmartShift transmission control is an electronic transmission control device. It is installed with the following transmissions: • Eaton ® Fuller ® AutoShift ™ • Eaton Fuller UltraShift ™ 01/24/2003 f270120 •...
  • Page 108 Transmissions SOLID 11/11/2002 f270080 To upshift manually, pull the lever up (towards you). To SOLID downshift manually, push the lever down (away from you). 1. SmartShift Control Lever FLASHING 2. Slide Switch 3. MAN Position (of slide switch) 4. AUTO Position (of slide switch) 5.
  • Page 109 Transmissions engage the clutch and drive the vehicle. In increases the starting gear by one gear, but no higher than fourth gear. manual shift mode, upshifts and downshifts re- quire either a pull upward or push downward on The number of the gear selected will flash on the the control.
  • Page 110: Zf-Freedomline Automated Transmissions

    With the transmission in neutral, release the pedal in the cab. Clutch actuation is fully automated. clutch. On Freightliner vehicles, it will be operated by a cus- NOTE: This allows the speed sensor on the tom version of the SmartShift controller. On Columbia input shaft to get a reading.
  • Page 111: Operation, Freedomline

    Transmissions This transmission requires an additional 10-liter air pedal. On the driver message center display, the first reservoir. After any transmission service, it will be character is a special character to indicate automatic necessary to charge this tank with air before the ve- mode.
  • Page 112: Eaton Fuller Range-Shift Transmissions

    Transmissions Upshifting Driver Message Center NOTE: A request to upshift or downshift can On the Columbia, the gear is displayed on the round Meritor message center display. See Fig. 8.4. only be accepted in the manual mode. With the transmission in drive, to request an upshift, pull the control lever up (towards you).
  • Page 113 Transmissions dash for the operating instructions for the specific transmission installed in your vehicle. 9-Speed RT/RTX Models Eaton Fuller 9-speed transmissions have a 5-speed front section and a 2-speed rear range section. The low gear in the front sections of the RT and RTX transmissions is used only as a starting ratio.
  • Page 114: Eaton Fuller Splitter And Range-Shift Transmissions

    Transmissions only when operating conditions permit, depend- Downshifting ing on the load, grade, and road speed. With the transmission in high range, shift pro- gressively downward to the bottom gear in high Upshifting range, double-clutching between shifts. Position the gear shift lever in neutral. Start the When in the bottom gear of the high range shift engine, and bring the air system pressure up to pattern, and ready for the next downshift, push...
  • Page 115 Transmissions button are built into the shift knob. The range prese- lection lever controls range selection and the splitter Dir OD Dir OD control button (located on the side of the shift knob) controls gear splits. Operation, Eaton Fuller Splitter and Range-Shift IMPORTANT: The shifter knob has an interlock Dir OD...
  • Page 116 Transmissions down into low range while operating in high For 18-speed transmissions: range—the splitter will become inoperative. Press the clutch to the floor, shift into low; then engage the clutch, with the engine at or near idle Do not shift from high range to low range at high speed, to start the vehicle moving.
  • Page 117: Eaton Fuller Deep-Reduction Transmissions

    Transmissions and accelerate. Do not move the control button the control button while the shift lever is in neu- while the shift lever is in neutral. tral. Shift up through the high range gears as follows: Continue downshifting from 4th to 1st as follows: For 13-speed transmissions: For 13-speed transmissions: To shift from 5th direct to 5th overdrive, move the...
  • Page 118 Transmissions 10-Speed RT–LL, RTO–LL and RTX–LL directly opposite in the RTO (overdrive ratio) transmissions. Models Eaton Fuller 10-speed deep-reduction transmissions Operation, Deep Reduction have a 5-speed front section, and a 2-speed rear range section, with a deep reduction button. The low- IMPORTANT: The shifter knob has an interlock low, deep reduction gear is used only when operating feature that prevents the deep reduction button...
  • Page 119 Transmissions Lo Hi Lo Hi DR Lo DR Lo DR Lo DR Lo DR Lo DR Lo DR Lo DR Lo DR Lo DR Lo 03/13/96 f260045a A. RT Models B. RTO Models 1. High Range 4. High Range 6. Forward for IN 2.
  • Page 120: Eaton Fuller Super 10, Top 2, And Lightning Semi-Automated Transmissions

    Transmissions Eaton Fuller Deep-Reduction and Range-Shift Shift Progressions DEEP REDUCTION LOW RANGE HIGH RANGE TRANSMISSION Adverse Conditions Off-Highway and On-Highway and Ideal MODEL All Conditions Only Adverse Conditions Conditions 15-Speed RT and RTX f260345 f260346 f260347 f260348 Table 8.2, Eaton Fuller Deep-Reduction and Range-Shift Shift Progressions With the transmission in high range, shift pro- Eaton Fuller Super 10, Top 2, gressively upward through each of the high...
  • Page 121 NOTE: If the service light stays on or flashes, or Operation, Super 10/Top 2/Lightning does not illuminate when the engine starts, take the vehicle to an authorized Freightliner or CAUTION Eaton service facility as soon as possible. Keep the transmission in gear at all times while Fig.
  • Page 122 Transmissions Use the clutch brake to stop gear rotation when The lever-only shift is used to skip a full gear. shifting into 1st or reverse when the vehicle is With the shift button rearward—1st to 3rd, 3rd to stationary. The clutch brake is actuated by de- 5th, 5th to 7th, and 7th to 9th.
  • Page 123: Meritor Range-Shift Transmissions

    Transmissions The lever-only shift is used to skip a full gear. gear in the front sections of the "A" and "B" ratio With the shift button rearward—9th to 7th, 7th to transmissions is used only as a starting ratio. The 5th, 5th to 3rd, and 3rd to 1st.
  • Page 124 Transmissions Meritor Range-Shift Shift Progressions LOW RANGE TRANS. HIGH MODEL RANGE Off-Highway On-Highway 9-Speed Direct (M) f260322 f260321 f260320 9-Speed Overdrive 03/13/96 f260155a (MO) A. All M Transmissions C. High Range f260327 f260327 f260328 B. All MO Transmissions D. Low Range 10-Speed Fig.
  • Page 125: Meritor Splitter And Range-Shift Transmissions

    Transmissions Double-clutch through neutral, and shift into the top gear of the low range shift pattern. As the Dir OD Dir OD shift lever passes through neutral, the transmis- sion will automatically shift from high range to low range. With the transmission in low range, downshift through the low range gears as conditions re- quire.
  • Page 126: Meritor Engine Synchro Shift (Ess) Automated Models

    Transmissions Push the clutch pedal to the bottom of travel so Shift upward through each of the high range the clutch brake slows the transmission for initial gears, alternating the procedures in steps 10 and gear engagement; holding the clutch pedal at the 11, above.
  • Page 127 Transmissions engines. Meritor RS and RSX series ESS trans- missions are only available on vehicles equipped with Detroit Diesel electronic engines. The ESS system works with the engine fuel control system to automatically synchronize en- gine rpm to road speed during gear changes. Use the clutch only to start and stop the vehicle and to shift into forward or reverse.
  • Page 128 Transmissions mission returns to manual operation. To reacti- vate the ESS system, press the shift-intent switch again. See the following procedures for upshifting and downshifting for instructions on how to use the shift-intent switch. Upshifting To upshift into the next higher gear: 02/17/98 f270060 A.
  • Page 129: Eaton Ultrashift Dm

    Transmissions Immediately move the shift lever to the Eaton UltraShift DM neutral position. General Information, UltraShift DM Allow engine rpm to speed up enough to synchronize with road speed. ® ® ™ Eaton Fuller UltraShift DM is a ten-speed heavy- duty fully automated transmission.
  • Page 130 Transmissions 02/17/98 f270061 A. 9-Speed Shift Pattern with LO B. 9-Speed Shift Pattern C. 10-Speed Shift Pattern Gear Fig. 8.21, Meritor ESS 9- and 10-Speed Shift Patterns BRAKE 10/27/2003 f610677 1. "CHECK TRANS" Light 2. "TRANS TEMP" Light Fig. 8.23, Telltale Lights 12/22/2003 f270079a To know what gear the transmission is in, look at the...
  • Page 131 Transmissions 10/13/2003 f610678 Fig. 8.24, Power-Up Dot Display 01/21/2004 f270079c On steep hills, set the parking brake. 1. Slide Switch (controls forward driving mode) When parking, chock the tires, front and/or 2. Selector Switch (controls gear selection) 3. Neutral Lock Button (prevents accidental shift into rear.
  • Page 132 Transmissions neutral. At this point, as the transmission is synchro- When reverse low is selected, the letter "R" displays nizing for the new (target) gear, the gear indicator on the current gear indicator. When reverse high is flashes the number of the new gear. selected, the letter "H"...
  • Page 133 Transmissions currently selected forward gear (1 through 10) dis- plays on the gear indicator. See Fig. 8.26. When in drive, requests to upshift or downshift are enabled. Either manual or automatic mode can be selected on the slide switch. Two starting gears are available, first and second. The default starting gear is second, but first can be selected by the driver, if desired.
  • Page 134 Transmissions If the transmission does not upshift quickly enough Ultrashift Diagnostics after power-up or a load change, begin the shift Clutch Protection Fault manually. The UltraShift DM TCU will learn the new load-based shift conditions after three or four shifts. Excessive clutch slippage creates heat and reduces the life of the clutch.
  • Page 135 "N" will appear on the current gear indicator and the vehicle will start. Make sure the service brakes are applied and the parking brake is set. If the current gear indicator continues to display a dash, contact an authorized Freightliner or Eaton ser- vice facility. 8.29...
  • Page 136 Rear Axles ™ Meritor Single Drive Axles with Traction Equalizer ........9.1 ™...
  • Page 137: Meritor Single Drive Axles With Traction Equalizer

    25 mph (40 ® km/h). Never lock the main differential when the See Group 35 of the Columbia Maintenance Manual for additional information on friction modifiers vehicle is traveling down steep grades or when the wheels are slipping.
  • Page 138: Meritor Tandem Drive Axles With Interaxle Differential

    Rear Axles the rear axle, so both axles turn together at the same speed. The LOCK position should be used when the vehicle encounters poor traction conditions; however, it also increases drivetrain and tire wear and should be used only when improved traction is required. Meritor ™...
  • Page 139: Dana Spicer Interaxle Differential Lockout Operation

    Rear Axles out in the UNLOCK position for normal driving on roads where traction is good. 09/26/95 f350142 Fig. 9.3, Traction Control Differential Control NOTE: The controlled traction differential can be engaged at any speed, except when one wheel is spinning. Dana Spicer ®...
  • Page 140: Fifth Wheels And Trailer Couplings

    Fifth Wheels and Trailer Couplings Holland Fifth Wheels ............. 10.1 ASF Simplex Series Fifth Wheels .
  • Page 141: Holland Fifth Wheels

    Fifth Wheels and Trailer Couplings Holland Fifth Wheels General Information The 2535 sliding fifth wheel models incorporate a Model 3500 fifth wheel (Fig. 10.1), equipped with either an air-operated release slide, or a manual re- lease slide. Sliding fifth wheel assemblies are mounted on a baseplate that permits forward and rear movement along notched rails.
  • Page 142 Lockguard will prevent the locks from engaging be- bricated with chassis grease. For lubrication in- fore the kingpin fully enters the locks. If the kingpin ® structions, see Group 31 of the Columbia Main- enters the fifth wheel incorrectly and does not de- tenance Manual .
  • Page 143 (3.2-mm) clearance exists between the lock halves, the lock must be adjusted. See Group The load distribution on the front steering axle ® 31 of the Columbia Workshop Manual for ad- and rear drive axle(s) will have a direct effect on justment procedures.
  • Page 144 Fifth Wheels and Trailer Couplings Standard (CMVSS) label attached to the left rear Release the kingpin locking mechanism by pull- door post of the tractor. The desired load on the ing the kingpin lock control handle (Fig. 10.1) to axle is no less than 80 percent of the maximum the outward position.
  • Page 145 Fifth Wheels and Trailer Couplings Apply the tractor parking brakes. NOTE: The fifth wheel may have to be moved slightly to enable the locking plungers to enter the fully locked position. Lock the sliding member into position using one of the following methods: WARNING Check to be sure that the slide plungers are in the locked position.
  • Page 146 4. Mounting Bracket injury or death. Fig. 10.8, Simplex Stationary Fifth Wheel For lubrication instructions, see Group 31 of the ® Columbia Maintenance Manual . ASF Simplex Series Fifth Wheels General Information The ASF Simplex series fifth wheels are used for pulling trailers having the standard 2-inch (51-mm) diameter kingpin.
  • Page 147 Fifth Wheels and Trailer Couplings The manually operated slide contains an operating tated to compensate for wear and maintain an (Fig. 10.9) that unlocks both sides of the plate at approximate 1/16-inch (1.6-mm) clearance during the same time. service. The air-operated sliding saddle plate contains an air Placing the operating rod in the lockset position cylinder that moves the operating lever to unlock moves the lock away from the jaw.
  • Page 148 Group 31 of the Rubbing may wear through hoses or cables, re- ® Columbia Maintenance Manual . sulting in air leaks, or exposed or broken wires, potentially affecting trailer brake or electrical sys- WARNING tems.
  • Page 149 1/2 inch (13 mm). and kingpin. For instructions, see Group 31 of Disconnect the tractor-to-trailer air system lines ® the Columbia Workshop Manual . and electrical cable. Plug the air lines to prevent Retract the trailer landing gear, and secure the dirt or foreign material from entering the lines.
  • Page 150 Fifth Wheels and Trailer Couplings IMPORTANT: If equipped with an air-operated CAUTION lock release, you still must make a visual check of the operating rod to make sure it is in the un- After moving the fifth wheel to the desired posi- locked position tion, be sure the trailer landing gear will not, at any time, come in contact with the tractor frame...
  • Page 151: Fontaine Fifth Wheels

    fifth wheel plate and the trailer. 1. Locking Wedge 2. Air Cylinder For lubrication instructions, see Group 31 of the Columbia ® Maintenance Manual . Fig. 10.14, Air-Operated Sliding Fifth Wheel Mount, AWB Model Fontaine Fifth Wheels...
  • Page 152 Fifth Wheels and Trailer Couplings 07/25/95 f310190 10/26/2010 f310184c 1. Locking Wedge A. Unlocked Position C. Locked 2. Slide Release Pull Handle B. Locking 1. Wedge 3. Trailer Kingpin Fig. 10.15, Manual Release Sliding Fifth Wheel Mount, 2. Jaw MWS Model Fig.
  • Page 153 The kingpin lock mechanism must be fully open, the fifth wheel plate must be completely lubri- cated with chassis grease. For lubrication in- structions, see Group 31 of the Columbia ® Main- tenance Manual . Position the tractor so that the fifth wheel lock opening is in line (both vertically and horizontally) with the trailer kingpin.
  • Page 154 Fifth Wheels and Trailer Couplings The load distribution on the front steering axle CAUTION and rear drive axle(s) will have a direct effect on the steering control of the vehicle. Before attempting to lock or unlock the fifth Determine the front and rear axle weights by wheel lock mechanism of a sliding type fifth weighing the vehicle on scales designed for this wheel, the slide release pull handle, if so...
  • Page 155 Fifth Wheels and Trailer Couplings Slowly move the tractor forward or backward until the fifth wheel is in the desired location. Apply the tractor parking brakes. NOTE: The fifth wheel may have to be moved slightly to enable the locking wedges to enter the fully locked position.
  • Page 156 For lubrication instructions, see Group 31 of the Model 690 (Fig. 10.21): Remove the linch pin ® Columbia Maintenance Manual . from the handle, then push in on the handle and turn it toward you. Open the pintle hook by pull- Premier Trailer Couplings ing it down and toward you.
  • Page 157 Fifth Wheels and Trailer Couplings 01/20/95 f310312a A. Model 260 B. Model 460 1. Pintle Hook 3. Pawl Assembly 5. Pawl Wedge 2. Latch 4. Pawl Lock 6. Shoe Fig. 10.20, Premier 260 and 460 Trailer Couplings WARNING Do not use the trailer air supply for parking trail- ers not equipped with spring parking brakes.
  • Page 158: Holland Trailer Coupling

    Fifth Wheels and Trailer Couplings Holland Trailer Coupling Hook up the trailer’s electrical and air lines. Remove the chocks from the trailer’s tires. General Information Trailer Release The Holland PH–T–60–AL trailer coupling is de- signed for use with trailers having a maximum gross Apply the truck and trailer parking brakes.
  • Page 159: Pretrip And Post-Trip Inspections And Maintenance

    Pretrip and Post-Trip Inspections and Maintenance Pretrip and Post-Trip Inspection Checklists ..........11.1 Pretrip and Post-Trip Maintenance Procedures .
  • Page 160 If any system or component does not pass this in- spection, it must be corrected before operating the vehicle. Whenever equipment requires adjustment, replacement, repair, addition of lubricants, or a change of lubricants, see the Columbia ® Workshop Manual for procedures and specifications, and see the Columbia ®...
  • Page 161 Pretrip and Post-Trip Inspections and Maintenance 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 Check _______ surge tank coolant level Inspect _______ radiator and charge air cooler...
  • Page 162 Daily Pretrip Inspection and sor. Block the valve open. Maintenance WARNING Whenever equipment requires adjustment, replace- ment, and/or repair, see the Columbia ® Workshop When draining the air reservoir, do not look into Manual for procedures and specifications. Specific the air jets or direct them toward anyone. Dirt or...
  • Page 163 Check the radiator for leaks. If leaks are type of antifreeze currently installed in your ve- found, have the radiator repaired or re- hicle. ® placed. See Group 20 of the Columbia Workshop Manual for instructions, or take Fig. 11.1. the vehicle to an authorized Freightliner dealer.
  • Page 164 O) for Cat- erpillar engines or 20 inH O (508 mmH for Mercedes-Benz or Detroit Diesel en- gines. See Group 09 of the Columbia ® Workshop Manual for filter element re- placement instructions, or take the vehicle to an authorized Freightliner dealer.
  • Page 165 Pretrip and Post-Trip Inspections and Maintenance drain hose, loosen the drain valve, and allow the WARNING water to run out. Close the drain valve, taking care not to overtighten it. Never operate the engine with the fuel tank shut- For a ConMet Model see Fig.
  • Page 166 Pretrip and Post-Trip Inspections and Maintenance 11.3 Tighten all loose fasteners and have any NOTE: If the air pressure in both systems is component(s) replaced that are worn, above the preset minimum when the engine is cracked, or otherwise damaged. started, test the low air pressure warning sys- tem by lowering the pressure to below this 11.4...
  • Page 167 Pretrip and Post-Trip Inspections and Maintenance and lines must be kept dry. Use well- maintained inline moisture traps and ser- vice them regularly. WARNING Do not operate the vehicle with underinflated or overinflated tires. Incorrect inflation can stress the tires and make the tires and rims more sus- ceptible to damage, possibly leading to rim or tire failure and loss of vehicle control, resulting in serious personal injury or death.
  • Page 168 If needed, fill the hubs to the level indicated on 21.2 Examine the rim and wheel assembly the hub cap. See Group 35 of the Columbia components (including rims, rings, flanges, Maintenance Manual for recommended lubri- studs, and nuts) for cracks, or other dam- cants.
  • Page 169 See if the chamber piston rod is in line with the slack adjuster. Misalignment can cause the piston rod to rub on the non- pressure chamber and cause a dragging brake. See Group 42 of the Columbia ® Workshop Manual . CAUTION...
  • Page 170 Pretrip and Post-Trip Inspections and Maintenance 24.3 Check for damage to hoses located near moving parts, such as drivelines, kingpins, suspensions, and axles. If moving parts are catching or pinching the lines, correct as needed. 24.4 Check for hose damage caused by abra- sion.
  • Page 171 Pretrip and Post-Trip Inspections and Maintenance higher than normal rotor corrosion. Tone 25.3 Haldex Slack Adjusters: Inspect each slack adjuster and anchor strap for dam- rings should be routinely inspected for corro- age. See Fig. 11.11. Have any damaged sion. Severe corrosion of the integral ABS components replaced.
  • Page 172 Pretrip and Post-Trip Inspections and Maintenance With the air system fully charged to 120 Maximum Allowable Service Brake Air Leakage psi (827 kPa), make one full brake appli- Air Leakage in psi cation and note the air pressure reading (kPa) Per Minute Description on the gauge.
  • Page 173 Check the condition of the serpentine drive belt. If needed, fill the hubs to the level indicated on the hub cap. See Group 35 of the Columbia Look for signs of glazing, wear (frayed edges), Maintenance Manual , for recommended lubri- damage (breaks or cracks), or oil contamination.
  • Page 174 If there is not proper ten- apply a thin coat of petroleum jelly to the sion, have the belt tensioner replaced. See posts and terminals to help retard corro- Group 01 of the Columbia ® Workshop Manual sion.
  • Page 175 (6.4 mm) at the thinnest point, have the linings replaced on all brake assemblies on that axle. See Group 42 of the ® Columbia Workshop Manual for lining replacement instructions and camshaft end-play inspection. Check the brake drums for wear and cracks.
  • Page 176: Cab Appearance

    Cab Appearance Cab Washing and Polishing ............12.1 Care of Fiberglass Parts .
  • Page 177: Cab Washing And Polishing

    UV coating all road tar and tree sap before waxing. from the surface, and result in yellowing of the Freightliner recommends that a quality brand of lens. cleaner or cleaner-polish and polishing wax be used.
  • Page 178: Ordinary Dirt

    Cab Appearance vinyl upholstery. To preserve the upholstery and pre- drogen peroxide onto the cloth. Allow the saturated vent damage, carefully review the following sections cloth to remain on the spot for 30 to 60 minutes. For for recommended cleaning procedures. Waxing or stubborn spots, allow the hydrogen-peroxide satu- refinishing improves soil resistance and cleanability rated cloth to remain on the area overnight.
  • Page 179: Grease And Oil-Based Stains

    Cab Appearance Grease and Oil-Based Stains Dampen a small absorbent cloth with dry-cleaning solvent or spot remover. Apply the cloth carefully to the spot from the outer edge to the center. Pat and blot the spot with a clean, dry cloth. Repeat several times, as necessary, turning the cloths so that the stain does not redeposit on the fabric.
  • Page 180 In an Emergency Hazard Warning Lights ............13.1 Fire Extinguisher .
  • Page 181: Hazard Warning Lights

    In an Emergency Hazard Warning Lights WARNING The hazard warning light switch tab is located on the Use extreme care when placing flares in emer- turn signal control lever. See Fig. 13.1.To operate the gency situations that involve exposure to flam- hazard lights, pull the tab out.
  • Page 182: Rear Towing Hookup

    In an Emergency Cover the ends of the hubs with metal plates or On vehicles equipped with an air fairing, repeat plywood cut to fit the axle opening, and drilled to the measurement taken in step 8. The difference fit the axle shaft studs. This prevents lubricant between the two measurements must not exceed from leaking out, and will keep contaminants 14 inches (36 cm).
  • Page 183: Emergency Starting With Jumper Cables

    In an Emergency f880694 01/11/2006 IMPORTANT: Do not reeve when towing. 1. Tow Hook 2. Chain Fig. 13.2, Reeving Lift the vehicle, and secure the safety chains. If NOTE: On vehicles equipped with an optional extra clearance is needed, remove the bumper jump-start post, attach the positive cable clamp extension, if equipped.
  • Page 184: Fire In The Cab

    In an Emergency Fire in the Cab The incidence of fire in heavy- and medium-duty trucks is rare, according to data from the National Highway Traffic Safety Administration. Federal Motor − Vehicle Safety Standard #302 limits the flammability of specified materials used inside the cab, but de- −...
  • Page 185: Headlight Aiming

    Headlight Aiming Preliminary Checks ............. . . 14.1 Checking Headlight Aim .
  • Page 186: Checking Headlight Aim

    Headlight Aiming Preliminary Checks CAUTION Before checking or adjusting the headlight aim, do Do not use a power buffer, paper towels, chemi- the following: cal solvents, or abrasive cleaners on the head- • Remove large amounts of mud or ice from the light lens, all of which can remove the UV coating underside of the fenders.
  • Page 187: Adjusting Headlight Aim

    Headlight Aiming 8" 8" 8" 01/20/2003 f544240 Measure beam height from the ground to the center of the low-beam bulb. 1. Low-Beam Bulb and Reflector 8" 01/11/2011 2. High-Beam Bulb f544153 NOTE: The top view shows the ideal beam pattern; the Fig.
  • Page 188 Headlight Aiming NOTE: Blocking off each light is not necessary, but it can help to present a clearer beam pat- tern. Remove the chocks from the front tires. 14.3...
  • Page 189 Index Subject Page Subject Page Cab-to-Sleeper Access ..... 3.3 Canadian Motor Vehicle Safety Standard (CMVSS) Labels ....1.2 Adjusting Headlight Aim .
  • Page 190 Index Subject Page Subject Page ™ Cummins CELECT Plus Turn Signal Lever ..... . 2.26 Electronic Engines Utility Light Switch, Optional .
  • Page 191 Emergency Kit, Optional ....13.1 Freightliner SmartShift Shift Control ......8.1...
  • Page 192 ......5.2 Meritor Range-Shift Freightliner/Bostrom Seat ....5.3 Transmissions .
  • Page 193 Index Subject Page Subject Page General Information ..... 5.7 General Information, FreedomLine ......8.4 Sleeper Compartment Vents .

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