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School Bus Chassis Operator`s Manual

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1. ACTIVE FAULTS FAULT CODE 8 SCREEN PRESS KEY OR KEY OR RELEASE PARK BRAKE A ar INFORMATION y APPLY PARK BRAKE PUSH RIGHT ARROW KEY 1040415 Fig 2 22 Ignition Sequence Level Ill ICU 2 20 Driver Controls and Instruments If there are no active faults the screen displays the Fasten Seat Belts Odometer screen If however the level Ill ICU has received active fault codes or an electronic control unit ECU fails to re spond to the roll call it shows the Active Faults screen and displays the number of active faults up to a total of eight If desired press RIGHT ARROW to see the ac tive fault codes See Fig 2 19 Continuing to press the right arrow key will display all additional fault codes if any To go on press LEFT ARROW or if the engine is run ning release the parking brake to go on to the Fasten Seat Belts Odometer screen Unless the engine is running the ignition sequence ends with the Fasten Seat Belts Odometer screen IMPORTANT At this point if the vehicle has a communications system and an incoming mes sage is available it will be displayed To dismiss the incoming message press any key on the key pad With the engine idling the vehicle not moving the igni tion sequence cycles on and displays the Idle Hours Idle Gallons Odometer screen See Fig 2 23 2 21 ZEN 1 Y as TANZ y Ke JS gy NS 07 29 97 ee Fig 2 23 Level Ill ICU at the E
2. y To trip information See applicable Figure f040326a Fig 2 29 Setup Information and Vehicle Information 2 30 Driver Controls and Instruments Engine Miles and Hours displays the total miles and hours logged by the engine since installation NOTE Engine information is supplied by the en gine Electronic Control Module ECM It can be reset using engine diagnostic tools For more in formation see the engine manufacturers manuals Engine Gallons and PTO Gallons displays the gallons of fuel used by the engine and PTO since installation Diagnostic Information Diagnostic information provides two sets of data screens Active Faults followed by a separate screen for each fault until all have been shown and Historical Dash Faults also followed by a separate screen for each fault until all have been shown See Fig 2 28 Active Faults cannot be reset Active faults can be cleared only by correcting the fault Historical Dash Faults displays all dash faults since the last reset The second line of the display shows the mileage the last time faults were cleared Setup Information Setup information allows the user to change the target MPG the brightness of the screen display the language of the display English French or Spanish and the units of measurement English US conventional or met ric 2 31 When prompted by the screen press SET push the SET RESET key once The units that
3. 3 16 Caterpillar 3 16 CUMMINS 4 4 86 aa eee es 3 17 Mercedes Benz 3 18 Engine Starting 3 1 Caterpillar cio 3 2 CUMMINS eosed ee rss 3 3 Index Subject Page Mercedes Benz 3 4 PRESI ona be os 3 1 Starting Precautions All Engines 3 2 Exhaust Braking System optional 3 19 General Information 3 19 Pacbrake Exhaust Brake 3 21 F Federal Motor Vehicle Safety Standard FMVSS Labels deal Fluids and Lubricants 10 1 Fuller Straight Shift Transmissions 5 1 General Information 5 1 Operation 5 1 Fuse Relay Circuit Breaker Identification 10 2 G General Information 4 1 H Hazard Warning Lights 9 1 Hood THING tas ge ce se ew 2 32 To Return the Hood to the Operating Position 2 32 To Tilt the Hood 2 32 Subject Page Hydraulic Brake System GA General Information 7A Meritor WABCO Antilock Braking System ABS Hydraulic Brake Systems Tae Operation s cs edah ena as Tie l Instrument and Control Panel 2 1 Instrumentation Control Unit Level Miera rial aio 2 15 Alert Screens 2 23 Brightness Control 2 17 Direct Access Screens 2 26 Fuel Use Efficiency Level PUED wos eae eek ee 2 16 Keypad a tea eee ee 2 19 Level III ICU Ignition Sequence 2 19 Level III ICU Odometer 2 22 Level III IC
4. Light Location Part Number Headlight Rectangular Halogen WEE H6054 Headlight Rectangular Standard WEE 6052 Front Turn Signal Light WEE 1156 Front Side Marker Light WEE 193 Instrument Panel Light WEE 161 Rocker Switch Light SPR 904 404 Table 10 1 Replacement Light Bulbs Fluids and Lubricants See Table 10 2 for a listing of fluid and lubricant specifi cations IMPORTANT For vehicles with extended warran ties and equipped with automatic transmissions use only TranSynd synthetic ATF 10 1 Hydraulic Brake Master Cylinder Brake and Clutch Pedal Pivots Heavy Duty DOT 3 Brake Fluid Starplex 2 lithium soap based grease Engine Oil SAE 15W 40 HD Transmission Eaton Fuller Allison SAE 40 or 50 above 10 F 12 C SAE 30 below 10 F 12 C Dexron III ATF Fuel Grade No 2 0 or 2 D Diesel Fuel Brake Caliper V Ways and Anchor Plate Rails Aeroshell Grade 5 ES 1246 Rear Axle Differential Hypoid Gear Oil API Service Classification GL 5 Specifications Fluid and Lubricant Specifications Component Recommended Fluid or e eN E Lubricant ks pi 50 Water 50 Ethylene CAY Y o Mi Engine Golam Glycol Antifreeze Y SINES E i F For vehicles with extended warranties use only TranSynd synthe
5. Ensure that the engine is at low idle rom below 1000 Transmissions Apply the parking brake and the emergency brake and make sure that they are properly engaged Chock the rear tires and take any other steps nec essary to keep the vehicle from moving 5 6 Steering System General Information 4 daiar eisat 2 ec edi ded bd bade eae ee ee Cade ee ad eed ds 6 1 Power Steering System 0 6 1 Tilt Telescope Steering Column optional 0 06000 ccc eee 6 2 Steering System General Information When there is no load on the vehicle and the front tires are pointed straight ahead the steering wheel spokes should be at the 9 and 3 o clock positions or within 10 degrees to either side See Fig 6 1 See Group 46 of the School Bus Chassis Workshop Manual for steering adjustment procedures 10 y y 10 e b 4 de TO 19 4 11 15 2000 460307b 1 9 0 Clock 2 30 Clock Fig 6 1 Steering Wheel Centered 6 1 4h CAUTION Never steam clean or high pressure wash the steer ing gear Internal damage to gear seals and ulti mately the steering gear can result Power Steering System The power steering system consists of a steering gear which includes a manual steering mechanism a hy draulic control valve and a hydraulic power cylinder hydraulic hoses power steering pump reservoir and other components The power steering pump driven by the engine provides the power assist for th
6. Pre Start NOTE These pre start steps apply to all engines 1 Perform the engine pretrip inspection and daily maintenance checks in Chapter 8 2 Set the parking brake For manual transmissions place the transmission in Neutral N and disengage the clutch For automatic transmissions make sure that the transmission shift control is in Neutral N or Park P NOTE On vehicles equipped with a neutral start switch the transmission must be in Neutral N Engines before the engine can be started For air start sys tems check the air supply before starting the en gine There must be at least 100 psi 689 kPa of air pressure available Starting Precautions All Engines Do not use any starting aid such as ether in en gines with an intake air preheater This could cause an explosion resulting in serious personal injury or death Ah CAUTION Don t crank the engine for more than 30 seconds at a time during any of the following procedures Wait two minutes after each try to allow the starter to cool Failure to do so could cause starter damage NOTE Some starters are equipped with optional overcrank protection If overcranking occurs a thermostat breaks the electrical circuit to the starter motor until the motor has cooled A CAUTION Protect the turbocharger during the start up by not opening the throttle or accelerating the engine above 1000 rpm until normal engine idle oil pres sure registers on t
7. nied by eight short beeps from the shift selector oper ating limits will be placed on the transmission such as restricting upshifts and downshifts However the vehicle can still be driven to reach service assistance In either situation have the problem repaired as soon as pos sible See the Allison Transmission Service Manual for 2 7 troubleshooting procedures See Chapter 5 for com plete transmission operating instructions Cruise Control The cruise control allows you to automatically control the speed of the vehicle The switches that operate the cruise control are located on the instrument panel Do not use the cruise control system when driving conditions do not permit maintaining a constant speed such as in heavy traffic or on roads that are winding icy snow covered slippery or with a loose driving surface Failure to follow this precaution could cause a collision or loss of vehicle control possibly resulting in personal injury or property damage CAUTION Do not shift to Neutral N when using the cruise control This will cause the engine to overspeed which can damage the engine Use the Cruise ON OFF switch on the instrument panel to turn the cruise control on or off Use the SET RESUME switch to select cruise speed or to re sume cruise control after slowing down See Chapter 3 Driver Controls and Instruments High Idle with cruise control option Place the shift lever in Neutral N Press
8. equipped with an integral release bolt an end cover cap is installed over the release bolt Be sure that the end cover cap is snapped tightly into place Check for rusted connections missing snap rings and damaged camshaft grease seals Repair or replace damaged or missing parts Check the air reservoir band fasteners Make sure that the outside surfaces of the reservoirs are painted to prevent corrosion damage Inspect the reservoir surfaces for damage such as cracks and dents Replace corroded or damaged reservoirs with new ones Do not repair damaged reservoirs Old or used reservoirs are not acceptable as re placements If a reservoir requires replacement see Group 42 of the School Bus Chassis Work shop Manual for instructions Inspect the air lines as follows 26 1 Check the clearance between the hoses exhaust manifold and turbocharger or other hot spots Excessive heat will cause the ma terial in the hoses to deteriorate rapidly or become brittle Provide at least six inches 150 mm of clearance More clearance is recommended if the hose is located above the heat source 26 2 Check for kinks dents or swelling of the hoses If a hose is damaged replace it with one of the same size and type 26 3 Do not route the hose on top of anything likely to be stepped on or walked on 26 4 Check for damage to hoses located near moving parts such as drivelines suspen sions and axles If the moving parts are catchi
9. with that ECU and no fault code is displayed NOTE Each ICU is configured to receive re sponses from a list of selected ECUs as installed on that particular vehicle If the ECU does not respond to this request the level Ill ICU displays an active fault code that indicates that the databus is not communicating with that ECU For a sample fault code and message of this type see Fig 2 25 Level Ill ICU Odometer The level Ill ICU odometer is a seven digit display with one decimal point after the sixth digit allowing it to dis play tenths of miles or kilometers When first installed the odometer starts at 0 0 miles or kilometers When replaced the odometer does not 2 22 Driver Controls and Instruments NN S AM a m ca nunun 7 n n f N Nau fo A C Controller NoRESPONSE190s254 07 07 29 97 1601413 Fig 2 25 Level Ill ICU Roll Call Fault Code and Message start with the engine miles but starts again from 0 0 and cannot be changed up or down IMPORTANT Although the odometer uses data supplied by the engine ECM to update its count it keeps its own mileage starting from the zero point which marks where it was first installed 2 23 Alert Screens Alert screens appear whenever a condition requiring an alert occurs They appear when the vehicle is moving they override the regular screen display They are warn ings cautions or other messages that require
10. 4h CAUTION Don t crank the engine for more than 30 seconds at a time during any of the following procedures Wait 9 4 In an Emergency two minutes after each try to allow the starter to cool Failure to do so could cause starter damage 5 Attempt to start the engine of the vehicle with the batteries receiving the charge 6 When the engine starts let it idle for a few minutes Do the next step exactly as instructed and do not allow the clamps of one cable to touch the clamps of the other cable Otherwise a spark could occur near a battery possibly resulting in severe personal injury from explosion and acid burns 7 Disconnect the grounded cable from the frame or other non battery location then disconnect the other end of the cable Disconnect the remaining cable from the newly charged battery first then disconnect the other end Running Out of Fuel Do not mix gasoline or alcohol with diesel fuel This mixture could cause an explosion When filling fuel tanks do not smoke or use an open flame near the 9 5 fuel tanks Combustion of diesel fuel oil or fuel va pors could result possibly causing personal injury or property damage 1 If possible stop the vehicle on a level surface away from traffic 2 Set the parking brake See the engine manufacturer s manual for instruc tions 4 Call the Freightliner Customer Assistance Center at 1 800 385 4357 or 1 800 FTL HELP CAUTION Do
11. As the vehicle slows down the transmission will downshift to the correct gear automatically The pressure of your foot on the accelerator pedal influences the automatic shifting When the pedal is fully depressed the transmission will automatically upshift near the governed speed of the engine A partially depressed position of the pedal will cause the upshifts to occur at a lower engine speed 4 Occasionally the road load or traffic conditions make it desirable to restrict the automatic shifting to a lower range The lower the gear range the greater the engine braking power 5 5 Use the UP or DOWN arrow buttons on the shift selector to reach the desired gear The Select indi cator will display your choice and the Monitor indi cator will show the selected gear once it is reached NOTE In the lower gear ranges the transmission will not upshift above the highest gear selected unless the engine governed speed is exceeded 5 Engage Neutral N and apply the parking brake when the vehicle is parked with the engine running A CAUTION Do not allow the vehicle to coast in neutral This can result in severe transmission damage Also no engine braking is available Safety Precautions Do the following steps if you have to leave the cab with the engine running for example when checking the transmission fluid 1 Bring the vehicle to a complete stop using the ser vice brakes 2 Put the transmission in Neutral N
12. SOMO ON OO RWND Contents Page Introduction Environmental Concerns and Recommendations Event Data Recorder Customer Assistance Center Reporting Safety Defects Foreword Vehicle Identification eae a eek oho a Raa Ke eR RMR RAS RD OE eh RR ER RS 1 1 Driver Controls and Instruments sannana eG a eke ew Rea eee a 2 1 Engs 1 3 kane ie eee ahaa hd eg a dala Gal bad aa nti 3 1 CRONES oro raan dusted A fen asta oe da Ba eee de ome eed a ee ee lad d ge eee 4 1 WaAMSMISSIONS sesi rina Da a dO Le REE ed RGAE eee eae ee 5 1 Steer Mg SYSTEM ist Leds a wae be baw he a Pade bee 6 1 Brake Systemi aia ls a EN ew Pach wae De iia a a este athe 7 1 Pretrip Inspection and Daily Maintenance 0 ee 8 1 INPANCEMENGeNGy 144 0 i400 dene Gade dae dd bad bbw a Ge how Seven ddhe a dba 9 1 SPSCMICAUONS mico weeded wae Hales Gale a aa TAa a E be add iia 10 1 A A SMEAR hs Reet a a a ght a Perna gat ese a a A doa cae de eg aS 1 1 Vehicle Identification Vehicle Specification Label 24 c24ec004eeemed a eee eee ee be eee 1 1 Federal Motor Vehicle Safety Standard FMVSS Labels 00 0000 c eee eee eee 1 1 Vehicle Identification Number VIN 0 000 ccc eee 1 1 Vehicle Identification Vehicle Specification Label The vehicle specification label lists the vehicle model identification number and major component models It also recaps the major assemblies and installations shown on the chassis specification s
13. System optional General Information An exhaust brake is an optional auxiliary braking sys tem that assists but does not replace the service brake system The exhaust brake switch located on the con trol panel in combination with the accelerator and clutch pedals allows the driver to make maximum use of the exhaust brake in off hignway and mountain driv ing as well as in traffic or in high speed highway driving The exhaust brake is a butterfly valve mounted in the exhaust pipe When the driver s foot is not on the accel erator pedal and the exhaust brake switch is in the ON Engines position an air cylinder shuts the butterfly valve which restricts the flow of exhaust gases and retards the en gine This retarding action is carried through the engine and drivetrain slowing the vehicle and reducing the need for frequent service brake applications IMPORTANT Exhaust brakes are not intended for use as the primary braking system during vehicle operation Starting the Engine Before starting the engine make sure that the exhaust brake switch is in the OFF position Do not turn the ex haust brake on until the engine has reached normal op erating temperatures Driving Downhill While approaching a steep grade make sure that the exhaust brake switch is in the ON position The exhaust brake comes on as soon as you remove your foot from the accelerator pedal While going down the grade use a low enough gear to safely
14. airflow across all areas of the cores 8 6 Pretrip Inspection and Daily Maintenance Repair or replace the radiator if it is leaking See Group 20 of the School Bus Chassis Workshop Manual for instructions NOTE When traveling through areas of high in sect concentrations it may be necessary to clean the exterior of the radiator or aftercooler core as often as every 200 miles 320 km 7 Check the condition and operation of the engine radiator shutters Inspect both pneumatic and hydraulic type engine radiator shutters and ensure that they are free of contaminants and corrosion and operate properly 8 Check the condition of the coolant hoses and heater hoses Make sure that the radiator inlet and outlet coolant hoses and heater hoses are pliable and are not cracking or ballooning Replace hoses that show signs of cracking weakening or ballooning Re place all hoses including heater hoses at the same time Service type knitted or braided yarn reinforced neoprene hose is acceptable Silicone hoses having an extended service life can be substituted for the reinforced neoprene type See the Service Parts Catalog or contact your dealer 8 7 Tighten hose clamps as necessary but do not over tighten as hose life can be adversely affected Be sure that the hose support brackets are securely fastened Make sure that the hoses are not located near sources of wear abrasion or high heat 9 Check the conditio
15. are setable will be blinking Use the arrow keys LEFT RIGHT and DOWN until the display shows the desired setup Press SET again when finished to save the new set tings See Fig 2 29 Vehicle Information Vehicle information displays important information in cluding datalink activity and status ICU part number and software identification number The Datalink Active screen is a dynamic display that shows if the datalink unit is active at the given time If all of the arrows are pointing down the level III ICU has not received any information on the datalink since the last time that the ignition switch was turned to the ON position The Datalink Status screen is also dynamic showing current datalink use and error rate The other screen which shows the ICU part number and the software identification number is informational only See Fig 2 29 After vehicle information pressing the DOWN ARROW takes you back to trip information and so on Driver Controls and Instruments Hood Tilting A grab handle at the front of the hood provides a hand hold for hood tilting Stop cables prevent the hood from overtravel In the operating position the hood is se cured to the lower cab half fenders by a hold down latch on each side of the hood To Tilt the Hood 1 Apply the parking brake 2 Release both hood hold down latches by pulling the ends up See Fig 2 30 3 Using the bumper step and grab handle slowly til
16. bars showing to the left of the display indicate that short term fuel economy is below the target 2 17 Brightness Control The panel light dimmer switch normally controls the brightness of all panel and gauge lights including the level III ICU message display screen With the parking brake set the ICU keypad can control the brightness of the message display screen independently of the other lights If the panel lights are set to maximum brightness the message display screen cannot be brightened any further NOTE Use the LEFT ARROW key to dim the message display screen and the RIGHT ARROW key to brighten it For more information on how to set the brightness of the message display screen see Setup Information later in this chapter When the parking brake is released the arrow keys no longer work to change the brightness of the message display screen but the settings stay in effect unless the headlights are turned on With the headlights on the message display screen dims slightly to adjust to night time conditions Warning and Indicator Lights There can be up to 18 warning and indicator lights in stalled in the level III ICU See Fig 2 20 Driver Controls and Instruments e The green right and left turn signal lights flash on and off whenever the outside turn signal lights are flashing 4 08 28 2002 FASTEN SEATBELTS 10 0000432 MILES 11 5 5 12 f600996d Typical installation shown Location a
17. brake system warning light to come on a warning buzzer also alerts the driver On hydraulic brake systems the warning light comes on and the buzzer sounds when the fluid level is low or whenever there is a fluid pressure problem within the master cylinder The oil pressure warning light and buzzer activate whenever the oil pressure falls below the minimum oil pressure recommended by the engine manufacturer See Fig 2 9 2 8 Driver Controls and Instruments 09 12 96 1 Low Oil Pressure High Water Temperature Warning Low Oil Level Warning Alternator Warning Light Brake System Warning Antilock Braking System ABS Warning Light apoyo SZ 1 2 3 4 5 pid ABS ENG ENG DO NOT TRANS SHIFT TEMP os 6 7 8 9 10 11 12 13 Stop Engine Indicator Engine Check Indicator Cold Start Manifold Heater Indicator Air Cleaner Restriction Indicator 0 Do Not Shift Indicator ZO Ao PANEL LIGHTS 601176 11 High Oil Temperature Warning automatic transmission 12 Water in Fuel Water Separator Warning 13 Parking Brake Indicator Light 2 9 Fig 2 9 Warning and Indicator Lights Driver Controls and Instruments See the engine manufacturers manual for minimum oil pressure levels The water temperature warning light and buzzer acti vate whenever the engine coolant temperature exceeds a preset point determined by the engine manufacturer See Fig 2 9 See the engine manufact
18. damage or personal injury Loss of air pressure in the primary system causes the rear service brakes to become inoperative front brakes will continue to be operated by secondary system air pressure Loss of secondary system air pressure causes the front axle brakes to become inoperative rear service brakes will continue to be operated by the primary system Before driving your vehicle allow time for the air com pressor to build up a minimum of 95 psi 655 kPa pres sure in both the primary and secondary systems Moni tor the air pressure system by observing the dual system air pressure gauges and the low air pressure warning light and buzzer The warning light and buzzer shut off when air pressure in both systems reaches 64 to 76 psi 441 to 524 kPa The warning light and buzzer come on if air pressure drops below 64 to 76 psi 441 to 524 kPa in either sys tem If this happens check the air system pressure 7 4 Brake System gauges to determine which system has low air pres sure Although the vehicle s speed can be reduced us ing the foot brake control pedal either the front or rear service brakes will not be operating causing a longer stopping distance Bring the vehicle to a safe stop and have the air system repaired before continuing Do not drive the vehicle with the parking brakes caged If the vehicle is driven with the parking brakes caged there would be no means of stopping the vehicle if a complete los
19. descend with a minimum application of the service brakes As a general guide line use the same gear as you would to ascend the hill A CAUTION Do not allow the engine to exceed its governed speed or serious engine damage could result Apply the service brakes to reduce the engine rpm or make a slower descent by using a lower gear WARNING Do not use the exhaust brake when driving on slip pery or low traction road surfaces Failure to follow this precaution could result in a loss of vehicle con trol and possible personal injury or property dam age Exhaust Brake Operating Characteristics When you remove your feet from both the accelerator and the clutch pedal and the exhaust brake switch is in the ON position the exhaust brake is applied The fol lowing conditions should exist if the brake is operating properly e A slight change in the sound of the engine may be noticed when the exhaust brake is applied e Exhaust smoke should appear normal e Engine temperature should remain in the normal operating range e Road speed usually decreases when the exhaust brake is applied during a descent When the ve hicle is carrying a heavy load or the grade is ex tremely steep you may need to apply the service brakes occasionally Engines e Do not expect a retarding effect similar to sudden hard application of the service brakes The ex haust brake retards the vehicle with a smooth braking effect During a desce
20. does not also reset Fuel Used and Average MPG or Idle Gallons and PTO Gallons Fuel Information must be reset separately Idle Gallons and PTO Gallons displays the gallons of fuel used idling and to operate the Power Take Off unit if installed At the start of a trip or whenever desired press RESET to set idle gallons and PTO gallons back to zero Engine Information Engine information provides two data screens Engine Miles and Hours and Engine Gallons and PTO Gal lons See Fig 2 27 or Fig 2 28 Driver Controls and Instruments gt IDLE HOURS 1234 56 12 3 GAL 1234567 MI FASTEN SEATBELTS _ 1234567 MILES IGNITION ON ONLY y y IDLING TRIP TRIP MILES 123456 7 IDLE HOURS 1234 56 LEG MILES 123456 7 INFORMATION TRIP HOURS 1234 56 AVERAGE MPH 12 3 LEG HOURS 1234 56 R R R a FUEL FUEL USED 12345 6 IDLE GALLONS 12345 6 INFORMATION AVERAGE MPG 12 34 PTO GALLONS 12345 6 R R a ENGINE ENG MILES 1234567 8 ENG GALLONS 123456 7 INFORMATION ENG HOURS 123456 78 PTO GALLONS 123456 7 Y y y R RESET PUSH RESET SET KEY TWICE e S SET PUSH RESET SET KEY ONCE 01 28 98 See applicable figure 1040324a Fig 2 27 Trip Information Fuel Information and Engine Information 2 28 Driver Controls and Instruments IDLE HOURS 1234 56 12 3 GAL 1234567 MI FASTEN SEATBELTS 1234567 MILES See applicable Figure for trip and fuel info
21. gauge for filter replace ment The filter must be changed at recommended intervals regardless of what the gauge reads NOTE Rain or snow can wet the filter and cause a higher than normal reading temporarily 2 14 Driver Controls and Instruments Va N 0 40 AIR FILTER 7 y InfH20 RESTR q J 05 14 2001 610552 0 100 AIR FILTER Cm H20 3 RESTR Fi 05 14 2001 1610553 Fig 2 17 Intake Air Restriction Gauge inH O Instrumentation Control Unit Level Ill The level IIl instrumentation control unit ICU2M is an advanced programmable electronic dashboard It can accept information from the sensors and electronic con trol units installed on the vehicle and feed it to elec tronic gauges Only air gauges operate mechanically There can be up to 14 removable gauges on the driv er s instrument panel 11 electronic one electrome chanical and two mechanical The Driver Message Center is the heart of the level III ICU It has three parts 2 15 Fig 2 18 Intake Air Restriction Gauge cm H 0O e aset of 18 warning and indicator lights similar to those found on a conventional lightbar e a 10 key keypad on the auxiliary instrument panel e a message display screen The message display screen is a 2 line by 20 character vacuum fluorescent display that provides a wide range of information to the driver Some of the information that can be provided by the message center includes e odometer readin
22. in en gine damage 15 Check the oil level in the automatic transmission if so equipped NOTE The fluid must be warm to ensure an accu rate check The fluid level rises as temperature in creases With the vehicle on a level surface check the oil level the dipstick is next to the windshield washer reservoir in the transmission using one of the fol lowing procedures Hot Check e Operate the transmission in a Drive D range until normal operating temperature 160 to 200 71 to 93 C is reached e Park the vehicle Shift to Neutral N and ap ply the parking brake Let the engine run at idle e Wipe the dipstick clean and check the fluid level A safe operating level is any level within the HOT run upper band on the dip stick See Fig 8 5 Pretrip Inspection and Daily Maintenance e f the fluid is not within this range add or drain fluid as needed to bring the level to the top of the HOT run band See the School Bus Chassis Maintenance Manual for fluid types and capacities 02 27 2002 A HOT Run Band B COLD Run Band 1270077 Fig 8 5 Automatic Transmission Dipstick Cold Check e A cold check may be made when the sump tem perature is 60 to 104 F 15 to 40 C e Run the engine for at least one minute to clear the fluid system of air 16 17 18 With the engine running wipe the dipstick clean and check the fluid level See Fig 8 5 Any level within the COLD ru
23. selector lever is lighted for night driving See Chapter 5 for complete transmission operating instructions NOTE Vehicles equipped with an Arens shift by wire shift control system have an electronic push button selector similar to that described below for MD series transmissions Allison automatic transmission models MD CR and MD WR are controlled by an electronic control unit ECU The ECU processes information from sensors pressure switches and the shift selector to automati cally control the transmission according to programmed specifications See Fig 2 8 Vehicles with these transmissions have a red do not shift light in the lens and bezel assembly Also there is a service light in the indicator panel on the shift selec tor With the ignition switch in the ON position both lights come on for a few seconds then if there is no nv gz I 07 09 96 1270004 Fig 2 7 Shift Selector problem with the transmission system the lights will go out Whenever there is a problem with the transmission system the lights will come on and stay on as long as the problem exists If service is displayed in the indicator panel some fea tures may not work but the vehicle can still be driven If 2 6 Driver Controls and Instruments SELECT MONITOR 1 Y SERVICE 10 28 94 1600368a 1 Indicator Panel 2 Mode ID Fig 2 8 MD Shift Selector the do not shift light illuminates while driving accompa
24. temperatures are definitely necessary whereas a change to a warmer climate normally requires only a minimum of revision Most of the accessories should be designed in such a way that they can be disconnected so that there is little effect on the engine when they are not in use IMPORTANT If a winterfront is used on a vehicle with an electronic engine equipped with a charge air cooler make sure that there are slit openings distributed across the face of the winterfront to allow airflow through the entire charge air cooler core Do not use a winterfront with closed areas that block uniform air flow across all sections of the charge air cooler crossflow tubes This will ad versely affect the operation and durability of the charge air cooler Caterpillar If the engine is in good mechanical condition and the precautions necessary for cold weather operation are taken ordinary cold weather will not cause difficulty in starting or loss of efficiency For cold weather operation use the following guide lines 1 When starting the engine in temperatures below 32 F 0 C use engine lubricants of lower viscosity For specifications see the Caterpillar Operation and Maintenance Manual for your engine 2 Use winter grade 1 D or winterized 2 D diesel fuel if available At temperatures below 32 F 0 C do not use summer grade 2 D diesel fuel 3 When the temperature is below freezing use suffi cient antifreeze solution in
25. that is unable to hold full charge or is physically damaged Check the condition and tension of the poly V belt 3 Periodically check the coolant mixing ratio concen tration of antifreeze in the coolant Add more if necessary The coolant mixing ratio should never rise above 60 percent antifreeze 4 Use low viscosity lubricating oils for adequate lubri cation 5 At temperatures below 32 F 0 C do not use summer grade 2 D diesel fuel To avoid fuel prob lems due to paraffin separation use winter grade 1 D or winterized 2 D diesel fuel only WARNING The addition of kerosene lowers the flash point of diesel fuel To prevent fire and risk of injuries due to burning do not smoke or use open flames around fuel mixed with kerosene Comply with all appropriate safety regulations 6 When winter grade diesel fuel is not adequate it is possible to mix kerosene with the diesel fuel Add the kerosene only when refilling the tank and be fore adding the diesel fuel NOTE Engine power may drop according to the proportion of kerosene For this reason never add more than 50 percent kerosene to the fuel Engine Shutdown Caterpillar CAUTION Stopping the engine immediately after it has been working under load can result in overheating and accelerated wear of the engine components Exces sive temperatures in the turbocharger centerhous ing will cause oil coking problems Follow the pro cedure outlined belo
26. the ON OFF switch on the instrument panel Accelerate to the de sired rom Press and release the SET RESUME switch To disengage high idle step on the brake pedal or move the ON OFF switch to the OFF position Tilt Telescope Steering Column optional The optional tilt telescope steering column is actuated by a control lever on the steering column The optional tilt only steering column is actuated by ei ther a control lever on the steering column or a foot operated control valve located to the left of the clutch or brake pedal Electric Horn To sound the electric horn push the button in the center of the steering wheel Warning and Indicator Lights All of the standard and optional warning and indicator lights are housed in a lens and bezel assembly located below the speedometer and tachometer Standard indicator lights include e The green right and left turn signal lights that flash on and off whenever the outside turn signal lights are flashing e The blue high beam indicator light located above the speedometer and tachometer that comes on when the headlights are on high beam e The red parking brake indicator light that comes on when the parking brake is applied and the ig nition switch is in the ON position See Fig 2 9 Standard Warning System Standard Warning Lights Standard red warning lights are for alternator no charge and the brake system warning See Fig 2 9 Whenever conditions cause the
27. the cooling system to prevent freezing See Group 20 of the School Bus Chassis Maintenance Manual for specifications 4 During cold weather give more attention to the con dition of the batteries See Group 15 and Group 54 of the School Bus Chassis Workshop Manual for detailed information 5 Idle the engine at 1000 to 1200 rpm This will warm up the engine more quickly 6 Customer parameters may include cold mode op eration When the sum of the coolant temperature and the intake air temperature is below 127 F 35 C the system puts the engine in cold mode limiting engine power advancing timing and adjust ing the low idle to 1000 rpm to improve warm up 3 14 Engines time The system will keep the engine in cold mode until the temperature condition has been met The system will then stop the cold mode and allow the engine to operate normally Cummins The two most commonly used terms associated with preparation of equipment for low temperature operation are winterization and arctic specifications Winterization of the engine and or components makes starting and operating possible down to 25 F 32 C This requires Adequate lubrication with low temperature lubri cating oils Protection from the cold air insulation The metal temperature does not change but the rate of heat dissipation is affected Fuel of the proper grade for the lowest tempera ture Coolant containing 50 corrosion resist
28. tires for bulges cracks cuts or penetrations A tire pressure check will assist in uncovering hidden damage A weekly Fig 8 12 Check for Proper Tire Inflation pressure loss of 4 psi 28 kPa or more in a tire may indicate damage Inspect and repair or replace the tire 29 5 If the tires are wearing irregularly rotate them If the front steering axle tires become irregularly worn move them to the drive axle See Fig 8 13 Have the front axle alignment checked to determine the cause of irregular tire wear In a dual assembly if one tire wears faster than its mate reverse the position of the two tires See Fig 8 14 Government regulations require the removal of front axle tires at 4 32 inch 3 mm re maining tread depth and rear axle tires at 8 20 Pretrip Inspection and Daily Maintenance 2 32 inch 1 5 mm remaining tread depth However front axle tires may be rotated to the drive axles to use the remaining 2 32 inch 1 5 mm tread rubber See Group 40 of the School Bus Chassis Workshop Manual for additional information on tire matching spacing of dual tires and causes of abnormal tire wear 07 25 96 1400116 Fig 8 14 Dual Assembly Rotation e Check the wheel nuts or rim nuts for indications of looseness Remove all dirt and foreign material l from the assembly Dirt or rust streaks from the AL stud holes metal buildup around stud holes or out Y of round or worn stud holes may be
29. warning message the alarm tone is optional comes on whenever the turn signal remains on beyond a preset time or distance traveled The word Warning flashes on the display screen above the message Turn Signal On To dismiss this message either turn off the turn signal or press any key on the keypad Service Warnings Service warning screens display during the ignition se quence and indicate that a service interval has been reached or exceeded and that maintenance is required The messages may indicate the number of miles or hours until the next service or once passed the num ber of miles or hours ago that maintenance should have Driver Controls and Instruments been performed The messages read X Miles To Next Service X Hours To Next Service Service Was Due X Mi Ago and Service Was Due X Hr Ago The letter X represents the number of miles or hours pro grammed The ICU2M can be programmed using Ser viceLink to generate service warnings in either miles or hours but not both No Datalink Activity Screen The No Datalink Activity screen comes on whenever the datalink is not receiving data If the condition persists take the vehicle in for service as soon as possible to discover the cause of the prob lem Direct Access Screens The driver can also override the regular screen display at any time by pressing the keypad to display one of the direct access screens e Press the TRIP key for the Trip
30. within 30 seconds of starting turn the ignition switch to the OFF position and wait one minute then repeat the starting procedure Mercedes Benz NOTE An intake air preheater is optional on Mercedes Benz engines The intake air preheater if so equipped is activated by turning the ignition switch to the ON position See Fig 3 1 If the engine is at normal temperature the IN TAKE HEATER indicator goes out after two seconds If the temperature is low enough to require the heater the INTAKE HEATER indicator stays on while the intake air preheater warms up After the indicator goes out start the engine If the engine doesn t start after about 30 seconds of cranking turn the ignition switch to the OFF position and wait two minutes then repeat the starting procedure NOTE If the engine doesn t start on the second try wait at least five minutes before using the in take air preheater again 3 6 Engines Starting After Extended Shutdown or Oil Change An engine in storage for an extended period of time over winter for example may accumulate water in the oil pan Oil diluted by water cannot provide adequate bearing protection at start up For this reason change the engine oil and filters after extended storage Follow the steps below after an oil change or after the engine has been shut down for more than three days 1 Make sure that the transmission is filled with the correct type of fluid as recommended b
31. within the engine and the exhaust system to create a corrosion haz ard that could affect the future operation of the Pacbrake The brake housing may trap water in the valve shaft bore causing corrosion in an im proper or non functioning brake If it is necessary to periodically start the engine it is recommended that normal operating temperatures be attained before shutting down the engine Allison World Transmission Pacbrake exhaust brakes on engines that are used with the Allison World Transmission MD series and 2000 and 2400 series are interfaced with the transmission electronic control module ECM An exhaust brake en abled transmission ECM will usually provide converter lockup in gears Two 2 through Six 6 Effective ex haust braking begins when the transmission automati cally downshifts into Fifth 5 gear 62 mph 100 km h or less Once on the Pacbrake exhaust brake will con trol road speed and or slow the vehicle sufficiently so that the transmission will automatically downshift if nec essary to Allison s preselect mode The preselect mode is normally assigned to Second 2 gear however the transmission can be reprogrammed by an Allison Transmission Distributor to Third 3 or Fourth 4 gear should the operator desire If additional retarding power is required before the automatic down shifting occurs you can select a lower transmission gear on the Allison shift selector 3 22 Clutches General IATOM
32. 11 C1 Thermal 681 822 00 21 Table 10 3 Fuse Relay Circuit Breaker Identification Solid State 680 822 00 21 231284 000010 10A Fuse C2 Accessory Feed 680 545 19 66 10A C B 231284 000010 10A Fuse C3 Ether Start 680 545 19 66 10A C B ca Fuel Water Separator LF 257020 20A Fuse Battery Power 680 545 21 66 20A C B ES Diagnostic Connector 231284 000005 5A Fuse Battery Power 680 545 19 66 10A C B Hydraulic ABS 231284 000005 Battery Power 680 545 19 66 Fuel Water Separator C10 Relay 23 11276 011 Automatic C15 Transmission PAC14100455 Modulator 10 4 Index Subject Page A Air Brake System 7 4 Automatic Slack Adjusters 7 8 General Information 7 4 Meritor WABCO Antilock Braking System ABS Air Brake Systems 7 6 Operation 24 244465 eared ee 75 Allison Automatic Transmissions 5 2 General Information 5 2 Operation bes ice 5 3 C Changing a Flat Tire 9 5 Clutch Adjustments 4 2 Clutch Lubrication 4 3 Clutch Operation 4 1 Coasting With the Clutch Released pedal depressed and the Transmission in Gear 4 2 Engaging the Clutch While Coasting 4 2 Gear Shifting Techniques 4 1 Holding the Vehicle on an Incline With a Slipping Clutch 4 2 Reporting Erratic Clutch Operation Promptly 4 2 Riding the Clutch Pedal 4 2 Subject Page Starting
33. 231284 000010 10A Fuse 231284 000015 15A Fuse Cio B4 Stoplight Switch ER 680 545 19 66 10A C B 680 545 16 66 15A C B A8 Hydraulic Brakes BE paimi Running p LF 257 020 20A Fuse S batter ee A10 Relay Coil Feeds 9 y 680 545 17 66 20A C B 680 545 19 66 10A C B 231284 000015 15A Fuse Ignition Controlled 680 545 01 34 20A Fuse B6 iorn angis atst ACB A15 Relay to Optional Ignition Bus 680 545 12 66 20A C B i eee ee LF 257020 20A Fuse BA Fog Light Relay 23 11276 011 9 680 545 21 66 20A C B BB ea Lights 53 11276 011 gg gnition Switch 231284 000015 15A Fuse Battery Feed BC Panel Light Relay 680 545 0005 ie As 680 545 20 66 i SAC r use BD Headlight Relay Right 680 545 00 05 B9 Headlight Right BE Headlight Relay Left 680 545 00 05 680 545 16 66 15A C B Se hiak 231284 000015 15A Fuse 231284 000015 15A Fuse aillights B10 Headlight Left 680 545 20 66 15A C B a 680 545 16 66 15A C B 10 3 Specifications Fuse Relay Circuit Breaker Identification Fuse Relay Circuit Breaker Identification pe Description Part Number Rating ce Description Part Number Rating Ignition Controlled 680 545 01 34 20A Fuse C17 ABS Relay 23 11276 011 B14 Relay to Standard C18 ABS Relay 23 11276 011 B aere a C20 ABS Relay 23 11276 0
34. ER SAFETY STANDARDS APPLICABLE TO THIS VEHICLE WHEN COMPLETED IS NOT SUBSTANTIALLY AFFECTED BY THE DESIGN OF THE CHASSIS CAB 09 28 98 1080023 Fig 1 2 Incomplete Vehicle Certification Label U S 12 3 NFRD BY FRONT AXLE GAWR 3 mE FIRST INTERMEDIATE AXLE GAWR E ewa 6 SECOND INTERMEDIATE AXLE GAWR i VEHICLE ID NO THIRD INTERMEDIATE AXLE GAWR REAR AXLE GAWR THIS VEHICLE CONFORMS TO ALL APPLICABLE FEDERAL MOTOR VEHICLE SAFETY STANDARDS IN EFFECT ON THE DATE OF MANUFACTURE SHOWN ABOVE VEHICLE TYPE CLASSIFICATION TRUCK TRACTOR 11 21 96 1080053 1 Date of Manufacture by month and year 2 Gross Vehicle Weight Rating developed by taking the sum of all the vehicle s gross axle ratings 3 Gross Axle Weight Ratings developed by considering each component in an axle system including suspension axle wheels and tires and using the lowest component capacity as the value for the system Fig 1 1 Vehicle Specification Label Fig 1 3 Certification Label U S 1 2 Vehicle Identification 12 04 2001 f080122 Fig 1 4 Vehicle Identification Number VIN Label Typical Driver Controls and Instruments Instrument and Control Panel 2 1 MONON Sst A E eee a a A 2 1 Warning and indicator Lighis 2 8 secu atk A soe Hae ade a dae dae 2 8 MSWM a dais Ds ad See daa Beale cdl an ira Ni A Nana dies 2 10 Instrumentation Control Unit Level I aaua ens 2 15 A wate a oie whedon Se a ae i al ee
35. Foreword Introduction This manual provides information needed to operate and understand the school bus chassis and its compo nents More detailed information is contained in the Owner s Warranty Information for North America book let and in the vehicle s workshop and maintenance manuals Freightliner chassis are equipped with various chassis and cab components Not all of the information con tained in this manual applies to every vehicle If parts on your chassis differ from those shown they may have been installed by the vehicle manufacturer if so ser vice part responsibility belongs to the vehicle manufac turer The safety or performance of your vehicle could be ad versely affected by the installation of nonstandard com ponents Note the limitations and specifications pro vided in the vehicle and chassis manuals and consult your selling dealer before making any alterations to the vehicle or chassis 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 Freightliner Custom Chassis Corporation reserves the right to dis continue models and to change specifications or design at any time without notice and without incurring obliga tion Descriptions and specifications contained in this publication provide no warranty expressed or implied and are subject to revisions and editions without notice Environm
36. If the engine is operated at low load it will reach normal operating temperature sooner than at idle speed Limit unnecessary idle time to 10 minutes or less 4 When the engine has reached the minimum operat ing temperature of 160 F 71 C the engine may be operated at full load Cummins Ah CAUTION Never attempt to start any Cummins IS series elec tronic engine ISB ISC ISL using ether or any other starting fluid Serious engine damage could result Engines NOTE Before attempting to start the engine fol low the steps in Pre Start 1 Turn the ignition switch to the ON position See Fig 3 1 The CHECK ENGINE indicator comes on for five seconds Leave the ignition switch in the ON position until the CHECK ENGINE indicator goes out IMPORTANT The INTAKE HEATER indicator stays on for a minimum of two seconds regard less of coolant temperature Wait until the INTAKE HEATER indicator goes out before attempting to start the engine 2 Turn the ignition switch to the START position After the engine starts release the key 3 Bring the engine up to operating speed gradually as it warms up and develops stable oil pressure NOTE When the engine is started it takes a short time to build up a lubricating oil film between the shafts and bearings and between the pistons and cylinder walls The oil pressure gauge indicates any drop in lubricating oil pressure within 15 sec onds of engine start up 4 If mi
37. MAMOM postas a cate ia apdok bee aed i A Gogh eal arate as Pal aden abba ai 4 1 Clutch Operation 224 van iiiar iiaae a wen A lke a bee ea eee a es 4 1 CHURCH AdjUStMENTE soi hd toa is a a id Le dee dale kee alah 4 2 MC ir UG o fap reese kes Saeed A A IA S 4 3 Clutches General Information The major reason that clutches wear out too soon is because they have been overheated Clutches are de signed to absorb and dissipate more heat than encoun tered in typical operation The temperatures developed in typical operation will not break down the clutch fric tion surfaces However if a clutch is slipped exces sively or required to do the job of a fluid coupling high temperatures develop quickly and destroy the clutch Temperatures generated between the flywheel driven discs and pressure plates can be high enough to cause the metal to flow and the friction facing material to char and burn Slipping and excessive heat are practically nonexistent when a clutch is fully engaged But during the moment of engagement when the clutch is picking up the load it generates considerable heat An incorrectly adjusted or slipping clutch will rapidly generate sufficient heat to destroy itself The most important items that a driver should be aware of to ensure long service life of the clutch include start ing in the correct gear recognizing clutch malfunctions and knowing when to adjust a clutch 4 1 Clutch Operation Starting the Ve
38. Miles and Trip Hours screen e Press the FUEL key for the Fuel Used and Aver age MPG screen e Press the LEG key for the Leg Miles and Leg Hours screen Data for each of the above screens can be reset cleared To reset display the screen and push the Set Reset key twice within six seconds a confirmation screen will display after you press the key once NOTE Resetting Trip Miles and Hours also re sets Leg Miles and Hours Press the TEMP key to display the outside air tempera ture If the vehicle has a data logging unit press the EVENT key to record data about a significant driving event en gine problem driving problem unusual vehicle opera tion etc Normally the screen displays Data Being Recorded NOTE If the memory in the data logger is full the screen instead displays Memory Full Data Not Recorded If the data logger is not connected or not responding the screen displays Data Recorder Not Responding If the EVENT key was pressed recently within the last two minutes the screen displays Still Recording Last Event Stationary Access Screens Used With Parking Brake Applied The stationary access screens are a series of informa tional displays that give trip fuel engine diagnostic setup and vehicle information 2 26 Driver Controls and Instruments For reasons of safety stationary access screens can be seen only when the vehicle is not moving and the park ing brake
39. Pacbrake exhaust brake may electroni cally interact with each other which automatically acti vates their functions Following are some examples of the programmed options that may be available with the cruise control in the ON position e The coast mode engages the Pacbrake when the service brake is applied and disengages when the service brake is released The latch mode engages the Pacbrake when the service brake is applied and the Pacbrake re mains on after the service brake is released The Pacbrake is disengaged when another input de pressing the throttle or clutch engine speed drops below 800 rpm or the exhaust brake switch is turned off is supplied Engines e The manual mode does not require the cruise control switch to be on and operates the Pacbrake manually at the driver s discretion The amount of braking power the engine will develop is related to the speed rpm of the engine The higher the engine rpm the greater the retarding power Certain conditions may require that the transmission be downshifted in order to generate adequate rpm for the amount of retarding power required Pacbrake exhaust brakes are designed and approved for safe use at 300 rpm above the engine s maximum governed rpm See the engine manufacturer s specifications NOTE Starting the engine idling for short periods of time and then shutting down the engine is not recommended During a cold engine start up enough moisture is developed
40. RE a eee oe eal 2 32 Driver Controls and Instruments Instrument and Control Panel Figure 2 1 represents a typical Freightliner dash equipped with all of the standard and many of the op tional instruments and controls A warning and indicator light module located below the speedometer and tachometer houses all of the stan dard and optional warning and indicator lights Figure 2 2 identifies the warning and indicator lights Controls Ignition Switch and Key The ignition switch can be turned to four positions AC CESSORY OFF ON and START See Fig 2 3 The key can be inserted and removed only from the OFF position The headlights low beams only fog lights turn signals hazard warning lights and the park ing lights operate with the ignition switch in the OFF position regardless of whether the key is inserted In the accessory ACC position key is turned counter clockwise all of the electric gauges operate Turn the key fully clockwise to the START position only when starting the engine When the engine starts re lease the key When released the key will rotate coun terclockwise to the ON position 2 1 In the ON position key turned 45 degrees clockwise all of the electrical systems are operable Warning lights and the buzzer for low air pressure if equipped with air brakes and low oil pressure operate until the engine is started and minimum pressures build up Panel Light Control Lever Turn o
41. U Roll Call 2 22 Stationary Access Screens Used With Parking Brake Applied 2 26 Target MPG 2 16 The Message Display Screen 2 21 Warning and Indicator Lights 2 17 INSTUMENTS ociosa 2 10 Engine Oil Pressure Gauge 2 11 Subject Page Fuel Gauge 2 13 Intake Air Restriction Gauge 2 14 Intake Air Restriction Indicator 2 14 Speedometer 2 11 Tachometer optional 2 10 Transmission Oil Temperature Gauge optional 2 13 Voltmeter optional 2 12 Water Temperature Gauge 2 11 P Power Steering System 6 1 Pretrip Inspection and Daily Maintenance Procedures 8 3 Pretrip Inspection Checklist 8 1 R Replacement Light Bulbs 10 1 Running Out of Fuel 9 5 S Starting After Extended Shutdown or Oil Change 3 7 Index Subject Page Tilt Telescope Steering Column Optional wg hero a pk a A ee 6 2 TOWING ee sor ci 9 1 Front Towing Hookup 9 1 Rear Towing Hookup 9 2 Vehicle Identification Number VIN 1 1 Vehicle Specification Label 1 1 Warning and Indicator Lights 2 8 Standard Warning System 2 8
42. ainte nance Manual for intervals and procedures CAUTION Failure to lubricate the release bearing as recom mended could result in release bearing damage and damage to the clutch 4 3 Transmissions Fuller Straight Shift Transmissions 0 0000 0c eee 5 1 Allison Automatic Transmissions Transmissions Fuller Straight Shift Transmissions General Information Fuller FS 4205A B FS 5205A B and FS 6305A B transmissions have five forward speeds and one Re verse R speed See Fig 5 1 for the shift pattern F R 2 uE 1 3 5 03 12 96 260080 Fig 5 1 Shift Pattern FS 4205A B FS 5205A B and FS 6305A B Fuller FS 5306A and FS 6306A transmissions have six forward speeds and one Reverse R speed See Fig 5 2 for the shift pattern These transmissions are designed for use with fuel economy engines where a minimum of shifting is de sired and less gear reduction is acceptable 5 1 R 1 3 5 N 2 4 6 10 19 2000 260085 Fig 5 2 Shift Pattern FS 5306A and FS 6306A Operation NOTE Always use First 1 gear when starting to move the vehicle forward 1 Depress the clutch pedal and engage First 1 gear 2 Accelerate and gradually engage release the clutch pedal to get moving 3 Accelerate smoothly until ready to upshift to the next gear 4 Release the accelerator disengage the clutch up shift engage the clutch and accelerate 5 Continue upshifting u
43. aise the vehicle until the wheel is off of the ground Remove the lug nuts and the wheel 11 12 13 Install the spare wheel and lug nuts Make sure that the beveled sides of the nuts face inward or on hub piloted wheels make sure that the hub pilot pad is centered at the top In a star pattern tighten the nuts evenly until snug See Group 40 of the School Bus Chassis Work shop Manual for wheel tightening patterns and torque specifications Lower the vehicle until the wheel touches the ground Tighten the nuts Finish lowering the vehicle to the ground then re move the jack Remove the block then stow the jack jack handle and lug wrench After operating the vehicle for 50 to 100 miles 80 to 160 km retighten the wheel nuts to the speci fied torque values 9 6 Replacement Light Bulbs Fluids and Lubricants Fuse Relay Circuit Breaker Identification Specifications Specifications Replacement Light Bulbs See Table 10 1 for a listing of replacement light bulbs Fluid and Lubricant Specifications Component Recommended Fluid or Lubricant Replacement Light Bulbs Front Axle Spindle Pins Tie Rods Drag Link Intermediate Steering Shaft Front Brake and Clutch Cable Pedal Shafts Slip Spline and Universal Joints Multipurpose Grease Lithium 12 Hydroxy Stearate NLGI No 2 for temperatures below 0 F 18 C use MIL G 10924B
44. aking sparks Other wise the vehicle charging systems could be se verely damaged Also do not attempt to charge iso lated deep cycle batteries with jumper cables Follow the manufacturer s instructions when charg ing deep cycle batteries In an Emergency 1 Set the parking brake and turn off the lights and all other electrical loads 2 Connect one end of a jumper cable to the positive terminal of the booster battery and connect the other end of the cable to the positive terminal of the discharged battery See Fig 9 2 Do the next step exactly as instructed and do not allow the clamps of one cable to touch the clamps of the other cable Otherwise a spark could occur near a battery possibly resulting in severe personal injury from explosion and acid burns 3 Connect one end of the second jumper cable to the negative terminal of the booster battery and con nect the other end of the cable to a ground at least 12 inches 300 mm away from the batteries of the vehicle needing the start The vehicle frame is usu ally a good ground Do not connect the cable to or near the discharged batteries 4 Start the engine of the vehicle with the booster bat teries and let the engine run for a few minutes to charge the batteries of the other vehicle D C 4 A 2 B vA MI 08 21 96 1541286 A ist C 3rd B 2nd D To Frame ground 1 Booster Battery 2 Discharged Battery Fig 9 2 Jumper Connections
45. al lights push it clockwise to turn on the right turn signal lights When one of the signal lights is on a green indicator light flashes at either the far left or far right of the warning and indicator light panel When the turn is completed the signal will cancel and the le ver will return to the neutral position See Fig 2 6 Hazard Warning Light Tab The hazard warning light tab is located beneath the turn signal lever Activate the hazard warning lights by pull 2 5 07 09 96 1 Turn Signal Lever 2 Hazard Warning Light Tab 1461080 Fig 2 6 Turn Signal Headlight Dimmer Switch and Hazard Warning Tab ing the tab out When the hazard warning light tab is pulled out all of the turn signal lights and both of the indicator lights on the control panel will flash To cancel the warning lights move the turn signal lever up or down then return the lever to the neutral position See Fig 2 6 Headlight Dimmer Switch Pull the turn signal lever up to change from low beam to high beam headlights or from high beams back to low beams See Fig 2 6 When the headlights are on Driver Controls and Instruments high beam a blue indicator light comes on above the speedometer and tachometer NOTE The ignition switch must be in the ON posi tion for the high beams to work Allison Automatic Transmission Controls Allison automatic transmissions have six shift positions on the selector lever See Fig 2 7 The
46. and to protect the components from corrosion Clean more frequently when unusually corrosive chemicals are being used IMPORTANT During winter months in areas where corrosive materials are used on the highways pe riodically clean the underside of the vehicle to en sure proper ABS functioning The electronic control unit also has a safety circuit that constantly monitors the wheel sensors solenoid control 7 7 valves and the electrical circuitry The ABS warning light comes on after turning the ignition switch to the ON position Once the vehicle moves faster than about 4 mph 6 km h the warning light goes out only if all of the ABS components are working The Meritor WABCO ABS system combines one front axle control channel with the rear axle the four sensor system to form one control circuit For example the sensor and solenoid control valve at the left front axle form a control circuit with the sensor and solenoid valve on the right rear axle If during vehicle operation the safety circuit senses a failure in any part of the ABS system a sensor solenoid control valve wiring connec tion short circuit etc the warning light ABS comes on and the control circuit where the failure occurred is switched to normal braking action The remaining con trol circuit will retain the ABS effect Even if the ABS system is partially or completely inoperative normal braking ability is maintained An exception would be if a sol
47. ant anti freeze Using an engine block heater oil pan heater or coolant heater to raise the engine block and com ponent temperatures above 25 F 32 C for starting in lower temperatures e Electrical equipment capable of operating in the lowest expected temperature All switches con nections and batteries in the electrical system should be inspected and kept in good condition to prevent losses through poor contacts Arctic specifications refer to the material and specifica tions of components needed for satisfactory engine op eration in extremely low temperatures down to 65 F 54 C Contact the nearest Freightliner dealer or Cummins engine dealer to obtain the special items re quired CAUTION Antileak antifreezes are not recommended for use in Cummins engines Although these antifreezes are chemically compatible with DCA water treatment the antileak agents may clog the coolant filters For more information see the Cummins Operation and Maintenance Manual Mercedes Benz Take special precautions during cold weather For ser vice products to use in cold weather see the engine Operator s Manual IMPORTANT At outside temperatures below 4 F 20 C a coolant preheater is recommended Engines 1 Check for cracks in the battery cases corrosion of the terminals and the tightness of the cable clamps at the terminals Charge the batteries to full capac ity Replace any battery
48. bles that exist in towing posi tioning the lifting and towing device is the sole re sponsibility of the tow vehicle operator The opera tor must be familiar with standard towing industry safety measures Improper procedures could result in personal injury or death 4 Attach the towing device 5 Lift the vehicle and secure the safety towing chains If additional clearance is needed remove the front wheels 6 Connect the clearance lights taillights and signal lights Connect any special towing lights required by local regulations Before releasing the parking brakes make the con nection to the towing vehicle or chock the tires on the disabled vehicle Failure to do so could result in hazardous conditions because the vehicle could suddenly roll and injury could occur CAUTION Before attempting to tow a vehicle with an air sus pension and during the towing operation ensure that the air suspension is properly charged Charge the suspension through the Schrader valve on the air dryer Attempting to tow a vehicle with an im properly charged air suspension may result in dam age to the chassis and body 7 Release the parking brake Rear Towing Hookup 1 Position the front tires so that they point straight ahead and secure the steering wheel in this posi tion 9 2 In an Emergency 2 Disconnect the battery ground cable A WARNING Due to the many variables that exist in towing posi tioning the li
49. brake system normal braking may be impaired or inoperative IMPORTANT If any of the ABS warning lights do not work as described above or come on while Brake System driving repair the ABS system immediately to en sure full antilock braking capability During emergency or reduced traction stops fully de press the brake pedal until the vehicle comes to a safe stop do not pumpthe brake pedal With the brake pedal fully depressed the ABS system will control all wheels to provide steering control and a reduced braking dis tance Although the ABS system improves vehicle control dur ing emergency braking situations the driver still has the responsibility to change driving styles depending on the existing traffic and road conditions For example the ABS system cannot prevent an accident if the driver is speeding or following too closely on slippery road sur faces Air Brake System General Information A dual air brake system consists of two independent air brake systems which use a single set of brake controls Each system has its own reservoir plumbing and brake chambers The primary system operates the service brakes on the rear axle the secondary system operates the service brakes on the front axle Do not operate the vehicle with the front brakes backed off or disconnected Backing off or discon necting the front brakes will not improve vehicle handling and may lead to loss of vehicle control resulting in property
50. cal malfunction in the lubricating oil system Minimum oil pressure at idle is 7 psi 50 kPa 4h CAUTION Do not rev the engine if the oil pressure gauge indi cates no oil pressure Shut down the engine if no oil pressure appears within approximately ten sec onds Check to determine the cause of the problem Operating the engine with no oil pressure will dam age the engine Cold Weather Starting Do not use any starting aid such as ether in en gines with an intake air preheater This could cause 3 5 an explosion resulting in serious personal injury or death Modern electronic engines do not normally require spe cial starting aids At low temperatures intake air pre heaters manifold preheaters oil pan heaters fuel heat ers or water jacket heaters are sometimes used to assist in starting If the engine does not start prime the fuel system For instructions see the engine manufacturer s Operation and Maintenance Manual In cold weather use winter grade 1 D or winterized 2 D diesel fuel if available At temperatures below 32 F 0 C do not use summer grade 2 D diesel fuel Caterpillar Caterpillar electronic engines are designed to start at temperatures above 32 F 0 C without using starting aids If the temperature is below 32 F 0 C startability will be improved by the use of an automatic ether injec tion system and or a water jacket heater CAUTION Directing ether at the heater ele
51. caused by AN loose wheel nuts See the School Bus Chassis Maintenance Manual for torque specifications and dl A P y the correct tightening sequences 07 25 96 1400115 Examine the wheel assembly components includ ing rims rings flanges studs and nuts for cracks Fig 8 13 Front Axle to Rear Axle Rotation 29 6 Also inspect tires for oil contamination Fuel oil gasoline and other petroleum deriva tives if allowed to contact the tires will soften the rubber and destroy the tire 30 Check for indications of loose wheel nuts or rim nuts and examine each wheel component or other damage See Group 33 and Group 35 of the School Bus Chassis Workshop Manual for service procedures for the studs and hubs and Group 40 of the School Bus Chassis Workshop Manual for wheel and tire servicing Replace broken cracked badly worn bent rusty or sprung rings and rims Be sure Pretrip Inspection and Daily Maintenance that the rim base lockring and side ring are matched according to size and type WARNING Have any worn or damaged wheel components re placed by a qualified person using the wheel manu facturer s instructions and the wheel industry s standard safety precautions and equipment Other wise a vehicle or workshop accident could occur possibly resulting in serious personal injury or death CAUTION Insufficient wheel nut rim nut torque can cause wheel shimmy resulting in wh
52. components Check the coolant level in the surge tank sight glass and check the radiator and the charge air cooler for clogging or damage Check the radiator for coolant leaks Pretrip Inspection and Daily Maintenance 10 11 12 13 14 15 16 17 18 19 Check the condition and operation of the engine radiator shutters Check the condition of the coolant hoses and heater hoses Check the condition of the drive belts Inspect the engine for fuel oil and coolant leaks Inspect the engine and chassis wiring Inspect the air intake system for leaks or damage Check the intake air restriction indicator if it is mounted on the air intake system Check the fluid level in the hydraulic brake fluid res ervoir if so equipped Check the engine lubricating oil level Check the oil level in the automatic transmission if so equipped Check the fuel water separator if so equipped for contaminants Close the hood and engage the hood hold down latches Inspect the fuel tank s and fuel line connections If so equipped be sure that the fuel tank shutoff valves are open Check the fuel level in the fuel tank s and be sure that the fuel cap vent area is clean If so equipped 20 2i 22 23 24 25 26 27 28 check the fuel water separator for leaks If needed prime the fuel system Inspect the front and rear suspension components including the springs and air sprin
53. e ignition switch is turned to the ON position 8 Use a combination of brakes and gears to keep the vehicle under control at all times and to keep the engine speed below the rated rpm 9 Check the coolant temperature and oil pressure gauges frequently A CAUTION Continuous operation below 140 F 60 C above 212 F 100 C or with the oil pressure below 10 psi 69 kPa can damage the engine 10 If the engine starts to overheat reduce the power output of the engine Do one or both of the follow ing 1 Release pressure on the accelerator pedal 3 11 2 Shift to a lower gear If the temperature does not return to normal shut down the engine Mercedes Benz While you are driving watch for any signs of engine problems If the engine overheats uses excessive fuel or lubricating oil vibrates misfires makes unusual noises or shows an unusual loss of power shut down the engine as soon as possible and determine the cause of the problem Frequently engine damage may be avoided by a quick response to early indications of problems 1 Use the tachometer to determine when to shift Fol low the pattern on the shift lever when moving through the gears 2 Depending on the vehicle gearing the posted speed limit can sometimes allow operation in either of the two top gears however for improved operat ing efficiency fuel economy and engine life oper ate in the top gear at reduced rpm rather than in the next
54. e manufacturer s recommenda tions for the correct tire inflation pressures for the vehicle load Overinflation gives the treaded surface of the tire a convex shape See Fig 8 12 This causes extreme tire wear in the middle part of the tire since this section is primarily in contact with the road Underinflation gives the tread surface a con cave shape See Fig 8 12 This causes ex cessive tire wear on the outer edges of the tire since they are primarily in contact with the road Do not operate the vehicle with underinflated or overinflated tires Incorrect inflation can stress the tires and make the tires and rims more susceptible to damage possibly leading to rim or tire failure and loss of vehicle control resulting in serious per sonal injury or death 29 2 If a tire has been run flat or underinflated check the wheel for proper lockring and side ring seating and possible wheel rim or tire damage before adding air Pretrip Inspection and Daily Maintenance 11 03 94 LQ gt 1400061 A B Cc 11 03 94 1400062a A Tire correctly inflated B Tire overinflated C Tire underinflated 29 3 29 4 Fig 8 11 Check Tire Inflation Pressures Moisture inside a tire can result in body ply separation or a sidewall rupture During tire inflation compressed air reservoirs and lines must be kept dry Use well maintained inline moisture traps and service them regularly Inspect the
55. e replaced During winter months in areas where corrosive ma terials are used on the highways periodically clean the underside of the vehicle including the tone rings and sensors to ensure proper ABS function 7 3 and to protect the components from corrosion Clean more frequently when unusually corrosive chemicals are being used IMPORTANT During winter months in areas where corrosive materials are used on the highways pe riodically clean the underside of the vehicle to en sure proper ABS functioning The electronic control unit also has a safety circuit that constantly monitors the wheel sensors brake pressure modulator and the electrical circuitry The dash warning light ABS comes on after the ignition switch is turned to the ON position Once the vehicle moves faster than about 4 mph 6 km h the warning light goes out only if all of the vehicle s ABS components are working If during vehicle operation the safety circuit senses a failure in any part of the ABS system a sensor brake pressure modulator wiring connection short circuit etc the warning light ABS comes on and the control circuit where the failure occurred is switched to normal braking action Even if the ABS system is partially or completely inoperative normal braking ability is main tained An exception would be if the brake pressure modulator or hydraulic fluid line is damaged As these components are an integral part of the hydraulic
56. e steering system If the engine is not running there is no power assist If the power assist feature does not work due to hydrau lic fluid loss steering pump damage or some other cause bring the vehicle to a safe stop Do not drive the vehicle until the cause of the problem has been cor rected WARNING Driving the vehicle without the power assist feature of the steering system requires much greater effort especially in sharp turns or at low speeds which could result in an accident and possible injury Steering System Drivers should use the power available with a power steering system carefully If the front tires become lodged in a deep chuckhole or rut drive the vehicle out instead of using the steering system to lift the tires from the hole Also avoid turning the tires when they are against a curb as this places a heavy load on steering components and could damage them Tilt Telescope Steering Column optional Adjust the seat to a comfortable position If the vehicle is equipped with a tilt telescope steering column pull the control lever on the column upward and adjust the steering wheel to the desired position See Fig 6 2 Push the lever downward and extend or retract the steering column as desired Release the control lever to lock the steering column in place If the vehicle is equipped with a tilt only column adjust the steering wheel with either a control lever on the col umn or a foot operated co
57. e the air compressor before operat ing the vehicle Check the air pressure reserve With the air system fully charged to 125 psi 862 kPa stop the engine and note the air pressure 8 22 Pretrip Inspection and Daily Maintenance Then make one full brake application and observe the pressure drop If it drops more than 25 psi 172 kPa all areas of leakage must be eliminated before operating the ve hicle A WARNING Before operating the vehicle be sure that the park ing brake passes the following tests Otherwise an unexpected parking brake application could occur causing some loss of vehicle control and possibly resulting in serious personal injury 31 4 Check the air leakage in the system With the parking brake applied the transmis sion out of gear and the tires chocked charge the air system until a cutoff pressure of 125 psi 862 kPa is reached With the service brakes released shut down the engine wait one minute and note the air pressure gauge reading Observe the air pressure drop in psi kPa per minute Charge the air system until a cutoff pressure of 125 psi 862 kPa is reached With the parking brake released and the service brake applied shut down the engine wait one minute and note the air pressure gauge reading Observe the air pressure drop in psi kPa per minute If leakage exceeds the limits shown in Table 8 1 repair all areas of leakage before driving the vehicle Maximum All
58. e when shifting from Neutral N into a Drive D gear range Transmissions 1 Use Reverse R to back the vehicle Completely stop the vehicle before shifting from a forward gear to Reverse R or from Reverse R to a forward gear There is only one Reverse R gear 2 Use Neutral N and set the parking brake to park the vehicle with the engine running or shut down The engine may be started in this position Always chock the tires for hilly or off road parking 4h CAUTION Do not allow the vehicle to coast in neutral This can result in severe transmission damage Also no engine braking is available 3 Select Drive D for all normal driving conditions The vehicle will start out in First 1 gear and as speed increases the transmission will upshift through each gear automatically As the vehicle slows down the transmission will downshift to the correct gear automatically Occasionally the road load or traffic conditions make it desirable to restrict the automatic shifting to a lower range The lower the gear range the greater the engine braking power 4 Use Second 2 or Third 3 for slow driving in heavy city traffic or on mountain roads when more precise speed control is desirable Use them also for climbing long grades and for engine braking when descending moderately steep grades To pre vent excessive engine speed do not drive faster than 45 miles per hour 72 km h in Second 2 or Third 3 5 U
59. economy and performance control the engine speed within the range of 1400 to 2000 rpm 7 On a downhill grade do not coast or put the trans mission in Neutral N A simple rule to follow is to select the same gear or one gear lower than would be needed to go up the grade Engines 7 1 7 2 7 3 7 4 Avoid downshifting on small hills even if the engine must be lugged down below peak torque rpm On longer downhill grades allow the engine to lug to peak torque rpm before downshift ing If the engine speed stabilizes at peak torque rpm stay in that gear Anticipate long steep downgrades Reduce vehicle speed before reaching the summit Select a gear that allows the engine to run near the high engine limit 2900 rpm To maintain a safe speed and increase fuel economy minimize the amount of braking needed Cummins Follow the directions in the Cummins Operation and Maintenance Manual and in this manual for trouble free economical vehicle engine operation CAUTION Do not operate the engine at excessive full throttle below the rated rpm for more than 30 seconds This can shorten the life of the engine and cause severe engine damage Cummins diesel engines are designed to operate successfully at full throttle under transient condi tions down to rated rpm This is consistent with rec ommended operating practices Depending on the vehicle gearing the posted speed limit can sometimes allow operation
60. ectric horn works 25 Make sure that all of the lights are working Pretrip Inspection and Daily Maintenance Turn on the headlights dash lights and emergency flashers and leave them on If any of the gauge bulbs the switch panel label bulb or the right and left turn indicator bulbs are not working replace them If they still don t work find and correct the problem Turn off all of the lights Shut down the engine Do not loosen or remove the parking brake clamp ring for any purpose See Fig 8 8 The parking emergency brake section of the brake chamber is not intended to be serviced Serious injury or death may result from sudden release of the power spring Before doing any repairs or adjustments on a service parking brake chamber read the applicable warnings and instructions in Group 42 of the School Bus Chassis Workshop Manual Do not operate the vehicle with the front brakes backed off or disconnected Backing off or discon necting the front brakes will not improve vehicle handling and may lead to loss of vehicle control resulting in property damage or personal injury Ah CAUTION If the external breather tube or breather cap is miss ing or incorrectly installed road dirt and debris can adversely affect the operation of the brake chamber Once inside of the chamber dirt and debris can cause the internal parts of the chamber to deterio rate faster NOTE Check vehicles operating under severe or adve
61. edal down and repeat the inspection If there is a leak the hose should be re placed See Group 42 of the School Bus Chassis Workshop Manual for the hose re placement procedure 26 8 26 9 26 10 Inspect air tubing especially tubing made of nylon In cold weather nylon tubing is sensi tive to damage such as nicks or cuts Re place nicked or cut tubing even if it is not leaking Check the bend radii of all hoses See Fig 8 10 The minimum bend radius of a hose is that bend which the hose will with stand without experiencing damaging stresses or kinking For minimum bend ra dius values see Group 42 of the School Bus Chassis Workshop Manual When a rubber hose bend does not meet minimum radius requirements the outside may appear smooth even if the inner tube is kinked Reroute the hose or replace it with one of adequate length if the bend radius is not within minimum specifications Check straight hose installations those hoses that do not bend along their routings Pressure changes can cause a hose to lengthen up to two percent or shorten up to four percent A 100 inch 2540 mm length of hose for example can contract to 96 inches 2440 mm If the hose has no slack when it is exhausted of air replace it with one of adequate length to avoid a possible blow off from the fitting during vehicle operation Pretrip Inspection and Daily Maintenance 11 03 94 A NOTE The center of the hose bend radius sh
62. eel damage stud breakage and extreme tire tread wear Excessive wheel nut torque can break studs damage threads and crack discs in the stud hole area Use the rec ommended torque values and follow the proper tightening sequence 31 Check air brake system components for correct op eration as follows 31 1 Release the parking brake by pushing in the parking brake control valve knob Check the air governor cut in and cut out pressures Run the engine at fast idle The air governor 31 2 31 3 should cut out the air compressor at approxi mately 125 psi 862 kPa With the engine idling make a series of foot valve applica tions The air governor should cut in the air compressor at approximately 95 psi 655 kPa If the air governor does not cut in and out as described above adjust it to these specifications If the air governor cannot be adjusted or repaired replace it before oper ating the vehicle Check the air pressure buildup time as fol lows Release the parking brake by pushing in the parking brake control valve knob With the air system fully charged to 125 psi 862 kPa make one full brake application and note the air pressure reading on the gauge Continue to reduce the air pressure by moderate brake applications to a maxi mum of 90 psi 620 kPa then run the en gine at governed rpm If the time required to raise the air pressure to 125 psi 862 kPa is more than 30 seconds eliminate any leaks or replac
63. ehicle there is likely a mechani cal problem with the foundation brake components or the adjuster is improperly installed Visit a repair facility as soon as possible when brakes equipped with automatic slack adjusters are determined to be out of adjustment Manually adjusting an automatic slack adjuster to bring the pushrod stroke within legal limits is likely masking a mechanical problem Adjustment is not repairing In fact continual adjustment of automatic slack adjusters may result in premature wear of the adjuster itself Further the improper adjustment of some automatic slack adjusters may cause internal damage to the adjuster thereby preventing it from properly functioning 7 8 Pretrip Inspection and Daily Maintenance Pretrip Inspection Checklist 5 6 io ake be eee he ee ee eed he mde Pe ee ee 8 1 Pretrip Inspection and Daily Maintenance Procedures 0 000 cee ee eee 8 3 Pretrip Inspection and Daily Maintenance Pretrip Inspection Checklist IMPORTANT If the vehicle is taken out of service for an extended period of time such as for the Summer follow the procedures below In regions where corrosive materials are applied to roads and highways to control ice thoroughly clean the underside of the vehicle to prevent cor rosion Ensure that the vehicle is not parked over dry brush or leaves This is a potential fire hazard Disconnect the batteries and charge them peri odically using a trickle c
64. em works an engine shutdown could occur causing a safety hazard See Chapter 2 for information on the control panel for these engines Caterpillar Proper operation and maintenance are key factors in obtaining maximum life and economy from a vehicle engine Follow the directions in the Caterpillar Opera tion and Maintenance Manualand this manual for trouble free economical engine operation 1 Operate the engine at low load After normal oil pressure is reached and the temperature gauge begins to move the engine may be operated at full load 2 Caterpillar electronic engines automatically idle at 1000 rpm for the correct warm up time after a cold engine start less than 40 F 5 C These electronic engine systems will reduce the idle speed to 600 rem when the engine is warm enough to drive the vehicle 3 8 Engines IMPORTANT Fuel heaters used on vehicles with Caterpillar electronic engines could cause exces sive fuel temperatures that affect engine perfor mance and operation of the electronic engine con trols If a fuel heater is used make sure that it has thermostatic controls If the fuel heater has a timer set the timer to activate only for a limited period of time before the engine starts Make sure that the fuel heater is used only for starting the engine 3 Avoid excess idling If extended idle time is re quired control the engine speed to 1000 rpm or higher 4 Select a gear that allows a smooth eas
65. enoid control valve or combination solenoid control valve is damaged and inoperative As these compo nents are an integral part of the air brake system nor mal braking may be impaired or inoperative IMPORTANT If any of the ABS warning lights do not work as described above or come on while driving repair the ABS system immediately to en sure full antilock braking capability Brake System During emergency or reduced traction stops fully de press the brake pedal until the vehicle comes to a safe stop do not pumpthe brake pedal With the brake pedal fully depressed the ABS system will control all wheels to provide steering control and a reduced braking dis tance Although the ABS system improves vehicle control dur ing emergency braking situations the driver still has the responsibility to change driving styles depending on the existing traffic and road conditions For example the ABS system cannot prevent an accident if the driver is speeding or following too closely on slippery road surfaces Automatic Slack Adjusters Automatic slack adjusters are required on all vehicles equipped with air brakes manufactured after October 20 1994 Automatic slack adjusters should never be manually adjusted except during routine maintenance of the foundation brakes e g replacing shoes during slack adjuster installation or in an emergency situation When the brake pushrod stroke exceeds the legal brake adjustment limit on a v
66. ental Concerns and Recommendations Whenever you see instructions in this manual to discard materials you should first attempt to reclaim and re cycle them To preserve our environment follow appro priate environmental rules and regulations when dispos ing 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 As sistance Center at 1 800 385 4357 or 1 800 FTL HELP Call night or day weekdays or weekends for STI 346 8 05P Printed in U S A Foreword dealer referral vehicle information or breakdown coor dination Our people are knowledgeable professional and committed to keeping your vehicle 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 Freightliner Custom Chassis Corporation 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 How
67. ever 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 1996 2005 Freightliner LLC All rights reserved 1 800 424 9153 go to http www safercar gov or write to Administrator NHTSA 400 Seventh Street SW Washington DC 20590 You can also obtain other information about motor vehicle safety from http www safercar gov 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 ON5 For additional road safety information please visit the Road Safety website at http www tc gc ca roadsafety menu htm 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 Freightliner LLC For additional information please contact Freightliner LLC Service Systems and Docu mentation P O Box 3849 Portland OR 97208 3849 U S A or refer to http www Freightliner com and http www FreightlinerChassis com Chapter
68. fting and towing device is the sole re sponsibility of the tow vehicle operator The opera tor must be familiar with standard towing industry safety measures Improper procedures could result in personal injury or death 3 Attach the towing device 4 Lift the vehicle and secure the safety towing chains 5 Connect the clearance lights taillights and signal lights Also connect any special towing lights re quired by local regulations 4h CAUTION Before attempting to tow a vehicle with an air sus pension and during the towing operation ensure that the air suspension is properly charged Charge the suspension through the Schrader valve on the air dryer Attempting to tow a vehicle with an im properly charged air suspension may result in dam age to the chassis and body 9 3 Emergency Starting With Jumper Cables When using jumper cables follow the instructions below WARNING Batteries release explosive gas Do not smoke when working around batteries Put out all flames and re move all sources of sparks or intense heat in the vicinity of the battery Do not allow the vehicles to touch each other Do not lean over the batteries when making connections and keep all other per sons away from the batteries Failure to follow these precautions could lead to severe personal in jury as a result of an explosion or acid burns 4h CAUTION Make sure both starting systems have the same voltage outputs and avoid m
69. gs e outside air temperature Driver Controls and Instruments trip information such as trip miles and hours idle hours average mph and leg miles and hours fuel information such as fuel used miles per gal lon and fuel used idling engine information such as miles hours and gallons of fuel used diagnostic information such as listings of active faults and troubleshooting information vehicle information such as datalink operation and use data dash part number and software number Some of the advanced features supported by the level Ill ICU are Fuel Use Efficiency Level FUEL system display target miles per gallon MPG and brightness control Fuel Use Efficiency Level FUEL If so equipped the FUEL system continuously monitors fuel usage efficiency and instantly transmits action mes sages through the Driver Message Center to help the driver get better mileage The system may suggest a different speed gear or throttle position and will calcu late and transmit estimated fuel savings based on the suggested action It also calculates and displays a bar graph that shows a fuel efficiency score as a percent age of optimum efficiency The messages this system displays are e Drive 60 MPH Gain X MPG e Shift to Next Gear Gain X MPG e End Idling Save X Gal Hr e Drive Steady Speed Gain X MPG e Move Throttle Slower Gain X MPG In each example the X value in the statement is vari able The syste
70. gs shocks and suspension brackets Check for excessive play at the steering wheel On mechanical clutch linkages if so equipped check the clutch pedal free travel Turn the ignition switch to the ON position and start the engine Be sure that the oil pressure warning system is operating Leave the engine running Make sure that the electric horn is operating prop erly Make sure that all of the lights are working includ ing the brake lights high and low beam headlights turn signals clearance lights and emergency flash ers Check the condition of the reflectors Turn the lights off Shut down the engine Inspect the air brake components if so equipped including the brake chamber pushrods air reser voirs and air lines Check the brake lining wear if equipped with air brakes Make sure that the brakes are adjusted on all ax les 8 2 Pretrip Inspection and Daily Maintenance 29 Check the tire inflation pressures and inspect each tire for bulges cracks cuts and punctures 30 Check for indications of loose wheel nuts or rim nuts and examine each rim and wheel component 31 Check the air brake system for proper operation 32 Test the service brakes before leaving the lot 33 Test the parking brakes on a 20 percent grade Pretrip Inspection and Daily Maintenance Procedures Whenever equipment requires adjustment replacement repair addition of lubricants or a change of lubricants see
71. h to the OFF position and shut down the engine Engine Braking System optional Constant Throttle Valves MBE900 only To increase braking performance the Mercedes Benz MBE900 engine can be equipped with constant throttles in each combustion chamber Small valves built into the cylinder head allow a small amount of compressed air to escape through the exhaust port during the combus tion stroke The constant throttle valves are open during the entire time that the engine brake is activated Al though some braking ability is lost because the valves are constantly open constant throttle braking is quieter in operation than other types of engine brakes When only the exhaust brake is installed a two position switch on the dash controls the engine braking system The exhaust brake is only active when the engine 3 19 speed is between 900 and 2 700 rpm Depressing the accelerator or clutch pedal deactivates the exhaust brake The ABS system when active also deactivates the exhaust brake When both the exhaust brake and the constant throttles are installed a three position switch on the dash con trols the engine braking system The exhaust brake can be used alone or together with constant throttle valves for steep or long grades Like the engine brake the constant throttles are deactivated when the accelerator or clutch pedal is depressed The ABS system when active also deactivates constant throttle braking Exhaust Braking
72. harger Approximately once a month connect the batter ies start the vehicle and allow the engine to reach normal operating temperature Once the engine reaches normal operating tem perature lubricate the radiator shutters This will prevent them from seizing The following pretrip inspection checklist helps ensure that the vehicle components are in good working condi tion before each trip Pretrip inspections cannot be performed in a short pe riod In checklist form the sequence below may seem to be overly time consuming However careful pretrip 8 1 inspections save time by eliminating stops later to ad just items overlooked or forgotten Each checklist step corresponds with detailed instruc tions found under Pretrip Inspection and Daily Mainte nance Procedures If any system or component does not pass this inspection it must be corrected before operating the vehicle See the School Bus Chassis Workshop Manual for repair procedures and the School Bus Chassis Maintenance Manual for lubricant recom mendations specifications and maintenance intervals and procedures NOTE Apply the parking brakes and chock the tires 1 Drain the air brake system air reservoirs if so equipped Inspect the batteries and battery cables 3 Check the fluid level in the windshield washer res ervoir 4 Check the front hub lubricant level if equipped with oil lubricated wheel bearings Tilt the hood Examine the steering
73. he gauge Caterpillar NOTE Before attempting to start the engine fol low the steps in Pre Start 1 Turn the ignition switch to the ON position See Fig 3 1 The CHECK ENGINE indicator comes on for five seconds IMPORTANT The INTAKE HEATER indicator stays on for a minimum of two seconds regard less of coolant temperature Wait until the INTAKE HEATER indicator goes out before attempting to start the engine 2 Turn the ignition switch to the START position Re lease the switch the moment the engine starts 2 1 If the engine does not start after 15 to 20 seconds of cranking turn the ignition switch to the OFF position 3 2 3 4 2 o Wg 1 0 fe a E 07 10 96 1601179 1 Accessory 3 On 2 Off 4 Start Fig 3 1 Ignition Switch Positions 2 2 Wait two minutes to allow the starter motor to cool Turn the ignition switch back to the ON position and try to start the engine again 2 3 As soon as the engine starts release the 3 3 ignition switch allowing the engine to run at a slow idle 4h CAUTION If the oil pressure is too low shut down the engine immediately to prevent serious damage If the ve hicle is equipped with an automatic shutdown sys tem the engine will shut down after 30 seconds 3 The engine may be operated at low load and speed once engine oil pressure has reached 10 psi 69 kPa and air pressure if applicable has reached 64 to 76 psi 441 to 524 kPa IMPORTANT
74. heet See Fig 1 1 NOTE Labels shown in this chapter are examples only Actual specifications may vary from vehicle to vehicle Federal Motor Vehicle Safety Standard FMVSS Labels If purchased for service in the U S chassis built with out a body have a certification label similar to that shown in Fig 1 2 In addition after completion of the vehicle a certification label similar to that shown in Fig 1 3 must be attached by the final stage manufac turer This label certifies that the vehicle conforms to all applicable FMVSS regulations in effect on the date of completion NOTE On incomplete vehicles it is the responsi bility of the final stage manufacturer to complete the vehicle and label it for compliance Vehicle Identification Number VIN The chassis vehicle identification number VIN is per manently attached to the chassis See Fig 1 4 NOTE Always include the chassis serial number last six digits of the VIN when communicating with Freightliner Custom Chassis Corporation Vehicle Identification 09 11 2002 1080123 CHASSIS CAB MFD BY VEHICLE ID NUMBER THIS CHASSIS CAB CONFORMS TO FEDERAL MOTOR VEHICLE SAFETY STANDARD NOS 101 102 108 04 106 107 111 113 115 120 121 124 205 206207 208209210302 IEHICLE WILL CONFORM TO STANDARD NO IF IT IS COMPLETED IN ACCORDANCE WITH THE INSTRUCTIONS CONTAINED IN THE INCOMPLETE VEHICLE DOCUMENT FURNISHED PURSUANT TO 49CFR PART S68 CONFORMITY TO THE OTH
75. hicle in the Correct Gear NOTE Manual transmission vehicles are equipped with an ignition interlock switch The engine will not start until the clutch has been fully depressed To drive forward always start in First 1 gear After the clutch is fully engaged accelerate to the correct rpm for the upshift into the next higher gear Gear Shifting Techniques Many drivers upshift into the next gear or even skip shift into a higher gear before the vehicle has reached the correct speed This type of shifting is almost as bad as starting off in a gear that is too high since the en gine rpm and vehicle speeds are too far apart requiring the clutch to absorb the speed difference by generating heat For transmission operating instructions see Chapter 5 Vehicle Overload or Overloading the Clutch Clutches are designed for specific vehicle applications and loads These limitations should not be exceeded Clutches A CAUTION Overloading will not only result in damage to the clutch but also to the entire power train Riding the Clutch Pedal Riding the clutch pedal is destructive to the clutch since partial clutch engagement permits slippage gen erating excessive heat Riding the clutch pedal will also put a constant thrust load on the release bearing which can thin out the lubricant Release bearing failures can be attributed to this type of misuse Holding the Vehicle on an Incline With a Slipping Clutch A slipp
76. ights and both of the indicator lights on the control panel will flash Push the tab in to cancel the hazard warning lights 07 09 96 NAN 1461080 1 Turn Signal Lever 2 Hazard Warning Light Tab Fig 9 1 Hazard Warning Light Tab 9 1 Towing Do not tow an unbraked vehicle if the combined weight of both vehicles is more than the sum of the gross axle weight ratings GAWR of the towing ve hicle Otherwise brake capacity will be inadequate which could result in personal injury or death IMPORTANT When it is necessary to tow the ve hicle follow the instructions below closely to pre vent damage to the vehicle When towing or pushing any vehicle equipped with an Allison transmission disconnect the driveshaft at the rear axle and support it as necessary re gardless of the distance or speed traveled Front Towing Hookup 1 Disconnect the battery ground cable 2 If the vehicle is to be lifted and towed remove the driveaxle shafts In an Emergency A CAUTION Failure to remove the axle shafts when towing the vehicle with the rear wheels on the ground could result in damage to the transmission and other parts 3 Cover the ends of the hubs with metal plates or plywood cut to fit the axle opening and drilled to fit the axle shaft studs This prevents lubricant from leaking out and will keep contaminants from getting into the axle lubricant and damaging the wheel bearings Due to the many varia
77. ime follow the instructions in the engine Operator s Manual Engines Engine Operation Operating vehicles with diesel engines in areas where there are concentrated flammable vapors such as die sel gasoline or propane fumes can create a hazard ous situation These vapors can be drawn into the en gine through the air intake and cause engine overspeed Be especially cautious of low lying or closed in areas and always check for signs that flam mable vapors may be present Don t operate the engine in an area where flam mable vapors such as gasoline or diesel fumes are present Shut down the engine when in an area where flammable liquids or gases are being handled Failure to observe these precautions could result in serious injury or death All diesel engines have been built to comply with the requirements of the Federal U S Clean Air Act Once an engine is placed in service the responsibility for meeting both state and local regulations is with the owner operator Good operating practices regular main tenance and correct adjustments are factors which will help to stay within the regulations Adequate maintenance of the engine which is the re sponsibility of the owner operator is essential to keep the emission levels low The driver should be familiar with the vehicle warning system in order to bring the vehicle to a safe stop if the engine malfunctions If the driver doesn t understand how the warning syst
78. in either of the two top gears however for improved operat ing efficiency fuel economy and engine life oper ate in the top gear at reduced rpm rather than in the next lower gear at the maximum rpm Cruise at partial throttle whenever road conditions and speed requirements permit This driving tech nique permits operating within the most economical power range of the engine When approaching a hill open the throttle smoothly to start the upgrade at full power then shift down as needed to maintain the optimum vehicle and engine speed The high torque of Cummins engines may permit topping some grades without shifting Cummins engines are designed to operate over a wide speed range More frequent shifting than nec essary does not allow proper utilization of this flex ibility The driver who stays in top gear and uses the wider speed range will achieve the best fuel economy The Cummins diesel engine is effective as a brake on downhill grades but take care not to overspeed the engine going downhill The governor has no 3 10 Engines control over engine speed when the engine is being pushed by the loaded vehicle CAUTION Do not allow the engine to exceed its governed speed or serious engine damage could result 7 Never turn the ignition switch to the OFF position while going downhill With the engine still in gear fuel pressure will build up against the shutdown valve and may prevent it from opening when th
79. ing clutch accumulates heat faster than it can be dissipated resulting in early clutch failures Never use the clutch to hold your position on a hill Coasting With the Clutch Released pedal depressed and the Transmission in Gear Coasting with the clutch released and the transmission in gear can cause high driven disc rpm through multipli cation of ratios from the final drive and transmission Do not coast with the clutch released pedal de pressed and the transmission in gear High driven disc rpm could cause the clutch facing to be thrown off the disc Flying debris could cause injury to per sons in the cab Engaging the Clutch While Coasting Engaging the clutch while coasting can result in tremen dous shock loads and possible damage to the clutch as well as to the entire drivetrain Reporting Erratic Clutch Operation Promptly Report erratic clutch operation as soon as possible so that maintenance personnel have a chance to inspect the clutch components Clutch Adjustments Some clutches have an internal adjustment See the applicable section in Group 25 of the School Bus Chas sis Workshop Manual for clutch adjustment procedures and specifications 4 2 Clutches CAUTION Operating the vehicle with the clutch incorrectly ad justed could result in clutch or clutch brake failure Clutch Lubrication Lubricate the clutch release bearing at frequent inter vals See Group 25 of the School Bus Chassis M
80. ion for oil pressure coolant temperature and the brake system Instruments Tachometer optional A tachometer indicates engine speed in revolutions per minute rpm and serves as a guide for shifting the transmission and keeping the engine in the appropriate rpm range See Fig 2 10 For low idle and rated rpm see the engine identification plate The tachometer may include an engine hourmeter An engine hourmeter records continuous operating hours of 2 10 Driver Controls and Instruments 10 28 94 1600374a 10 28 94 1600375a Fig 2 10 Tachometer the engine In cases where actual mileage does not in dicate overall usage maintenance and lubrication inter vals for the engine and engine operated equipment can be determined by operating hours Speedometer A speedometer registers vehicle speed in both miles per hour mph and kilometers per hour km h Stan dard speedometer gauges are equipped with an odom eter that records total distance traveled in either miles or kilometers See Fig 2 11 Water Temperature Gauge During normal engine operation the water temperature gauge should read from 175 to 203 F 79 to 95 C See 2 11 Fig 2 11 Speedometer Fig 2 12 If the temperature remains below 160 F 71 C or exceeds a maximum temperature of 210 F 99 C inspect the cooling system to determine the cause See the School Bus Chassis Workshop Manual for troubleshooting and repair p
81. ions have electronic shift controls that can be programmed to allow the use of different num bers of geared speeds For instance the transmission can be programmed to operate as a four speed five speed or six speed unit in the primary shift mode If needed a secondary shift mode can be programmed to provide another shift configuration to optimize vehicle use under different operating conditions To activate a secondary shift mode or other special function pro grammed into the electronic control unit ECU depress the mode button Mode On is displayed in the indica tor panel just above the push buttons A label just above the Mode button identifies the special function NOTE Each time that a push button is depressed on the shift selector a short beep is heard This indicates that the ECU has received input to change operation 52 Transmissions The MD series transmission system is designed to warn the driver of transmission malfunctions The driver of a vehicle equipped with one of these transmissions should know the extent of the warning system in order to safely operate the vehicle See Chapter 2 for infor mation on the warning system N0UZJI 07 09 96 1270004 SELECT MONITOR gt MODE ON 10 31 94 1 Digital Display 2 Mode Identification 1600369a Fig 5 3 Shift Indicator Lever 5 3 Fig 5 4 Allison Push Button Shift Selector Operation IMPORTANT Do not race the engin
82. is applied Each set of stationary access screens has a title screen followed by one or more data screens To move forward and backward through these screens use the three ar row keys as shown in Fig 2 27 Fig 2 28 and Fig 2 29 Trip Information Trip information provides three data screens Trip Miles and Hours Idle Hours and Average MPH and Leg Miles and Hours See Fig 2 27 Trip Miles and Hours displays the number of miles and hours driven since the start of the trip At the start of a trip press RESET SET RESET twice to set trip miles and hours back to zero NOTE Resetting Trip Miles and Hours also re sets Idle Hours and Average MPH Idle Hours and Average MPH displays the hours spent idling and the average miles per hour Leg Miles and Hours records the number of miles and hours driven since the start of the leg At the start of a new leg press RESET to set leg miles and hours back to zero 2 27 NOTE Resetting Trip Miles and Hours also re sets Leg Miles and Hours Fuel Information Fuel information provides two data screens Fuel Used and Average MPG and Idle Gallons and PTO Gal lons See Fig 2 27 Fuel Used and Average MPG displays the gallons of fuel used since the last reset At the start of a trip after refueling or whenever desired press RESET SET RESET twice to set fuel used and average miles per gallon back to zero NOTE Resetting Trip Miles and Hours
83. ke lever all the way up 2 3 NOTE Turning the knob clockwise will also in crease the effort needed to apply or release the parking brake lever Driver Controls and Instruments 3 4 o Y 07 10 96 a 601179 1 Accessory 3 On 2 Off 4 Start Fig 2 3 Ignition Switch If the parking brake still doesn t hold the vehicle se curely after adjustment check the parking brake lin ings for the correct thickness or for contamination For instructions see Group 42 of the School Bus Chassis Maintenance Manual if equipped with hydraulic brakes If equipped with air brakes see Chapter 8 of this manual 10 26 94 1600363a Fig 2 4 Panel Light Control Lever Parking Brake Control Valve Vehicles With Air Brakes A diamond shaped knob to the right of the control panel operates the parking brake control valve When the knob is pulled out the vehicle s spring parking brake is applied When the knob is pushed in the parking brake is released Before the parking brake can be released air pressure in the brake system must be at least 65 psi 447 kPa See Chapter 7 under the heading Air Brake System for instructions on how to use the parking brake valve 2 4 Driver Controls and Instruments 10 26 94 1600356a Fig 2 5 Headlight Switch Turn Signal Lever The turn signal lever is mounted on the steering col umn Push the lever counterclockwise to turn on the left turn sign
84. l speed at all times but controls wheel speed during an emergency or reduced traction stop In normal braking applications the stan dard hydraulic brake system is in effect IMPORTANT For proper ABS system operation do not change tire sizes The sizes of the tires in stalled during production are programmed into the electronic control unit Installing different sized 7 2 Brake System tires could result in inaccurate wheel speed sig nals to the ECU resulting in reduced braking force which could lead to longer stopping distances ABS includes signal generating tone wheels and sen sors located in the wheel hubs of each sensed axle The sensors transmit vehicle wheel speed information to an electronic control unit located on the frontwall that interprets these signals to calculate wheel speed and a vehicle reference speed If the calculations indi cate wheel lockup the appropriate control circuit signals the brake pressure modulator to increase or decrease braking pressure until wheelslip has been corrected A CAUTION An accumulation of road salt dirt or debris on the ABS tone wheels and sensors can cause the ABS warning light to come on If the ABS light does come on the tone rings and sensors should be in spected for corrosion and serviced if necessary The service should include cleaning of the tone rings and sensors If any tone ring on a vehicle shows severe corrosion all tone rings on that ve hicle should b
85. le stopped apply the parking brake and place the transmission in Neutral N 2 Idle the engine for three to five minutes before shutting it down This allows the lubricating oil and the water to carry heat away from the combustion chambers bearings shafts etc This is especially important with turbocharged engines The extreme heat may cause bearings to seize or oil seals to leak IMPORTANT Bearings and seals in the turbo charger are subjected to the high heat of combus tion exhaust gases While the engine is running this heat is carried away by oil circulation but if the engine is shut down suddenly the turbo charger temperature may rise as much as 115 F 46 C NOTE Long periods of idling are not good for an engine because the combustion chamber tempera tures drop so low that the fuel may not burn com pletely This will cause carbon to clog the injector spray holes and piston rings and may result in stuck valves 3 Do not idle the engine for more than 10 minutes Engines A CAUTION Stop the engine at the first sign of malfunction Al most all malfunctions give some warning to the op erator before significant damage occurs Many en gines are saved because alert operators heed the warning signs sudden drop in oil pressure un usual noises etc and immediately shut down the engine 4 Turn the ignition switch to the OFF position and shut down the engine Mercedes Benz If any of the following occ
86. lower gear at the maximum rpm 3 Cruise at partial throttle whenever road conditions and speed requirements permit This driving tech nique permits operating within the most economical power range of the engine Engines 4 Use lower gears in steep downhill driving Normally the gear used to descend a hill is the same gear used to climb a hill of the same grade 5 Never allow the engine to exceed the rated speed Use the exhaust brake and the optional constant throttle brake if so equipped to lower engine rpm below the rated speed 6 Never allow the engine to idle for more than 30 minutes Excessive idling can cause oil to leak from the turbocharger 4h CAUTION Stop the engine at the first sign of malfunction Al most all malfunctions give some warning to the op erator before significant damage occurs Many en gines are saved because alert operators heed the warning signs sudden drop in oil pressure un usual noises etc and immediately shut down the engine NOTE Long periods of idling are not good for an engine because the combustion chamber tempera tures drop so low that the fuel may not burn com pletely This will cause carbon to clog the injector spray holes and piston rings and may result in stuck valves If the engine coolant temperature becomes too low raw fuel will wash the lubricating oil off of the cylinder walls and dilute the crankcase oil causing all moving parts of the engine to suffer fro
87. m poor lubrication Cruise Control Use the ON OFF switch on the instrument panel to acti vate the cruise control Do not activate the fifth wheel air slider control valve when the vehicle is in motion Doing so could result in damage to the fifth wheel member kingpin cab or trailer and ultimately to the drivetrain A guard is positioned around the switch to prevent it from being accidentally activated 4h CAUTION Do not attempt to shift gears without using the clutch when the cruise control is engaged Failure to follow this precaution will result in a temporarily uncontrolled increase in engine speed transmis sion damage and gear stripping could result 1 To cruise at a particular speed 3 12 Engines il 1 2 1 3 Move the ON OFF switch on the instrument panel to the ON position Accelerate to the desired speed Momentarily move the SET RESUME switch on the instrument panel to the SET position To disengage cruise control 2 1 2 2 Depress the brake pedal or clutch pedal or Move the ON OFF switch on the instrument panel to the OFF position To resume a preselected cruise speed 3 1 3 2 If the ON OFF switch on the instrument panel is in the OFF position move it to the ON position Momentarily move the SET RESUME switch on the instrument panel to RESUME Cruise will return to the last speed selected To adjust cruise speed up or down hold the SET RESUME switch on the instrume
88. m will estimate and display a numerical savings gain in place of the X NOTE The information provided by the FUEL effi ciency system is different than and should not be confused with the information available by press ing the FUEL key on the 10 key keypad The key pad and its direct access keys are described in more detail later in this chapter Target MPG The target MPG feature allows quick and easy checking of fuel economy through the MPG Graph Target MP G Odometer screen See Fig 2 19 NOTE Use the LEFT ARROW key to lower the target MPG and the RIGHT ARROW key to raise it For more information on how to set target MPG 2 16 Driver Controls and Instruments 0 ll 12 3MPG 9012 0MI R f601412b 10 31 2000 Fig 2 19 MPG Graph Target MPG Odometer Screen adjust screen display brightness change lan guages or switch between US and metric units of measure see Setup Information later in this chapter The Target MPG area is on the second line of the dis play to the left of the odometer It shows the actual tar get miles per gallon MPG Example A reading of 12 3 MPG indicates that the target MPG is 12 3 miles per gallon The MPG Graph on the first line of the display gives the same information in dynamic form The 0 mark in the center of the line gives the target MPG Bars showing to the right of the display indicate that short term fuel economy is above the target
89. ment in the intake air preheater could cause extensive engine damage Engines The intake air preheater is activated by turning the igni tion switch to the ON position See Fig 3 1 If the en gine is at normal temperature the INTAKE HEATER indicator goes out after two seconds If the temperature is low enough to require use of the heater the INTAKE HEATER indicator stays on while the intake air preheater warms up After the indicator goes out start the engine IMPORTANT Attempting to start the engine before the INTAKE HEATER indicator has gone out could result in excessive white smoke at startup If the engine doesn t start after 15 to 20 seconds of cranking turn the ignition switch to the OFF position and wait two minutes then repeat the starting proce dure Cummins The cold start system approved for use on Cummins engines has been based upon starting aid capabilities to 25 F 32 C For more information see the Cum mins Operation and Maintenance Manual Turn the ignition switch to the ON position See Fig 3 1 If the engine is at normal temperature the IN TAKE HEATER indicator goes out after two seconds If the temperature is low enough to require the heater the INTAKE HEATER indicator stays on while the intake air preheater warms up After the indicator goes out start the engine Run the engine slightly above idle until oil pressure shows on the gauge If oil pressure doesn t show on the gauge
90. n t crank the engine for more than 30 seconds at a time during any of the following procedures Wait two minutes after each try to allow the starter to cool Failure to do so could cause starter damage 5 Start the engine Changing a Flat Tire IMPORTANT If a flat tire occurs while driving gradually decrease vehicle speed Holding the steering wheel firmly move to a safe place on the side of the road In an Emergency 1 If possible stop the vehicle on a level surface away from traffic 2 Apply the parking brake and place the transmission in Park P or Neutral N for automatic transmis sions or in First 1 gear for manual transmissions Turn the ignition switch to the OFF position 3 Turn on the emergency flashers Block the wheel diagonally opposite the wheel be ing changed 5 Remove the spare wheel jack jack handle and lug wrench from storage NOTE The jacking point for the front and rear wheels is directly under the axle 6 Place the jack on a solid surface Insert the jack handle and pump the handle slightly Do not raise the wheel off of the ground yet Loosen the wheel lug nuts but do not remove them IMPORTANT The dual rear wheels are attached using two element lug nuts The larger nut retains the outer dual The inner square stud retains the inner dual Remove and install these nuts sepa rately The rear dual outer lug nut must be loos ened to check and retighten the inner nut 7 R
91. n lower band is satisfactory for operating the vehicle If the level is not within the COLD run band add or drain fluid until it reaches the middle of the COLD run band Perform a hot check at the first opportunity after normal operating temperature 160 to 200 F 71 to 93 C is reached Check the fuel water separator if so equipped for contaminants With the engine shut down partially open the drain valve under the collection bowl and drain water and contaminants as needed Close the hood and engage the hood hold down latches Inspect the fuel tank s and fuel line connections If so equipped be sure that the fuel tank shutoff valves are open Replace leaking fuel tanks Repair or replace any lines or connections that are leaking For proce dures see Group 47 of the School Bus Chassis Workshop Manual If equipped with fuel tank shutoff valves be sure that the valves are fully open 8 10 Pretrip Inspection and Daily Maintenance CAUTION Never operate the engine with the fuel tank shutoff valves partly closed This could damage the fuel pump causing a sudden loss of engine power 19 Check the fuel level in the tank s and be sure that the fuel cap vent area is clean Check the fuel water separator if so equipped for leaks and if needed prime the fuel tank system A WARNING Never fill fuel tanks to more than 95 percent of their liquid capacity This could make them more likely to rupture fr
92. n above the mes sage Low Oil Pressure To dismiss the message press any key on the keypad NOTE If there is more than one alert message to display pressing any key takes you to the next message and so on until all of the messages have been received If low oil pressure is detected during the ignition se quence it displays as an active fault and the alert screen does not appear After 30 seconds this message displays again and can be dismissed as before by pressing any key Low Coolant Level Screen This warning message and alarm tone activate when ever the coolant level falls below a preset point The word Warning flashes on the message display screen above the message Low Coolant Level This message follows the same rules of dismissal and display as Low Oil Pressure High Coolant Temp Screen This message and alarm tone come on whenever the engine coolant temperature exceeds a preset point specified by the engine manufacturer see the engine manual for this temperature The word Warning flashes on the message display screen above the mes sage High Coolant Temp This message follows the same rules of dismissal and display as Low Oil Pressure 2 24 Driver Controls and Instruments Low Voltage Screen On some vehicles this message and alarm tone come on whenever a low voltage condition is detected by the instrumentation control unit The word Warning flashes on the message display scree
93. n above the message Low Voltage This message follows the same rules of dismissal and display as Low Oil Pressure Faulty Speedo Gauge Screen This message is displayed when the system detects a faulty speedometer This becomes the default screen and vehicle speed is displayed as a digital readout at the bottom left of the screen All other screens and functions operate normally Recirc Mode Engaged and Provide Fresh Air Screens The Recirc Mode Engaged screen comes on when ever recirculated air is selected on the fresh air recircu lation switch or the air circulation switch is rotated to the maximum air conditioning position It displays one time only for seven seconds It notifies the driver that recir culated air is being used and that fresh air needs to be provided after 20 minutes If fresh air is not provided after 20 minutes the Provide Fresh Air message is displayed It displays for seven 2 25 seconds every 254 seconds about every four minutes until the driver switches to fresh air either by selecting fresh air on the fresh air recirculation switch or by rotat ing the air circulation switch away from maximum air conditioning and to one of the other positions Low Fuel Level Screen Fuel level is continuously monitored by the ICU When the fuel level drops to 1 8th full the word Warning flashes on the message display screen above the mes sage Low Fuel Level Turn Signal On Screen This
94. n of the drive belts Check the fan belt s and the alternator belt for signs of glazing wear frayed edges damage breaks or cracks or oil contamination If a belt is glazed worn damaged or oil soaked replace the belt following the instructions in Group 01 of the School Bus Chassis Workshop Manual Check all of the belts for proper tension See Group 01 of the School Bus Chassis Workshop Manual for instructions NOTE On Cummins engines a belt tensioner au tomatically adjusts the fan and alternator belt to the correct tension If the belt slips repair or re place the tensioner For instructions see the Cum mins Engine Operation and Maintenance Manual 10 Inspect the engine for fuel oil and coolant leaks Correct any leaks found 11 Inspect the engine and chassis wiring Pretrip Inspection and Daily Maintenance Inspect the engine and chassis for loose wiring chafed insulation and damaged or loose hold down clamps Tighten loose wires or hold down clamps replace damaged wiring or clamps 12 Check the air intake system for leaks or damage Check the intake air restriction indicator to deter mine if the air cleaner filter element needs to be changed Replace the filter element if the yellow signal stays locked at 25 inH20 See Group 09 of the School Bus Chassis Workshop Manual for filter element replacement instructions Check the engine air intake piping from the air cleaner to the engine intake Inspec
95. n the panel lights with the headlight switch The panel light lever controls the brightness of the instru ment panel lights Slide the control lever up to brighten the lights and down to dim them Move the control le ver all the way down to turn them off See Fig 2 4 Headlight Switch and Daytime Running Lights In the down position all lights are off Move the switch to the middle position to turn on the parking lights Move the switch to the up position to turn on the head lights See Fig 2 5 For vehicles built to operate in Canada turn the ignition switch to the ON position and release the parking brake to automatically activate the low beam headlights later model vehicles at half voltage as daytime running lights The daytime running lights operate until the park ing brake is applied and then will switch off Turning on the regular headlights overrides the daytime running Driver Controls and Instruments lt 7 1 6 es POE ON ES 15 Est 13 14 PA 5 Y 25 E TIA Dp A lt goezo OE NS 7 5 77180 Sk RS x100 LS N ie ER AL Low aes x aes f o D Y ia 4 to N SS Yous 44 11 SE rst ip A gt 09 12 96 1601174 1 Application Air Pressure Gauge 6 Engine Oil Pressure Gauge 11 Secondary Air Pressure Gauge 2 Air Restriction Gauge 7 Tachometer 12 Warning and Indicator Light 3 Pyrometer 8 Speedometer Module 4 Voltmeter 9 Fuel Gauge 13 Panel Light Control Lever 5 Water Temperature Gauge 10 Primary Air Pre
96. nd function of optional lights may vary VLCONDARONDN i colo NO Left Turn Indicator Engine Protection Warning Lamp Indicator Check Engine Indicator Stop Engine Warning Optional Indicator Message Display Screen High Beam Indicator Low Air Warning Right Turn Indicator Air Bag Warning optional ABS Warning Wheel Spin Indicator Fig 2 20 Driver Message Center Level Ill ICU e The blue high beam indicator light comes on when the headlights are on high beam The yellow Check Engine CHK ENG light comes on to indicate an engine condition such as low coolant level high coolant temperature or low oil pressure It also comes on when a fault is detected or recorded The red Engine Protection ENG PROT light comes on to warn that the protection system available on the engine has been activated Installed on Cummins engines only the red Stop Engine STOP ENG light comes on to warn that the engine is not functioning normally Pull the vehicle over to the side of the road and shut down the engine immediately The red low air pressure LOW AIR warning light and buzzer come on whenever air pressure in the primary or secondary air reservoir falls below 64 to 76 psi 440 to 525 kPa Depending on options installed other warning and indicator lights can be installed in the spaces marked OPT Available optional indicator lights include air bag warning alternator no charge warning automatic tran
97. nd of the Ignition Sequence The Message Display Screen To understand the information displayed on the mes sage display screen here is an example of screen lay out On the Idle Hours Idle Gallons Odometer screen idle hours are displayed on the top line with the words Idle Hours on the left side of the screen and the num ber of hours on the right On the bottom line the num ber of idle gallons is on the left and the odometer miles are on the right with a space in between See Fig 2 24 Driver Controls and Instruments onan J IDLE HOURS 7 15 132 5 GAL 0007475 MI 07 29 97 1601411 Fig 2 24 Idle Hours Idle Gallons Odometer Screen Once the parking brake is released whether the vehicle is moving or not the regular message screen display is the MPG Graph Target MPG Odometer screen The MPG graph is a dynamic display graph demonstrating how the actions of the driver affect fuel economy The graph moves to the right as fuel economy improves See Fig 2 19 NOTE Press the LEFT ARROW key to lower the target MPG and the RIGHT ARROW key to raise it For more information on how to set the target MPG see Setup Information later in this chapter Level III ICU Roll Call Each time that the ignition switch is turned to the ON position the level III ICU roll call function requests data from each ECU on the databus lf the ECU does re spond to this request the databus is communicating
98. ng or pinching the lines make correc tions as needed Pretrip Inspection and Daily Maintenance 02 22 2000 A Do not remove this clamp ring 1 Brake Chamber 421352 Fig 8 8 Brake Chamber and Clamp Ring MGM TR series 2 3 o A B Y A A 4 T 5 08 20 93 f420225a A Minimum of 1 inch 25 mm of clearance between B 1 2 3 center line of clevis pin hole and piston rod end Minimum of 7 threads engagement Piston Rod 4 Cotter Key Piston Rod Nut 5 Clevis Pin Clevis Fig 8 9 Piston Rod Engagement with the Clevis 8 16 Pretrip Inspection and Daily Maintenance 8 17 26 5 26 6 26 7 Check for hose damage caused by abrasion If a hose is abraded replace it Check for the cause of the abrasion such as loose or damaged hose clamps Repair or replace the clamps as needed Observe the hose cover condition especially hoses exposed to water splash and ice If any hose is dried out or ragged the wire or liner is showing through the cover replace the hose Inspect the front air brake lines for leaks at the fitting where they enter the air chamber With an assistant at the front wheels to in spect the brake lines turn the wheels to full lock in one direction While holding the ser vice brake pedal down inspect the front brake air lines closely where they enter the air chambers Turn the wheels to full lock in the other di rection hold the service brake p
99. nimum engine oil pressure at idle of 10 psi 69 kPa does not register within 15 seconds shut down the engine CAUTION Protect the turbocharger during the start up by not opening the throttle or accelerating the engine above 1000 rpm until normal engine idle oil pres sure registers on the gauge 5 Idle the engine for three to five minutes at 1000 rem before operating the engine under load Mercedes Benz NOTE Before attempting to start the engine fol low the steps in Pre Start 4h CAUTION Never attempt to start any Mercedes Benz elec tronic engine using ether or any other starting fluid Serious engine damage could result 1 Turn the ignition switch to the ON position See Fig 3 1 All of the electronic gauges on the ICU instrumentation control unit complete a full sweep of their dials the warning and indicator lights light up and the buzzer sounds for three seconds IMPORTANT The INTAKE HEATER indicator stays on for a minimum of two seconds regard less of coolant temperature Wait until the INTAKE 3 4 Engines HEATER indicator goes out before attempting to start the engine 2 Turn the ignition switch to the START position Without touching the throttle pedal start the engine 3 Idle the engine for one to three minutes at 700 rpm 600 rpm for 6 cylinder engines before operating the engine under load 4 Check the oil pressure gauge for any drop in lubri cating oil pressure or mechani
100. nit Installing different sized tires could result in a reduced braking force lead ing to longer stopping distances ABS includes signal generating tone wheels and sen sors located in the wheel hubs of each sensed axle The sensors transmit vehicle wheel speed information to an electronic control unit located on the frontwall The control unit s main circuit interprets the speed sen sor signals and calculates wheel speed wheel retarda tion and a vehicle reference speed If the calculations indicate wheel lockup the main circuit signals the ap propriate solenoid control valve to reduce braking pres sure During emergency braking the solenoid control valve alternately reduces increases or maintains air 7 6 Brake System pressure supply in the brake chamber to prevent front and rear wheel lockup CAUTION An accumulation of road salt dirt or debris on the ABS tone wheels and sensors can cause the ABS warning light to come on If the ABS light does come on the tone rings and sensors should be in spected for corrosion and serviced if necessary The service should include cleaning of the tone rings and sensors If any tone ring on a vehicle shows severe corrosion all tone rings on that ve hicle should be replaced During winter months in areas where corrosive ma terials are used on the highways periodically clean the underside of the vehicle including the tone rings and sensors to ensure proper ABS function
101. nt panel at RESUME to accelerate or at SET to decelerate NOTE The resume vehicle speed memory is not maintained if the ignition switch is turned to the OFF position Also it is not maintained with Cummins engines if the ON OFF switch is turned to OFF Cold Weather Operation General Information Satisfactory performance of a diesel engine operating in low ambient temperatures requires modification of the engine surrounding equipment operating practices and maintenance procedures The lower the tempera tures the greater the amount of modification required and yet with the modifications applied the engines must still be capable of operation in warmer climates without extensive changes The following information is provided to engine owners operators and maintenance personnel on how cold weather modifications can be applied to get satisfactory performance from their diesel engines There are three basic objectives e Reasonable starting characteristics followed by practical and dependable warm up of the engine and equipment e A unit or installation which is as independent as possible from external influences Engines e Modifications which maintain satisfactory operat ing temperatures with a minimum increase in maintenance of the equipment and accessories If satisfactory engine temperature is not maintained higher maintenance cost will result due to increased engine wear Special provisions to overcome low
102. nt the tachometer usually shows a drop in rpm depending on the grade and the vehicle load Depending on the grade and vehicle load you may or may not feel the retarding force acting against your body when the brake is applied The retarding force of the brake may not always be noticed but it is actually preventing the vehicle from going much faster Shutting Down the Engine Make sure that the exhaust brake is turned off before shutting down the engine Pacbrake Exhaust Brake The Pacbrake exhaust brake is intended as a supple ment to the service brakes and will not bring the vehicle to a complete stop The Pacbrake will assist in the con trol or reduction of road speed in conjunction with or independent of the service brakes The amount of re tarding or braking force is controlled by the driver 3 21 Pacbrake Operation The Pacbrake is controlled by the exhaust brake switch and the throttle pedal All applications are additionally affected controlled or governed by engine speed through transmission gear selection The Allison MD3060 transmission has automatic downshifting when the exhaust brake is requested See the information on the Allison World Transmission later in this chapter On some applications when the Pacbrake is in use it may be necessary to check that the cruise control is not set and that the throttle is in the idle position On some applications the engine transmission cruise control and the
103. ntrol valve located to the left of the clutch or brake pedal See Fig 6 3 Release the control lever or valve to lock the steering column in place 11 15 2000 1 Tilt Telescope Lever 1461176a Fig 6 2 Tilt Telescope Steering Column Make sure that the control lever or valve is released and that the steering column is locked before driv ing the vehicle Never tilt or telescope the column while driving the vehicle Doing so could cause loss 6 2 Steering System 04 05 2002 1461234a 1 Adjustment Valve Knob yellow 2 Air Line Connections Fig 6 3 Foot Operated Tilt Column Control Valve of vehicle control personal injury and property damage 6 3 Brake System Driveline Parking Brake Burnishing lt 02 4 6400 esse ee ee ee ee be eee eee ee 7 1 Hydraulic Brake SYSTEM soc ssa aaaea hig e eee eee ee E oe ed 7 1 Air Brake System Brake System Driveline Parking Brake Burnishing A WARNING Vehicles equipped with hydraulic brakes are equipped with a driveline parking brake If your ve hicle is equipped with a driveline parking brake you must burnish the parking brake before you put the vehicle into regular service An unburnished park ing brake may not have full effectiveness If the parking brake slips personal injury or property damage could result Burnish the driveline parking brake as follows 1 Load the vehicle to its gross vehicle weight GVW 2 With the
104. om impact possibly causing fire and re sulting in serious personal injury or death by burn ing IMPORTANT Use only low sulfur diesel fuels Low sulfur diesel fuels have a maximum 0 05 percent sulfur content compared to a 0 26 to 0 30 percent sulfur content for other fuels Fail ure to use low sulfur diesel fuels may void the warranty on emissions components 8 11 19 1 To keep condensation to a minimum fill the fuel tanks at the end of each day but not to more than 95 percent of liquid capacity Se lect the proper grade of fuel as specified by the engine manufacturer WARNING Do not mix gasoline or alcohol with diesel fuel This mixture could cause an explosion When filling fuel tanks do not smoke or use an open flame near the fuel tanks Combustion of diesel fuel oil or fuel va pors could result possibly causing personal injury or property damage 19 2 Always strain or filter fuel before filling the tanks This will lengthen the life of the en gine fuel filter and reduce the chances of dirt entering the engine 20 Inspect the front and rear suspension components including the springs and air springs shocks and suspension brackets Check for broken spring leaves loose U bolts cracks in the suspension brackets and loose fas teners in the spring hangers and shackles Inspect the shock absorbers for loose fasteners and leaks Tighten all loose fasteners and replace any compo nent that is worn cracked or
105. on if there is a problem within the system Bring the vehicle to a safe stop and correct the problem before continuing operation of the vehicle See Group 42 of the School Bus Chassis Workshop Manual for hydraulic brake system trouble shooting and adjustment procedures Brake System 10 31 94 1460513a A Open caps and check fluid level B Fill to this level Fig 7 1 Hydraulic Brake Reservoir Operation Before driving the vehicle secure all loose items in the cab so that they will not fly forward during a full brake application Check that the brake system warning light is out after releasing the hand brake If the warning light does not go out correct the problem before continuing operation of the vehicle During normal brake stops depress the foot brake con trol pedal until braking action slows the vehicle In crease or decrease the pressure on the pedal so that the vehicle comes to a smooth safe stop When the forward speed of the vehicle has decreased to almost the idling speed of the engine push the clutch pedal in if so equipped and shift the transmission into Neutral N Apply the hand parking brake if the vehicle is to be parked Meritor WABCO Antilock Braking System ABS Hydraulic Brake Systems The Meritor WABCO Antilock Braking System ABS is an electronic wheel speed monitoring and control sys tem that works with the hydraulic brake system ABS passively monitors vehicle whee
106. op Driver Controls and Instruments and investigate the cause to prevent further dam age Do not operate the vehicle until the cause has been determined and corrected Intake Air Restriction Indicator An intake air restriction indicator measures the vacuum on the engine side of the air cleaner at the air cleaner outlet See Fig 2 16 If the yellow signal stays locked at or above the values shown in Table 2 1 after the engine is shut down service the air cleaner Then press the yellow button to reset the indicator 01 18 95 1600148a Fig 2 16 Intake Air Restriction Indicator Maximum Air Restriction in Inches of Water inH O Engine At Full Load and At No Load and Governed RPM Governed RPM Caterpillar 25 63 cm 12 30 cm Cummins 25 63 cm 12 30 cm Mercedes Benz 25 63 cm 12 30 cm Table 2 1 Maximum Air Restriction in Inches of Water in H20 NOTE Rain or snow can wet the filter and cause a higher than normal reading temporarily Intake Air Restriction Gauge The intake air restriction gauge measures the vacuum on the engine side of the air cleaner at the air cleaner outlet See Fig 2 17 and Fig 2 18 Vacuum is mea sured in inH20 inches centimeters of water When the vacuum reading in normal operation equals the appli cable level shown in Table 2 1 the air cleaner needs to be serviced IMPORTANT Do not rely exclusively on the accu racy of the air restriction
107. or for assessing clutch wear is clutch pedal free travel Free travel is a decreased resistance felt at the top of the clutch pedal stroke With the clutch pedal in this range the clutch is fully engaged and the only resistance to clutch pedal movement is return spring tension Clutch pedal free travel should be approximately 1 1 2 to 2 inches 38 to 51 mm See Fig 8 7 If the clutch 8 12 Pretrip Inspection and Daily Maintenance pedal free travel is less than 3 4 inch 19 mm ad just the clutch internally For instructions see Group 25 of the School Bus Chassis Workshop Manual 4h CAUTION Excessive clutch free pedal may prevent complete clutch disengagement insufficient clutch pedal free travel causes slippage and short clutch life Never wait for the clutch to slip before making a clutch adjustment 23 Start the engine and make sure that the oil pressure warning system is working When the engine is started the oil pressure warn ing will come on until the oil pressure rises above a preset minimum If the warning does not come on when the ignition switch is turned to the ON position repair the sys tem 4h CAUTION Failure to repair the engine shutdown warning sys tem could result in a sudden engine shutdown with out warning during vehicle operation 8 13 09 06 96 A About 1 1 2 to 2 inches 38 to 51 mm 1250344 Fig 8 7 Check Clutch Pedal Free Travel 24 Make sure that the el
108. otherwise damaged Pretrip Inspection and Daily Maintenance Do not replace individual leaves of a damaged front or rear suspension leaf spring assembly replace the complete spring assembly Visible damage such as cracks or breaks to one leaf causes hidden damage to other leaves Replacement of only the visibly damaged part s is no assurance that the spring is safe If cracks or breaks exist on front spring assemblies in either of the two top leaves a loss of vehicle control could occur Failure to re place a damaged spring assembly could cause an accident resulting in serious personal injury or property damage 21 Check the steering wheel for excessive play With the front tires pointing straight ahead turn the steering wheel until motion is observed at the front wheels Align a reference mark on a ruler then slowly turn the steering wheel in the opposite direc tion until motion is again detected at the wheels Measure the lash free play at the rim of the steer ing wheel See Fig 8 6 Excessive lash exists if steering wheel movement exceeds 4 3 4 inches 121 mm with an 18 inch 470 mm steering wheel If there is excessive lash check the steering system for wear or incorrect ad justment of the linkage and steering gear before operating the vehicle 11 15 2000 A Lash Area 1460158c Fig 8 6 Measure Lash at the Steering Wheel 22 Check the clutch pedal free travel if applicable The main indicat
109. ould be well away from the fitting A Bend Radius 420329a Fig 8 10 Bend Radius 26 11 Check for kinked or twisted hoses A seven percent twist in the hose can reduce its life by up to 90 percent Also a twisted hose under pressure tends to untwist This could cause it to loosen the fitting Reconnect hoses that are twisted 27 Check the brake lining wear on vehicles equipped with air brakes Proper brake operation is depen dant on periodic maintenance and inspection of the brake linings 27 1 Set the parking brake and chock the tires to prevent vehicle movement 28 27 2 If the axle assembly is not equipped with a dust shield or backing plate measure the axle brake lining thickness If any of the brake linings are worn to less than 1 4 inch 6 5 mm at the thinnest point replace the linings on all brake assemblies on that axle See Group 42 of the School Bus Chassis Workshop Manual for lining replacement in structions and camshaft endplay inspection 27 3 If the axle assembly is equipped with a dust shield or backing plate remove the inspec tion plugs to inspect the brake lining thick ness If any of the brake linings are worn to less than approximately 1 4 inch at the thin nest point replace the linings on all brake assemblies on that axle See Group 42 of the School Bus Chassis Workshop Manual for lining replacement instructions and cam shaft endplay inspection 27 4 Install the ins
110. owable Service Brake Air Leakage in psi kPa Per Minute Released Applied 2 14 3 21 Table 8 1 Maximum Allowable Service Brake Air Leakage 32 Test the service brakes before leaving the lot Depress the brake pedal release the parking brake and check that the brake system warning light goes out If the warning light remains on after releasing the parking brake correct the problem before driving off If equipped with air brakes test the brakes when starting to move the vehicle and before picking up speed with the foot valve and parking brake valve to be sure that they will bring the vehicle to a safe stop 33 Test the parking brakes on a 20 percent grade Pretrip Inspection and Daily Maintenance Apply the hand brake or pull the parking brake con trol valve knob with the vehicle on a 20 percent grade the ramp surface should be made of Port land cement or the equivalent If the parking brake does not hold the vehicle repair the parking brake system 8 24 In an Emergency Hazard Warming HOMS est5 eae A ee donde wi ad See wR A ge EE 9 1 A A A A 9 1 Emergency Starting With Jumper Cables o oocccccccooco ee 9 3 RUNNING QUO Fuel ir a a Ad a ia AA 9 5 Changing a Flat Tie sio a a de as ta ia a 9 5 In an Emergency Hazard Warning Lights The hazard warning light tab is located on the turn sig nal lever See Fig 9 1 To operate the hazard lights pull the tab out All of the turn signal l
111. parking brake released turn the knob on the end of the parking brake handle clockwise to adjust the parking brake Adjust the brakes until you can stop the vehicle traveling at 10 mph 16 km h within stopping distances of 21 to 36 feet 8 to 11 m using only the parking brake 3 Using only the parking brake make 10 stops from 10 mph 16 km h on a hard dry road surface After each stop release the parking brake and drive the vehicle at 20 mph 32 km h for 2 5 miles 4 km to cool the brake 7 1 4 Adjust the parking brake linkage and hand lever knob to suit your load and road grade conditions Hydraulic Brake System General Information The Bendix hydraulic brake system includes a power booster master cylinder reservoir hydraulic lines a brake rotor on each wheel hub and a brake caliper and pad assembly at each rotor See Fig 7 1 IMPORTANT Make sure that the fluid level in the master cylinder reservoir is up to the ridge that surrounds the reservoir Use only heavy duty brake fluid DOT 3 in the hydraulic brake system The master cylinder controls braking power to the front and rear brakes The power booster is attached to the rear of the master cylinder and is connected to the power steering system which provides pressurized power steering fluid An electrically powered reserve pump operates if there is inadequate fluid flow from the power steering pump to the power booster The brake system warning light comes
112. pection and Daily Maintenance particles may be in the airstream and could cause injury 1 2 Exhaust the remaining air and moisture from the system by opening the drain cocks on the bottoms of the remaining air reservoirs Block the valves open 1 3 Water and oil emulsion often forms pockets which will not drain while compressed air is in the reservoirs Because of these pockets leave the valves blocked open during the first part of the pretrip inspection 2 Inspect the batteries and battery cables as follows Battery posts terminals and related accessories contain lead and lead compounds chemicals known to the State of California to cause cancer and reproductive harm To prevent possible per sonal injury always wash your hands after handling battery parts and related accessories 2 1 Access the batteries Be sure that the bat tery hold down is secure If it is loose tighten the hold down bolts if it is broken replace it A CAUTION Take care to keep the vent plugs tight so that the neutralizing solution does not enter any of the bat tery cells and damage the battery 2 2 Remove any corrosion from the hold down and the top of the battery Use diluted am monia or a soda solution to neutralize the acid present then rinse off the ammonia or soda solution with clean water If the battery posts or cable terminals are corroded disconnect the terminals from the posts Clean them with a soda solution and a wire bru
113. pection plugs in the dust shields or backing plates if so equipped 27 5 Remove the chocks from the tires Make sure that the brakes are adjusted on all ax les Adjust the brakes if necessary See Group 42 of the School Bus Chassis Maintenance Manual for checking and adjusting procedures 8 18 Pretrip Inspection and Daily Maintenance IMP ORTANT Brake checking and adjusting is nec essary for all vehicles including those equipped with 29 automatic slack adjusters Check the tire inflation pressures and inspect each tire for bulges cracks cuts and punctures IMPORTANT The load and cold inflation pres sure must not exceed the rim or wheel manu facturer s recommendations even though the tire may be approved for a higher load or infla tion Some rims and wheels are stamped with a maximum load and maximum cold inflation rating See Group 40 of the School Bus Chas sis Workshop Manual for the correct tire infla tion pressure for the vehicle load or consult the rim or wheel manufacturer if they are not stamped If the load exceeds the maximum rim or wheel capacity the load must be adjusted or reduced 29 1 Check the inflation pressures of the tires be fore each trip using an accurate tire pres sure gauge See Fig 8 11 Check the tires when cool Be sure that valve stem caps are on every tire and that they are screwed on finger tight Inflate the tires to the correct pressures if needed See the tir
114. pension system do not move the vehicle with the air sus pension deflated Doing so could result in a loss of vehicle control possibly causing personal injury and property damage A CAUTION Do not use the spring parking brakes if the service brakes are hot such as after descending a steep grade Also do not use the spring parking brakes during freezing temperatures if the service brakes are wet To do so could damage the brakes if hot or cause them to freeze during cold weather If the brakes are wet drive the vehicle in low gear and lightly apply the brakes to heat and dry them Allow hot brakes to cool before using the spring parking brakes Always chock the tires If the brakes are wet drive the vehicle in low gear and lightly apply the brakes to heat and dry them Allow hot brakes to cool before using the parking brake Always chock the tires Meritor WABCO Antilock Braking System ABS Air Brake Systems The Meritor WABCO Antilock Braking System ABS is an electronic wheel speed monitoring and control sys tem that works with the air brake system ABS passively monitors vehicle wheel speed at all times but controls wheel speed during an emergency or reduced traction stop In normal braking applications the standard air brake system is in effect IMPORTANT For proper ABS system operation do not change tire sizes The sizes of the tires in stalled during production are programmed into the electronic control u
115. ries checked at a repair facility NOTE On a vehicle equipped with a battery isola tor system the voltmeter measures the average voltage of all of the batteries when the engine is running When the engine is stopped the voltme ter shows only the gel cell battery voltage and does not indicate the voltage of the engine starting batteries 2 12 Driver Controls and Instruments 10 28 94 1600378a ES 10 28 94 1600380a Fig 2 14 Voltmeter CAUTION Gel cell batteries can be damaged if the battery voltage is allowed to drop below 12 0 volts or if the charging voltage is more than 14 1 volts Start the engine to recharge the gel cell before the battery becomes fully discharged If an external charger is needed disconnect the gel cell battery and use only an external battery charger that has been approved for gel cell batteries Fuel Gauge The fuel gauge indicates the amount of fuel in the fuel tank s See Fig 2 15 2 13 Fig 2 15 Fuel Gauge Transmission Oil Temperature Gauge optional With an Allison automatic transmission the transmission oil temperature gauge reading should not exceed 300 F 149 C during normal operation A warning light will illuminate to alert the driver if normal operating tem peratures are exceeded 4h CAUTION A sudden increase in transmission oil temperature that is not caused by a load increase may indicate mechanical failure Bring the vehicle to a safe st
116. rmation A IGNITION ON ONLY Y Y IDLING ENGINE ENG MILES 1234567 8 ENG GALLONS 123456 7 Bag INFORMATION ENG HOURS 123456 78 PTO GALLONS 123456 7 Y Y Y Y For each fault display fault codes and description DIAGNOSTIC ACTIVE FAULTS INFORMATION 1234 or NONE FIRST SECOND LAST A Y Y Y YY For each fault display fault codes and description 123 HIST DASH FAULTS PUSH RESET TO LAST CLEAR 1234567 FIRST LAST CLEAR DASH FAULTS 24 R Y Y LAST OCCR LAST OCCR Y Y FIRST OCCR FIRST OCCR O Y R RESET PUSH RESET SET KEY TWICE 02 13 96 See applicable Figure S SET PUSH RESET SET KEY ONCE 1040325 Fig 2 28 Engine Information and Diagnostic Information 2 29 Driver Controls and Instruments 01 29 98 See applicable lt SETUP Figure INFORMATION A TYY al VEHICLE INFORMATION a PUSH SET KEY TO CHANGE TARGET MPG st PUSH SET KEY TO Ss CHANGE BRIGHTNESS ry PUSH SET KEY TO CHANGE LANGUAGE 7 ry PUSH SET KEY TO CHANGE UNITS S Me DATA LINK ACTIVE tttttittt TARGET MPG 7 0 lt LESS MORE gt DISPLAY BRIGHTNESS lt LIGHT DARK gt CURRENT LANGUAGE IS FLASHING LANGUAGE ENGLISH FRENCH SPANISH CURRENT UNITS IS FLASHING UNITS ENGLISH METRIC DATA LINK STATUS USAGE 40 ERROR 6 DASH A06 XXXXX XXX SW 7 3 9 R RESET PUSH RESET SET KEY TWICE S SET PUSH RESET SET KEY ONCE
117. rocedures Engine Oil Pressure Gauge See the engine manufacturer s manual for recom mended engine oil pressure gauge readings See Fig 2 13 CAUTION A sudden decrease or absence of oil pressure may indicate mechanical failure Bring the vehicle to a Driver Controls and Instruments safe stop and investigate the cause to prevent fur ther damage Do not operate the engine until the cause has been determined and corrected 10 28 94 1600376a Fig 2 12 Water Temperature Gauge Voltmeter optional The voltmeter indicates the vehicle charging system voltage when the engine is running and the battery volt age when the engine is stopped See Fig 2 14 By monitoring the voltmeter the driver can be aware of po tential charging system problems and have them re paired before the batteries discharge enough to create starting difficulties The voltmeter will normally show approximately 13 7 to 14 1 volts when the engine is running The voltage of a fully charged battery is 12 7 to 12 8 volts when the en 10 28 94 1600377a Fig 2 13 Engine Oil Pressure Gauge gine is stopped A completely discharged battery will produce only about 12 0 volts The voltmeter will indi cate lower voltage as the vehicle is being started or when electrical devices in the vehicle are being used If the voltmeter shows an undercharged or overcharged condition for an extended period have the charging system and batte
118. rse conditions more frequently 26 Inspect the air brake components if so equipped including the brake chamber pushrods air reser voirs and air lines Look for worn clevis pins on brake chamber push rods and missing or damaged cotter keys on the brake chamber pushrod clevis pins Replace worn clevis pins and install new cotter keys if necessary Visually inspect the piston rod engagement with the clevis At least seven threads of engagement are required there should be 1 inch 25 mm of clear ance from the center line of the clevis pin hole to the end of the piston rod See Fig 8 9 See Group 42 of the School Bus Chassis Workshop Manual for adjustment procedures 8 14 Pretrip Inspection and Daily Maintenance See if the chamber piston rod is in line with the slack adjuster Misalignment can cause the piston rod to rub on the nonpressure chamber and cause a dragging brake See Group 42 of the School Bus Chassis Workshop Manual if the chamber piston rod is improperly aligned Visually inspect the exterior surfaces of the cham ber for damage Make sure that breather holes in the nonpressure section s are open and free of debris See Group 42 of the School Bus Chassis Workshop Manual for instructions to replace dam aged parts On all parking brake installations check for the presence of an end cover cap or dust plug and make sure that the cap or plug is securely snapped into place On most MGM parking brake chambers
119. s of air pressure oc curred This could result in serious personal injury or vehicle damage Before caging the spring park ing brakes make the connection to a towing vehicle or chock the tires NOTE Before a vehicle with insufficient system air pressure can be moved the spring parking brakes must be released by applying an external air source or by manually caging manually releas ing the parking brake springs After correcting the brake system problem uncage the spring parking brakes before resuming normal vehicle operation 7 5 Operation Before driving the vehicle secure all loose items in the cab so that they will not fly forward during a full brake application During normal brake stops depress the foot brake con trol pedal until braking action slows the vehicle In crease or decrease the pressure on the pedal so that the vehicle comes to a smooth safe stop When the forward speed of the vehicle has decreased almost to the idling speed of the engine push the clutch pedal in if so equipped and shift the transmission into Neutral N Apply the parking brake if the vehicle is to be parked The yellow diamond shaped knob on the control panel actuates the parking brake valve See Fig 7 2 Pull the knob out to apply the parking brake fo y SAR SYSTEM PARK g Aro rary 02 09 95 1600631 Fig 7 2 Parking Brake Valve Knob Brake System If the vehicle is equipped with an air sus
120. se First 1 for climbing very steep grades and for engine braking at low speeds when going downhill To prevent excessive engine speed do not drive faster than 25 miles per hour 40 km h in First 1 NOTE In the lower gear ranges the transmission will not upshift above the highest gear selected unless the engine governed speed is exceeded MD Series Transmissions Ah CAUTION The engine should never be operated for more than 30 seconds at full throttle with the transmission in gear and the output stalled Prolonged operation of this type will overheat the transmission fluid and will result in severe damage to the transmission 1 Start the engine then check the digital display on the push button shift selector Under Select at the top of the unit the display shows the primary shift mode Under Monitor the gear that is engaged is displayed 5 4 Transmissions Never shift from neutral N to drive D or reverse R at engine speeds above idle The vehicle will lurch forward or backward which could cause prop erty damage and personal injury 2 Use Reverse R to back the vehicle Completely stop the vehicle before shifting from a forward gear to Reverse R or from Reverse R to a forward gear There is only one Reverse R gear 3 Select Drive D for all normal driving conditions The vehicle will start out in First 1 gear and as speed increases the transmission will upshift through each gear automatically
121. seness or other damage Tighten loose nuts and replace damaged parts as needed For instructions see Group 46 of the School Bus Chassis Workshop Manual Pretrip Inspection and Daily Maintenance SS ZL OJ A Y 10 05 94 j 1 Steering Gear Mounting Bolt 2 Pitman Arm Pinch Bolt Nut 1460512b Fig 8 2 Steering Gear TAS series CAUTION Coolant must be filled to the full line of the surge tank Low coolant could result in engine overheat ing which could cause engine damage 6 Check the coolant level in the surge tank sight glass See Fig 8 1 Check the condition of the ra diator fins and the charge air cooler If the coolant level is low check the amount of anti freeze protection If the protection is adequate add a 50 50 mixture of water and antifreeze If addi tional protection is needed add antifreeze only Fill to the level of the bottom of the surge tank fill neck Good airflow through the radiator core and air to air aftercooler core is essential for proper engine cool ing The cores allow air passage but form a particle barrier which tends to collect insects and airborne debris Inspect for clogged fins Use compressed air or wa ter directed from the fan side of the core to back flush any material restricting airflow Inspect and clean the charge air cooler If clogged the airflow through the radiator could be restricted Straighten bent or damaged fins to permit
122. sh After cleaning connect the ter minals to the battery posts then apply a thin coat of petroleum jelly to the posts and ter minals to help retard corrosion Check the fluid level in the windshield washer res ervoir Tilt the hood to access the reservoir located next to the surge tank Add washer fluid as needed See Fig 8 1 8 4 Pretrip Inspection and Daily Maintenance 07 30 96 1500273 1 Windshield Washer Reservoir 2 Surge Tank 3 Sight Glass Fig 8 1 Check the Surge Tank Fluid Level Washer fluids may be flammable and poisonous Do not expose washer fluid to an open flame or any 8 5 burning material such as a cigarette Always com ply with the washer fluid manufacturer s recom mended safety precautions 4 Check the front hub lubricant level if equipped with oil lubricated wheel bearings Observe the level of the wheel bearing lubricant in the hub cap at each end of the front axle and if needed fill the hubs to the level indicated on the hub cap See Group 33 of the School Bus Chassis Maintenance Manual for recommended lubricants IMPORTANT Before removing the fill plug always clean the hub cap and plug 5 Tilt the hood Examine the steering components Examine the steering gear mounting bolts pitman arm nut and the drag link nuts for tightness See Fig 8 2 Be sure that the steering driveline and the U joints are in roadworthy condition without cracks breaks loo
123. sing the sequence described in the previous steps Follow the pattern on the shift lever Transmissions 6 When downshifting shift progressively down through each successive lower gear as follows When the engine speed drops to the same rpm to which it fell immediately after upshifting to that same gear disengage the clutch and move the shift lever to the next lower gear engage the clutch smoothly Continue downshifting as conditions require using the same sequence described above IMPORTANT Do not rest your foot on the clutch pedal while driving This causes partial clutch dis engagement and will cause premature clutch wear NOTE Always disengage the clutch completely when shifting gears Double clutching is unneces sary Allison Automatic Transmissions General Information Allison four five and six speed automatic transmis sions have six shift positions on the selector lever See Fig 5 3 The selector lever is lighted for night driving Each forward shift position provides a range of forward gears that are selected automatically according to the speed of the vehicle engine temperature and throttle position NOTE Vehicles equipped with an Arens shift by wire shift control system have an electronic push button selector similar to that described below for MD series transmissions MD series automatic transmissions have six forward speeds and one Reverse R speed See Fig 5 4 These transmiss
124. smission overheat warn ing trailer ABS warning ECAS electronic sus pension transfer indicator and ECAS failure warning 2 18 Driver Controls and Instruments NOTE The functions of the ABS warning light are explained under Meritor WABCO Antilock Braking System ABS in Chapter 7 Keypad The level III ICU is controlled by a keypad located on the auxiliary dash panel See Fig 2 21 This keypad which has 10 keys can be used to e Call up information onto direct access screens e Move about from screen to screen while the ve hicle is stationary e Set up the display RESET TEMP FUEL TRIP LEG SET Dedicated Keys General Keys Control Keys 08 08 96 f601009 Fig 2 21 10 Key Keypad Set a target MPG to monitor fuel economy while driving Press the LEFT ARROW key to lower the target MPG and the RIGHT ARROW key to raise it 2 19 e Set the brightness of the message display screen independently of the panel dimmer switch Use the LEFT ARROW key to dim the display and the RIGHT ARROW key to brighten it e Record significant data using the EVENT key optional if a data logging unit is installed NOTE One key is blank and is not usable at this time Level Ill ICU Ignition Sequence If the headlights are turned on the screen displays the odometer and waits for the ignition switch to be turned to the ON posi
125. ssure Gauge 14 Headlight Switch Fig 2 1 Instrument and Control Panel Layout 2 2 Driver Controls and Instruments 09 12 96 1 NAO ENG ENG DOWN CHK 6 7 Low Oil Pressure High Water Temperature Warning Low Oil Level Warning Alternator Warning Light Brake System Warning ABS Warning Light 2 3 4 5 Low OIL ABS DONOT TRANS SHIFT TEMP 8 9 10 11 Stop Engine Indicator Engine Check Indicator Cold Start Manifold Heater Indicator Air Cleaner Restriction Indicator 10 Do Not Shift Indicator oO ON 12 13 601175 11 High Oil Temperature Warning automatic transmission 12 Water in Fuel Water Separator Warning 13 Parking Brake Indicator Light lights The vehicle cannot be driven unless either the headlights or the daytime running lights are activated Parking Brake Control Lever Vehicles With Hydraulic Brakes Fig 2 2 Warning and Indicator Lights Turning the knob counterclockwise decreases the effort needed to move the lever If the parking brake does not hold the vehicle securely depress the brake pedal and release the parking brake Turn the knob on the end of the lever clockwise to in crease the parking brake application A parking brake control lever is located to the left of the steering column To apply the parking brake depress the brake pedal then pull down on the parking brake lever To release the parking brake depress the brake pedal and pull the parking bra
126. t the hood until the stop cables support it See Fig 2 31 CAUTION Do not let the hood free fall to the full open posi tion To do so could cause damage to the hood or hood straps To Return the Hood to the Operating Position 1 Grasp the grab handle and lift the hood to the 45 degree position SS 10 01 93 E UR 720073 Fig 2 30 Unlatch the Hood 2 As the hood goes over center use the bumper step and grab handle to control the rate of descent to the operating position 3 Make sure that the hood is flush with the cowl then secure the hood by engaging both hood hold down latches IMPORTANT Make sure that both hold down latches are fully engaged before operating the ve hicle 2 32 Driver Controls and Instruments 01 06 95 880178 Fig 2 31 Hood Tilting Engines Engine Stating ccd etd hk A A ple aa arad ana Cet tina are edad 3 1 Gold Weather Staing 0525 24 bucks eed a ede eee had oe Se ee ds ee Soe aS 3 5 Starting After Extended Shutdown or Oil Change 0 0000 eee 3 7 ENGIN Break 5 ocd oye ee eee Oe Pa AG es we ee De ee ba el dg ade aS ite 3 7 Engine Operation vi08 e2cna coheed et Pe ee ee als oo Se ae 3 8 Gold Weather Operation saison aa dodania a ee a ara Be dees Ei ek ed a ea ek a ed 3 13 Engine SHULGOWM 12 citaci bot il GOS dba ba See Sere ede ee eee ha Ba 3 16 Engine Braking System optional ossaa ecas iraran pi aa ee 3 19 Exhaust Braking System op
127. t the piping for loose connections cracks torn or collapsed hoses punctures and other damage Tighten loose con nections and replace damaged components Make sure that the piping system is airtight so that all of the intake air passes through the air cleaner CAUTION Failure to maintain a sealed air intake system could allow the entry of dirt and contaminants into the engine This could adversely affect engine perfor mance and result in engine damage NOTE After replacing the filter element reset the restriction indicator by pressing the reset button 13 Check the fluid level in the hydraulic brake fluid res ervoir if so equipped See Fig 8 3 If needed fill the reservoir up to the ridge that sur rounds the reservoir Use only heavy duty brake fluid DOT 3 10 31 94 DI 1460513a A Open caps and check fluid level B Fill to this level Fig 8 3 Check the Hydraulic Brake Fluid Level 8 8 Pretrip Inspection and Daily Maintenance 14 Check the engine oil level See Fig 8 4 The oil level should show between the upper and lower marks on the dipstick Add enough oil to bring the level up to the operating range See the engine manufacturer s Operation and Maintenance Manual for recommended lubricants and capacities Y 1010346 Fig 8 4 Check the Engine Oil Level 8 9 CAUTION Operating the engine with the oil level below the low mark or above the high mark could result
128. the School Bus Chassis Workshop Manual for re pair procedures and specifications See the School Bus Chassis Maintenance Manual for lubricant recommen dations specifications and maintenance intervals and procedures 1 Drain the air brake system air reservoirs if so equipped Air reservoirs serve as storage tanks for com pressed air They collect water condensed from the air and small amounts of oil from the air compres sor Water and oil normally enter the reservoir in the form of vapor because of the heat generated during compression 8 3 After the water and oil condense they collect near the tank drain valves Drain the resulting emulsion as follows Failure to drain the air reservoirs as instructed could cause sludge formation in the air brake sys tem Sludge could adversely affect braking causing loss of control which could cause death personal injury or property damage IMPORTANT If the air tanks are not equipped with automatic drain valves they must be drained daily If they are equipped with auto matic drain valves they must be drained in this same manner at least once a week 1 1 Open the wet tank valve the drain cock or pull chain drain located on the forward end of the supply air reservoir which is con nected directly to the air compressor Block the valve open 4h WARNING When draining the air reservoir do not look into the air jets or direct them toward anyone Dirt or sludge Pretrip Ins
129. the Vehicle in the Correct Gear 4 1 Vehicle Overload or Overloading the Clutch 4 1 Cold Weather Operation 3 13 Caterpillar 3 14 CUMMINS s cu a 3 15 General Information 3 13 Mercedes Benz 3 15 Cold Weather Starting 3 5 Caterpillar 3 5 CUMMINS poa is aa 3 6 Mercedes Benz 3 6 Controls aa 2 2 lt 4 se ae A 2 1 Allison Automatic Transmission Controls 2 6 Cruise Control 2 7 Electric HORM ocos ees eee aa 2 8 Hazard Warning Light Tab 2 5 Headlight Dimmer Switch 2 5 Headlight Switch and Daytime Running Lights 2 1 Ignition Switch and Key 2 1 Panel Light Control Lever 2 1 Parking Brake Control Lever 2 3 Parking Brake Control Valve 2 4 Tilt Telescope Steering Column optional ss a sus oom ae 2 8 Subject Turn Signal Lever 2 5 D Driveline Parking Brake Burnishing 7 1 E Emergency Starting With Jumper Cables 2 ok bake eee o 9 3 Engine Braking System optional 3 19 Constant Throttle Valves MBE900 only 3 19 Engine Break In 3 7 Caterpillar ek eee oo ae i 3 7 CUMMINS 4 406 44 4 64 be ee aes 3 7 Mercedes Benz 3 7 Engine Operation 3 8 Caterpillar 3 8 Cruise Control 3 12 CUMMINS aros ais aoe des 3 10 Mercedes Benz 3 11 Engine Shutdown
130. the driv er s attention but not all of them are critical to the op eration of the vehicle Warning messages always display at full brightness More important messages take priority over less impor tant messages The order of importance or priority is 1 Eaton VORAD Warnings if so equipped 2 Parking Brake On with the vehicle moving 3 Low Oil Pressure High Coolant Temperature Low Coolant Level and Low Voltage Alternate Speedometer Recirc Mode Engaged and Provide Fresh Air Low Fuel Level Turn Signal On Service Warnings No Datalink Activity OOo NO oO Parking Brake On Screen This warning message and alarm tone come on when ever the parking brake is applied and the vehicle is Driver Controls and Instruments moving faster than 2 5 miles per hour or the clutch has been depressed The word Warning flashes on the message display screen above the message Parking Brake On The screen and alarm tone go away only when the parking brake is released See Fig 2 26 WARNING PARKING BRAKE ON 07 29 97 1601414 Fig 2 26 Parking Brake On Screen The Parking Brake On screen overrides any other screen message Low Oil Pressure Screen This warning message and alarm tone come on when ever the oil pressure falls below the minimum oil pres sure specified by the engine manufacturer whether the vehicle is idling or in motion The word Warning flashes on the message display scree
131. tic ATF pe T POS n t See Group 20 of the School Bus Chassis Maintenance Manual for Lf an a JOTA IIA tl III i Freightliner specifications OJJA a s F eian a S T g Table 10 2 Fluid and Lubricant Specifications EE AA a LT EER ANE 1 a E mO 13 G2 ft Fuse Relay Circuit Breaker a ac ra Identification lie a AE NOTE The fuse relay circuit breaker panel is lo 06 13 96 1541287 cated on the right side of the dash Depending on vehicle options fuse relay circuit breaker locations may vary See Fig 10 1 or Table 10 3 for fuse relay circuit breaker locations and identification Fig 10 1 Fuse Relay Circuit Breaker Panel Fuse Relay Circuit Breaker Identification Pos No Description Part Number Rating Ignition Bus Standard AA Circuits 680 545 00 05 AB Parking Brake Relay 680 545 00 05 _ DRL Ignition Bus Optional E AC Circuits 680 545 00 05 AD Brake Light Relay 23 11276 011 10 2 Specifications Fuse Relay Circuit Breaker Identification Fuse Relay Circuit Breaker Identification fee Description Part Number Rating ag Description Part Number Rating 231284 000010 10A Fuse 231284 000015 15A Fuse A2 bee Solenoid Backup B2 Panel Lights ights 680 545 19 66 10AC B 680 545 20 66 15A C B 231284 000010 10A Fuse LF 257020 20A Fuse A4 Fan Clutch Relay B3 Fog Lights 680 545 19 66 10AC B 680 545 21 66 20AC B
132. tion When the ignition switch is first turned to the ON posi tion all of the electronic gauges complete a full sweep of their dials the warning and indicator lights light up for five seconds and the buzzer sounds for two seconds See Fig 2 22 NOTE The air gauges and voltmeter do not sweep Once the ignition switch has been turned to the ON po sition the screen displays the Freightliner message At the same time the level III ICU conducts a roll call of all of the electronic control units ECUs installed on the vehicle looking for active faults Driver Controls and Instruments HEADLIGHTS ON y FASTEN SEATBELTS 123456 7 MILES IF WERE DETECTED AND ALL ECU S RESPONDED POWER ON IGNITION ON NO FAULTS DURING ICU ROLLCALL IF MESSAGE AVAILABLE 7T Y INCOMING MESSAGE FASTEN SEATBELTS TEXT gt 123456 7 MILES IF MESSAGE IDLIN AVAILABLE Y a INCOMING MESSAGE IDLE HOURS 1234 56 TEXT gt 12 3 GAL 123456 7 MI PARK BRAKE IF MESSAGE RELEASED AVAILABLE MOVING INCOMING MESSAGE 0 11111111 TEXT gt 12 3 TMPG 123456 7 MI 03 18 98 B FREIGHTLINER ICU ROLL CALL TRANSMITS REQUEST FOR FAULT ONTO THE DATALINK IGNITION ON Y ELECTRONIC GAUGE NEEDLES SWEEP AND WARNING INDICATOR LIGHTS COME ON IF FAULT DETECTED AND OR AN ECU DID NOT RESPOND DURING ICU ROLL CALL Y
133. tional Engines Engine Starting NOTE Before starting the engine read Chapter 2 for detailed information on how to read the instru ments and operate the controls Whenever you start an engine watch for any signs of engine problems If the engine vibrates misfires or makes unusual noises shut down the engine as soon as possible and determine the cause of the problem Frequently engine damage may be avoided by a quick response to early indications of problems 4h CAUTION When starting a vehicle equipped with a manual transmission and clutch lock out switch the clutch pedal must be fully depressed during the entire start sequence Failure to do so can cause the pin ion to release and re engage which could cause ring gear and starter pinion damage If a vehicle does not start on the first attempt make sure that the engine has completely stopped rotat ing before reapplying the starter switch Failure to do so can cause the pinion to release and re 3 1 engage which could cause ring gear and starter pinion damage Moving a vehicle with the starter and or using the starter to bump the engine for maintenance proce dures is strictly prohibited Use of these methods to bump the engine over or move the vehicle can cause the pinion to release and re engage which could cause ring gear and starter pinion damage IMPORTANT Ring gear and starter pinion damage caused by improper starting procedures is not warrantable
134. ur shut down the engine im mediately The oil pressure gauge needle swings back and forth or falls sharply Engine power and rpm fall even though the ac celerator pedal remains steady The exhaust pipe gives off heavy smoke The coolant and or oil temperature gauge read ings climb abnormally Abnormal sounds suddenly occur in the engine or turbocharger 1 With the vehicle stopped apply the parking brake and place the transmission in Neutral N Ah CAUTION Idle the engine one to two minutes before shutting it down if this can be done without damage to the engine After hard operation shutting down the en gine without idling may cause damage to the turbo charger 2 Allow the engine to idle one to two minutes before shutting it down This allows the lubricating oil and the coolant to carry heat away from the combustion chambers bearings shafts and seals The extreme heat may cause bearings to seize or oil seals to leak IMPORTANT Bearings and seals in the turbo charger are subjected to the high heat of combus tion exhaust gases While the engine is running this heat is carried away by oil circulation but if the engine is shut down suddenly the turbo charger temperature may rise as much as 115 F 46 C Engines 4h CAUTION Except in emergency do not shut down the MBE900 engine when the coolant temperature is above 194 F 90 C To do so could damage the engine 3 Turn the ignition switc
135. urer s manual for maxi mum water temperature levels Optional Warning and Indicator Lights A CAUTION The vehicle may be programmed for the engine to derate and eventually shut down if there is a loss of oil pressure or if coolant temperature becomes too high This protects the engine from damage Under these conditions first the check engine light will come on If the driver continues to drive the vehicle the engine derate or shut down light will come on and the engine will start to power down or derate Eventually the engine will shut down Be aware that the vehicle could derate and or shut down if this option is programmed Be prepared to park the ve hicle in a safe location if it does derate or shut down Optional warning and indicator lights may include air intake warmer transmission oil temperature air cleaner restriction check engine and engine shutdown When the ignition switch is turned to the ON position oil and brake system warnings as equipped activate until the engine starts and minimum pressures are ex ceeded If the low oil pressure warning light or brake system warning light remains on after running the en gine for 15 seconds shut down the engine and deter mine the cause of the problem See the School Bus Chassis Workshop Manual for repair procedures IMPORTANT If the warning system does not acti vate when the ignition switch is turned to the ON position repair the system to provide warning pro tect
136. w to allow the engine to cool 1 With the vehicle stopped set the parking brake Reduce engine speed to a low idle 2 Place the transmission shift lever in Neutral N NOTE If the engine has been operating at low loads run it at low idle for 30 seconds before shutting it down If the engine has been operating at highway speed or at high loads run it at low Engines idle for 3 minutes to reduce and stabilize internal engine temperatures before shutdown 3 Turn the ignition switch to the OFF position and shut down the engine After shutting down the engine fill the fuel tank 5 Check the crankcase oil level with the engine shut down Maintain the oil level between the ADD and FULL marks on the dipstick 6 If temperatures below 32 F 0 C are expected al low the engine water jacket expansion tank to cool then check the coolant for proper antifreeze protec tion Add antifreeze if required For additional infor mation see Group 20 of the School Bus Chassis Maintenance Manual IMPORTANT The cooling system must be able to protect against freezing to the lowest expected outside temperature 7 Repair any leaks perform minor adjustments tighten loose bolts etc Observe the vehicle mile age or the service meter reading if so equipped Perform periodic maintenance as instructed in the Maintenance Interval Schedule in the Caterpillar Operation and Maintenance Manual 3 17 Cummins 1 With the vehic
137. y start with out increasing engine speed above low idle or slip ping the clutch Engage the clutch smoothly Jerky starts waste fuel and put stress on the drivetrain It is not necessary to accelerate Caterpillar elec tronic engines to governed speed in the lower gears to get the vehicle moving except in a high power demand situation such as starting on a grade 5 Continue to upshift until cruising speed is reached Use only the rpm needed to make an upshift into the next gear When cruising speed is reached se lect the highest gear available that will pull the load Experience with your vehicle will show you what 3 9 rpm is needed to make upshifts under various con ditions This progressive shifting technique will lower fuel costs because the engine will be operat ing at the lowest rpm needed to pull the load NOTE Caterpillar electronic engines can be pro grammed to limit engine rpm while the vehicle is operated in the lower and higher gears This fea ture assists the driver in following progressive shifting techniques 6 On uphill grades allow the engine to lug downward to peak torque rpm 1440 to 1550 rpm before downshifting Continue to downshift until you reach a gear that will maintain the desired speed 6 1 Continue to operate at peak torque rpm as long as the vehicle will maintain its speed 6 2 If the grade decreases begin to upshift when the engine speed goes above 2000 rpm 6 3 For the best fuel
138. y the trans mission manufacturer 2 Make sure that the fuel tank is full If air has en tered the fuel system prime the fuel system using the engine manufacturer s instructions 3 If the engine is equipped with a fuel water separa tor drain off any accumulated water 4 Check the drive belts to make sure that they are in good condition and properly adjusted Replace any drive belts that are cracked worn or glazed 5 Check the turbocharger if so equipped for signs of oil or exhaust leaks Correct any problems before starting the engine 6 Check the engine mounting bolts for tightness Tighten them if necessary 3 7 7 Make sure that the battery cable connections are clean and tight Check that the batteries are charged 8 Start the engine See Engine Starting above Engine Break In Caterpillar Every Caterpillar engine must pass a full load operation test on a dynamometer before shipment eliminating the need for a break in period Only an initial operational check is necessary Cummins Cummins electronic engines are run on a dynamometer before being shipped from the factory They do not re quire a break in period IMPORTANT Special break in oils are not recom mended for new or rebuilt Cummins engines Mercedes Benz Every Mercedes Benz engine is tested on a dynamom eter before shipment Therefore no break in period is necessary for the MBE900 engine Before running the engine for the first t

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