& Operator’s Manual

Contents

Safety 1

Emergency 2

Controls 3

Driving 4

Maintenance 5

Information 6

Index 7 Contents

©2013 Paccar Inc - All Rights Reserved

This manual illustrates and describes the operation of features or equipment which may be either standard or optional on this vehicle. This manual may also include a description of features and equipment which are no longer available or were not ordered on this vehicle. Please disregard any illustrations or descriptions relating to features or equipment which are not on this vehicle.

PACCAR reserves the right to discontinue, change specifications, or change the design of its vehicles at any time without notice and without incurring any obligation.

The information contained in this manual is proprietary to PACCAR. Reproduction, in whole or in part, by any means is strictly prohibited without prior written authorization from PACCAR Inc. Truck Model Example

i

SAFETY

1 INTRODUCTION About the Manual ...... 1-3 Safety Alerts ...... 1-3 Vehicle Safety ...... 1-5 A Special Word About Repairs ...... 1-7 Additional Sources of Information ...... 1-8 CAB AND FRAME ACCESS Safety ...... 1-10 Door Lock and Keys...... 1-11 Remote Keyless Entry (RKE) ...... 1-12 Climbing onto the Deck Plate ...... 1-13 GETTING TO YOUR ENGINE Hood Hold Downs...... 1-15 Hood Tilt...... 1-16 Hood Hold-Open Device ...... 1-17

(04/13) Y53-1200-1B1 1-1 SAFETY

1 SEATS AND RESTRAINTS Introduction ...... 1-19 Safety Restraint Belts ...... 1-22 Tether Belts ...... 1-25 Komfort-Latch® Feature ...... 1-26 During Pregnancy...... 1-28 Belt Damage and Repair ...... 1-28 Sleeper Bunks and Restraints ...... 1-29 Safety Restraint Tips ...... 1-31 START-UP Introduction ...... 1-33 Safe Vehicle Operation ...... 1-33 Vehicle Loading...... 1-34 Emergency Equipment ...... 1-36 Driver's Check List ...... 1-36

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INTRODUCTION Safety Alerts Your Kenworth may not have all the 1 About the Manual features or options mentioned in this Please read and follow all of the manual. Therefore, you should pay safety alerts contained in this manual. Congratulations! Your selection of a careful attention to the instructions that They are there for your protection Kenworth truck was a wise investment. pertain to just your vehicle. In addition, and information. These alerts can Kenworth trucks are recognized as if your vehicle is equipped with special help you avoid injury to yourself, your the industry standard for quality and equipment or options not discussed in passengers, and help prevent costly reliability. this manual, consult your dealer or the damage to the vehicle. Safety alerts manufacturer of the equipment. are highlighted by safety alert symbols Please take the time to get acquainted and signal words such as "WARNING", with your vehicle by reading this All information contained in this "CAUTION", or "NOTE". Please do not Operator’s Manual. We recommend manual is based on the latest ignore any of these alerts. that you read and understand this production information available at the manual from beginning to end before time of publication. Kenworth Truck you operate your truck. This manual Company reserves the right to make explains the safe, efficient operation changes at any time without notice. and maintenance of your Kenworth.

NOTE After you’ve read this manual, it should be stored in the cab for convenient reference and remain with this truck when sold.

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WARNING CAUTION 1 Example: WARNING! CAUTION WARNING! Do not carry additional fuel containers in your vehicle. Fuel containers, either The safety message following this The safety alert following this symbol full or empty, may leak, explode, and symbol and signal word provides a and signal word provides a caution cause or feed a fire. Do not carry ex- warning against operating procedures against operating procedures which tra fuel containers. Even empty ones which could cause death or personal could cause equipment or property are dangerous. Failure to comply may injury. They could also cause damage. The alert will identify the result in death or personal injury. equipment or property damage. The hazard, how to avoid it, and the alert will identify the hazard, how to probable consequence of not avoiding avoid it, and the probable consequence the hazard. of not avoiding the hazard. Example:

CAUTION Continuing to operate your vehicle with insufficient oil pressure will cause serious engine damage. Failure to comply may result in equipment or property damage.

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NOTE Vehicle Safety out on the road, it is the responsible driver's duty to do so. Inspect the 1 NOTE WARNING! vehicle according to the Driver's Check Do not drink alcohol and drive. Your List beginning on page 1-36. reflexes, perceptions, and judgment Every new vehicle is designed to can be affected by even a small The alert following this symbol and conform to all Federal Motor Vehicle amount of alcohol. You could have a signal word provides important Safety Standards applicable at the time serious or even fatal accident, if you information that is not safety related of manufacture. Even with these safety drive after drinking. Please do not but should be followed. The alert features, continued safe and reliable drink and drive or ride with a driver will highlight things that may not be operation depends greatly upon who has been drinking. Failure to obvious and is useful to your efficient regular vehicle maintenance. Follow comply may result in death, personal operation of the vehicle. the maintenance recommendations injury, equipment or property damage. found in Preventive Maintenance on Example: page 5-9. This will help preserve your WARNING! investment. NOTE Do not text and drive. Your reaction Pumping the accelerator will not assist time, perceptions and judgment can Keep in mind that even a well in starting the engine. be affected while texting or using any maintained vehicle must be operated other form of mobile messaging while within the range of its mechanical driving. Failure to comply may result capabilities and the limits of its load in death, personal injury, equipment or ratings. See the Weight Ratings label property damage. on the driver's door edge. Safe driving is only possible with the Make sure your vehicle is in top proper concentration on the driving working condition before heading

(04/13) Y53-1200-1B1 1-5 INTRODUCTION

task. Keep distraction to a minimum to California Proposition 65 Warning Data Recorder 1 improve your concentration. Examples of distractions may include radio • Diesel engine exhaust and some California Vehicle Code - Section controls, GPS navigation controls, of its constituents are known to 9951- Disclosure of Recording Device cellular telephone calls, cellular text the State of California to cause messages, reading or reaching for cancer, birth defects, and other Your vehicle may be equipped with one something on the floor. Minimizing reproductive harm. or more recording devices commonly your distractions will improve safe referred to as “event data recorders • Other chemicals in this vehicle (EDR)” or “sensing and diagnostic driving and will help avoid an accident are also known to the State of involving death or personal injury. modules (SDM)”. If you are involved in California to cause cancer, birth an accident, the device(s) may have defects or other reproductive Be aware of local regulations that may the ability to record vehicle data that harm. prohibit the use of cellular telephones occurred just prior to and/or during the while driving. In addition to being an • Battery posts, terminals, and accident. For additional information on unsafe practice, it may be against local related accessories contain lead your rights associated with the use of or federal ordinances to use cellular and lead compounds, chemicals this data, contact devices while operating the vehicle. known to the State of California • the California Department of Motor to cause cancer and reproductive Vehicles - Licensing Operations This manual is not a training manual. harm. Wash hands after handling. It cannot tell you everything you need Division to know about driving your vehicle. For – or – that you need a good training program • http://www.dmv.ca.gov/ or truck driving school. If you have not been trained, get the proper training before you drive. Only qualified drivers should drive this vehicle.

1-6 Y53-1200-1B1 (04/13) INTRODUCTION

Environmental Protection for information concerning proper A Special Word About 1 disposal. Repairs WARNING! Diesel engine exhaust and some of its WARNING! constituents are known to the State Do not attempt repair work without suf- of California to cause cancer, birth ficient training, service manuals, and defects, and other reproductive harm. the proper tools. You could be killed Other chemicals in this vehicle are or injured, or you could make your ve- also known to the State of California hicle unsafe. Do only those tasks you to cause cancer, birth defects or other are fully qualified to do. reproductive harm. This warning re- quirement is mandated by California Your dealer’s service center is the best law (Proposition 65) and does not re- place to have your vehicle repaired. sult from any change in the manner in You can find dealers all over the which vehicles are manufactured. country with the equipment and trained personnel to get you back on the road Some of the ingredients in engine quickly—and keep you there. oil, hydraulic oil, transmission and axle oil, engine coolant, diesel fuel, Your vehicle is a complex machine. air conditioning refrigerant (R12, Anyone attempting repairs on it needs R134a, and PAG oil), batteries, etc., good mechanical training and the may contaminate the environment if proper tools. If you are sure you spilled or not disposed of properly. have these requirements, then you Contact your local government agency can probably perform some repairs yourself. However, all warranty repairs

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1 must be performed by an authorized Additional Sources of service facility. If you aren’t an WARNING! Information experienced mechanic, or don’t have Modifying your vehicle can make it un- Installed Equipment - Operator's the right equipment, please leave all safe. Some modifications can affect Manuals repairs to an authorized service facility. your vehicle's electrical system, stabil- They are the ones equipped to do the ity, or other important functions. Be- Major component suppliers also supply job safely and correctly. fore modifying your vehicle, check with operation manuals specific to their your dealer to make sure it can be products. Additional manuals and Maintenance Manuals. If you do done safely. Improper modifications other pieces of literature are included decide to do any complex repair work, can cause death or personal injury. in the glove box literature package. you’ll need the maintenance manuals. Look for information on products Order them from your authorized such as the engine, driver's seat, dealer. Please provide your Chassis transmission, axles, wheels, tires, Serial Number when you order, to be ABS/ESP (if applicable), radio, 5th sure you get the correct manuals for wheel, lane departure and adaptive your vehicle. Allow about four weeks cruise control. If you are missing these for delivery. There will be a charge for pieces of literature, ask your Dealer these manuals. for copies. Final Chassis Bill of Material. A complete, non-illustrated computer printout listing of the parts used to custom-build your vehicle is available through the dealer from whom you purchased your vehicle.

1-8 Y53-1200-1B1 (04/13) INTRODUCTION

Other Sources 1 Another place to learn more about trucking is from local truck driving schools. Contact one near you to learn about courses they offer.

Federal and state agencies such as the department of licensing also have information. The Interstate Commerce Commission can give you information about regulations governing transportation across state lines.

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1 CAB AND FRAME ACCESS WARNING! Jumping out of the cab or getting into Safety the cab without proper caution is dan- gerous. You could slip and fall, which WARNING! could lead to death or personal injury. Keep steps clean. Clean any fuel, oil, Always reinstall steps before entering or grease off of the steps before enter- the cab or accessing the deck plate. ing the cab. Use the steps and grab Without steps you could slip and fall. handles provided, and always keep at Failure to comply may result in death least three points of contact between or personal injury. your hands and feet and the truck. Al- ways face toward the vehicle when Be careful whenever you get into or out entering or exiting the cab and look of your vehicle’s cab. Always maintain where you are going. at least three points of contact with your hands on the grab handles and The following picture shows the best your feet on the steps. way to enter and exit a Conventional Cab.

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Door Lock and Keys Keys Door Lock To lock or unlock the doors from 1 outside the cab, insert the key in the The same key fits your ignition, doors, Doors can be locked from the inside by lock. Turn the key toward the rear to and sleeper luggage compartment. using the lock button. Close the door lock; forward to unlock. then push the button down to lock. Frame-mounted tool box locks and Doors automatically unlock when you locking fuel tank caps each have open them from inside, and can be individual keys. locked from the outside with the key or the optional remote keyless entry key fob.

WARNING! To reduce the chance of death or per- sonal injury, always lock the doors while driving. Along with using the lap shoulder belts properly, locking the doors helps prevent doors from inad- vertently opening and occupants from being ejected from the vehicle.

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1 Remote Keyless Entry (RKE) Operation (Optional) NOTE To Unlock the Driver’s Door FCC ID: L2C0031T IC: 3432A-0031T This vehicle may be equipped with a FCC ID: L2C0032R IC: 3432A-0032R Press the UNLOCK button once. The Remote Keyless Entry (RKE) system This device complies with Part 15 of driver's door will unlock and the parking that adds security and convenience the FCC Rules and with RSS-210 of lights will come on for 40 seconds. to your vehicle. The system will Industry Canada. To Unlock the Passenger’s Door lock or unlock the driver’s door and Operation is subject to the following passenger’s door with the key fob and two conditions: Press the UNLOCK button once and alert you with parking lights when the (1) This device may not cause harmful press again within 5 seconds. The selected doors are locked or unlocked. interference, and passenger door will unlock. The system includes two key fobs that (2) This device must accept any in- provide secure rolling code technology terference received, including interfer- To Lock All Doors that prevents someone from recording ence that may cause undesired oper- the entry signal. ation. Press the LOCK button. The doors will Changes or modifications not expres- lock and the parking lights will come sively approved by the party respon- on for 2 seconds. If the doors are open sible for compliance could void the they will not lock. The range of the user's authority to operate the equip- RKE system should be approximately ment. The term “IC:” before the radio 30 ft. This will be reduced if it is certification number only signifies that operated close to other RF sources Industry Canada technical specifica- such as TV/radio transmitters and cell tions were met. towers.

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Batteries Synchronization Climbing onto the Deck 1 Plate The key fob uses one CR2032, The key fob may need to be 3V battery. Batteries should last synchronized to the truck when the WARNING! approximately three years, depending battery is replaced or when the key fob on use. Consistently reduced range has not been used for an extended When you are climbing onto and off is an indicator that the battery needs period of time. the deck plate, maintain at least three replacement. Batteries are available points of contact with your hands on at most discount, hardware, and drug To Synchronize A Key Fob: the grab handles and your feet on the stores. steps. Always face toward the vehicle 1. Hold the key fob near the receiver when entering or exiting the cab and which is located behind the The battery can be accessed by look where you are going. Failure to speedometer and tachometer. removing the cover of the key fob. comply may result in death or personal After a new battery is installed, the 2. Press and hold both the Lock and injury. key fob must be synchronized with the Unlock buttons at the same time vehicle. for approximately 7 seconds. WARNING! 3. When the key fob is When stepping onto a surface to enter resynchronized, the doors the cab or access the deck plate, only will lock then immediately unlock. use the steps and grab handles in- stalled and designed for that purpose. 4. If the fob fails to synchronize, Failure to use the proper steps and it could be programmed to a grabhandles could cause a fall which different truck or could have failed. may result in death or personal injury. Contact your dealer to re-program your key fob.

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1 WARNING! The following pictures show you the Keep steps clean. Clean any fuel, right way to get on and off the area oil, or grease off the steps before en- behind your cab. tering the cab or accessing the deck plate. Stepping on a slippery surface can cause a fall which may result in death or personal injury.

WARNING! Always reinstall steps before entering the cab or accessing the deck plate. Without steps you could slip and fall. Failure to comply may result in death or personal injury.

NOTE Maintain three points of contact. Any alteration (adding bulkheads, headache racks, tool boxes, etc.) be- hind the cab that affects the utilization Hold handles as you step up. of installed grab handles, deck plates, or frame access steps should com- ply with Federal Motor Carrier Safety Regulation 399.

1-14 Y53-1200-1B1 (04/13) GETTING TO YOUR ENGINE

GETTING TO YOUR 1 ENGINE 1. Hood Latch in the Closed Position

Hood Hold Downs

Hood hold downs keep a hood from opening unexpectedly.

CAUTION A hood not latched securely could open during operation and cause ve- hicle damage. Be sure to latch the hood securely.

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Hood Tilt 1 2. Pull Latch to Open 3. Pull Up to Separate To open your hood, unlock the hood hold downs by unlatching them. Put one or both hands on the top of the hood front. Tilt the hood forward by pulling at the top of the hood, pivoting on the foot placed on the bumper and using the foot on the ground for stability. Keep pulling on the hood until you are certain that the hood hold open device is engaged. When closing the hood, be sure that you maintain the same points of contact (top of hood and bumper) to control the movement of the hood as it closes.

WARNING! A pivoting hood could hurt someone or be damaged itself. Before opening or closing the hood, be sure there are no people or objects in the way. Failure to stand in a position of safety can cause death or personal injury.

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Hood Hold-Open Device The release lever for the hood hold 1 The hood is equipped with a hood open device is located near the front hold-open device. In order for the hood hinge of the hood. Press the lever in to hold-open device to become engaged, disengage the hood hold open device. the vehicle hood must be fully open. Once the vehicle hood is fully open, the hold-open latch will automatically engage and will need to be disengaged by the operator.

Pull with hand from here

Press in to disengage

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1 WARNING! Before opening or closing the hood, make sure your footing is secure and stable. Failure to do so may cause the hood to close uncontrollably which may result in death or personal injury.

WARNING! Always ensure the hood hold-open latch is engaged to keep the hood fully open any time anyone gets under the hood for any reason. Failure to do so may cause the hood to close uncon- trollably which may result in death or personal injury.

WARNING! Before closing the hood, be sure the area is clear—no people or objects are in the way. Failure to do so may result in death or personal injury.

1-18 Y53-1200-1B1 (04/13) SEATS AND RESTRAINTS

SEATS AND Seat Adjustment 1 RESTRAINTS Suggested Control Setting Order: WARNING! 1. Seat fore/aft position Do not adjust the driver's seat while Introduction 2. Seat height the vehicle is moving. The seat could This section covers the operation move suddenly and unexpectedly and 3. Thigh support and safe use of your seats. For can cause the driver to lose control of 4. Seat bottom angle further information on features and the vehicle. Make all adjustments to adjustment of the seat, see the the seat while the vehicle is stopped. 5. Seat back recline angle manufacturer's Service and Operation After adjusting the seat and before 6. Lumbar Manual included with the vehicle. driving off, always check to ensure that the seat is firmly latched in position. 7. Adjust steering wheel Failure to comply may result in death, personal injury or property damage. 8. Adjust mirrors The suspension seat in this vehicle will WARNING! have the following controls to adjust Before driving or riding in vehicle, the seat to the operator’s specific ensure that there is adequate head needs. clearance at maximum upward travel of seat. Injury may occur if head clearance is not adequate. Failure to comply may result in death or personal injury.

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1 WARNING! Seat heaters should not be used if the operator or passenger has difficulty in sensing and reacting to an increased temperature of the seat. The heater function may result in personal injury.

CAUTION Do not use the seat heater for more than 10 minutes at one time. Always turn off the seat heaters when they are not needed. Overuse of the seat heater may decrease the capacity of the vehicle’s batteries and may result in poor starting and potential equip- ment damage. 1. Seat fore/aft 1. Seat heater/cooler 2. Express down 2. Seat thigh support up/down 3. Suspension stiffness 3. Seat bottom angle adjustment 4. Seat height up/down 5. Lumbar and bolster* controls 6. Recline adjustment 7. Armrest angle adjustment *This is an optional feature and may vary depending on the vehicle.

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WARNING! 1 Do not drive or ride with your seat back in the reclined position. You could be injured by sliding under the seat belts in a collision. Failure to comply may result in death or personal injury.

Lumbar (and bolster support if available) are provided for superior support to the back during operation. 1. Lower and Upper* lumbar adjustment Lower support is standard and the 2. Bolster* adjustment optional functions include upper *This is an optional feature and may vary depending on the vehicle. lumbar and bolster functions. Pressing on the “+” symbol of the button will The seats in this vehicle are equipped add support in the area. Pressing the with a switch that locks out the fore-aft opposite side of the button will release isolator function in the seat. When pressure and will reduce support in the locked, the seat will not move back area. and forth. It will be rigidly fixed and only allowed to move up and down with the vehicle’s movements.

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Passenger Seat Swivel (Optional) Safety Restraint Belts 1 WARNING! This vehicle may be equipped with a Do not use the swivel function while a swivel function on the passenger seat. passenger is in the seat and the vehi- This function allows the passenger cle is in motion. The seat belt will not seat to rotate and face towards the provide proper protection if the pas- inside of the cab. senger is not facing forward and the vehicle is in an accident. Failure to WARNING! comply may result in death or personal Always ensure that the passenger injury. seat is locked into the forward-facing position when the vehicle is in mo- tion. Locking the swivel seat into the forward facing position maximizes vis- ibility to the surrounding area. Failure to comply creates a safety hazard that may result in death or personal injury. Safety belts have proven to be the single most effective means available for reducing the potential for either death or personal injury in motor vehicle accidents. Unbelted riders could be thrown into the windshield or other parts of the cab or could be thrown out of the cab. They could strike another person. Injuries can be

1-22 Y53-1200-1B1 (04/13) SEATS AND RESTRAINTS much worse when riders are unbelted. above the speedometer/tachometer Lap/Shoulder Belt Always fasten your seat belt and be (see “Seat Belt, Fasten” on page 3-41). 1 sure anyone riding with you does the The combination lap-shoulder belt is same. Therefore, read the following equipped with a locking mechanism. instructions and always observe user The system adjusts automatically to a warnings pertaining to safety belts. person's size and movements as long as the pull on the belt is slow. WARNING! Hard braking or a collision locks the Do not drive vehicle without your seat belt. The belt will also lock when belt and your riders belts fastened. driving up or down a steep hill or in a Riding without a safety belt properly sharp curve. fastened can lead to death or personal injury in an emergency. To fasten the belt: 1. Grasp the belt tongue. WARNING! 2. Pull belt in a continuous slow In vehicles equipped with passenger motion across your chest and lap. seat swivel function, the seat belts will only perform their intended function 3. Insert belt tongue into buckle on when the seat is facing forward. Fail- inboard side of seat. ure to comply can lead to death or per- sonal injury in an emergency. 4. Push down until the tongue is securely locked with an audible click. Your vehicle is equipped with a seat belt indicator in the warning light display

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1 5. Pull belt to check for proper If the belt is locked, lean the body back fastening and adjustment, as to remove any tension in the belt. After follows: releasing the belt, allow the belt to retract completely by guiding the belt • Pull shoulder section to make sure tongue until the belt comes to a stop. belt fits snugly across the chest and pelvis. • There should be less than 1 inch (25 mm) gap between the body and the belt. • The shoulder belt must be positioned over the shoulder, it must never rest against the neck or be worn under the arm. • Make sure any slack is wound up on the retractor and that the belt is not twisted. To unfasten the belt: 1. Push in the release button on the buckle. 2. The belt will spring out of the buckle.

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Safety Restraint Belts 1

Lap Belt Shoulder Belt

Correct Incorrect (too high on hips) Correct (over arm) Incorrect (under arm) Incorrect (twisted)

WARNING! Tether Belts Internal tether belts do not require Proper seat belt adjustment and use This vehicle may have an external adjustment. is important to maximize occupant tether belt installed with a seat, instead safety. Failure to wear or adjust the of the internal tethering device. Tether safety belt properly may result in death belts are designed to restrain the seat or personal injury. in the event of a sudden stop or an accident.

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To adjust an external tether belt: Komfort-Latch® Feature 1 WARNING! • Make sure that the tether belt is Do not remove, modify, or replace Your vehicle includes a feature attached to the cab floor and seat the tether belt system with a different designed to eliminate cinching and frame. It should be routed through tether system. A failed or missing provide improved safety and comfort. the buckle on each side. tether belt could allow the seat base Cinching is the condition where a belt becomes continually tighter around to fully extend in the event of an acci- • Often the attachments are made you during a rough, bouncy ride. The dent. Failure to comply may result in using a split-type hook. Make sure need for this feature increases with death or personal injury. both halves of the hook are around rough road conditions, particularly over the anchor bracket. long distances. WARNING! • To lengthen the tether, turn the Failure to adjust tether belts properly buckle to a right angle to the To eliminate cinching, simply activate can cause excessive movement of webbing. Then pull the buckle. the Komfort-Latch feature located the seat in an accident. Tether belts To shorten the tether, pull on the on the seat belt webbing at the should be adjusted so that they are strap. appropriate time: taut when the seat is in its most up- 1. Adjust the seat to its proper driving ward and forward position. Failure to position. comply may result in death or personal injury. 2. Latch the seat belt. 3. If available, adjust the seat belt height adjuster to a comfortable driving position.

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4. While seated appropriately, push WARNING! 1 the "on" button to engage the Komfort Latch. Do not set the Komfort Latch with too much slack. Too much slack may re- 5. Learn forward in the seat until you duce the effectiveness of the seat belt. hear a "click." Failure to comply may result in death 6. Return to normal driving position, or personal injury. and the Komfort Latch maintains the preset amount of tension relief.

To disengage the mechanism: 1. Unbuckle the seat belt 2. Press the “OFF” button of the Komfort Latch or tug on the shoulder strap. Komfort-Latch®

More information and video tutorials can be found at: http://www.clicktugsnug.com/ .

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1 During Pregnancy Belt Damage and Repair Pregnant women should always wear Damaged belts in the cab must combination lap/shoulder belts. The be replaced. Belts that have been lap belt portion must be worn snugly stretched, cut, or worn out may not and as low as possible across the protect you in an accident. pelvis. To avoid pressure on the abdomen, the belt must never pass If any seat belt is not working properly, over the waist. A properly worn seat see an Authorized Service Center for belt may significantly reduce the risks repair or replacement. to woman and baby in the event of a crash. For further information on seat belts and seat belt maintenance, see Safety Restraint System - Inspection on page Pregnant Woman with Belt Properly 5-68. Worn

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Sleeper Bunks and may have belts and/or a net restraint Lower 1 Restraints system which are over the bunk or cover the opening. WARNING! Always keep the lower bunk in its down If your vehicle has an upper and lower position while the vehicle is moving. bunk, the upper bunk can be folded up If left in the up position, stored items out of the way to provide you with more could become loose during an acci- room in the sleeper. Fold the upper dent and strike you, causing death or bunk up and insert the metal end of the personal injury. bunk retaining belts into the buckles.

WARNING! Before you move the vehicle, check to be sure the lower bunk is in the down Be sure the restraint system is used position. when anyone is occupying the sleeper while the vehicle is moving. In an ac- cident, an unrestrained person lying in a sleeper bunk could be seriously in- jured. He or she could be thrown from the bunk. Failure to comply may result in death, personal injury, equipment or property damage.

For cabs equipped with a sleeper, be sure to use the restraint devices when the vehicle is in motion. Your vehicle

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Upper Upper Rear Sleeper Storage 1 WARNING! WARNING! Any loose items on the upper or lower Your vehicle may be equipped with an upper storage shelf that extends over Be sure the latch that holds the upper bunk should be moved to a secured the lower bunk and across the rear bunk in the folded position is working place before driving the vehicle. Fail- of the sleeper. The following warning properly so the bunk will not fall down. ure to comply may result in death, applies: Pull on the bunk to be sure it is latched personal injury, equipment or property securely. If the bunk falls, you could be damage. WARNING! injured. Failure to comply may result in death, personal injury, equipment or Overhead compartments are not in- property damage. tended for items exceeding their de- signed weight limits. Exceeding the Per FMCSR 392.60 - Unauthorized weight limits may cause the shelf to Persons Not to be Transported. collapse and or items may fall out in a Federal law prohibits the transportation sudden stop which may lead to death of persons in commercial vehicles or personal injury. unless they are specifically authorized in writing by the motor carrier. See Compartments in the cab and sleeper the cited FMCSR for a complete are provided for storage of necessary description of the regulation and items used during operation. The exemptions. storage areas above the door are designed to hold a combined total not exceeding 14 lbs (6 kg) per compartment and the other overhead compartments (including those in

1-30 Y53-1200-1B1 (04/13) SEATS AND RESTRAINTS the optional sleeper) should hold a Safety Restraint Tips • Keep seat belt and bunk restraint 1 combined total not exceeding 5 lbs buckles free of any obstruction (2.2 kg) per compartment. • Do not wear a belt over rigid or breakable objects in or on your that may prevent secure locking. clothing, such as eye glasses, • Damaged or worn belts in the cab pens, keys, etc., as these may or sleeper, subjected to excessive cause injury in an accident. stretch forces from normal wear, • Any authorized person sleeping must be replaced. They may in your vehicle while it is moving not protect you if you have an should use the bunk restraint. accident. • Any authorized person sitting in • Any belts or restraints that have the sleeper area on the sofa bed been subjected to an accident (if equipped) while it is moving should be inspected for any loose should wear a seat belt. (attaching) hardware or damaged buckles. • A responsible operator sees to it that everyone in the vehicle rides • If belts show damage to any part or sleeps safely. The operator of assembly, such as webbing, is responsible to inform any bindings, buckles or retractors, passengers or co-drivers how to they must be replaced. properly use the seat belts and • Do not allow safety belts (seat bunk restraint in the vehicle. or bunk) to become damaged by • Do not strap in more than one getting caught in door, bunk or person with each belt. seat hardware, or rubbing against sharp objects.

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1 • All belts must be kept clean or the to keep you and your passengers retractors may not work properly. safe. • Never bleach or dye seat or bunk • If any seat belt or bunk restraint restraint belts: chemicals can is not working properly, see an weaken them. Do, however, keep authorized dealer for repair or them clean by following the care replacement. label on the belts. Let them dry completely before allowing them to retract or be stowed away. • Make sure the seat belts and bunk restraint of the unoccupied passenger seat or bunk is fully wound up on its retractor or is stowed, so that the belt or restraint tongue is in its properly stowed position. This reduces the possibility of the tongue becoming a striking object in case of a sudden stop. • Do not modify or disassemble the seat belts or bunk restraint in your vehicle. They will not be available

1-32 Y53-1200-1B1 (04/13) START-UP

START-UP Safe Vehicle Operation or federal ordinances to use cellular devices while operating the vehicle. 1 Introduction For your safety, as well as those around you, be a responsible driver: Much has gone into the manufacturing of your vehicle including advanced The following section covers start-up • If you drink alcohol, do not drive. procedures for getting your vehicle engineering techniques, rigid quality ready for the road. • Do not drive if you are tired, ill, or control, and demanding inspections. under emotional stress. These manufacturing processes will be enhanced by you, the safe driver, Safe driving is only possible with the who observes the following: proper concentration on the driving • Knows and understands how to task. Keep distraction to a minimum to operate the vehicle and all its improve your concentration. Examples controls. of distractions may include radio controls, GPS navigation controls, • Maintains the vehicle properly. cellular telephone calls, cellular text messages, reading or reaching for • Uses driving skills wisely. something on the floor. Minimizing your distractions will improve safe For more information, refer to driving and will help avoid an accident Department of Transportation involving death or personal injury. Regulation 392.7, which states that interstate commercial motor vehicles Be aware of local regulations that may are not to be driven unless the driver is prohibit the use of cellular telephones sure that certain parts and accessories while driving. In addition to being an are in working order. unsafe practice, it may be against local

(04/13) Y53-1200-1B1 1-33 START-UP

Vehicle Loading 1 WARNING! WARNING! The use of alcohol, drugs, and cer- Do not text and drive. Your reaction Compare your vehicle's load capacity tain medications will seriously impair time, perceptions and judgment can with the total load you are carrying. If perception, reactions, and driving abil- be affected while texting or using any adjustments need to be made, make ity. These circumstances can substan- other form of mobile messaging while them, do not drive an overloaded tially increase the risk of an accident. driving. Failure to comply may result vehicle. If you are overloaded or your Failure to comply may result in death, in death, personal injury, equipment or load has shifted, your vehicle may be personal injury, equipment or property property damage. unsafe to drive. damage. WARNING! Do not drink alcohol and drive. Your Do not exceed the specified load rat- reflexes, perceptions, and judgment ing. Overloading can result in loss of can be affected by even a small vehicle control, either by causing com- amount of alcohol. You could have a ponent failures or by affecting vehicle serious or even fatal accident, if you handling. Exceeding load ratings can drive after drinking. Please do not also shorten the service life of the ve- drink and drive or ride with a driver hicle. Failure to comply may result in who has been drinking. death or personal injury.

The gross vehicle weight rating (GVWR), or the maximum front and rear gross axle weight ratings (GAWRs) are determined by the components installed from the factory

1-34 Y53-1200-1B1 (04/13) START-UP on to the vehicle and their designed specifications. (Axle weight ratings are Load Distribution: be sure any load WARNING! 1 you carry is distributed so that no axle listed on the driver's door edge.) An unevenly distributed load or a load has to support more than its GAWR. too heavy over one axle can affect The following are some definitions of the braking and handling of your vehi- weight you should know: cle, which could result in an accident. Even if your load is under the legal GVWR: is the Gross Vehicle Weight limits, be sure it is distributed evenly. Rating. This is the MAXIMUM Failure to comply may result in death, WEIGHT your vehicle is allowed to personal injury, equipment or property carry, including the weight of the empty damage. vehicle, loading platform, occupants, fuel, and any load. Never exceed the GVWR of your vehicle.

GCW: is the actual combined weight, or Gross Combination Weight (GCW), of your vehicle and its load: vehicle, plus trailer(s), plus cargo.

GAWR: is the Gross Axle Weight Rating. This is the total weight that one axle is designed to transmit to the ground. You will find this number listed on the driver's door edge.

(04/13) Y53-1200-1B1 1-35 START-UP

Emergency Equipment Driver's Check List 1 The following operations are to be It is good practice to carry an To keep your vehicle in top shape and performed by the driver. Performing emergency equipment kit in your maintain a high level of safety for you, these checks and following the vehicle. One day, if you have a your passengers, and your load, make maintenance procedures in this roadside emergency, you will be glad a thorough inspection every day before manual will help keep your vehicle the following items are with you: you drive. You will save maintenance running properly. time later, and the safety checks • window scraper could help prevent a serious accident. • snow brush Please remember, too, that Federal Motor Carrier Safety Regulation 392.7 • container or bag of sand or salt requires a pre-trip inspection and so do commercial trucking companies. • emergency light You are not expected to become a • warning triangles professional mechanic. The purpose • small shovel of your inspections is to find anything that might interfere with the safe and • first aid kit efficient transportation of yourself, any passengers, and your load. If you do • fire extinguisher find something wrong and cannot fix it • vehicle recovery hitches (see yourself, have an authorized dealer or Vehicle Recovery Guidelines on qualified mechanic repair your vehicle page 2-12 for details). right away.

1-36 Y53-1200-1B1 (04/13) START-UP

Approaching Your Vehicle Daily Checks b. Replace belts that are cracked 1 • Check the overall appearance and torn or broken. Engine Compartment Checks - Daily condition. Are windows, mirrors, 3. Fuel Filter/Water Separator and lights clean and unobstructed? 1. Engine Fluid Levels - add more if Draining - check and drain. necessary. • Check beneath the vehicle. Are Depending on the fuel storage there signs of fuel, oil, or water a. Engine oil facility, more frequent draining may be required. leaks? b. Coolant (check while engine • Check for damaged, loose, or is cold) 4. Windshield washer reservoir fluid level - fill if necessary. missing parts. Are there parts c. Power steering fluid level showing signs of excessive wear 5. Battery Cables - check the 2. Engine Belt - check tension and or lack of lubrication? Have a condition of the battery and condition of belts. qualified mechanic examine any alternator cables for signs of questionable items and repair a. See Accessory Drive Belts chafing or rubbing. Make sure them without delay. on page 5-97 for further that all clamps (straps) holding the cables are present and in good • Check your load. Is it secured information on checking belt working order. properly? tension. 6. Hood closed before entering cab. NOTE Is it latched properly? Deflection should be one belt thick- 7. Check brake lines and hoses. ness for each foot distance between the pulley centers. 8. Check the steering components (pitman arm, draglink, power steering hoses, etc.).

(04/13) Y53-1200-1B1 1-37 START-UP

to springs or other suspension 9. Check clutch hydraulic fluid. 1 parts such as cracks, gouges, 9. Fuel Tank Hardware - is the tank Chassis and Cab Checks - Daily distortions, bulges or chafing. fill cap secure? Are the tank straps tight? Is the strap webbing in Before entering the cab and operating 5. Brake Components - check lines, place? the vehicle, check the following linkages, chambers, parking and equipment for proper maintenance: service brake operation. WARNING! 1. Lights - are any exterior lights 6. Air System - are there leaks? Diesel fuel in the presence of an igni- cracked or damaged? Air Tanks - drain water from all air tion source (such as a cigarette) could Perform an exterior light test using tanks. Make sure the drain cocks cause an explosion. Do not remove the dash mounted switch next to are closed. This procedure is also a fuel tank cap near an open flame. the steering wheel. See Exterior required for air suspension tanks Use only the fuel and/or additives rec- Lighting Self-Test on page 3-64. equipped with automatic drain ommended for your engine. A mix- valves. ture of gasoline or alcohol with diesel 2. Windows and Mirrors - are they For further details See Using the fuel increases this risk of explosion. clean and adjusted properly? Brake System on page 4-21. Failure to comply may result in death, personal injury, equipment or property 3. Tires and Wheels - are they 7. Steps and Handholds - check damage. See Refueling on page 4-60, inflated properly? Are all wheel for worn surfaces and loose or for more information. cap nuts in place and torqued missing fasteners (which includes properly - tighten if necessary. any fuel tank steps). 10. Trailer Connections - are they Check front wheel bearing oil secure and the lines clear? If levels. Inspect all tires and wheels 8. Fluid Tanks (Fuel, DEF, etc.) - they are not being used, are they for damage - correct if found. check underneath the vehicle for signs of fluid leaks. If any are stored properly? 4. Suspension - check for loose or found, correct before operating the missing fasteners. Check damage vehicle.

1-38 Y53-1200-1B1 (04/13) START-UP

of turn signals and emergency a. Is the trailer spare wheel lights. The above items should be checked 1 secure and inflated? daily, as a minimum. They are in 6. Instruments - check all b. Is the landing gear up and the addition to, not in place of, Federal instruments. handle secured? Motor Carrier Safety Regulations. 7. Windshield - check operation of These regulations may be purchased 11. Check the fifth wheel. Is the windshield wipers and washers. by writing to: kingpin locked? 8. Horn - check operation of horn. Superintendent of Documents a. Is the sliding fifth wheel locked? 9. Fuel - check fuel. Is there enough U.S. Government Printing Office fuel? Cab Interior - Daily 10. Diesel Exhaust Fluid (DEF) - Washington, DC 20402 1. Seat - adjust the seat for easy check level. Is there enough fluid? reach of controls and visibility. 11. Sleeper Air Conditioning Air Filter - 2. Seat Belts - fasten and adjust check the condition of the sleeper safety restraint belts (which may air conditioning air filter. Keep include restraints in the sleeper). the sleeper floor area behind 3. Steering Column - adjust for easy the passenger front seat clear of reach and visibility. debris and pet hair. The sleeper air conditioner draws air from this 4. Mirrors - check and readjust area and excessive dirt or pet hair mirrors if necessary. may shorten the service life of the 5. Lights - turn ignition key to the ON sleeper air conditioning air filter. position and check for warning lights and buzzer. Check operation

(04/13) Y53-1200-1B1 1-39 START-UP

Weekly Operations 1 b. Check the air cleaner, muffler, 1. Battery - check battery and and exhaust pipes. Are they terminals. tight and secure? 2. Wheel Cap Nuts - are they all c. For vocational vehicles in place and torqued properly - with optional engine air tighten if necessary. See Wheel pre-cleaner, check the purge Cap Nut Torque on page 5-142. valve at the bottom of the hood mounted engine air precleaner 3. Other Controls and Wiring - check for any obstructions. Make for condition and adjustment sure the purge valve will open 4. Steering Components - check and close as needed to purge pitman arm, draglink, and power dirt and water from the engine steering hoses, etc., for loose, intake air. broken, or missing parts. d. Automatic Transmission Fluid 5. HVAC Fresh Air Filter - check for (when applicable) - Check condition and cleanliness. level, after the engine has warmed up to operating 6. Other Engine Compartment temperature. Checks: a. Check condition and fastening of engine belt, hoses, clamps, and radiator.

1-40 Y53-1200-1B1 (04/13) EMERGENCY

WHAT TO DO IF... You Need Roadside Assistance...... 2-3 Low Air Alarm Turns On ...... 2-3 2 Stop Engine Lamp Turns On ...... 2-4 Engine Oil Pressure Lamp Turns On...... 2-4 Engine is Overheating ...... 2-5 Fuse or Relay Blows ...... 2-6 JUMP STARTING VEHICLES Introduction ...... 2-8 VEHICLE RECOVERY AND SPRING BRAKES Vehicle Recovery Guidelines ...... 2-12 Returning Vehicle to Service ...... 2-20 Spring Brakes—Manual Release ...... 2-20 Sand, Mud, Snow and Ice ...... 2-22 Towing the Vehicle ...... 2-23

(04/13) Y53-1200-1B1 2-1

WHAT TO DO IF...

WHAT TO DO IF... permits, chains, towing, hazardous Low Air Alarm Turns On clean-up, out of fuel (roadside), You Need Roadside mechanical repairs and preventive Assistance maintenance services. • They have bilingual agents and 2 access to a translation service to ensure quality assistance 1. Slow down carefully. for customers who speak any 2. Move a safe distance off the road Call toll-FREE 1-800-KW-ASSIST language. and stop. (1-800-592-7747) to talk to someone • They can’t answer your warranty 3. Place the transmission in at the PACCAR Customer Center. questions but can get you in neutral (park with automatic • Open 24-7-365 days a year contact with a Kenworth dealer transmissions, if equipped) and who can. set the parking brake. (Refer • They can help you get roadside to Parking Brake Valve on assistance. • The PACCAR Customer Center page 4-23 and Operating the service is FREE even if you don’t Transmission on page 4-19, for • They have a custom mapping drive a Kenworth. transmission shifting and parking system which locates Kenworth brake information.) Dealers and Independent Service Providers (ISPs) near you and lists 4. Turn OFF the engine. types of services offered, hours of 5. Turn ON the emergency flasher operation and contact information. and use other warning devices to • They can assist with jump and alert other motorists. pull starts, tires, trailers, fines and

(04/13) Y53-1200-1B1 2-3 WHAT TO DO IF...

Stop Engine Lamp Turns On Engine Oil Pressure Lamp WARNING! Stop Engine Lamp - If the Turns On If the air pressure falls below 60 psi Stop Engine warning lamp Engine Oil Pressure Lamp (414 kPa) the spring brakes may illuminates, it means you have a serious engine system - If the oil pressure suddenly 2 stop the vehicle abruptly, which could problem. drops, or the audible alarm and cause an accident resulting in death engine oil pressure warning light come on while driving, do or personal injury. Observe the red the following: warning lamps on the gauges. If one WARNING! comes on, do not continue to drive 1. Slow down carefully. the vehicle until it has been properly This should be considered an emer- repaired or serviced. gency. You should stop the vehicle as 2. Move a safe distance off the road safely as possible and turn OFF the and stop. If the light and alarm do not turn off at ignition. The vehicle must be serviced 3. Place the transmission in park startup, do not try to drive the vehicle and the problem corrected before driv- and set the parking brake. until the problem is found and fixed. ing again. Failure to do so may cause (See Parking Brake Valve on (Refer to Using the Brake System on severe engine or DPF damage, or page 4-23 and Operating the page 4-21, for more brake information.) cause an accident which may result in Transmission on page 4-19, for death or personal injury. transmission shifting and parking brake information.) 4. Turn OFF the engine. 5. Turn ON the emergency flasher and use other warning devices to alert other motorists.

2-4 Y53-1200-1B1 (04/13) WHAT TO DO IF...

Engine is Overheating parking brake. (See Parking Brake 6. Wait a few minutes to allow oil to Valve on page 4-23 and Putting drain into the engine oil pan, and The cooling system may overheat if the Vehicle in Motion on page then check the oil level. (See Oil the coolant level is below normal or if 4-16, for transmission shifting and Level Check on page 5-94, for there is sudden loss of coolant, such parking brake information.) Keep details on checking oil level.) as a split hose. The system may also the engine running. 2 7. Add oil if necessary. If the problem temporarily overheat during severe operating conditions such as: 2. Check to ensure the Oil Pressure persists, contact an authorized Gauge reads normal. (See Engine dealer as soon as possible. • Climbing a long hill on a hot day Oil Pressure Gauge on page 3-11, for further information.) CAUTION • Stopping after high-speed driving 3. Make sure the engine fan is Continuing to operate your vehicle If either one of the above occurs, DO turning by switching the Engine with insufficient oil pressure may NOT TURN OFF THE ENGINE unless: Fan Switch from AUTO to MAN cause severe engine damage or a) the Low Water warning device (Manual). cause an accident which may result in indicates a loss of coolant, b) the Red equipment or property damage. 4. Increase the engine speed to Warning lamp (on the gauge) and about one-half of full operating Check Engine lamp comes ON, c) the speed, or 1,100 to 1,200 rpm, It is important to maintain oil pressure Buzzer sounds showing an overheat maximum. within acceptable limits. If oil pressure condition, or d) if you have any other drops below the minimum psi (kPa) a reason to suspect the engine may be 5. Return the engine speed to normal Red Warning Lamp on the oil pressure overheating - follow these steps. idle after 2 or 3 minutes. gauge will illuminate and the Stop Engine Lamp will come ON. 1. Reduce engine speed and 6. Monitor the engine temperature. stop. When stopped, place the After the temperature returns to transmission in Neutral and set the normal, allow the engine to idle

(04/13) Y53-1200-1B1 2-5 WHAT TO DO IF...

3 to 5 minutes before shutting it Fuse or Relay Blows off. This allows the engine to cool WARNING! gradually and uniformly. To reduce the chance of death, per- Fuses are located behind the drivers sonal injury and/or vehicle damage side kick panel, below the ignition 7. If overheating came from switch, and accessible by a door panel. 2 severe operating conditions, the from overheated engines, which can result in a fire, never leave the engine See Power Distribution Box on page temperature should have cooled 5-84. by this time. If it has not, stop idling without an alert driver present. If the engine should overheat, as indi- the engine and let it cool before The vehicle main power relays are cated by the engine coolant tempera- checking to see if the coolant is located in the engine compartment. ture light, immediate action is required low. See Power Distribution Center (PDC) to correct the condition. Continued on page 5-81. For further information on engine unattended operation of the engine, even for a short time, may result in temperature and operating engines WARNING! properly, see the Engine Operation serious engine damage or a fire. and Maintenance Manual and Starting Do not replace a fuse with a fuse of a higher rating. Doing so may damage and Operating the Vehicle on page WARNING! 4-5. Check the coolant level after the electrical system and cause a fire. Do not remove the radiator fill cap each trip when the engine has cooled. Failure to comply may result in death, while the engine is hot. Scalding The coolant level should be visible personal injury, equipment or property steam and fluid under pressure may within the surge tank—add coolant if damage. escape. You could be badly burned. necessary. See Topping Off in Engine Failure to comply may result in death Cooling System on page 5-72, for or personal injury. instructions on checking and filling the coolant expansion tank.

2-6 Y53-1200-1B1 (04/13) WHAT TO DO IF...

Fuse Inspection and Replacement CAUTION If it is blown, replace it with a fuse of All the electrical circuits have fuses the same rating. Before replacing a fuse, turn OFF all to protect them from a short circuit or lights and accessories and remove overload. If something electrical on If a fuse of the same rating is not the ignition key to avoid damaging the your chassis stops working, the first available, a fuse of a lower rating may 2 electrical system. thing you should check for is a blown be temporarily substituted. You can fuse. also use a fuse from a circuit you can CAUTION do temporarily without (for example an 1. Turn OFF all lights and accessories accessory circuit or radio). Never patch fuses with tin foil or wire. and remove the ignition key to This may cause serious damage else- avoid damaging the electrical CAUTION where in the electrical circuit, and it system. may cause a fire. When replacing a failed circuit 2. Determine from the chart on the breaker, always use an approved cir- fuse panel which fuse controls that CAUTION cuit breaker with a current rating equal component. to or less than the circuit breaker be- If a circuit keeps blowing fuses, have 3. Remove that fuse and see if it is ing replaced. Only use the approved the electrical system inspected for a blown. Type II modified reset circuit breakers. short circuit or overload by an autho- NEVER use a Type I (automatic re- rized dealer as soon as possible. Fail- set) or Type III (manual reset) circuit ure to do so could cause serious dam- breaker. A fuse with a current rating age to the electrical system and/or ve- equal to or less than the circuit breaker hicle. being replaced can also be used.

1 Blown

(04/13) Y53-1200-1B1 2-7 JUMP STARTING VEHICLES

JUMP STARTING metal jewelry and avoid leaning over VEHICLES WARNING! the battery. Never jump start a battery near fire, Introduction flames, or electrical sparks. Batteries 2 generate explosive gases that could Jump starting a vehicle is not a explode. Keep sparks, flame, and recommended practice due to the lighted cigarettes away from batteries. various battery installations and Failure to comply may result in death, electrical options. personal injury, equipment or property damage. However, if your battery is discharged (dead), you may be able to start it WARNING! by using energy from a good battery in another vehicle. This is termed Never remove or tamper with battery jump starting. Be sure to follow the caps. Ignoring this could allow battery precautions and instructions below. acid to contact eyes, skin, fabrics, or painted surfaces. Failure to comply WARNING! may result in death, personal injury, equipment or property damage. Batteries contain acid that can burn and gasses that can explode. Ignoring Be careful that metal tools (or any safety procedures may result in death, metal in contact with the positive personal injury, equipment or property terminal) do not contact the positive damage. battery terminal and any other metal on the vehicle at the same time. Remove

2-8 Y53-1200-1B1 (04/13) JUMP STARTING VEHICLES

To Jump Start your Vehicle Preparing the vehicles: CAUTION 1. Remove any personal jewelry WARNING! Improper hook-up of jumper cables that may come in contact with the When jump starting using a battery or not following these procedures can battery terminals. booster, it is best to jump start with damage the alternator or cause seri- 2 an equivalently powered vehicle. Ver- ous damage to both vehicles. 2. Select a jumper cable that is long ify that the booster battery has the enough to attach to both vehicles in a way that ensures neither same volt and CCA specifications as WARNING! the dead battery before attempting to vehicle touches each other. Heed all warnings and instructions of jump start. Failure to comply may 3. Position the two vehicles together, the jumper cable manufacturer. Fail- cause an explosion resulting in death, but do not allow them to touch. personal injury, equipment or property ure to comply may result in death, damage. personal injury, equipment or property 4. Turn OFF all lights, heater, radio, damage. and any other accessory on both vehicles. CAUTION 5. Set the parking brakes: pull out Applying a higher voltage booster bat- the Yellow button located on the tery may cause expensive damage to dash. sensitive electronic components, such as relays, Electronic Control units or 6. Shift the transmission into park electronics in general. Failure to com- position or neutral for manual ply may result in equipment damage. transmissions. (See Operating the Transmission on page 4-19 and Parking Brake Valve on page 4-23, for transmission shifting and parking brake information.)

(04/13) Y53-1200-1B1 2-9 JUMP STARTING VEHICLES

Connect the batteries: 7. If either vehicle is equipped with 6. Start the vehicle that has the battery disconnects ensure they 1. Attach one end of a jumper cable good battery first. Let it run for 5 are in the "OFF" position prior to to the positive (+) terminal of the minutes. connecting the two vehicles. discharged (dead) battery. This 7. Start the vehicle that has the will have a large red + or P on the 2 discharged (dead) battery. battery case, post, or clamp. 2. Attach the other end of the same If the engine fails to start, do not cable to the positive (+) terminal continue to crank the starter but of the good (booster) battery. contact the nearest authorized dealer. 3. Attach the remaining jumper cable FIRST to the negative (-) terminal (black or N) of the good battery. 4. Attach the other end of the negative cable to a bare metal part not bolted to the engine block.

NOTE Always connect positive (+) to pos- itive (+) and negative (-) to negative (-).

5. If either vehicle is equipped with battery disconnects, ensure that they are in the "ON" position.

2-10 Y53-1200-1B1 (04/13) JUMP STARTING VEHICLES

Remove jumper cables:

WARNING! When disconnecting jumper cables, make sure they do not get caught in 2 any moving parts in the engine com- partment. Failure to comply may result in death, personal injury, equipment or property damage.

Reverse the above procedure exactly when removing the jumper cables. With engine running, disconnect jumper cables from both vehicles in the exact reverse order, making sure to first remove the negative cable from the vehicle with the discharged battery.

(04/13) Y53-1200-1B1 2-11 VEHICLE RECOVERY AND SPRING BRAKES

VEHICLE RECOVERY the lubricant in the top front of the AND SPRING BRAKES drive axle will drain to the rear. This CAUTION will leave the top components dry. The Connect only to the Recovery Hitches, resulting friction may damage them. Vehicle Recovery Guidelines see Vehicle Recovery Guidelines on Always remove the main drive axle page 2-12. Connections to other struc- 2 shafts before towing your vehicle. Your vehicle is equipped with tural parts could damage the vehicle. removable Recovery Hitches, Do not attach to bumpers or brackets. CAUTION designed for short distance recovery Use only equipment designed for this purposes only. Use only the provided Remove the drive axle shafts or lift the purpose. Failure to comply may result hitches, according the following driving wheels off the ground before in equipment damage. instructions. When using this towing the vehicle. Towing the vehicle connection, do not transport your with either the wheels on the ground or vehicle over long distances. (If your the axle shafts in the axles will cause vehicle does not have the proper damage to the axle gears. hitches, contact your dealer.) CAUTION All lubricating and clutch application oil pressure is provided by an If your vehicle has a Meritor axle with a engine-driven pump, which will not driver-controlled main differential lock, work when the engine is stopped. install the caging bolt before removing You could seriously damage your the axles for towing, see Driver Con- vehicle by towing it with the driveline trolled Main Differential Lock on page connected and the drive wheels on 2-16. Installing the caging bolt pre- the ground. Worse, when vehicles are vents damage by locking internal axle towed, either by wrecker or piggyback, components in position.

2-12 Y53-1200-1B1 (04/13) VEHICLE RECOVERY AND SPRING BRAKES

Recovery Procedure the vehicle’s air system is connected to that of the recovery 1. Review and understand all the vehicle. Ensure that any air line cautions and warnings of this that has been removed from a section, see Vehicle Recovery driver-controlled main differential Guidelines on page 2-12. lock is firmly capped to prevent 2 2. Install the recovery hitches, see loss of air pressure from the Recovery Hitch Installation on recovery vehicle if it is supplying page 2-15. air pressure. If you don’t desire to use the 3. Disconnect the drive axle shafts recovered vehicle’s brakes, and cover the open hubs. This ensure that you cage the spring is necessary because if the brakes before attempting to move transmission is driven by the the vehicle, see Driver Controlled driveshaft (rear wheels on the Main Differential Lock on page ground), no lubricant will reach 1 Recovery Hitch Sockets 2-16. the gears and bearings, causing damage to the transmission. WARNING! 4. Install the recovery rigging using a Before towing a vehicle, test your air safety chain system, see Recovery brakes to ensure that you have prop- Rigging on page 2-19. erly connected and inspected the re- 5. Make sure the recovered vehicle's covery vehicle’s brake system. Failure parking brakes are released. to do so could lead to a loss of vehicle control which may result in an accident 6. If you desire to use the recovered involving death or personal injury. vehicle’s brakes, ensure that

(04/13) Y53-1200-1B1 2-13 VEHICLE RECOVERY AND SPRING BRAKES

Recovery Hitch Connection 7. Follow state/provincial and local Technology & Maintenance Council laws that apply to vehicles in tow. 950 N. Glebe Road (703) 838-1763 Specially designed hitches are 8. Do not tow vehicles at speeds in Arlington, VA 22203 required to recover your vehicle. The excess of 55 mph (90 km/h). Email: [email protected] recovery hitches attach to the frame, 2 http://tmc.truckline.com see Recovery Hitch Assembly on page For additional information concerning 2-15. heavy duty truck recovery, refer to the following Technology & Maintenance Two hitch assemblies, made up of the Council (TMC) literature. following parts, are recommended for the proper recovery of your vehicle: • Recommended Practice #602–A see Recovery Hitch Assembly on page — “Front Towing Devices For 2-15. Trucks and Tractors.” WARNING! • Recommended Practice #602–B — “Recovery Attachment Points Do not use parts from other trucks or For Trucks, Tractors, and materials from other sources to repair Combination Vehicles." a hitch or to replace a missing hitch. The parts provided for recovery are • Recommended Practice #626 made of high strength steel specifically — “Heavy Duty Truck Towing designed for vehicle recovery. Fail- Procedures.” ure to use the correct factory equip- ment may result in an accident involv- Copies of these can be obtained from ing death or personal injury. the following address:

2-14 Y53-1200-1B1 (04/13) VEHICLE RECOVERY AND SPRING BRAKES

Recovery Hitch Installation If your vehicle is not equipped with the proper recovery hitch assembly, Use the following procedure to install contact an authorized dealer to obtain the Vehicle Recovery Hitches. See the proper equipment. Recovery Hitch Assembly illustration for part identification. 2 1. Check square sockets behind lower bumper for obstructions, clear if necessary. 2. With lock pins removed, insert hitches through bumper and into the square hitch socket. 3. Align the hole in the tow hitch with the square hitch socket hole. Recovery Hitch Assembly 4. Insert the lock pin into the square 1 Tow Pin hitch socket hole and through 2 Tow Hitch the hole in the tow hitch until the 3 Square Hitch Socket lock tab is within the square hitch 4 Lock Pin socket. 5 Lock Tab 5. Rotate the lock pin 90 degrees to secure the pin in place. 6. Remove the hitches and store all parts after recovering the vehicle.

(04/13) Y53-1200-1B1 2-15 VEHICLE RECOVERY AND SPRING BRAKES

Driver Controlled Main Differential CAUTION Follow these steps to lock a Failure to lift the driving wheels off driver-controlled main differential. the ground or remove the driveline 2 and axle shafts before towing the ve- WARNING! hicle could seriously damage your An open air line on the recovered ve- vehicle. All lubricating and clutch ap- hicle will cause a leak in the air sys- plication oil pressure is provided by tem of the recovery vehicle if both ve- an engine-driven pump, which does hicles’ brake systems are connected. not work when the engine is stopped. This could cause a loss of system air, When vehicles are towed either by which can cause the service brakes wrecker or piggyback, lubricant in the not to function, resulting in the sudden top front of the drive axle will drain to application of the spring brakes caus- Driver Controlled Main Differential the rear. This will leave the top compo- ing wheel lock-up, loss of control, or Lock nents dry, resulting in friction that will overtake by following vehicles. You 1 Air Line (remove to install seriously damage these components. could be in an accident involving death Caging Bolt) 2. Cover open hubs when removing or personal injury. Ensure that any 2 Caging Bolt (in storage drive axle shafts. air line that has been removed from a location) driver-controlled main differential lock is firmly capped to prevent loss of air 1. Lift driving wheels off the ground pressure from the recovery vehicle if it or remove the driveline and axle is supplying air pressure. shafts before towing the vehicle.

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This action will lock the CAUTION differential by pushing a piston CAUTION Water, dirt and other material can en- into a “lock” position. A recovered vehicle will have no op- ter an open hub or axle. This can con- erational brake system. Additionally, taminate the axle fluid and cause pos- CAUTION the rear axle spring brakes will prob- 2 sible damage to components. Ensure Failure to install the caging bolt when ably be applied. that the hubs are covered with plas- towing vehicles with driver-control • If you desire to use the recovered tic whenever a drive axle shaft is re- main differential lock can result in vehicle’s brakes, ensure that the moved. damage by failing to lock internal com- vehicles air system is connected ponents in position. 3. For vehicles with driver-controlled to that of the recovery vehicle. main differential lock, install the Also ensure that any air line WARNING! caging bolt before removing the that has been removed from a axle shafts for towing. Ensure there are no open air lines on driver-controlled main differential the recovered vehicle if the recovery lock is firmly capped to prevent a. Remove the air line and firmly vehicle and recovered vehicle brake loss of air pressure from the cap. systems are connected. An open recovery vehicle. b. Remove the caging bolt from air line on the recovered vehicle will • If you don’t desire to use the its storage hole. cause a leak in the air brake system of recovered vehicle’s brakes, the recovery vehicle possibly causing c. Screw the caging bolt into ensure that you cage the spring death, personal injury, equipment or brakes before attempting to move the air line hole. When property damage. fully engaged, a 0.25 - 0.5 the vehicle. in. (6.35-12.7 mm) space 4. Install recovery hitches and will remain between the air rigging. cylinder and the bolt head.

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Recovery Hitch Capacities CAUTION CAUTION Connect recovery rigging only to The maximum rated loads for vehicle recovery varies depending on the Recovery pull maximums assume the hitches intended for that purpose. Do tow rigging evenly distributes the load not attach to bumpers or brackets. direction or angle of pull. These 2 capacities are listed in the table below between both recovery hitches. See Connections to other structural parts examples in Recovery Rigging on could damage the vehicle. and are for the two hitches working together, simultaneously. page 2-19 for details. Serious damage to the vehicle may occur if rigging is Hitch Capacities not connected properly.

MAXIMUM DIRECTION OF CAPACITY PULL CAUTION (Lb) * Directly Forward 80,000 When recovering ditched or bogged Directly Vertical or 14,600 vehicles, stay well below Maximum Horizontally to the Capacities. Even at loads below maxi- Side mum, the physical strain of recovering 45º in any Direction 20,000 * Both hitches pulled simultaneously. a vehicle could damage axles, sus- pensions, fifth wheels, etc.

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Recovery Rigging • Never loop a single chain or cable cable no closer than 6 ft. from the through both hitches (3). vehicle (2). To connect to the vehicle, follow the suggested rigging methods below. • Use a spreader or equalizer bar to distribute the load on both hitches • Use a double chain or cable setup (1). 2 that distributes the load equally to both hitches. See 1 or 2 in • If no spreader bar is available, Recovery Rigging illustration. connect the main tow chain or

1. Spreader Bar or Equalizer 2. Minimum 6 FT. 3. NEVER USE SINGLE CHAIN OR CABLE Preferred Acceptable LOOPED THROUGH TOW DEVICES

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Returning Vehicle to Service Spring Brakes—Manual Release The brakes can be released in this You will have to add lubricant to manner should the pressure in the air prevent damage after your vehicle has Recovering a vehicle requires that you system not be enough to release them. been towed. release the parking brakes. There may This may occur in instances where 2 the engine's air compressor is not 1. Into the pinion cage, add 1 pint be times when there is not enough air able to get the system up to operating (.47 liter) of lubricant or into the pressure to release the parking brakes. pressure. interaxle differential, add 2 pints In such cases, the parking brakes (.94 liter) of approved lubricant. (or Spring Brakes) can be manually released. WARNING! 2. After adding the specified type Do not disassemble a spring brake and amount of lubricant, drive the WARNING! chamber. These chambers contain a vehicle. It should be unloaded. Do not drive vehicle with malfunc- powerful spring that is compressed. Drive 1 to 2 miles (1.5 to 3 km) tioning brakes. If one of the brake Sudden release of this spring may re- at a speed lower than 25 mph circuits should become inoperative, sult in death or personal injury. (40 km/h). This will thoroughly braking distances will increase sub- circulate the lubricant through the stantially and handling characteristics assembly. WARNING! while braking will be affected. You Do not operate a vehicle when the could lose control of your vehicle or spring brakes have been manually cause an accident. Have it towed to released. Driving a vehicle after its the nearest dealer or qualified repair spring brakes are manually released facility for repair. Failure to comply is extremely dangerous. The brakes may result in death, personal injury, may not function. Failure to comply equipment or property damage. may result in death, personal injury, equipment or property damage.

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2. Remove the release 5. Assemble the release WARNING! stud assembly from the stud washer and nut on Always secure the vehicle with wheel side pocket, and remove the release stud. the release nut and chocks, chains, or other safe means to washer from the release prevent rolling before manually releas- stud. 2 ing the spring brakes. Releasing the spring brakes on an unsecured vehicle 3. Slide out the release 6. With a wrench, could lead to an accident. The vehicle stud. turn the release stud assembly nut until the could roll, which may result in death, compression spring is personal injury, equipment or property 90-95 percent caged. damage. While doing this, check to make sure the push 4. Insert the release stud rod (adapter push To move a vehicle immobilized by through the opening in rod or service push the spring brakes due to loss of air the spring chamber rod) is retracting. Do where the cap was not over-torque the pressure in the brake system, perform removed. Insert it into release stud assembly. the following procedure: the pressure plate. Turn (S-Cam type maximum: the release stud 1/4 50 lb-ft, Wedge type 1. Remove the cap from turn clockwise in the maximum: 30 lb-ft). the spring chamber. pressure plate. This The spring brake is now secures the cross pin mechanically released. into the cross pin area of the pressure plate and locks it into the manual release position.

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Sand, Mud, Snow and Ice • Do not shift into reverse while the WARNING! vehicle is moving. If the vehicle gets stuck in sand, Do not spin the wheels faster than mud, snow, or ice: 35 mph (55 km/h). Spinning a tire • If the vehicle needs to be recovered from being stuck, do not • Move the gearshift lever or at speedometer readings faster than 2 permit the vehicle to be towed for selector from First to Reverse. 35 mph (55 km/h) can be dangerous. Tires can explode from spinning too long distances without removing • Apply light pressure on the fast. Under some conditions, a tire the driveshaft. accelerator pedal while the may be spinning at a speed twice transmission is in gear. that shown on the speedometer. Any Tire Chains resulting tire explosion could cause If you need tire chains, install them on • Remove your foot from the death or personal injury to a bystander both sides of the driving axle. accelerator while shifting. or passenger, as well as extensive vehicle damage: including tire, trans- • Do not race the engine. CAUTION mission and/or rear axle malfunction. • For best traction and safety, avoid Chains on the tires of only one tandem spinning the wheels. Comply with the following axle can damage the driveline U-joints instructions to avoid transmission and the interaxle differential. Repairs damage: could be costly and time-consuming. Failure to comply may result in equip- • Always start vehicle in motion with ment damage. the shift lever in first gear. • Be sure that transmission is fully engaged in gear before releasing the clutch pedal (manual only).

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Towing the Vehicle • If towing from the front, ensure that the rear axles are prepared Towing the vehicle should be done for towing. by either an authorized dealer or a commercial vehicle towing • If towing from the rear, ensure service. The dealer or commercial that all body components such as 2 towing service will have the necessary roof, side and chassis fairings are equipment to safely tow the vehicle and secured properly to avoid damage should be able to make arrangements while in transit. to limit any damage to the vehicle. The towing service and the dealer should WARNING! be aware of towing regulations and Secure the roof, side and chassis fair- safety precautions. ings while towing from the rear. An un- The towing service will ensure that the secured fairing may come off of the ve- following precautions are taken: hicle during transit. Failure to secure the fairings while towing may cause • Use of a safety chain system. an injury accident resulting in death or personal injury. • Abide by all local towing regulations. • Ensure that the towing device does not contact any surfaces that could be damaged while in transit.

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CONTROLS

INSTRUMENT PANEL Getting to know your Instrument Panel...... 3-5 Instrument Cluster ...... 3-7 Instrument Cluster Description ...... 3-8 Driver Performance Center ...... 3-14 Driver Performance Center Description . . . . . 3-15 3 How to Navigate the Functions in the Driver Performance Center...... 3-19 WARNING SYMBOLS Guide to the Warning Symbols ...... 3-29 Description of Warning Symbols ...... 3-37 OPTIONAL GAUGES Introduction ...... 3-43 Axle, Pusher Air Pressure ...... 3-43 Axle, Tag Air Pressure ...... 3-43 Fuel Filter Restriction Pressure ...... 3-44 Air Filter Restriction Indicator or Gauge . . . . . 3-44

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Engine, Oil Pressure ...... 3-45 Engine, Oil Temperature ...... 3-45 Manifold Pressure Gauge ...... 3-45 Fuel Pressure Gauge ...... 3-46 Transmission Temperature Gauge...... 3-46 Drive Axle Temperature Gauge (Forward and Rear) 3-46 3 Suspension Load Air Pressure, #1, #2 ...... 3-47 Tractor Brake Application Air Pressure ...... 3-47 Trailer Brake Application Air Pressure ...... 3-48 Trailer Air Tank Air Pressure ...... 3-48 Transfer Case Oil Temperature ...... 3-48 Transmission Oil Temperature, Auxiliary . . . . . 3-49 Transmission Retarder Oil Temperature . . . . . 3-49 SWITCHES Dash Switches ...... 3-50 Steering Column Controls ...... 3-67 Steering Wheel Controls (Optional) ...... 3-73 Door Mounted Controls ...... 3-75

3-2 Y53-1200-1B1 (04/13) CONTROLS

Exterior Lights Self Test ...... 3-77 HEATING AND AIR CONDITIONING Cab Controls ...... 3-79 Introduction ...... 3-80 Manual Control Mode ...... 3-82 Automatic Control Mode ...... 3-83 MAX Defrost Mode ...... 3-84 3 Buttons and Dials ...... 3-85 Operating Tips ...... 3-86 Sleeper Heater - A/C Controls (optional) . . . . . 3-89 ACCESSORIES Sleeper Alarm Clock ...... 3-91 Radio (Option) ...... 3-94 Cigarette Lighter and Ashtray (Option) ...... 3-94 Cab Storage ...... 3-95 Ignition Key Switch ...... 3-96 Vehicle Telematic System ...... 3-97 Passenger Side 'down' Mirror...... 3-99

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INSTRUMENT PANEL INSTRUMENT PANEL

Getting to know your Instrument Panel

This part explains the location of the various features on your vehicle and describes their function. For information on using these features in 3 driving, see the paragraphs that follow. Please remember that each vehicle is custom-made. Your instrument panel may not look exactly like the one in the pictures that follow. We have tried to describe the most common features and controls available. You can pick out the parts that apply to you and read them to be fully informed on how your particular vehicle operates.

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1. Instrument Cluster 6. Glove Box 12. Optional Gauge 2. PACCAR Navigation 7. Overhead Storage 13. Menu Control Switch (MCS) (optional) 8. Park Brake Controls 14. Switches 3. Switches 9. Radio 4. Air Conditioning 10. Ignition Switch 5. Cup Holder 11. Headlight Switch

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Instrument Cluster

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1. Speedometer 6. Engine Oil Pressure 11. Diesel Exhaust Fluid (DEF) 2. Fuel Level (primary) 7. Voltmeter 12. Menu Control Switch (MCS) 3. Tachometer 8. Driver Performance Center 13. Trip Reset Button 4. Ignition Switch 9. Brake Application Pressure 5. Engine Coolant 10. Primary/Secondary Air Temperature Pressure

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Instrument Cluster Audible Alarm Optional Icon Description Instrument System Self Test The audible alarm will sound during Additional icon may be operational the Instrumentation System Self Test. depending on individual vehicle When the ignition switch is turned The audible alarm will also sound in specifications. These will be included on the instrumentation system will conjunction with most warning lights. in the Instrument System Self Test. undergo a Self Test. This test will These events include but are not verify the operation of the gauges and limited to headlight on, fifth wheel, stop NOTE engine, primary/secondary air, and 3 warnings. Some optional lights may illumi- driver door open warnings. nate even though your vehicle is not During the Instrumentation System equipped with that particular feature. Self Test, multiple warning icons will be displayed in a sequence. The total sequence should only take no more than 10 seconds to complete.

Refer to Warning Light/Indicator Symbols on page 3-30 for information on each symbol.

Completing this sequence will indicate a successful Self Test. Have your instrumentation system checked by a qualified service technician if does not successfully complete.

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Check Messages 1. Speedometer 2. Fuel Level, Primary

Check messages are provided to give The Speedometer indicates the vehicle The Primary Fuel gauge indicates the the operator additional information speed in miles per hour (mph) and total (approximate) amount of fuel in regarding systems that require in kilometers per hour (km/h). The the fuel tank. In addition to indicating attention due to a system malfunction Speedometer cluster also includes empty and full, the gauge(s) also and/or operating conditions that may several warning and indicator lamps indicate the fuel level in graduated hinder safe and proper performance (see Audible Alerts on page 3-29). increments. When the fuel level for the for the vehicle. Some messages can tank is below 1/4 full, a red warning be managed by the operator while light in the gauge will come on. 3 others may require an authorized dealer repair.

Primary

Secondary

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3. Tachometer NOTE WARNING! The Tachometer measures the engine For Export vehicles, the fuel gauges Do not carry fuel containers or any speed in revolutions per minute (RPM). will not state: ULTRA LOW SULFUR container used to store combustible DIESEL FUEL ONLY. liquids. Failure to comply may result The RPM Detail is also available in death, personal injury, equipment or as a viewable screen in the Driver NOTE property damage. Performance Center. Viewing the RPM This vehicle may be manufactured detail is accomplished by using the 3 with different fuel systems and differ- WARNING! MCS dial to rotate to the [VIRTUAL ent draw tube locations. Because of Do not remove a fuel tank cap near GAUGES]. this and the amount of road crown, an open flame. Fuel vapors may be The tachometer is a useful gauge it is recommended that you do not hot and combustible and can cause when attempting to drive efficiently. operate your vehicle with less than an explosion or fire. Failure to comply It will let you match driving speed one-quarter of your truck’s fuel capac- may result in death, personal injury, and gear selection to the operating ity. Allowing the fuel level to go below equipment or property damage. one-quarter of capacity could result range of your engine. If the engine in the lack of fuel to keep the engine speed gets too high, you can select a Refer to Refueling on page 4-60 for higher gear to lower the RPM's. If the running. In addition, you will want to more information. keep the fuel tanks at least half-full to engine speed drops too low, you can reduce condensation of moisture in select a lower gear to raise the RPM's. the tanks. This moisture can damage (Refer to Driving Tips and Techniques the engine. on page 4-52 for further instructions on driving techniques and using the tachometer.) To avoid engine damage, do not let the pointer exceed maximum

3-10 Y53-1200-1B1 (04/13) INSTRUMENT PANEL governed speed. (See your Engine 5. Engine, Coolant Temperature 6. Engine, Oil Pressure Operation and Maintenance Manual for RPM recommendations.)

The tachometer will illuminate a small It is important to maintain oil pressure green light just below the numbers within acceptable limits. If oil pressure of the gauge. This is to indicate the The water temperature gauge shows drops below the minimum psi a red engine speed for optimal fuel economy. the temperature of the engine coolant. warning light in the gauge will turn on, See Optimal Engine Speed on page Under normal operating conditions the Stop Engine light will come on and 3 4-54 for more information on how the water temperature gauge should an audible alarm tone will sound. to use this indicator during normal register between 165° and 205°F (74° operation. and 90°C). Under certain conditions, For further information on engine oil somewhat higher temperatures may and normal operating pressures, see be acceptable. But the maximum the Engine Operation and Maintenance allowable temperature is 210°F (99°C), Manual. except for certain special engines. Check your engine manual to be sure. CAUTION Please refer to Engine is Overheating Operating your vehicle with insufficient on page 2-5 for instructions on what to oil pressure will cause serious engine do if the engine is overheating. damage.

If the oil pressure fails to rise within 10 seconds after the engine starts, stop the engine and determine the cause.

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8. Driver Performance Center 10. Primary and Secondary Air Check the engine manufacturer's Pressure manual for the correct oil pressure The display can show multiple warning ranges for your vehicle's engine. lights. Warning information will appear momentarily and then will minimize in If the oil pressure suddenly drops, the screen. Reviewing the warnings or the audible alarm and engine oil can be done by navigating the menu Primary Air Pressure pressure warning light come on while via the Menu Control Switch. driving, please refer to Engine Oil 3 Pressure Lamp Turns On on page 2-4 regarding what to do if oil pressure is insufficient. Secondary Air Pressure

For further information on engine The air gauge indicates the air gauges and operating your engine pressure in the brake system. There properly, refer to Engine Maintenance are two dial indicators, the primary on page 5-93. indicator and icon is for the rear brake system while the secondary dial and icon is for the front brake system. The gauge indicates the amount of air pressure in each system in pounds per square inch (psi).

On vehicles equipped with metric air pressure gauges, the gauge face plate includes a kPa (major) scale and psi (minor) scale.

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Please refer to Low Air Alarm Turns WARNING! WARNING! On on page 2-3 for instructions on what to do if the air system becomes If the air pressure falls below 60 psi The air pressure warning light and the inoperative. (414 kPa), the spring brakes may stop audible alarm tone indicate a danger- the vehicle abruptly which could cause ous situation: there is not enough air NOTE an accident resulting in death or per- pressure in the air tanks for repeated sonal injury. Observe the red warning braking and the brake system has Be sure the air pressure registers lamps on the gauges. If one comes on, failed. Without the use of your service more than 100 psi (690 kPa) in both do not continue to drive the vehicle un- brakes your spring brakes could sud- 3 service systems before you move the til it has been properly repaired or ser- denly apply causing a wheel lock-up, vehicle. viced. If the light and alarm do not turn loss of control, or over-take by fol- off at start-up, do not try to drive the lowing vehicles. This may cause an NOTE vehicle until the problem is found and accident resulting in death or personal fixed. injury. Bring the vehicle to a safe stop If the pressure in either or both cir- right away, while you still have control cuits falls below 65 psi (448 kPa), a red of the vehicle. warning light in the gauge will turn on and an audible alarm tone will sound when the engine is running.

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11. Diesel Exhaust Fluid (DEF) 13. Trip Reset Driver Performance Center

The cluster mounted trip reset button is the only way to zero trip data. After toggling the trip ODO (short pushes to select Trip A, B, C, or D) to the desired The diesel exhaust fluid gauge shows trip, HOLD the trip reset button, that the approximate amount of DEF fluid resets the displayed trip data. in the DEF tank. Besides empty and 3 full, the gauge also indicates 1/4, 1/2, and 3/4 of total capacity. DEF fluid is required to meet certain emission 1 Odometer/Trip Odometer requirements. Do not allow your DEF 2 Outside Air Temperature tank to remain empty. Please refer to 3 Clock your Engine Aftertreatment Controls 4 Active Warnings Operator's Manual for more details 5 Cruise Control Indicator about DEF fluid. 6 Automated Transmission and Shift Indicator Area CAUTION 7 Header Use Diesel Exhaust Fluid only. Failure 8 MCS Knob Cue to do so may damage components of 9 Main Content Window the Diesel Particulate Filter (DPF).

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Driver Performance Center • MCS button is pushed or spun Description (independent of ignition key switch NOTE position) Some Driver Performance Center WARNING! functions are only accessible when the • clock alarm sounds Do not look at the Driver Performance vehicle is parked. Other functions are Center for prolonged periods while the • driver or passenger door is opened accessible while the vehicle is mov- vehicle is moving. Only glance at the ing or when parked. Each function is monitor briefly while driving. Failure to • hazard warning lamp switch is on identified in the following descriptions: do so can result in the driver not being • Service brake switch is on 3 attentive to the vehicle’s road position or situation, which could lead to an • Tractor marker lamp switch is on accident and possible death, personal injury or equipment damage. • Trailer marker lamp switch is on • Low Voltage Display not active The Driver Performance Center, located at the top of the instrument • and the screen has not been put cluster, displays important vehicle into "Display Off Mode" information through a constant monitoring of systems when any of the In addition to a blank screen, the following conditions are met: following are menu items and the information available within each menu • ignition key in ON or ACC positions selections. • ignition timer is active

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1. Odometer/Trip Odometer 2. Outside Air Temperature The outside air temperature display The Odometer/Trip Meter comes on Used to display outside air temperature uses a sensor (located at the bottom when the door is opened and when information and a warning of low of the driver's side mirror assembly) the ignition key is in the ACC or ON temperatures. to measure outside air temperature position. only. It is not capable of displaying The display will also alert the the temperature of the road surface The odometer displays the distance driver when the outside temperate on either the temperature display or your vehicle has traveled. The display approaches freezing (32° F or 0° C) the snowflake icon. Additionally, the 3 can be configured to display Metric by displaying a snowflake symbol. outside air temperature reading may units or English units. The symbol will turn on when the be affected by exposure to direct temperature drops below 34° F or 11° sunlight. The current trip odometer displays how C and flash for the first 3 seconds, far the vehicle has gone on a particular then stay on until the temperature goes trip and can display in increments of a above 37° F or 28° C. tenth of a unit. The systems unit of measure Please refer to Trip Information on (Fahrenheit or Celsius) can be page 3-24 for more information. changed by navigating to the settings menu.

The outside air temperature display will come on when the door is open and when the ignition key is in the ACC or ON position and turn off when the ignition switch is turned off.

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3. Clock 4. Active Warnings Please refer to Settings on page 3-27 The clock presents either the home to read more about how to set the Active warnings will appear in this time or the local time when the clock is clock. area in addition to areas around the set. If the clock is not set, the words center of the display. Active Warnings "SET CLOCK" will appear when the are those pop-up messages that have ignition is turned ON. If the clock does come up on the screen and/or been not get set, the message will disappear suppressed with an MCS button push. and no time will be displayed. The time If there are warning icons active while can be set while the "SET CLOCK" the cruise control is enabled, icons 3 prompt is showing or it can be set by will appear on each side of the cruise navigating to the settings menu via the control icon. If there are multiple Menu Control Switch. warnings, the display will show how many are active. The numbers may The clock will display either the local change without user interaction if or the home time of day. individual warnings are intermittent, time based, self correcting, or the Set the Home time to the current situation is rectified. time at the base of operation. Set the local time according to a time zone of destination. Reset the local time anytime the destination location changes and you need to use this function.

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5. Cruise Control Indicator 6. Automated Transmission and 7. Header Shift Indicator Area This area is used to provide the This area displays the function driver with a dedicated location for This area will provide the operator with category in which the MCS knob and cruise control set speed and if so feedback from the transmission. The display software are currently set. equipped, adaptive cruise control with display may reflect the transmission Depending on the display operation, it’s following distance information. gear being operated, may provide the text color may change to indicate a Vehicles with adaptive cruise control Progressive Shift Cues (for vehicles user selection. will display many different icons in built with PACCAR MX Engines with 3 this area to alert the operator to take Progressive Shift option) or fault specific actions. indicators specific for the transmission.

NOTE If there are secondary telltales active while the cruise control is enabled, icons will appear on each side of the cruise control icon.

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8. MCS Knob Cue 9. Main Content Area How to Navigate the Functions in the Driver Used to provide the driver with screen There are 5 functions allowed when navigation feedback. Cues are driving, and 7 when the vehicle is Performance Center Menu Control Switch (MCS) provided regarding when a user can parked. Some functions are available push or spin the input control, shows in both modes, but have different The MCS is used to navigate the in icon format which function is active, content available dependent on the instrument display. It comprises of a and which function will come up next if mode back button and a push and spin knob. the knob is rotated either clockwise or The Menu Control Switch is located on counter clockwise. 3 the right side panel.

The MCS knob can perform two functions. It can select and set values when spun and enter your settings when pushed.

The indicator image on the left lets you know whether to spin or push is available. The back button is always available even if there is no indicator image being displayed.

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button will go back to the previous • Virtual gauges - This menu item menu. provides dynamic information to the operator. NOTE If the button is held for 2 seconds, it will • Ignition timer - Use this menu to turn off the display screen. set the time to idle the engine after removing the ignition key. • Trip Information - Use this 3 information to get trip summary details. • Truck Information - Provides information about the vehicle. • Active Warnings - Use this menu to view vehicle fault codes and messages. In addition to the prompts for spin and Here is a list of the available menu • Settings - Use this menus to push, this area will show the current items: change preferences. menu item as a larger icon and the • Blank screen - Use this menu item available menus before and after as Fuel Economy - Use this display to minimize information on the • smaller icons. to view the fuel economy screen. performance of the vehicle. The MCS button has a BACK button (available in driving mode) located above the knob. Pressing this

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Navigation of the system is organized Trunk Level Branch Level into 3 levels of functions. The first level of organization is identified as "Trunk" At this level, you can navigate between In the branch level of functions, level functions. The second level is functions by turning the MCS knob. the MCS knob rotation controls a identified as "Branch" level functions. You can enter a function by pushing cursor highlight. When something is The lowest level of functions are the knob; at which you would then be highlighted, an MCS Push will select identified as the "Leaf" level functions. going to what is termed the “branch” that item or toggle its contents. Toggle Some screens will appear differently level of the software. fields typically use a darker colored depending if the vehicle is moving text to distinguish them from fields that 3 or parked. The following images Display of a trunk level option take the user to the “Leaf level”. provide an example of a screen to get familiarized with the interface. Display of a branch level option

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Description of Menu Screens Leaf Level The blank screen mode is selected through the rotary MCS knob. The At this level, there are no more options Display OFF Mode is selected by to choose from. The MCS can be used pressing the button above the MCS to scroll through various information knob for more than 2 seconds. and the back button can be used to revert up to the branch (1 push) or the trunk (2 pushes) levels of the system. 3 Display of a leaf level option Blank Screen

This screen is available in both parked and driving modes.

The blank screen mode is to allow for minimized screen content, while still maintaining some of the more permanent screen elements such as the odometer, outside air temperature, warning cue, etc. This is different from the Display OFF Mode where the entire display shuts off.

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Tire Pressure Monitoring System parameters. This information is only Virtual Gauges available when parked.

3

The tire pressure monitor menu The virtual gauges function is selected provides individual tire pressure through the rotary MCS knob and is and temperature information for available in both parked and driving each tire identified on the vehicle modes. when the vehicle is parked only. A push on the MCS knob will open Virtual gauges provide dynamic the menu item. Spinning the MCS information about the vehicle's knob will scroll through the tires and performance. Spin the MCS button display the information accordingly. to scroll through the available gauges When scrolling through each tire’s and push to select the desired gauge information, the relevant tire will to view. appear highlighted in the menu screen. A warning message will appear if the system detects a tire temperature or pressure that is outside of normal

(04/13) Y53-1200-1B1 3-23 INSTRUMENT PANEL

Ignition Timer Fuel Economy Trip Information

This function displays the dynamic fuel economy performance of the vehicle. It shows Average Speed, Average Fuel Economy, and a dynamic instantaneous indication of fuel economy above or below the current average. The screen is available 3 when driving. Average fuel economy is computed by the fuel consumed during the trip (see the next section for This function allows the driver to set a This function allows you to keep trip Trip information). The fuel economy timer to shut off the truck. This feature information data on up to 4 separate for a trip will be reset when that trip is only available when the vehicle trips – labeled A, B, C, and D. Trips odometer is reset. is parked. After the timer is set, the are also selectable as “Active” or ignition key may be turned to the off “Inactive” so you can use the data position and removed. The engine will logging function to treat trips separate continue to run for the programmed from each other, or as segments of time, then will shut off automatically. a combined trip. When driving, the screen only allows you to toggle which trip is viewed in the trip odometer and set the active/inactive status. When parked you can select and view a variety of data collected for each trip, as seen in the list below:

3-24 Y53-1200-1B1 (04/13) INSTRUMENT PANEL

Truck Information • Fuel Economy • % PTO Fuel Used • Average Speed • PTO Economy NOTE Only available truck information will be • Engine Hours The cluster mounted trip reset button shown (e.g., manual transmissions do is used to zero and clear accumulated • Idle Hours not have a software version). trip data. Short presses toggle % Idle Hours between the odometer view, and the • This information is available when the 4 trips. Holding the button when on a vehicle is parked. • Fuel Used particular trip will zero the stored data 3 and also automatically set the cleared • Idle Fuel Used trip to “active” status. • % Idle Fuel Used Using the MCS knob while in this • Sweetspot Hours screen will only activate or deactivate a trip function. • Cruise Control Hours • Average Engine % Load NOTE PTO options in the display will only be • Drive Hours shown if the vehicle is equipped with a 1. Chassis Information • PTO Hours PTO. a. Chassis Number • % PTO Hours b. Fleet ID • PTO Fuel Used c. CECU Software Version #

(04/13) Y53-1200-1B1 3-25 INSTRUMENT PANEL

Warning and Faults a spin of the MCS knob will allow you 2. Engine Information to see the different warnings. The a. Engine Make highest priority warning defaults to the top of the stack. b. Engine Model c. Engine Software Version When the vehicle is parked, the “Warnings and Faults” function will d. Governed Speed Limit access suppressed pop-ups that are e. Engine Power counted and presented in the upper 3 left corner of the screen. 3. Transmission Information

a. Transmission Make The display has a message alerting b. Transmission Model function that overrides the normal viewing and navigation of functions c. Transmission Software when an issue occurs on the truck. Version # These alert messages are called 4. ABS Information “pop-ups” because they take over the screen. Some messages are a. ABS Make low enough priority that they can be “suppressed”, which is done by b. ABS Model pushing the MCS button. There will By selecting “Review Warnings” the c. ABS Software Version # be a screen indicator showing which pop-up messages are recalled, and if messages are suppressible. If multiple multiple are active, the stack can be pop-ups are present at the same time, navigated by spinning the MCS knob. they are viewed in a stack format, and The warning description can be viewed when driving or when parked, but

3-26 Y53-1200-1B1 (04/13) INSTRUMENT PANEL the fault details are visible only when Settings parked. The menu selection shown An example of a Fault Details screen in the image above simply won’t be is shown below: This function is available only when there if the truck is driving, though the vehicle is parked. Fault Details Example the warnings and tell-tale indicators on the cluster will still be available as Various settings may be changed using indicators if the problem is serious. this function. The operator can change Fault details screens include: the time format (12hr/24hr), the time of day, alarm settings, units of measure 1. how many faults, shown in a for the display (mile/kilometer), and the 3 scrollable stack format language being displayed. Changing 2. which ECU the fault is being settings functions are typically done generated from one of two ways. Items can be toggled straight from the highlighted selection 3. a text description of the issue (at the branch level); these cases use 4. it’s actual fault code dark blue text that changes to the set value. Others are menu selections that 5. action instructions telling you what bring up new “leaf level” screens. The to do (e.g. seek service soon vs. following shows examples of turning correct at next scheduled service the alarm on/off vs. screens that are visit) navigated to in order to set the clock time.

(04/13) Y53-1200-1B1 3-27 INSTRUMENT PANEL

To turn alarm ON/OFF: To set home, local or alarm time: Display Mode

The display off mode is available at any time in menu navigation, but the screen minimize mode can only be done when on this screen.

NOTE 3 There are times when the “Display Off” mode is not allowed or over-ridden by the system, for example if a “pop-up” 1. When in the Settings Menu, scroll 1. When in the Settings Menu, scroll message appears, the screen will turn through the list of menu items to through the list of menu items. back on, or if the truck is equipped with “Alarm”. Press the MCS. 2. Press the MCS to select the item an adaptive cruise control system, the 2. Press the MCS to turn the alarm to change. screen cannot be turned off when it is ON or OFF. active. 3. Rotate the MCS knob to change To set clock display format: the hour. Press the MCS. 1. When in the Settings Menu, scroll 4. Rotate the MCS knob to change through the list of menu items to the minutes. Press the MCS. “Format”. 5. Rotate the MCS to toggle AM/PM. 2. Press the MCS to display either 12 Press the MCS. hour (AM/PM) or 24 hour (military) time. 6. Press the button above the MCS to Exit.

3-28 Y53-1200-1B1 (04/13) WARNING SYMBOLS

WARNING SYMBOLS in the instrument cluster and Driver WARNING! Performance Center. Do not ignore a warning light or audible Guide to the Warning • the Symbol Name Symbols alarm. These signals tell you some- thing is wrong with your vehicle. It • the appearance of the Symbol The warning lights and audible alarm could be a failure in an important sys- may indicate a system malfunction. tem, such as the brakes, which could • the Symbol Color when it is Check the lights frequently, and lead to an accident causing death or illuminated injury. Have the appropriate system respond properly as soon as you see • whether the symbol is standard 3 checked immediately. one go on. These lights could save (Std) or optional (Opt) you from a serious accident. Check messages are provided to give • whether the symbol has an When multiple warning icons are the operator additional information associated check message shown on the instrument cluster, regarding systems that require they will appear at first and then attention due to a system malfunction • the Page Number reference for minimize. When minimized they and/or operating conditions that may additional information will be represented in the active hinder safe and proper performance Symbols are listed by major component warnings area of the display (see for the vehicle. The system will emit sections. Driver Performance Center on page a chime to alert the operator that a 3-14 for details). A triangle represents message is appearing on the cluster. Example: Engine, and then in a warning registered and a diamond Some messages can be managed by alphabetical order. represents a check message. the operator while others may require an authorized dealer repair.

The following is a list of Warning Light/Indicator Symbols that appear

(04/13) Y53-1200-1B1 3-29 WARNING SYMBOLS

Warning Light/Indicator Symbols

Symbol Name Symbol Color Std/Opt Msg Page

1. Axle, Traction Control Yellow OPT on page 3-37

3 2. Brakes, Anti-Lock Brake System (ABS) Yellow STD on page 3-37

3. Brakes, Low Air Red STD on page 2-3

4. Brake, Park Brake Red STD on page 3-37

5. Brake, Service Brakes Red OPT on page 3-37

3-30 Y53-1200-1B1 (04/13) WARNING SYMBOLS

Symbol Name Symbol Color Std/Opt Msg Page

6. Brakes, Trailer Anti-Lock Brake System (ABS) Yellow STD on page 3-38

7. Differential, Inter Axle Diff Lock Yellow OPT on page 3-60. 3

8. Dump Truck, Body Up Red OPT on page 3-38

9. Dump Truck, Gate Yellow OPT on page 3-38

10. Dump Truck, Trailer Body Up Red OPT on page 3-38

11. Emissions, Diesel Particulate Filter (DPF) Yellow STD on page 3-38

(04/13) Y53-1200-1B1 3-31 WARNING SYMBOLS

Symbol Name Symbol Color Std/Opt Msg Page

12. Emissions, High Exhaust System Temperature (HEST) Yellow STD on page 3-39

13. Emissions, Malfunction Indicator Lamp (MIL) Yellow STD on page 3-39 3

14. Engine, Check Engine Yellow STD on page 3-40

15. Engine, Ether Start Green OPT on page 3-40

16. Engine, Engine Fan Green STD on page 3-40

17. Engine, Heater Yellow OPT on page 3-40

3-32 Y53-1200-1B1 (04/13) WARNING SYMBOLS

Symbol Name Symbol Color Std/Opt Msg Page

18. Engine, Low Coolant Level Yellow STD on page 3-40

19. Engine, Overspeed Air Shutdown Red OPT on page 3-40 3

20. Engine, Retarder (Brake) Green OPT on page 3-40

21. Engine, Stop Engine Red STD on page 3-40

22. Engine, Wait To Start Yellow OPT on page 3-41

23. Fuel, Water In Fuel (WIF) Yellow OPT on page 3-41

(04/13) Y53-1200-1B1 3-33 WARNING SYMBOLS

Symbol Name Symbol Color Std/Opt Msg Page

24. Lane Departure Warning (LDW) Yellow OPT on page 3-41

25. Lights, High Beam Blue STD on page 3-41 3

26. Power Take-off (PTO) Yellow OPT on page 3-41

27. Power Take-off (PTO), Pump Mode Green OPT on page 3-41

28. Refrigerator Green OPT on page 3-41

29. Seat Belt, Fasten Red STD on page 3-41

3-34 Y53-1200-1B1 (04/13) WARNING SYMBOLS

Symbol Name Symbol Color Std/Opt Msg Page

30. Suspension Dump Yellow STD on page 3-41

31. Tire Inflation Yellow OPT on page 3-41 3

32. Transmission, Auxiliary Yellow OPT on page 3-42

33. Transmission, Check Red OPT on page 3-42

34. Transmission, Retarder (may include BrakeSaver when Yellow OPT ● on page 3-42 applicable)

35. Transmission, Service Transmission (Allison only) Yellow OPT ● on page 3-42

(04/13) Y53-1200-1B1 3-35 WARNING SYMBOLS

Symbol Name Symbol Color Std/Opt Msg Page

36. Turn Signal, Left Green STD on page 3-42

37. Turn Signal, Right Green STD on page 3-42 3

3-36 Y53-1200-1B1 (04/13) WARNING SYMBOLS

Description of Warning NOTE 2. Brakes, Anti-Lock Brake System Symbols (ABS) For vehicles equipped with Electronic 1. Axle, Traction Control (ATC or Stability Program, please refer to ad- Automatic Traction Control) Illuminates during the Instrumentation ditional material supplied with this op- System Self Test. Have the ABS erator manual, included in your glove system checked by an authorized A. Illuminates during the power-on box informational packet. dealer if the ABS Warning Lamp stays self test when the ignition is turned on for more than 3 seconds. ON. It turns off after a few seconds if WARNING! 3 no system problems are detected. If Illuminates during normal operating an ATC problem is detected, the ATC If this chassis is equipped with an elec- conditions to indicate a problem Warning lamp will turn on and stay on. tronic stability program (ESP) and is with the ABS System. See ABS modified (e.g. adding or removing an Warning Lamps on page 4-21 for more B. Flashes when the ATC is regulating axle, converting from a truck to a trac- information. wheel spin. (Refer to Automatic tor, converting from a tractor to a truck, Traction Control for more information.) changing the body, lengthening of Illuminates when a problem exists the wheelbase and/or frame, relocat- with the optional Wheel Spin Control C. It blinks continuously when the ing frame components, or modifying feature. See Advanced ABS with Deep Snow and Mud switch is turned pneumatic or electrical ABS/ESP har- Stability Control on page 4-21 for more on, indicating that this feature is active. nesses) the ESP must be disabled by information. (Refer to Deep Snow and Mud Switch a qualified technician. If you have any and Anti-Lock Braking System on page questions, contact your authorized 4. Brake, Park Brake 4-21 for more information.) dealer. Failure to comply may result in death, personal injury, equipment or property damage. Illuminates in the status indicator when parking brakes are applied.

(04/13) Y53-1200-1B1 3-37 WARNING SYMBOLS

is turned off (inter-axle differential 5. Brake, Service Brake NOTE unlocked) the engine power is allowed Tractors/Trucks and trailers built af- to flow to any of the 4 drive tires based on the differential effect (mostly to the Indicates that a fault exists in the brake ter 3/1/01 must be able to turn on an forward rear differential). (This feature system. This should be checked by an In-Cab Trailer ABS Warning Lamp (per is standard on all tandem axles). authorized dealer as soon as possible. U.S. FMVSS121). The industry chose Power Line Communication (PLC) as 6. Brakes, Trailer Anti-Lock Brake the standard method to turn it on. See 8. Dump Truck, Body Up System (ABS) 3 Trailer ABS Warning Lamp on page 4-21 for more information. Illuminates during the Instrumentation Illuminates when Truck Dump Body is On trailers built prior to 3/1/01 verify up. System Self Test and the tractor/truck trailer ABS system status via the re- is connected with a ABS equipped quired external warning lamp mounted 9. Dump Truck, Gate trailer. on the trailer. The indicator lamp on the trailer should be yellow and identi- Illuminates during normal operating fied with the letters “ABS”. Illuminates when Truck Dump gate is conditions to indicate a problem open. with the Trailer ABS System. This should be checked by an authorized 7. Differential, Inter Axle Diff Lock dealer as soon as possible. See ABS 10. Dump Truck, Trailer Body Up Warning Lamps on page 4-21 for more Illuminates when the inter-axle information. Illuminates when Trailer Dump Body differential switch is ON thus locking is up. the inter-axle differential. This powers the forward rear and the rear rear 11. Emissions, Diesel Particulate differentials equally. When the switch Filter (DPF)

3-38 Y53-1200-1B1 (04/13) WARNING SYMBOLS

Illuminates when diesel particulate WARNING! WARNING! filter is plugged. This warning will also If this light is on, do not park in an If this light is on, temperature of the illuminate when regeneration operation area of combustible vapors or materi- tail pipe, exhaust pipes, diesel partic- is disabled. als. You must keep combustibles at ular filter (DPF), selective catalytic re- 12. Emissions, High Exhaust least five (5) feet away from the ex- duction (SCR) device and surrounding System Temperature (HEST) haust (outlet) stream (as it exits the tail components including enclosures and pipe) while the HEST lamp is illumi- steps becomes elevated during engine Illuminates when the exhaust gas nated. Always park your vehicle out- operation or any regeneration event 3 temperature and exhaust components side. Failure to do so could ignite an and can cause serious burns to the become extremely hot. explosion or harm bystanders which skin. Allow adequate cooling time be- could result in serious injury. fore approaching, working on or near Refer to the Engine Aftertreatment any part of the exhaust system or sur- control operator manual for complete WARNING! rounding components. instructions and warnings. If this light is on, do not park in an area 13. Emissions, Malfunction where people are close by. You must Indicator Lamp (MIL) keep combustibles at least five (5) feet away from the exhaust outlet while the Illuminates when an engine emissions HEST lamp is illuminated. Failure to failure has occurred. The vehicle do so could result in serious injury. can be safely driven but should be serviced to correct the problem. The situation should not be considered an emergency. In some cases, the Malfunction Indicator Lamp will activate

(04/13) Y53-1200-1B1 3-39 WARNING SYMBOLS

in conjunction with the High Exhaust switch is turned on. (Engine retarders Temperature, Diesel Particulate Filter 17. Engine, Heater are an option.) (DPF) and Diesel Exhaust Fluid (DEF) Warning Lights. Illuminates when Engine Heater switch 21. Engine, Stop Engine is on. 14. Engine, Check Engine 18. Engine, Low Coolant Level Illuminates and an audible alarm tone Illuminates when a non emissions will sound when a major engine system problem exists. 3 related problem exists, but the vehicle Illuminates with an audible alarm can still be safely driven. Vehicle indicating critically low coolant level. WARNING! should be serviced to correct the The vehicle must be serviced to correct problem but the situation should not be the problem but the situation should The illumination of the Stop Engine considered an emergency. not be considered an emergency. Light should be considered an emer- gency. You should stop the vehicle as 15. Engine, Ether Start 19. Engine, Overspeed Air safely as possible and turn OFF the ig- Shutdown (EOAS) nition. The vehicle must be serviced Illuminates when ether start switch is and the problem corrected before driv- on. Illuminates when the Engine ing again. Failure to do so may cause Overspeed Air Shutdown system is severe engine damage or cause an 16. Engine, Engine Fan activated. accident involving death or personal injury. 20. Engine, Retarder (Brake) Illuminates when fan is active.

Illuminates when the engine retarder (compression brake or exhaust brake)

3-40 Y53-1200-1B1 (04/13) WARNING SYMBOLS

25. Lights, High Beam 27. Power Take-off (PTO), Pump 22. Engine, Wait To Start Mode

Illuminates when engine grid heater is Illuminates when the high beams are Illuminates with remote throttle on. (Cummins ISL engines) on. This icon will flash with audible application. Indicates pump mode is alarm if the headlamps are left on active. 23. Fuel, Water In Fuel (WIF) when the door is open. In addition, this icon will flash, but without an audible 28. Refrigerator alarm, if there is a problem with the 3 Illuminates when water has been low beam headlights or the low beam detected in the fuel. headlight wiring. In such event, the Illuminates to indicate that the high beam headlights will turn on at refrigerator is on and ignition is off. 24. Lane Departure Warning (LDW) 50% normal brightness.

29. Seat Belt, Fasten 26. Power Take-off (PTO) Illuminates when optional LDW system is not able to track the vehicle's position within the lane. Illuminates when the PTO is engaged. Illuminates when the ignition key is turned on as a reminder to fasten your NOTE NOTE seat belt. For vehicles equipped with Lane De- Do not drive vehicle with PTO en- 30. Suspension Dump parture Warning, please refer to Lane gaged. Departure Warning Driver's Guide for additional information. Illuminates when suspension air bags are deflated.

(04/13) Y53-1200-1B1 3-41 WARNING SYMBOLS

34. Transmission, Retarder 31. Tire Inflation (may include BrakeSaver when applicable) Illuminates when tire pressures need to be checked. (Tire Pressure Monitoring Illuminates when BrakeSaver (export System is an option.) only) or Transmission Retarder is active.

32. Transmission, Auxiliary 35. Transmission, Service 3 Transmission (Allison only) Illuminates to indicate auxiliary transmission is in neutral. Illuminates when Allison 1000/2000 transmission requires service. 33. Transmission, Check 36. Turn Signal, Left

Illuminates when transmission has recorded a fault code. This Blinks when the left turn signal or the icon may also appear in the hazard light function is operating. Transmission Display menu of the Driver Performance Center. If the user 37. Turn Signal, Right is in this display menu, the icon does not indicate a fault code. Blinks when the right turn signal or the hazard light function is operating.

3-42 Y53-1200-1B1 (04/13) OPTIONAL GAUGES

OPTIONAL GAUGES Axle, Pusher Air Pressure Axle, Tag Air Pressure

Introduction

Listed here are gauges that may or may not be on your dashboard or The Pusher Axle Air Pressure gauge(s) The Tag Axle Air Pressure gauge the center instrument cluster. For indicate the air pressure in the pusher indicates the amount of air pressure in vehicles with a telematic navigation axle(s) suspension air bags. This icon the tag axle suspension air bags. This screen, optional gauges will be part of may have a numeral above the image icon may have a numeral above the 3 the screen functions. Please refer to of the wheel to indicate which pusher image of the wheel to indicate which the navigation system supplement for axle if there are multiple pusher axles pusher axle if there are multiple pusher further details about its functions and on the vehicle. axles on the vehicle. how it works.

(04/13) Y53-1200-1B1 3-43 OPTIONAL GAUGES

Fuel Filter Restriction Air Filter Restriction Pressure Indicator or Gauge CAUTION Continued operation with the Air Filter Restriction Gauge reading 25 in. H2O may cause damage to the engine. In- spect the filter and replace if neces- sary. Holes in the paper element ren- This gauge tells you the condition This gauge indicates the condition of der an air cleaner useless and may 3 of the fuel filter by indicating the the engine air cleaner and is measured cause the Air Filter Restriction Gauge restriction from the fuel filter to the fuel by inches of water (H2O). A clean filter to give a false reading, even if the ele- pump. Check the engine manual for should register 7 in. H2O (may vary ment is clogged. Replace the element proper restriction. Replace the filter with system design) and a filter whose if it is damaged. with an approved filter only. Do not life is over will register approximately substitute the wrong micron element. 25 in. H2O.

NOTE The maximum allowable restriction could vary according to the type or make of engine. Consult the en- gine manufacturers manual or engine dealer for fuel restriction specifica- tions.

3-44 Y53-1200-1B1 (04/13) OPTIONAL GAUGES

Engine, Oil Pressure Engine, Oil Temperature Manifold Pressure Gauge

It is important to maintain oil pressure within acceptable limits. If oil pressure The Engine Oil Temperature gauge Your manifold pressure gauge drops below the minimum psi a red indicates the engine oil temperature. indicates the power your engine is warning light in the gauge will turn on, If the oil temperature exceeds the putting out by showing the amount of the Stop Engine light will come on and maximum limits, a red warning turbo boost. If the pressure indicated 3 an audible alarm tone will sound. light in the gauge will turn on. Do by your manifold pressure gauge goes not exceed maximum engine oil down, there may be something wrong temperature recommended by the with your engine. Have it checked by a engine manufacturer. (See the Engine qualified service person. Operation and Maintenance Manual for details.)

(04/13) Y53-1200-1B1 3-45 OPTIONAL GAUGES

Fuel Pressure Gauge Transmission Temperature Drive Axle Temperature Gauge Gauge (Forward and Rear)

These gauges indicate the temperature of the lubricant in your vehicle’s axle(s). These temperatures will vary with Your vehicle may also have a fuel the kind of load you are carrying and pressure gauge. Your Transmission Temperature the driving conditions you encounter. Gauge indicates the temperature of Maximum axle temperature may vary, 3 WARNING! the oil in your transmission. Watch depending upon the axle and type Do not carry additional fuel containers this gauge to know when your of lubricant. Very high temperatures in your vehicle. Fuel containers, either transmission is overheating. If it is, signal a need to have your axle(s) full or empty, may leak, explode, and have it checked by an authorized lubrication checked. cause or feed a fire, possibly causing service representative. death or personal injury. Do not carry extra fuel containers, even empty ones Maximum transmission temperature are dangerous. may vary, depending upon the transmission and type of lubricant. Check your transmission’s owner’s manual.

Depending on the vehicle configuration, there may be a drive axle temperature gauge for more than just the forward and rear

3-46 Y53-1200-1B1 (04/13) OPTIONAL GAUGES driver. The icon will have an X over Suspension Load Air Tractor Brake Application the representative axle to indicate Pressure, #1, #2 Air Pressure which axle the temperature is being displayed in the gauge.

CAUTION

Driving with very hot temperatures in Suspension Load Air Pressure #1 The Tractor Brake Application Air your rear drive axles can cause se- Pressure gauge indicates the amount rious damage to axle bearings and of air pressure applied to the tractor 3 seals. Have your axle lubrication brakes. checked if you notice a sign of over- heating. Suspension Load Air Pressure #2

The Suspension Load Air Pressure gauge indicates the amount of air pressure in the air suspension air bags.

When the vehicle is equipped with dual leveling valves, the #1 gauge indicates the air pressure in the driver's side air bags. The #2 gauge indicates the air pressure in the passenger's side air bags.

(04/13) Y53-1200-1B1 3-47 OPTIONAL GAUGES

Trailer Brake Application Air Trailer Air Tank Air Pressure Transfer Case Oil Pressure Temperature

The Trailer Air Tank Air Pressure The Trailer Brake Application Air gauge indicates the amount of air The Transfer Case Oil Temperature Pressure gauge indicates the amount pressure in the trailer brake air tank. gauge indicates the temperature of 3 of air pressure applied to the trailer the oil in the transfer case. If the oil brakes during brake foot valve and/or temperature exceeds maximum limits, hand brake control valve applications. a red warning light in the gauge will turn on. Do not exceed maximum oil temperature recommended by the manufacturer. (See the Transfer Case Operation and Maintenance Manual for details.)

3-48 Y53-1200-1B1 (04/13) OPTIONAL GAUGES

Transmission Oil Transmission Retarder Oil Temperature, Auxiliary Temperature

The Transmission Retarder Oil The Auxiliary Transmission Oil Temperature gauge indicates Temperature gauge indicates the the temperature of the oil in the temperature of the oil in the auxiliary transmission retarder. 3 transmission. NOTE NOTE Watch this gauge to know when the Watch this gauge to know when the transmission is overheating. transmission is overheating. Do not exceed maximum oil Do not exceed maximum oil temperature recommended by the temperature recommended by the manufacturer. (See the Transmission manufacturer. (See the Transmission Operation and Maintenance Manual Operation and Maintenance Manual for details.) for details.)

(04/13) Y53-1200-1B1 3-49 SWITCHES

SWITCHES The instrument display will display position and the switch needs to be information regarding what needs to re-engaged. Some of the switches that Dash Switches change in order for the air device to control air functions will not disengage operate as expected. when the vehicle ignition is turned off. This custom vehicle will have a wide If the ignition is turned off, air pressure variety of switch controlled equipment. Some of these switches control air will be maintained in the circuit for However, this particular vehicle may system functions and may require the that control switch. The few switches not have every switch identified in this vehicle’s ignition to be in the ACC that do not require ignition power are section of the operator manual. or ON position for switch to maintain described accordingly after the Dash 3 control via air pressure. If the switch Switch table. Some air device switches on the requires ignition power, it will allow that dash may require that the vehicle air circuit to lose pressure (deactivate) The Dash Switch table provides a either be at a specific speed, park once the ignition is turned off. To complete list of icons that may be brakes set or another device to be activate that function again, the ignition found on the switch. on or off for the air device to operate. needs to be turned to the ACC or ON

Dash Switches

Symbol Name Symbol Color Standard Option Page

1. Axle, Diff-Lock - Dual Amber ● See Axle, Diff-Lock - Dual on page 3-60.

See Axle, Diff-Lock - Forward Rear on page 2. Axle, Diff-Lock - Forward Rear Amber ● 3-60.

3-50 Y53-1200-1B1 (04/13) SWITCHES

Symbol Name Symbol Color Standard Option Page

3. Axle, Diff-Lock - Steer Amber ● See Axle, Diff-Lock - Front on page 3-60.

4. Axle, Diff-Lock - Rear Rear Amber ● See Axle, Diff-Lock - Rear Rear on page 3-60.

5. Axle, Diff-Lock - Single Rear Amber ● See Axle, Diff-Lock - Single Rear on page 3-60. 3

See Axle, Inter-Axle Differential Locked 6. Axle, Inter-Axle Differential Locked (Tandem) Amber ● (Tandem) on page 3-60.

7. Axle, Two Speed Green ● See Axle, Two Speed on page 3-60.

8. Back Up Alarm Mute Amber ● See Back Up Alarm Mute on page 3-60.

See Batteries, Low Voltage Disconnect (LVD) 9. Batteries, Low Voltage Disconnect (LVD) None ● on page 3-60.

(04/13) Y53-1200-1B1 3-51 SWITCHES

Symbol Name Symbol Color Standard Option Page

10. Brakes, ABS Off-Road Amber ● See Brakes, ABS Off-Road on page 3-60.

11. Brakes, Parking Brake Valve Red ● See Brakes, Parking Brake Valve on page 3-60.

3 12. Cab Dimmer Switch None ● See Cab Dimmer Switch on page 3-60.

13. Dump Truck Gate Red ● See Dump Truck Gate on page 3-60.

14. Engine, Brake Level None ● See Engine, Brake Level on page 3-60.

15. Engine, Brake On/Off Green ● See Engine, Brake On/Off on page 3-61.

See Engine, Cruise Control On/Off on page 16. Engine, Cruise Control On/Off Green ● 3-61.

3-52 Y53-1200-1B1 (04/13) SWITCHES

Symbol Name Symbol Color Standard Option Page

See Engine, Cruise Control Set/Resume on 17. Engine, Cruise Control Set/Resume None ● page 3-61.

18. Engine, Ether Start (Optional) None ● See Engine, Ether Start on page 3-61.

19. Engine, Fan Override Green ● See Engine, Fan Override on page 3-61. 3

20. Engine, Heater Green ● See Engine, Heater on page 3-62.

See Engine, Overspeed Air Shutdown on page 21. Engine, Overspeed Air Shutdown (Manual) None ● 3-62.

See Engine, Overspeed Air Shutdown (Test) 22. Engine, Overspeed Air Shutdown (Test) Amber ● on page 3-62.

23. Engine, Remote Throttle Amber ● See Engine, Remote Throttle on page 3-62.

(04/13) Y53-1200-1B1 3-53 SWITCHES

Symbol Name Symbol Color Standard Option Page

See Engine, Under Hood Air Intake on page 24. Engine, Under Hood Air Intake None ● 3-62.

25. Exhaust, Diesel Particulate Filter (DPF) See Exhaust, Diesel Particulate Filter (DPF) None ● Regeneration Regeneration on page 3-62.

3 26. Fifth Wheel Slide Red ● See Fifth Wheel Slide on page 3-62.

27. Fuel Heater Amber ● See Fuel Heater on page 3-63.

28. Generic Air, Accessory Green ● See Generic Air, Accessory on page 3-63.

29. Generic, Spare SPARE Green ● See Generic, Spare on page 3-63.

30. Lights, Auxiliary Green ● See Lights, Auxiliary on page 3-63.

3-54 Y53-1200-1B1 (04/13) SWITCHES

Symbol Name Symbol Color Standard Option Page

31. Lights, Beacon Green ● See Lights, Beacon on page 3-63.

32. Lights, Daytime Running (Override) Green ● See Lights, Daytime Running on page 3-63.

33. Lights, Dome None ● See Lights, Dome on page 3-63. 3

See Lights, Exterior Lights Self Test on page 34. Lights, Lights, Exterior Lights Self Test None ● 3-64.

35. Lights, Flood Amber ● See Lights, Flood on page 3-64.

See Lights, Flood ISO 3732 Spare on page 36. Lights, Flood ISO 3732 Spare Amber ● 3-64.

37. Lights, Fog Green ● See Lights, Fog on page 3-64.

(04/13) Y53-1200-1B1 3-55 SWITCHES

Symbol Name Symbol Color Standard Option Page

38. Lights, Hazard Red ● See Lights, Hazard on page 3-64.

39. Lights, Headlight and Parking Lights None ● See Lights, Headlight on page 3-64.

3 40. Lights, Marker/Clearance None ● See Lights, Marker/Clearance on page 3-65.

See Lights, Marker/Clearance/Cab on page 41. Lights, Marker/Clearance/Cab None ● 3-65.

See Lights, Marker/Clearance/Trailer on page 42. Lights, Marker/Clearance/Trailer None ● 3-65.

43. Lights, Spot Green ● See Lights, Spot on page 3-65.

See Mud and Snow Traction Control on page 44. Mud and Snow Traction Control None ● 3-65.

3-56 Y53-1200-1B1 (04/13) SWITCHES

Symbol Name Symbol Color Standard Option Page

45. Power Take-off (PTO) Amber ● See Power Take-off (PTO) on page 3-65.

See Power Take-off (PTO), Forward on page 46. Power Take-off (PTO), Forward Amber ● 3-66.

47. Power Take-off (PTO), Rear Amber ● See Power Take-off (PTO), Rear on page 3-66. 3

48. Roofdenser Green ● See Roofdenser on page 3-66.

49. Suspension, Axle, Pusher Green ● See Suspension, Axle, Pusher on page 3-66.

50. Suspension, Axle, Tag Green ● See Suspension, Axle, Tag on page 3-66.

51. Suspension, Dump Amber ● See Suspension, Dump on page 3-66.

(04/13) Y53-1200-1B1 3-57 SWITCHES

Symbol Name Symbol Color Standard Option Page

52. Suspension, Lift Amber ● See Suspension, Lift on page 3-66.

53. Suspension, Third Axle Lift Green ● See Suspension, Third Axle Lift on page 3-66.

3 54. Pintle Hook Green ● See Tow Hook on page 3-66.

55. Trailer, Axle (3rd Axle) Lift Green ● See Trailer, Axle (3rd Axle) Lift on page 3-66.

56. Trailer, Axle Lift Forward Green ● See Trailer, Axle Lift Forward on page 3-66.

57. Trailer, Axle Lift Rear Green ● See Trailer, Axle Lift Rear on page 3-66.

58. Trailer, Belly Dump Red ● See Trailer, Belly Dump on page 3-67.

3-58 Y53-1200-1B1 (04/13) SWITCHES

Symbol Name Symbol Color Standard Option Page

59. Trailer, Dump Gate Red ● See Trailer, Dump Gate on page 3-67.

60. Trailer, Hotline Green ● See Trailer, Hotline on page 3-67.

See Trailer, Suspension Air Dump on page 61. Trailer, Suspension Air Dump Amber ● 3 3-67.

See Transmission, Transfer Case on page 62. Transmission, Transfer Case Amber ● 3-67.

See Transmission, Transfer Case 2 Speed on 63. Transmission, Transfer Case 2 Speed Amber ● page 3-67.

64. Winch Clutch Green ● See Winch Clutch on page 3-67.

(04/13) Y53-1200-1B1 3-59 SWITCHES

1. Axle Diff-Lock - Dual Turn switch on to engage Front 7. Axle, Two Speed 10. Brakes, ABS Off-Road and Rear Axle Diff Lock. If equipped, the two speed axle Turn switch on to engage ABS switch allows you to select axle high Off-Road mode. See Anti-Lock 2. Axle Diff-Lock - Forward Rear and low ranges. The low range Braking System on page 4-21. Turn switch on to engage Forward (Off) provides maximum torque for Rear Axle Diff Lock. operating off-highway. The high 11. Brakes, Parking Brake Valve range (On) is a faster ratio for Pull yellow knob to activate parking 3. Axle Diff Lock - Steer highway speeds. This switch does brakes. See Parking Brake Valve not require ignition power to maintain Turn switch on to engage Front on page 4-23. the desired switch setting. 3 Axle Diff Lock. 12. Cab Dimmer Switch 8. Back Up Alarm Mute 4. Axle Diff-Lock Rear Rear This switch is used to alter the Turn switch on to mute Back Turn switch on to engage Rear brightness of the instrument Up Alarm. Rear Axle Diff Lock. panel lights.

5. Axle Diff Lock - Single Rear NOTE NOTE Turn switch on to engage Single Rear Axle Diff Lock. The mute function use is discouraged. The Headlamp Switch is an "ON" or Only use mute when legally required. "OFF" switch. The panel lights are 6. Axle, Inter-Axle Differential on full intensity during the day and go Locked (Tandem) 9. Batteries, Low Voltage Turn switch on to engage Inter-Axle Disconnect (LVD) to Dimmer mode when headlamps are Differential Lock. If your vehicle is equipped with a Low on. Voltage Disconnect (LVD) feature, the LVD module is located inside 13. Dump Truck Gate the driver's side kick panel. Turn switch on to open Dump Truck Gate.

3-60 Y53-1200-1B1 (04/13) SWITCHES

14. Engine, Brake Level 17. Engine, Cruise Control 19. Engine Fan Override In the up position there will be 100% Set/Resume The engine fan switch allows you engine retarding. In the middle The Cruise Control Set/Resume to control the engine fan manually position there will be 60% engine switch allows you to SET the desired or automatically. Please refer to retarding. In the down position there speed or RESUME the desired Engine Fan Control on page 4-12 will be 33% engine retarding. speed after the cruise control function for more information on how to For more information on when has been interrupted. operate this switch. and how to use the engine brake in your vehicle, see the engine brake owner’s manual for additional WARNING! WARNING! engine brake information. Do not operate the cruise control when Do not work on or near the fan with the 3 15. Engine, Brake On/Off operating on road surfaces with poor engine running. Anyone near the en- Turn switch on to activate Engine traction (wet, icy, or snow covered gine fan when it turns on could be se- Brake system. roads) or in heavy traffic. Accelera- riously injured. If it is set at MANUAL, For more information on when tions caused by the normal operation the fan will turn on any time the igni- and how to use the engine brake in your vehicle, see the engine of the cruise control could cause you tion key switch is turned to the ON po- brake owner’s manual for additional to lose control of the vehicle resulting sition. In AUTO, it could engage sud- engine brake information. in an injury accident. denly without warning. Before turning on the ignition or switching from AUTO 16. Engine, Cruise Control On/Off 18. Engine, Ether Start (optional) to MANUAL, be sure no workers are Turn switch on to activate Cruise Momentarily push switch in to near the fan. Control System. activate the Ether Start system.

(04/13) Y53-1200-1B1 3-61 SWITCHES

21. Engine, Overspeed Air 25. Exhaust, Diesel Particulate CAUTION Shutdown (Manual) Filter (DPF) Regeneration Switch The fan or equipment near it could be Turn switch on to engage the Manually controls the diesel Engine Overspeed Air Shutdown particulate filter regeneration process. damaged if the fan turns on suddenly system. A system reset will be Refer to Engine Aftertreatment when you do not expect it. Keep all required before re-starting engine. Controls Operator's Manual for tools and equipment away from the See EOAS system manufacturer's additional information. fan. instruction manual for details. 26. Fifth Wheel Slide 22. Engine, Overspeed Air Turn switch on to “Unlock” Fifth 3 CAUTION Shutdown (Test) Wheel Slide mechanism. Hold down switch and increase The switch is guarded to protect Do not operate the engine fan in the engine RPM to test that Engine you from accidentally activating MANUAL position for extended peri- Overspeed Air Shutdown system or releasing the lock. functions correctly. A system ods of time. The fan hub was de- reset will be required before signed for intermittent operation. Sus- restarting engine. See EOAS NOTE tained operation will shorten the fan system manufacturer's instruction manual for details. Vehicles having an air slide fifth wheel hub’s service life as well as reduce fuel have a fifth wheel slider lock controlled economy. 23. Engine, Remote Throttle by a switch on the instrument panel. Turn switch on to activate Remote By placing the switch in the unlock po- 20. Engine Heater Throttle Control. Turn switch on to activate the sition you can slide the fifth wheel to Engine Heater. 24. Engine, Under Hood Air Intake various positions to adjust weight dis- Operate this switch to control tribution. whether the engine intake is from under the hood or fresh air from the air inlet grille.

3-62 Y53-1200-1B1 (04/13) SWITCHES

32. Lights, Daytime Running WARNING! NOTE Lights (DRL) (with optional Do not move the fifth wheel while the The generic air accessory switch is de- over-ride switch) Three controls (or conditions) tractor-trailer is in motion. Your load signed by the original equipment man- will affect whether the system could shift suddenly, causing you to ufacturer to reset when the ignition is ON or OFF: lose control of the vehicle. Never op- power is turned off. When ignition is • headlight (master) switch erate the vehicle with the switch in the turned off, this circuit will exhaust air • engine cranking UNLOCK position. Always inspect the pressure. • parking brake fifth wheel after you lock the switch to If the headlight switch is turned 3 SPARE 29. Generic, Spare OFF, the DRL system engages be sure the fifth wheel slide lock is en- automatically after the engine starts Turn switch on to power customer gaged. Failure to comply may result and you release the parking brake. installed accessory. in death, personal injury, equipment or If the headlight switch is ON, the property damage. DRL system is overridden, and 30. Lights, Auxiliary headlights operate normally. Also, Turn switch on for Auxiliary Lights. during engine cranking the DRL 27. Fuel Heater is temporarily turned off. Turn switch on to activate Fuel Heater. 31. Lights, Beacon Turn switch on for Beacon Light(s). 28. Generic, Air, Accessory WARNING! Provides accessory air to the Do not use daytime running lights end of frame connection when switch is turned on. (DRL) during periods of darkness or reduced visibility. Do not use DRL as a substitute for headlights or other lights during operations that require lighting of your vehicle. Failure to comply may result in death, personal injury, equip- ment or property damage.

(04/13) Y53-1200-1B1 3-63 SWITCHES

33. Lights, Dome WARNING! Turn switch on for Cab Dome Lights. NOTE Across the U.S.A. and Canada, Use your Hazard Warning Light Sys- 34. Lights, Exterior Lights Self Test State/Provincial requirements vary as tem any time you have to stop off the This switch will engage a program to when high beams and fog lights can road or on the side of the road, day which will illuminate exterior light for the operator to verify functionality. and cannot be used together. Some or night. A hard-to-see vehicle can re- Please refer to Exterior Lights Self states allow only four lights to be used sult in an injury accident. Another ve- Test on page 3-77 for more detail together, while some allow more. How hicle could run into you if you do not on how to use the program. 3 your lights are arranged will affect set your flashers and follow the place- 35. Lights, Flood whether you can operate headlights ment of emergency signals per FM- Turn switch on for cab mounted and fog lights concurrently—always CSR 392.22. Flood Lights. comply with the state or provincial re- quirements where you are driving. 39. Lights, Headlight and 36. Lights, Flood ISO 3732 Spare Parking Lights Turn switch on for trailer mounted Turn switch on for headlights. When 38. Lights, Hazard Flood Lights. the Headlights are ON, side, and With the switch in the ON position, tail lights are also on. This switch the emergency flasher makes all four 37. Lights, Fog also controls the park lights. turn signals (front and rear) flash Turn switch on for Fog Lights. simultaneously. The flasher works independently of the ignition switch. You should always use the flasher if the vehicle is disabled or parked under emergency conditions.

3-64 Y53-1200-1B1 (04/13) SWITCHES

41. Lights, Marker/Clearance/Cab 45. Power Take-off (PTO) CAUTION Turn switch on to control Cab Turn switch on to engage PTO. If you have confirmed there is a prob- Marker/Clearance lights separately Your vehicle may be equipped with from the trailer. lem in the low beam wiring circuit, pro- a dash mounted switch that controls PTO engagement/disengagement. ceed with caution to the next available 42. Lights, When the operator activates the exit/turnoff and safely pull your vehi- Marker/Clearance/Trailer switch for the PTO, the status cle completely off the road and call for Turn switch on to control indicator lamp (located on the switch) will immediately illuminate assistance. Driving your vehicle with Trailer Marker/Clearance lights separately from the vehicle even though PTO engagement the headlamps on high beam (at re- marker/clearance lights. may not have occurred. 3 duced intensity) for a prolonged period If the PTO is engaged and the could lead to an injury accident. Con- 43. Lights, Spot operator turns the switch OFF, the Turn switch on for Spot Light. PTO status indicator lamp (located tact your nearest dealer to have the on the switch) will go out immediately problem corrected as soon as possi- even though PTO disengagement ble. 44. Mud and Snow Traction Control may not have occurred. Momentarily push switch in to engage Traction Control (TC). 40. Lights, Marker/Clearance NOTE Turn switch on to control Cab and Vehicle Marker/Clearance lights. Actual PTO engagement/ disengage- ment may be delayed momentarily since it is controlled by the air system NOTE and mechanical movement. An interrupt switch for the trailer marker lights is mounted on the end of the turn signal lever.

(04/13) Y53-1200-1B1 3-65 SWITCHES

51. Suspension, Dump 52. Suspension, Lift CAUTION Turn switch on to deflate Suspension Turn switch on to over-inflate Increasing engine RPM before the Air Bags. The switch is guarded Suspension Air Bags. Turn switch off to protect you from accidentally for normal suspension height. PTO is actually engaged could pre- deflating the suspension. This switch vent the PTO from engaging and/or does not require ignition power to 53. Suspension, Third Axle Lift cause PTO damage. maintain the desired switch setting. Turn switch on to raise Third Axle. This switch does not require 46. Power Take-off (PTO), Forward WARNING! ignition power to maintain the 3 Turn switch on to engage desired switch setting. Forward PTO. Do not operate the Air Suspension De- flate Switch (Dump Valve) while driv- 54. Pintle Hook 47. Power Take-off (PTO), Rear Turn switch on to remove the slack ing. Sudden deflation while your vehi- from the Tow Hook. Turn switch on to engage Rear PTO. cle is moving can affect handling and control and could lead to an accident. 48. Roofdenser 55. Trailer, Axle (3rd Axle) Lift Turn switch on for roof mounted Use this switch only when your vehicle Turn switch on to lift 3rd Trailer condenser fan. is not moving. Axle. This switch does not require ignition power to maintain the desired switch setting. 49. Suspension, Axle, Pusher Turn switch on to lower Single or CAUTION 56. Trailer, Axle Lift Forward Forward Pusher Axle. This switch Operating a vehicle with air suspen- does not require ignition power to Turn switch on to lift Forward maintain the desired switch setting. sion bags either overinflated or under- Trailer Axle. This switch does not inflated may cause damage to drive- require ignition power to maintain the desired switch setting. 50. Suspension, Axle, Tag line components. If a vehicle must Turn switch on to lower Tag Axle. This be operated under such conditions, do switch does not require ignition power to maintain the desired switch setting. not exceed 5 mph (8 km/h).

3-66 Y53-1200-1B1 (04/13) SWITCHES

Steering Column Controls 57. Trailer, Axle Lift Rear 63. Transmission, Transfer Introduction Turn switch on to lift Rear Trailer Case 2 Speed Axle. This switch does not require Turn switch on to shift the 2 ignition power to maintain the Speed Transfer Case. desired switch setting. 64. Winch Clutch 58. Trailer, Belly Dump Turn switch on to engage Turn switch on to open Trailer Winch Clutch. Belly Dump.

59. Trailer, Dump Gate 3 Turn switch on to open Trailer Dump Gate. 1. Tilt Telescoping Lever 60. Trailer Hotline Turn switch on to supply electrical 2. Turn Signal Lever power to trailer accessories. 3. Trailer Hand Brake 61. Trailer, Suspension Air Dump Turn switch on to deflate Trailer Air Suspension. This switch does not NOTE require ignition power to maintain The ignition key must be turned to ON the desired switch setting. for the signal/switch to operate. 62. Transmission, Transfer Case Turn switch on to shift the The turn signal lever is mounted on the Transfer Case. left side of the steering column. The lever controls several functions: turn

(04/13) Y53-1200-1B1 3-67 SWITCHES

signal, ID Clearance lights, high beam 1. Tilt/Telescoping Steering Column and windshield wiper control. To adjust the steering wheel, PUSH Depending on your vehicle’s and HOLD the lever down fully. Push configuration, you may have either or pull the wheel to the desired height a Tilt/Telescoping or a fixed steering and angle, then PUSH the lever back column. into the locked position. • The tilt feature allows forward and rearward movement of the wheel. 3 • The telescoping feature allows you to move the wheel up and down.

To activate these features, locate the Tilt/Telescoping lever.

WARNING! Make all adjustments to the steer- ing mechanism while the vehicle is stopped. Adjusting the Tilt-Telescop- Steering Column Locked ing Steering Wheel while the vehicle is in motion could cause loss of control. You wouldn’t be able to steer properly and could have an accident resulting in death or personal injury.

3-68 Y53-1200-1B1 (04/13) SWITCHES

2. Turn Signal/High Beam Switch • To signal a left turn, pull the lever back (counterclockwise). NOTE The ignition key must be turned to ON • Each time the turn indicator is for the signal/switch to operate. activated the audible warning emits a short beep. The lever-action turn signal/high beam NOTE switch is located on the left side of the steering column.Each time a turn If the vehicle turn signals and turn sig- 3 indicator is activated the buzzer emits nal indicators in the dash gauge clus- a short beep. ter ever begin flashing at an acceler- ated rate (115 cycles per minute) when Turn Signals the turn signal lever is in the OFF (cen- Steering Column Unlocked ter) position, or when a Right/Left turn has been selected, the problem may be related to a failed turn signal switch or turn signal module. In either case, the problem is not a failed bulb. Con- tact your nearest authorized dealer to have the problem corrected as soon as possible.

Turn Signal • To signal a right turn, push the lever forward (clockwise).

(04/13) Y53-1200-1B1 3-69 SWITCHES

• To return to previous beam: pull WARNING! the lever towards the steering After you complete a turn, shut the wheel again. system off by returning the lever to the “OFF” (center) position. Failure • The high beams can be to shut off a turn signal could confuse momentarily flashed with or other drivers and result in an injury ac- without the headlights being on. cident. An indicator light in the instru- To flash the high beams, gently 3 ment panel will flash until the turn sig- push the headlight lever away from nal is turned off. the steering wheel to momentarily turn on the lights. High Beam NOTE NOTE NOTE Continued pressing of the high beam flash will not keep the high beams on. The “flash to pass” functionality of the The headlights must be ON for the headlight switch is not available for high beam switch to operate. vehicles manufactured with High In- tensity Discharge (HID) headlamps. • To switch your headlights to lower Please check with local regulations or higher beam, gently pull the turn regarding restrictions on using high signal lever, toward the steering beam flashing. wheel, until you hear the switch click and the beam changes. The blue indicator light in the instrument panel will be ON when the high beam is being used.

3-70 Y53-1200-1B1 (04/13) SWITCHES

Windshield Wipers/Washer NOTE Your vehicle is equipped with a The ignition key must be turned to ON two-speed, intermittent windshield or ACC for the wiper/washer switches wiper system. The windshield wiper to operate. system is integrated with the exterior lights so that the low beam headlights will turn on when the windshield wipers Flash to pass turn on. 3 To override this function, turn the headlights on and then off again and the low beams will turn Wiper/Washer off. Permanently overriding this functionality is attainable via the The first position after OFF is the Settings Menu in the instrument cluster ID and Clearance Lights Flash intermittent #1 cycle. The next display. Go to Settings - > Wiper positions are intermittent #2, #3, and Interlock and turn this value to OFF. #4. The last two positions are wiper low speed and wiper high speed. A seven-position rotary wiper switch (located on the turn signal lever) To wash the windshield: operates the windshield wipers and washer. Rotate the end of the turn Push the rotary wash/wipe knob in signal lever to change the wiper mode. (towards steering column), hold for more than 0.8 seconds and then release. hold the knob in to extend

(04/13) Y53-1200-1B1 3-71 SWITCHES

the washing cycle. after the lever 3. Trailer Brake Hand Valve is released, the wipers will shut off CAUTION This hand valve, mounted on the automatically or resume the wiper’s Do not use antifreeze or engine steering wheel column, provides air setting speed. coolant in the windshield washer pressure to apply the trailer brakes reservoir - damage to seals and other To activate the wipers for one swipe only. It operates independently of components will result. without activating the washer (“mist” the foot treadle valve. See Using the function), push the turn signal lever Brake System on page 4-21, for more in (towards the steering column) and CAUTION instructions on proper use of the Trailer 3 release in less than 0.5 seconds. The If the electric pump is operated for a Brake Hand Valve. wipers will perform a single swipe and long period (more than 15 seconds) then resume the wiper’s setting speed. with a dry reservoir, the pump motor may be damaged. WARNING! Clean blades regularly with a damp Check the windshield washing fluid cloth to remove road film and wax level daily. If necessary, fill to top. build-up. Do not drive with worn or dirty wiper blades. They can reduce Clean all inside and outside windows visibility, making driving hazardous regularly. Use an alcohol-based which may lead to an injury accident cleaning solution and wipe dry with resulting in death or personal injury. either a lint-free or a chamois cloth. Avoid running the wiper blades over a dry windshield to prevent scratching the glass. Spray on washer fluid first. A scratched windshield will reduce visibility.

3-72 Y53-1200-1B1 (04/13) SWITCHES

Steering Wheel Controls System Description (Optional) The steering wheel contains controls CAUTION for commonly used functions so that the operator does not have to take Under no circumstances should you their hands off of the steering wheel to attempt to service the steering wheel, operate. clockspring, or any of the electrical wiring in the multiplex system, or any steering components (steering col- 3 umn, steering driveline or steering gear). Tampering with these com- ponents may result in an inoperable multiplex system. 1. Left Switch Pod This vehicle may be equipped with an 2. Horn optional steering wheel with audio and 3. Right Switch Pod cruise control button mounted on the spokes of the steering wheel.

(04/13) Y53-1200-1B1 3-73 SWITCHES

Operating the System

Horn - Depressing the bottom center bar activates the electric horn.

Cruise Control - Vehicles with steering wheel controls will have cruise control options on the right hand of the wheel instead of the switches on the 3 dashboard. These optional switches for cruise control include a third switch to allow the operator to accelerate or coast while maintaining cruise control operation. For complete operating Left Switch Pod instructions, see Cruise Control on page 4-35. 1. Audio Volume +/- Right Switch Pod 2. Audio Seek +/- 1. Cruise Control 3. Audio Mute/Mode On/Off/Cancel 2. Cruise Control Set/Resume 3. Cruise Control Accelerate/Coast

3-74 Y53-1200-1B1 (04/13) SWITCHES

Door Mounted Controls WARNING! Introduction Do not operate the cruise control when If your vehicle is equipped with power operating on road surfaces with poor mirrors, the mirror controls will be traction (wet, icy, or snow covered located on the driver side door pad. roads) or in heavy traffic. Accelera- Mirrors can be adjusted in 4 directions. tions caused by the normal operation of the cruise control could cause you to lose control of the vehicle resulting 3 in an injury accident.

Horn

To use the electric horn, press the button in the center of the steering wheel, which is the standard location 1. Mirror Heat Switch for electric horns. Your vehicle may be 2. Power Mirror Switch equipped with air horns. To operate, 3. Mirror Selector Switch pull on the lanyard extending from the 4. Power Door Lock Switch overhead header panel. 5. Power Window Switch

(04/13) Y53-1200-1B1 3-75 SWITCHES

1. Mirror Heat Switch 2. Power Mirror Switch WARNING! Your vehicle may be equipped with If your vehicle is equipped with power Adjust all mirrors before driving. Ad- optional heated mirrors. Mirror heat mirrors, the directional controls for justing the mirrors while driving can is controlled by the mirror heat switch both mirrors are located near the top of cause you to take your eyes off the button, which is part of the mirror the driver side door trim pad. road, which could result in an accident. switch module located on the driver Failure to do so could lead to serious 1. Move the mirror selector switch side door pad. injury or equipment damage. (3) to the right or left from the neutral center position to select 3 NOTE To provide good visibility, adjust the the desired mirror for adjustment. The Mirror Heat switch also controls mirror so the side of your vehicle 2. Depress the mirror directional appears in the inboard part of the the optional hood mounted mirror heat. control pad (2) in one of its four mirror. arrow directions to adjust the mirror in/out or up/down. WARNING! Convex mirrors can distort images NOTE and make objects appear smaller and After mirror adjustments have been farther away than they really are. You completed, return the mirror selector could have an accident if you are too switch back (3) to the center (neutral) close to another vehicle or other ob- position to prevent unintentional ad- ject. Keep plenty of space between justments to the mirrors. your vehicle and others when you turn or change lanes. Remember that other objects are closer than they may appear.

3-76 Y53-1200-1B1 (04/13) SWITCHES

4. Power Door Lock Switch 5. Power Window Switch Exterior Lights Self Test

Power door lock rocker switches are Power window rocker switches are To start the Exterior Light Self-Test located on the door pads. To lock or located on the door pads. Depress (ELST) feature: unlock both cab doors as well as a the switch to open the window or pull 1. Park the vehicle and set the sleeper door, depress any door lock up on the switch to close the window. parking brakes. switch at the end that displays a closed Release the switch to stop window or open padlock symbol, respectively, movement. The drivers side window 2. Insert the key into the ignition, start on the switch face. has an express down feature. Pushing the engine and allow the vehicle on the switch all the way down until the to run through its own Power On 3 switch bumps will activate the express Self Test. down feature. Release the button and 3. Press the momentary switch on the window will continue to open until it the dash to start the ELST. is completely open. This feature allows the operator to verify and inspect exterior lighting operation typically performed during a pre-trip inspection. When the feature is engaged, via a switch on the dash, it will illuminate the: • Park lights • Side marker lights • Hazard/turn signals

(04/13) Y53-1200-1B1 3-77 SWITCHES

• Lo beam headlamps • First set of fog/driving lights

The test will turn those lights off and then illuminate the: • Park lights 3 • Side marker lights • Hi beam headlamps • Stop/Brake lights

After turning these lights off, the system will resume testing the first set of lights. The light test will eventually stop on its own. The operator may interrupt the test by turning the vehicle off or pressing the switch a second time while the test is running. The operator can verify the light functionality by visibly watching the light from outside the vehicle during the test or can read the instrument cluster for any faults displayed that are lighting related.

3-78 Y53-1200-1B1 (04/13) HEATING AND AIR CONDITIONING HEATING AND AIR CONDITIONING

Cab Controls

3

1. Fan Control Dial 4. MAX Defrost Button 7. Temperature Sensor 2. AUTO Mode Button 5. Air Distribution Dial 8. Air Conditioner Button 3. Temperature Control Dial 6. Sleeper Override Button (for vehicles with a 9. Outside Air / Recirculation Air Button sleeper)

(04/13) Y53-1200-1B1 3-79 HEATING AND AIR CONDITIONING

Introduction WARNING! WARNING! Your vehicles heating and air Do not drive with visibility reduced Exhaust fumes from the engine con- conditioning system operates in three by fog, condensation, or frost on the tain carbon monoxide, a colorless and distinct modes; manual, automatic, windshield. Your view may be ob- odorless gas. Do not breathe the and maximum defrost. Each mode scured, which may result in death, engine exhaust gas. A poorly main- provides the driver with the greatest personal injury, equipment or prop- tained, damaged or corroded exhaust level of comfort and convenience while erty damage. For clear visibility and system can allow carbon monoxide to maintaining the flexibility of traditional safe driving it is extremely important enter the cab. Entry of carbon monox- 3 systems. for you to follow the instructions per- ide into the cab is also possible from The recommended mode for all taining to the function and use of the other vehicles nearby. Failure to prop- conditions that do not require ventilation/heating and defogging/de- erly maintain your vehicle could cause windshield defrosting is the automatic frosting system. If in doubt, consult carbon monoxide to enter the cab, mode on page 3-83. This mode is your dealer. Maximum heating output resulting in death or personal injury. capable of maintaining cab comfort and fast defrosting can be obtained under various driving conditions only after the engine has reached op- without driver interaction. erating temperature.

The cab heater and A/C controls are located together in the center of the dash just to the right of the steering column. The sleeper heater and A/C controls are located in the sleeper cabinet.

3-80 Y53-1200-1B1 (04/13) HEATING AND AIR CONDITIONING

WARNING! NOTE CAUTION Never idle your vehicle for prolonged Keep the engine exhaust system and Do not stay in the vehicle with the en- periods of time if you sense that ex- the vehicles cab ventilation system gine running or idling for more than 10 haust fumes are entering the cab. In- properly maintained. It is recom- minutes with the vehicle's Heater and vestigate the cause of the fumes and mended that the vehicles exhaust A/C ventilation system in RECIRC or correct it as soon as possible. If the ve- system and cab be inspected: at LOW FAN SPEED. Even with the hicle must be driven under these con- ventilation system on, running the en- • By a competent technician every ditions, drive only with the windows gine while parked or stopped for pro- 15,000 miles, 3 open. Failure to repair the source of longed periods of time is not recom- the exhaust fumes may result in death, • Whenever a change is noticed in mended. personal injury, equipment or property the sound of the exhaust system, damage. • Whenever the exhaust system, NOTE underbody, or cab is damaged. When idling for short periods of time: • Set the heating or cooling system NOTE to Heat or A/C To allow for proper operation of the ve- • Set the fan to Medium or High hicle ventilation system, keep the in- speed let grille at the base of the windshield clear of snow, ice, leaves and other ob- • Set the controls to FRESH AIR structions at all times.

(04/13) Y53-1200-1B1 3-81 HEATING AND AIR CONDITIONING

Manual Control Mode NOTE For vehicles with a sleeper, the The manual mode is the default mode cab control can be used to If you are required to idle your vehi- when the heating and air conditioning activate/deactivate the sleeper cle for long periods of time, install an system is turned on. The fan speed, HVAC using the button inside the auxiliary heater or automatic idle con- air temperature, and air outlets mode dial. trol. These auxiliary devices can re- are selected using the dials on the duce fuel consumption and save you controller. The temperature of the air from the money. vents will fluctuate as the vehicle 3 Adjusting the settings: works to achieve the chosen cab NOTE temperature. Note that in manual Step 1: To adjust the fan speed, mode the system does not engage If you are parked next to idling vehi- turn the fan control dial clockwise to the A/C compressor automatically. To cles, move your vehicle or do not stay increase speed or counterclockwise engage the air conditioning, press the in your vehicle for prolonged periods of to decrease speed. Setting the fan button inside the temperature dial. To time. dial to “O” turns the HVAC system off. engage recirculation of cab air, press Step 2: To adjust the temperature the button inside the fan speed dial. setting, turn the temperature control dial to the desired temperature. The system automatically adjusts the outlet air temperature to achieve the desired cab temperature. Step 3: To adjust the air distribution, turn the air distribution dial to the desired position as indicated by the graphics.

3-82 Y53-1200-1B1 (04/13) HEATING AND AIR CONDITIONING

Automatic Control Mode is located at the base of the windshield Using the automatic mode: on the driver’s side of the instrument Your vehicle’s air conditioning system panel. Do not block this sensor. is equipped with an automatic button Step 1: Turn on HVAC by rotating that provides complete cab climate fan speed control clockwise. control without driver interaction. When Step 2: To engage automatic selected, the system will manipulate mode, press the AUTO button. the air distribution, air temperature, fan Step 3: To adjust cab temperature, speed, A/C compressor, and cab air rotate the temperature dial to the recirculation to achieve the comfort desired temperature. The system 3 level selected on the temperature dial. automatically adjusts to achieve the The button that enables automatic desired cab temperature. mode is labeled AUTO. The system The system will achieve the comfort will remain in automatic mode until the level associated with the selected driver adjusts the dials on the control. temperature on the temperature dial. Therefore, depending on the specific environmental conditions, the air temperature can be slightly higher or 1 Sunlight Sensor Adjust the temperature knob and the lower than the set point. This is a system will respond to obtain the normal function of the AUTO mode and Partial Automatic selected comfort level as quickly as is not to mistaken for a malfunctioning possible. system. During AUTO mode the operator may override any setting and operate in The AUTO function uses a sun light a partial automatic mode. This can sensor to measure the amount of be done via the dials and/or buttons sunlight entering the cab. This sensor

(04/13) Y53-1200-1B1 3-83 HEATING AND AIR CONDITIONING

on the HVAC control. In the partial without the use of the A/C compressor. MAX Defrost Mode automatic mode, the AUTO button The operator may select economy indicator will cease to be illuminated. by initiating AUTO mode and then The heating and air conditioning Instead, the indicator of the adjusted pressing the A/C button to disengage system provides for one touch setting will illuminate. the compressor. The indicators for A/C windshield defrosting. Certain driving compressor and AUTO mode do not conditions will cause fog or ice to form For example, if the driver adjusts the illuminate while operating in economy on the windshield. By pressing the fan dial while in AUTO mode, the mode. MAX defrost button, the HVAC system fan dial indicator will illuminate and will automatically adjust the blower 3 fan speed will adjust to the setting of speed, air temperature, and air outlet the dial. However, the temperature distribution to maximize clearing of the and air outlet settings will continue to windshield. The system will remain in function automatically. Similarly, if user this mode until the driver presses the adjusts the air distribution setting while button again or adjusts the dials. in AUTO mode, the air distribution dial indicator will illuminate and the distribution will adjust to the setting of the dial. The fan and temperature settings will continue to function automatically. Note that the air temperature in MAX defrost mode will be set to the warmest Economy Function temperature setting. This setting helps to clear the windshield of ice and fog An economy function is also available more quickly. Outside air mode and in partial automatic mode. In this mode A/C compressor are also active to the system will operate in AUTO mode maximize performance.

3-84 Y53-1200-1B1 (04/13) HEATING AND AIR CONDITIONING

Buttons and Dials Air Distribution Dial Fan Speed Control Dial *Defrost Vents The mode of air distribution inside the The fan speed is adjusted by rotating cab is set using the air distribution *Automatically engages outside air and A/C the dial clockwise to increase speed or dial. Five icons on the dial indicate compressor. counterclockwise to decrease speed. the primary mode options. The driver Setting the fan dial to “O” turns the may also select a secondary mode in Power to the sleeper HVAC unit can HVAC system off. between the primary modes indicated be toggled using the button inside the by points on the dial. Airflow is air distribution dial. When activated, provided to the side windows in all the indicator on the button illuminates. 3 Fan Speed Adjustment modes. The sleeper HVAC unit will function to the settings of the sleeper control.

Panel Vents Sleeper Override Button (for The source of air entering the cab vehicles with a sleeper) can be set to either outside air or recirculation air using the button inside Panel and Floor Vents the fan speed control dial. Recirculated air is automatically selected in defrost modes. Floor Vents

Outside Air/Recirculation Air Button Floor and *Defrost Vents

(04/13) Y53-1200-1B1 3-85 HEATING AND AIR CONDITIONING

Temperature Control Dial Operating Tips Defrosting and Defogging the The cab temperature is set using the Air Conditioner Button Windshield temperature control dial. The operating range is 60°F (16°C) and 84°F (28°C). The cab windshield and side windows Adjustments of 2° increments. NOTE can be cleared of ice and fog in two ways. The first is to use the MAX Fan control dial must also be in the defrost mode (See MAX defrost Temperature Control Set Point ON position to engage the A/C com- section). The second is to manually 3 pressor. A/C engages automatically in adjust the air distribution dial to the AUTO, defrost and floor/defrost. The button inside the temperature defrost position. control dial engages the A/C compressor. When activated the indicator on the button will illuminate. During AUTO mode, the A/C button indicator will remain illuminated at all times even though the compressor may be cycling.

3-86 Y53-1200-1B1 (04/13) HEATING AND AIR CONDITIONING

Manual Windshield dial to maintain a clear windshield while CAUTION Defrosting/Defogging providing heat to the floor. This setting During extreme cold weather, do not may be helpful in conditions where the blow hot defroster air onto cold wind- The manual defrost/defogging mode windshield re-fogs. To increase the shields. This could crack the glass. differs from the MAX defrost mode effectiveness of the defroster, engage Turn the Air Flow Control Dial to by allowing the driver to select an air the A/C compressor. Defrost and adjust the fan speed ac- temperature other than full heat. This cordingly while the engine warms. If allows the driver to maintain a constant cab temperature while defrosting the engine is already warm, move the 3 Temperature Control Dial to cool, then the windshield. Note however that gradually increase the temperature performance may be reduced. when you see that the windshield is Step 1: Adjust the fan speed to high by starting to warm up. Failure to comply rotating the fan control dial clockwise. may result in equipment damage. Step 2: Set the air distribution dial to the defrost mode setting. This automatically engages the outside air and A/C compressor. Step 3: Adjust the temperature dial to add heat as needed. For maximum performance, adjust the temperature to maximum heat by rotating the temperature dial clockwise.

The driver may also use the floor/defrost setting on the air control

(04/13) Y53-1200-1B1 3-87 HEATING AND AIR CONDITIONING

For Maximum Cooling For Maximum Heating Air Dehumidification

Step 1: Adjust the fan speed to high by Step 1: Adjust the fan speed to high by The HVAC system can be used to rotating the fan control dial clockwise. rotating the fan control dial clockwise. reduce the humidity level of the cab Step 2: Set the air distribution Step 2: Set the air distribution and clear fog from the windshield. dial to the panel setting. dial to the floor setting. Step 3: Adjust the air temperature Step 3: Adjust the air temperature Step 1: Adjust fan speed to to maximum cool by rotating the to maximum heat by rotating the the desired airflow setting. temperature dial counterclockwise. temperature dial clockwise. Step 2: Engage the A/C compressor 3 Step 4: Engage the A/C compressor by pressing the air conditioner button. by pressing the air conditioner button. NOTE Step 3: Set the air source to outside air mode by pressing the outside Step 5: Set the air source to The engine must be at operating tem- air / recirculation air button. The recirculation mode by pressing the perature for maximum heating. If op- button indicator light should NOT be outside air / recirculation air button. erating in AUTO mode, heating airflow illuminated. The button indicator light should be is not allowed until the engine warms illuminated. sufficiently to provide required coolant NOTE temperatures. That the A/C compressor may not en- gage when the outside temperature is below 34ºF (1ºC).

3-88 Y53-1200-1B1 (04/13) HEATING AND AIR CONDITIONING

Cab Air Distribution Outside Air / Recirculation Air Sleeper Heater - A/C Controls (optional) Equal distribution of air is important Selecting air recirculation mode in maintaining a constant cab interior completely isolates the cab interior Sleeper Controls temperature. For best performance, all from the outside air. This mode is vents should remain open to allow the helpful in preventing dust, pollen, AUTO mode to function properly. and odors from entering the cab. Additionally, recirculation mode can To maintain the selected cab reduce the amount of time needed temperature the AUTO mode may to cool down the vehicle while in 3 provide an air temperature from the maximum cool down. Note that the vents that differs from the temperature mode may increase fogging on the set point. To ensure proper operation, windshield. A coarse air filter is 1. Fan Control Dial it is recommended that the driver provided for recirculation air and is 2. Temperature Control Dial 3. Air Conditioner Button redirects the air instead of adjusting located under the IP. the temperature set point or closing the vent. The system may have The outside air mode provides for Unlike the cabin air temperature difficulties in obtaining the desired 100% outside air into the cab. This controls, the sleeper temperature cabin temperature if the temperature mode is helpful with windshield control will alter the air temperature setting is repeatedly changed. defogging. A pleated air filter located based on the knob setting. The under hood provides filtration for dust, temperature control is not keyed pollen, and debris. If equipped, your to specific temperatures. Turning vehicle may also provide for ember counterclockwise means cooler than filtration or fine particulate filtration. it is now. Clockwise means warmer than it is now. Once the desired

(04/13) Y53-1200-1B1 3-89 HEATING AND AIR CONDITIONING

temperature is reached, the system will maintain it automatically. NOTE The sensor is located on the sleeper A separate switch on the dash HVAC heater - A/C control panel and mea- unit will send power to the “bunk” or sures the sleeper air temperature at sleeper control unit The button on the the panel. There will be a time de- cab HVAC unit must be pressed and lay between temperature control ad- in the on mode to use the sleeper justment and sleeper air temperature controls. 3 change. Also, be careful of any heat source, which could affect the air tem- The sleeper control unit has three perature by the sensor. Avoid hanging controls: items (e.g. shirt, jacket, etc.) which 1. Air Speed Control could block the air flow to the sensor. 2. Air Conditioner Compressor On/Off 3. Air Temperature Control

3-90 Y53-1200-1B1 (04/13) ACCESSORIES ACCESSORIES

Sleeper Alarm Clock

3

1. Alarm - press to turn on the 5. Increase value of setting time/date and or alarm alarm 6. Decrease value of setting setting 2. Snooze - press to snooze 7. Select - press to choose the 9. Active alarm icon - alarm the alarm bell setting being changed while is activated when this icon 3. Dimmer/brighter - press to adjusting the either the time appears make display brighter or the alarm 4. Dimmer/darker - press to 8. Time and Alarm value make display less bright setting - press to change

(04/13) Y53-1200-1B1 3-91 ACCESSORIES

Setting System Time Setting System Alarm d. Hours 1. Press the MODE button twice until NOTE e. Minutes the screen displays the AL icon. The year “2010” will display when set- 5. To exit and save your settings, 2. Use the UP and DOWN buttons to ting the clock for the first time or if bat- press the MODE button once you adjust the setting. tery power had been lost. have set the minutes. 3. Press the SEL button to adjust 1. Press the MODE button until the the next setting and use the UP 3 screen begins flashing. and DOWN buttons to change the 2. Use the UP and DOWN buttons to setting. adjust the value. 4. Repeat this for all areas. The 3. Press the SEL button to adjust alarm clock will scroll in the the next setting and use the UP following order each time you and DOWN buttons to change the press the SEL button. value. a. Hours 4. Repeat this for all settings. The b. Minutes alarm clock will scroll in the following order each time you 5. To exit and save your settings, press the SEL button. press the MODE button once you have set the minutes. a. Year b. Month c. Day

3-92 Y53-1200-1B1 (04/13) ACCESSORIES

Turning the Alarm On/Off Snooze Operation Dim Control Operation

Press the ALM button to turn the alarm When the alarm is ringing press the Press the DIM+ or DIM- buttons (3, 4) on and off. The icon (9) will illuminate SNZ button (2) to silence the alarm for to change the brightness of the display. when the alarm is active. 9 minutes. The small bell icon (9) will flash until the alarm is shut off. The When time reaches the set time snooze button can be used as many the alarm will ring. If the snooze times as desired. button is not pressed, the alarm will continue ringing for 15 minutes then 3 will automatically stop. Pressing any other button except SNZ (2) will turn the alarm off.

(04/13) Y53-1200-1B1 3-93 ACCESSORIES

Radio (Option) Cigarette Lighter and appliances, such as a hand spotlight Ashtray (Option) or small vacuum cleaner. As an option, your vehicle has either an AM/FM Stereo Receiver, which may NOTE WARNING! or may not have a CD, or may have Do not place paper or other com- the stereo system integrated with your The cigarette lighter will operate with bustible substances in an ashtray, it Navigation and telematics unit. the ignition key in either the OFF, ACC (accessory), or ON position. could cause a fire. Keep all burnable Other radio options include a bluetooth materials, besides smoking materials, out of the ashtray. Failure to comply 3 or satellite receiver. This vehicle comes standard with two may result in death, personal injury, cupholders and power ports located equipment or property damage. For instructions on how to operate your in the center of the dashboard. This particular radio, see the supplemental vehicle may have the optional ashtray operating manual for those units. insert (for the cupholder) and the WARNING! optional cigarette lighter in a power Do not exceed the voltage/amperage port. capacity of the cigarette lighter. It could result in a fire. Follow all warn- To operate, push in on the knob end ings and instructions in the operator's of the lighter. After a few moments, manual for the appliance you are us- the lighter will automatically pop out, ing. Failure to comply may result in glowing hot and ready to use. After death, personal injury, equipment or use, insert the lighter back into the property damage. socket without pushing all the way in.

The socket of the cigarette lighter may be used to operate 12 volt, 15 ampere

3-94 Y53-1200-1B1 (04/13) ACCESSORIES

Cab Storage Appliances Glove Box You can choose from a variety of other interior storage options to store your If your vehicle is equipped with a A glove box is provided to store personal supplies or small tools: television, or other appliance, be sure important documents, the vehicle they are compatible with your vehicle's literature set (including this Operator's - center console electrical system. Secure them in the Manual) and other related materials. cab so they cannot come loose in a - map pocket on the door sudden stop. WARNING! - overhead storage compartments 3 Do not drive with the glove box open, WARNING! it can be dangerous. In an accident WARNING! In a sudden stop or collision a heavy or sudden stop, you or a passenger object in your cab could strike you or could be thrown against the cover and Do not carry loose objects in your cab, anyone with you. You could be injured be injured. To reduce the risk of per- it can be dangerous. In a sudden or even killed. Secure any appliance sonal injury during an accident or sud- stop, or even going over a bump in the (such as a radio, or TV) you add to den stop, keep the glove box closed road, they could fly through the air and your sleeper or cab. when the vehicle is in motion. strike you or a passenger. You could be injured or even killed. Secure all loose objects in the cab before moving the vehicle. Carry any heavy objects such as luggage in the exterior storage compartment and close it securely.

(04/13) Y53-1200-1B1 3-95 ACCESSORIES

Ignition Key Switch • brake lights ON: In the ON position all circuits are The ignition key switch (located to the • emergency hazard flasher energized. Panel warning lights will left of the steering column) has four light and the buzzer will sound until positions: ACC (Accessories), OFF, • dome and courtesy lamps (on (1) the engine is started, (2) normal oil ON, and START. doors) operating pressure is reached, and (3) air brake system pressure is above • electric horn 65 psi (441 kPa). In this position, the ignition key cannot be removed. 3 • cigarette lighter • tail lights START: Turn the key to this position to start your engine. Release the • marker lamps key after the engine has started. For • headlights complete engine starting procedures, see Operating The Engine on page • radio station memory 4-5. • instrument lights • auxiliary power OFF: In this position all accessories are OFF (except those listed below) • instrument panel memory settings and you can remove the key. ACC (Accessory): With the key in this The following lights and accessories position you can play the radio, defrost have power when the key is in the OFF mirrors (if equipped with mirror heat) position: or use other accessories.

3-96 Y53-1200-1B1 (04/13) ACCESSORIES

Vehicle Telematic System WARNING! WARNING! Your vehicle may be equipped with Only glance at the system monitor Regardless of how and where the nav- an onboard telematics system. This while driving. Prolonged periods of igation system directs you, it is your re- system is a Global Positioning Satellite viewing while driving could result in an sponsibility to operate the vehicle in a (GPS)-linked computer. It receives accident involving death or personal safe and legal manner. Failure to com- input from multiple sources to locate injury. ply may result in death, personal injury, your vehicle. Read and understand equipment or property damage. the Supplemental Telematics and Navigation System Owner’s Manual WARNING! 3 and observe the Warnings, Cautions, Do not program the telematic system WARNING! and Notes that follow before using the while driving. Always stop your ve- Ensure the volume level of all audio system. hicle when programming or changing devices is set to a level that still allows the settings on the telematic system. you to hear outside traffic and emer- WARNING! Programming the system while driving gency vehicles. Failure to comply may Verify legal weight and height restric- can cause you to take your eyes off result in death, personal injury, equip- tions for the route suggested by the the road, which could result in an ac- ment or property damage. telematic system. Failure to verify cident involving death, personal injury height restrictions could lead to caus- or equipment damage. CAUTION ing death, personal injury or property Do not rely on the telematic system damage. Failure to verify weight re- to route you to the closest emergency strictions could result in a traffic infrac- services. Not all emergency services tion. are in the database.

(04/13) Y53-1200-1B1 3-97 ACCESSORIES

Care of the Display Screen Screen Display On/Off NOTE From time to time it may be necessary 1. Press and hold the POWER/LIGHT The map database is the most cur- to clean the display screen. To clean button for approximately 1 second. rent available at the time of produc- the screen, dampen a clean, soft, tion. The database is designed to pro- lint-free cloth with water only. A mild 2. After the display has been turned vide you with route suggestions and glass cleaner that does not contain on, the following Warning/Informational does not take into account the relative alcohol or ammonia may also be screen will appear: safety of a suggested route or of fac- used. Cleaners that contain alcohol tors that may affect the time required to 3 and/or ammonia will eventually dry-out, reach your destination. See the Sup- crack and "yellow" the screen. Wipe plemental Navigation System Owner’s the screen gently back and forth. You Manual for more information. can also use a commercial cleaner especially designed for LCD screens.

3-98 Y53-1200-1B1 (04/13) ACCESSORIES

information. The MENU screen will Passenger Side 'down' Warning/Informational Screen automatically appear next. Mirror 4. To turn the system off, press and hold the POWER/LIGHT button for 3 WARNING seconds. Do not let this device distract you while driving. Always concentrate on you driving. Distractions could cause an Disclaimer accident resulting in injuries to you or others. The vehicle manufacturer is not 3 IMPORTANT responsible for erroneous map data, misrouting or any downtime or other Disclaimer: Map data may be inaccurate and damages associated with or arising out navigation routes may not be available for of the use of the Navigation System. A mirror is located above the larger size vehicles. passenger door that provides a quick Regardless of how and where the navigation view of the blind spot created by the system directs you, it is your responsibility passenger door. to operate the vehicle in a safe and legal manner. Note: Before using this system, read the Owner's Manual and learn how it operates. Some functions of this syste will not operate when the truck is moving.

3. After reading the information, touch the T in the upper right corner of the screen with your finger indicating you acknowledge and understand the

(04/13) Y53-1200-1B1 3-99 ACCESSORIES

3

Rotate the mirror up or down to get the desired view.

3-100 Y53-1200-1B1 (04/13) STARTING AND OPERATING

STARTING AND OPERATING Introduction ...... 4-5 Normal Weather ...... 4-5 Cold Weather ...... 4-6 Engine Block Heater (Option)...... 4-6 Engine Warm-up ...... 4-7 Ether Metering Equipment ...... 4-10 OPERATING THE ENGINE Stationary PTO Operation ...... 4-12 4 Engine Fan Control ...... 4-12 Winterfronts ...... 4-13 Engine Control Display ...... 4-14 OPERATING THE TRANSMISSION Operating Hydraulic Clutch (Manual Transmission) 4-15 Operating Manual Transmissions ...... 4-15 Putting the Vehicle in Motion ...... 4-16 Automatic and Automated Transmissions . . . . 4-19

(04/13) Y53-1200-1B1 4-1 STARTING AND OPERATING

Auxiliary Transmission ...... 4-20 More Transmission Tips ...... 4-20 OPERATING THE BRAKE SYSTEM Introduction ...... 4-21 Retarders ...... 4-33 CRUISE CONTROL Cruise Control Switch ...... 4-35 Adaptive Cruise Control (Optional) ...... 4-37 4 AXLE Differential Lock ...... 4-40 Dual Range (Two-Speed) Rear Axle ...... 4-41 Auxiliary Axles - Pusher or Tag ...... 4-43 SUSPENSION Air Suspension Height/Air Pressure ...... 4-49 Driving with Deflated Air Springs ...... 4-50 AFTER-TREATMENT SYSTEM Introduction ...... 4-51

4-2 Y53-1200-1B1 (04/13) STARTING AND OPERATING

DRIVING TIPS AND TECHNIQUES Introduction ...... 4-52 Coasting ...... 4-52 Descending a Grade ...... 4-53 Engine Overspeed ...... 4-53 Fuel - Excess Consumption ...... 4-55 SLEEPER BUNKS Sleeper Bunk...... 4-58 STOPPING THE ENGINE 4 Before Stopping the Engine ...... 4-60 Refueling ...... 4-60 Refuel Before the Final Stop ...... 4-61 Final Stop ...... 4-62

(04/13) Y53-1200-1B1 4-3

STARTING AND OPERATING

STARTING AND Normal Weather OPERATING NOTE When the outside temperature is Some starters are equipped with over- above 50° F (10° C), you can use the crank protection. Check the “Engine Introduction following procedure: Operation and Maintenance Manual” Since each vehicle is 1. Set the parking brake. for details. custom-equipped, all engine operation 2. Put your main transmission in instructions in this manual are general. 5. Turn the ignition key to the START Neutral. You will want to consult the manual for position. If the engine does not your engine to find out details about 3. Disengage (depress) the clutch start within 30 seconds, release your specific engine’s needs. You (with manual transmission). the ignition switch. To avoid may need to use a slightly different overtaxing the starter motor or 4. Turn the key switch to ON. procedure from the one outlined here. the batteries, don’t use the starter 4 for more than 30 seconds. Let Below are instructions for both CAUTION the starter motor cool and the normal-temperature starting and Never operate the starter motor while batteries recover for two minutes cold-weather starting. the engine is running. The starter and before trying again. flywheel gears could clash or jam, se- If the engine still won’t start after a verely damaging them. couple of tries, check the fuel lines for possible fuel starvation or air leaks. Starting failure may mean fuel isn’t reaching the injectors. 6. As soon as the engine starts, begin to watch the oil pressure gauge. Check your engine manufacturer’s

(04/13) Y53-1200-1B1 4-5 STARTING AND OPERATING

manual for the right pressure for Cold Weather Engine Block Heater your engine. If the oil pressure (Option) doesn’t rise within a few seconds, In cold weather, fast engine starting stop the engine. Find out what helps relieve the loads on the electrical To preheat the engine before starting, is wrong before restarting the system and cranking motor. Using the plug the optional engine block heater engine. special cold starting equipment will into a properly grounded AC electrical help starting. If you follow a few simple source. Do not start the engine with 7. Slowly engage (release) the clutch guidelines, you will extend the service the heater plugged in. after the engine has started. life of your engine: 8. Wait for the oil pressure gauge to WARNING! • Keep the electrical system in top reach normal operating pressure condition. Engine block heaters can cause fires before operating the vehicle or which may result in death, injury idling faster than 1000 rpm. 4 • Use the best quality fuel of the and/or property damage if not properly recommended grade. maintained and operated. Regularly • Use recommended engine inspect the engine block heater wiring lubricating oil. and connector for damaged or frayed wires. Do not use the heater if there • For manual transmissions and are any signs of problems. Contact auxiliary transmissions, leave the your authorized dealer or the manu- transmission in neutral and allow facturer of the heater if you are in need the transmission lubricating oil of repairs or information. to warm up (approximately 3-5 minutes) before operating vehicle.

4-6 Y53-1200-1B1 (04/13) STARTING AND OPERATING

Engine Warm-up slowly and evenly. In extremely CAUTION Engine cold temperatures, you may have Always unplug heater before starting to increase idle speed. The purpose of engine warm-up is to the engine. Damage to the cooling allow oil film to be established between system could occur if the heater is not NOTE pistons and liners, shafts and bearings turned OFF (unplugged). In colder climates where the tem- while your engine gradually reaches perature is often below freezing, the operating temperature. Depending on engine make, when the warm-up for turbocharged engines is temperature falls below -10° F (-24° Warm-up Procedure especially important. Chilled external C), the block heater is required. oil lines leading to the turbocharger 1. After you’ve started your engine, will slow the oil flow until the oil warms, • Use a solution of half ethylene idle it at approximately 600 RPM reducing oil available for the bearings. glycol antifreeze and half water for while you check: Watch the engine oil temperature or 4 best heater performance. Do not a. oil pressure pressure gauge for a warming trend exceed 65 percent concentration before increasing engine idle speed of antifreeze, as a shortened b. air pressure (RPM). heater life will result. See Engine c. alternator output Cooling System on page 5-72, for 3. Continue the engine warm-up until more information. 2. After a few minutes of idling at the coolant temperature reaches 600 RPM, increase your idle at least 130° F (54° C). At this • After servicing the cooling system, speed to 900 or 1000 RPM. temperature, you can use partial operate the vehicle for a day or two Continue your warm-up. This throttle. Wait until the coolant before using the heater. Trapped procedure allows oil to warm and temperature is at least 160° F (71° air inside the engine needs time flow freely while pistons, liners, C) before operating at full throttle. to escape. shafts, and bearings expand

(04/13) Y53-1200-1B1 4-7 STARTING AND OPERATING

WARNING! CAUTION NOTE Exhaust fumes from the engine con- The use of a winterfront can result Keep the engine exhaust system and tain carbon monoxide, a colorless and in excessive engine coolant, oil, and the vehicle’s cab/sleeper ventilation odorless gas. A poorly maintained, charge air (intake) temperatures, system properly maintained. It is rec- damaged, or corroded exhaust system which can lead to overheating and ommended that the vehicle’s exhaust can allow carbon monoxide to enter possible engine damage. If you must system and cab/sleeper be inspected: the cab or sleeper. Failure to prop- use a winterfront: erly maintain your vehicle could cause • By a competent technician every carbon monoxide to enter the cab and • Refer to the “Engine Operation 15,000 miles, and Maintenance Manual” cause death or personal injury. • Whenever a change is noticed in for operating restrictions and the sound of the exhaust system, recommendations. 4 WARNING! • Whenever the exhaust system, • Use only a winterfront available Never idle your vehicle for prolonged underbody, cab or sleeper is from your dealer that is periods of time if you sense that ex- damaged. compatible with an EPA-compliant haust fumes are entering the cab. In- engine cooling system. These vestigate the cause of the fumes and winterfronts are specifically correct it as soon as possible. If the ve- designed for use with new grill hicle must be driven under these con- snap patterns. ditions, drive only with the windows slightly open. Failure to repair the source of the exhaust fumes may lead to death or personal injury.

4-8 Y53-1200-1B1 (04/13) STARTING AND OPERATING

NOTE WARNING! CAUTION • Do not stay in the vehicle with To reduce the chance of death or per- Do not allow your engine to idle, at the engine running or idling sonal injury and/or vehicle damage low rpm's (400–600 rpm), longer than for more than 10 minutes with from overheated engines, which can five minutes. Long periods of idling the vehicle’s Heater and A/C result in a fire, never leave the engine after the engine has reached operat- ventilation system in RECIRC idling without an alert driver present. ing temperatures can decrease engine or at LOW FAN SPEED. Even If the engine should overheat, as indi- temperature and cause gummed pis- with the ventilation system On, cated by the engine coolant tempera- ton rings, clogged injectors, and pos- running the engine while parked ture light, immediate action is required sible engine damage from lack of lu- or stopped for prolonged periods to correct the condition. Continued brication. The normal torsional vibra- of time is not recommended. unattended operation of the engine, tions generated can also cause trans- even for a short time, may result in mission wear. 4 • If other vehicles are parked next serious engine damage or a fire. to you idling, move your vehicle or do not stay in your vehicle for prolonged periods of time.

Idling the Engine

Under most circumstances, idling your engine for long periods merely wastes fuel. In severe arctic weather conditions, however, you may need longer idling to be sure all parts of your engine are fully lubricated.

(04/13) Y53-1200-1B1 4-9 STARTING AND OPERATING

Transmission Ether Metering Equipment a. Put the main transmission in In cold weather [below 32° F (0° gear. WARNING! C)], you may find shifting sluggish b. Put the auxiliary transmission Ether starting fluid is flammable and when you first start up. Transmission in Neutral. This will allow poisonous. Do not smoke near ether warm-up is especially important at the transmission countershaft or ether equipment, do not ingest this time, but it is always a good to turn, agitating the oil and ether fluid and wear safety goggles idea to warm-up your transmission warming it. when handling ether fluid. Follow all before starting out on the road. To safety literature provided with your warm-up the transmission, follow these ether equipment. Failure to take these procedures. precautions may result in death, per- To warm-up the transmission sonal injury. 4 lubricating oil during engine warm-up, with a single transmission (manual and WARNING! automatic): Do not move or relocate the ether 1. Put the transmission in Neutral. cylinder or tubing from its original installation. It must be mounted to pro- 2. Release the clutch pedal (manual tect it from engine exhaust heat and only) and operate the transmission from moving parts which could dam- in neutral for 3 to 5 minutes prior age it. Failure to comply may result in to operating the transmission in death, personal injury, equipment or either forward or reverse range. property damage. 3. If you have a two-transmission combination:

4-10 Y53-1200-1B1 (04/13) STARTING AND OPERATING

store it safely. Return the protective WARNING! cap to the bottle mounting connector. Do not store the spare cylinder in the cab. Failure to comply may result in For more helpful starting information, death, personal injury, equipment or refer to the engine manual that came property damage. with your vehicle. Ether injected into the engine cylinder Do not smoke when testing, installing, during cold weather startup will help or servicing an ether starting unit. the engine start faster. Using ether Service it in a well-ventilated area away during cold weather startup will result from heat, open flames, or sparks. in reduced demands on the batteries and the starter motor. If swallowed, do not induce vomiting. 4 Call a physician immediately. When you turn the ignition switch to the START position, the cranking motor Wear goggles to avoid getting fluid in and the ether system are engaged. your eyes. Avoid getting it on your skin When needed, starting fluid is released and avoid breathing the fumes. If fluid from a pressurized cylinder, flows does get in your eyes or fumes irritate through a valve and tubing, and sprays your eyes, flush for 15 minutes with from a nozzle in you engine’s air intake large amounts of clean water. Contact system. an eye specialist.

In warm weather, when you will not need the ether starting system, remove the ether bottle from your truck and

(04/13) Y53-1200-1B1 4-11 OPERATING THE ENGINE

OPERATING THE 5. Toggle the SET/RESUME switch Engine Fan Control ENGINE to obtain the desired engine rpm.

Stationary PTO Operation Cancelling Cruise Control

The cruise control buttons for this You can cancel cruise control in any vehicle may be used to control the of these ways: The engine fan can be turned ON using a switch that is mounted on the engine rpm when the vehicle is • Tap the brake pedal. stationary and the operator wants to accessory switch panel. This lets you use the PTO on the engine. Use the • Tap the clutch pedal. set the fan to manual or automatic cruise control options in the same operation. manner as with the vehicle in motion, • Move the ON/OFF switch to the • With the ignition key turned ON but instead of setting vehicle speed, "OFF" position. 4 and the fan switch in the MANUAL the engine speed (RPM) is set instead. position, the engine fan will be ON Setting Idle Speed regardless of engine temperature. 1. Ensure parking brakes are applied. • With the engine fan switch in the AUTO position, the engine fan will 2. Ensure transmission is in Neutral. automatically turn ON when the 3. Engage PTO per the engine computer sends a signal manufacturer's operating requiring the engine fan to be on. instructions. 4. Move the ON/OFF switch to the "ON" position.

4-12 Y53-1200-1B1 (04/13) OPERATING THE ENGINE

Winterfronts WARNING! NOTE A winterfront or other air flow restriction Do not work on or near the fan with the Do not operate the engine fan in the device may be mounted in front of engine running. Anyone near the en- MANUAL position for extended peri- the radiator to increase cab heater gine fan when it turns on could be in- ods of time. The fan hub was de- temperature in cold climates. jured. If it is set at MANUAL, the fan signed for intermittent operation. Sus- will turn on any time the ignition key tained operation will shorten the fan CAUTION switch is turned to the ON position. In hub's service life as well as reduce fuel AUTO, it could engage suddenly with- economy. A winterfront should only be used at out warning. Before turning on the ig- temperatures below 40°F (4°C). Use nition or switching from AUTO to MAN- of a winterfront above 40°F (4°C) can UAL, be sure no workers are near the decrease life of cooling module com- fan. ponents. Remove winterfront as soon 4 as the ambient temp reaches 41°F CAUTION (5°C). The use of a winterfront above 40°F (4°C) can result in excessive The fan or equipment near it could be engine coolant, oil, and charge air damaged if the fan turns on suddenly (intake) temperatures, which can lead when you do not expect it. Keep all to overheating and possible engine tools and equipment away from the or coolant module damage and emis- fan. sions non-compliance.

(04/13) Y53-1200-1B1 4-13 OPERATING THE ENGINE

Engine Control Display NOTE Your vehicle may come with an optional The winterfront is designed to min- Engine and Driver Information Display. imize the temperature differences This instrument records information across the radiator and reduce the on engine diagnostics, scheduled possibility of cooling module damage. maintenance, driving conditions, and Aftermarket winterfronts may not pro- general trip information. The specific vide the proper airflow distribution and features of your display may vary could cause cooling module damage. depending on engine make.

4

4-14 Y53-1200-1B1 (04/13) OPERATING THE TRANSMISSION

OPERATING THE Operating Manual If the transmission is not shifting Transmissions TRANSMISSION smoothly into gear while the clutch pedal is completely pressed to the Operating Hydraulic Clutch The transmission shift pattern for floor, then it is time to have the clutch your vehicle may be located on the (Manual Transmission) and hydraulic system inspected and shift control knob. In addition to serviced. understanding the shift pattern and Manual transmissions will also have a its location, you should read the clutch pedal situated to the left of the CAUTION transmission manufacturer’s manual brake pedal. Pressing down on the Do not push the clutch pedal com- provided with your vehicle before clutch pedal will disengage the clutch pletely to the floor when shifting while operating the vehicle. and will allow the transmission gears the vehicle is in motion. using the to be shifted. clutch brake while shifting a vehicle in motion will damage the clutch brake. A 4 At the beginning of the pedal stroke, non functioning clutch brake will make there will be about ½ inch (13 mm) of shifting very difficult when the vehicle movement before any resistance is is stationary. felt. As the pedal is pressed further, the operator will feel increased resistance as the clutch is disengaged. After If the clutch pedal is pressed the clutch has been fully disengaged, completely to the floor and the there will be another 1 - 1 1/2 inches transmission is not shifting, then it is (25 -40 mm) of pedal travel which will time to have the clutch adjusted or engage the clutch brake. At this full serviced. stroke, the pedal will feel like it cannot be pressed anymore.

(04/13) Y53-1200-1B1 4-15 OPERATING THE TRANSMISSION

Putting the Vehicle in Motion start up on an incline, apply your CAUTION service brakes before you release After making sure the vehicle's oil Always use first gear or a low speed the parking brake. Then release and air pressure are correct and all range to start the vehicle in motion. your service brakes as you engage other parts and systems are in proper The use of a higher gear or speed the clutch and apply throttle. working condition: range forces undue strain on the en- For further instructions on 1. Fully depress the clutch pedal (for gine, clutch, other transmission com- operating your transmission, see manual transmission) until the ponents, and may cause damage. the transmission manufacturer's clutch brake makes contact. 2. Evaluate the road surface Driver/Operator's Instruction Manual. a. The total stroke of the clutch conditions and terrain your vehicle If you have a misaligned gear condition pedal is about 6 inches (152 is on. Select a gear low enough to in your vehicle's transmission and mm). The first ½ inch (13 let your vehicle start forward with 4 cannot start, gradually release the mm) is free travel. After the the throttle at idle. free travel comes the release clutch, allowing the drive gear teeth to stroke, which is the part that 3. Push the parking brake valve line up properly. Then the drive gear fully releases the clutch. The handle (Yellow) against the dash can roll enough to allow the teeth to last ½ inch (13 mm) engages panel to release the brakes. line up properly and complete the shift. the clutch brake. 4. Release the clutch pedal (manual The best engine performance and b. Always start out in a low only), then gradually accelerate to maximum economy is obtained if gears gear. Starting in higher gears, permit smooth starting, are properly selected. This efficiency even with a light load, will 5. Do not allow your vehicle is achieved by always selecting gears cause a very jumpy start and to roll (even a little) in the within optimum engine RPM, which is excessive wear. opposite direction during clutch where maximum torque and power are engagement. If you need to obtained. For further information, see

4-16 Y53-1200-1B1 (04/13) OPERATING THE TRANSMISSION

More Driving Tips and Techniques on Shifting Gears in a New Vehicle Clutch Brake and Travel page 4-52. Shift carefully in a new vehicle. The The clutch brake is used for stopping transmission may be a little stiff at transmission gears, allowing you to first. Avoid gear clashing, by closely easily shift into first gear or reverse following these procedures. without grinding gears. Approximately the last ½ inch (13 mm) of clutch pedal When you are operating a new vehicle travel activates the clutch brake. or one that has been exposed to cold weather, you want the transmission To apply the clutch brake (while the lubricant (fluid) to circulate and coat vehicle is stopped) fully depress the the contacting surfaces of the gears. clutch pedal to stop the gears. With Metal contacting metal in moving the throttle at idle, select first gear parts may seriously damage your then release the clutch pedal to let the 4 transmission, do not drive in one vehicle start forward, until the clutch is gear for long periods of time until the fully engaged. See the transmission transmission lubricant has a chance to manufacturer's Driver/Operator's coat all contacting surfaces. Instruction Manual for further details.

If the transmission has a butt-tooth condition and you cannot engage a gear, gradually release the clutch. Then the drive gear can roll enough to allow the teeth to line up properly and complete the shift.

(04/13) Y53-1200-1B1 4-17 OPERATING THE TRANSMISSION

During Normal Driving Double Clutching b. Downshifts: press accelerator, increase engine and gear If you want to shift directly into any gear Whether you are upshifting or down speed to the RPM required in other than first or reverse, depress the shifting, it is best to double clutch. the lower gear. clutch pedal only far enough to release Double clutching is easier on the the clutch. Fully depressing the pedal transmission and on the engine, 4. Now quickly press the pedal to applies the clutch brake and could helping your vehicle match engine disengage the clutch and move cause gear hang-up. speed with driveline speed and the gear shift lever to the next gear achieving clash-free shifts. speed position. CAUTION To double clutch: 5. Release the pedal to engage the Be careful not to apply the clutch brake clutch. while the vehicle is moving. The pur- 1. Push the clutch pedal down to 4 pose of the clutch brake is to stop the disengage the clutch. transmission so that you can shift into 2. Move the gear shift lever to a starting gear without grinding gears. neutral. Applying the clutch brake when the ve- hicle is moving will render the clutch in- 3. Release the pedal to engage operative. the clutch. This lets you control the RPM of the mainshaft gears, allowing you to match the RPM of the mainshaft gears to those of the output shaft. a. Upshifts: let the engine and gears slow down to the RPM required for the next gear.

4-18 Y53-1200-1B1 (04/13) OPERATING THE TRANSMISSION

Automatic and Automated Hill Hold Transmissions WARNING! If your vehicle has an automated trans- An automatic or automated mission, be aware that it can roll back- transmission makes shifting much wards when stopped on a hill or grade, easier. It remains important to or when starting from a stop on a hill completely understand how to operate or grade. Failure to comply may result the transmission to optimize its in death, personal injury, equipment or efficiency. Please read the manual The hill hold feature is available as property damage. Observe the follow- for your automatic or automated an option with certain automated ing guidelines: transmission included with your transmissions. This feature holds the vehicle. vehicle while on a hill to allow the • When stopped on a hill or grade, operator to release the service brakes press the brake pedal. For automated transmissions, there is and press the accelerator. This feature 4 • When starting from a stop on a no “park” position. So you will need to will hold the vehicle if the vehicle is hill or grade, quickly remove your apply the parking brake before leaving attempting to go up a hill from a stop in foot from the brake pedal and the cab. either drive or reverse. firmly press on the accelerator pedal. WARNING! Do not leave the cab of your vehi- cle without applying the parking brake. The truck could roll and cause an acci- dent resulting in death or personal in- jury. Always apply the parking brake before you leave the cab.

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Auxiliary Transmission More Transmission Tips • Never downshift when the vehicle Riding the Clutch If you have an auxiliary transmission, is moving too fast. see your transmission manufacturer’s The clutch is not a footrest. Do not • Never slam or jerk the shift lever manual for its proper operation. drive with your foot resting on the to complete gear engagement. clutch pedal. It will allow your clutch to slip, causing excessive heat and wear, • Never coast with the transmission damage could result. in neutral and the clutch disengaged. Release Bearing Wear • To provide smooth gear When you must idle your engine for any engagements while shifting, period of time, shift your transmission use proper coordination between 4 to neutral and disengage the clutch shift lever and clutch. (take your foot OFF of the pedal). This helps prevent unnecessary wear to Double clutching is a very effective your clutch release bearing, and it is means to increase the service life of less tiring for you, too. your transmission. Double clutching refers to a technique where the clutch Tips pedal is used twice per shift instead of once. It also requires that you adjust • Always use the clutch when the engine rpm in the middle of the making upshifts or downshifts. shift which ultimately synchronizes the gears during shifting. Synchronizing • Always select a starting gear reduces wear on the gears. See that will provide sufficient gear Double Clutching on page 4-18. reduction for the load and terrain.

4-20 Y53-1200-1B1 (04/13) OPERATING THE BRAKE SYSTEM OPERATING THE BRAKE SYSTEM The air compressor on the engine will Certain conditions may result in your typically provide 100-130 psi (690-896 brake surfaces becoming overheated kPa) to the air tanks. The vehicle (above 800° F or 427° C). Overheated Introduction is also designed with an air dryer, brakes will damage linings and which removes moisture from the drum surfaces, ultimately decreasing This vehicle’s brake system functions compressed air in order to protect all braking performance. Refer to with the use of compressed air components in the air system. Retarders and Descending a grade to generated from the engine’s air avoid overheating the brakes. compressor. The compressed air is The brake system may be further stored in various air tanks to ensure enhanced by additional devices This vehicle may be equipped with that air pressure is available whenever such as brake proportioning valves, an anti-lock braking system (ABS). the driver needs it. Anti-lock braking systems or sensors This ABS reduces the possibility of designed to let you know if your brake wheel lock-up. If a wheel is about 4 Compressed air is delivered to the pads need to be serviced. to lock during braking, the ABS will brake system through the valve at automatically adjust air pressure to the the brake pedal and is controlled Certain conditions may result in the brake chambers on the appropriate with various valves and braking brake surfaces getting wet. Brake wheel(s) to prevent wheel lock-up. The circuits. The brake system is designed surfaces that are wet do not perform ABS is automatically turned on when with separate front, rear and (when as well as when they are dry. There the ignition switch is turned on. applicable) trailer circuits so that if one may be situations where wet brake circuit is compromised and loses air, surfaces cannot be avoided. In such the other circuits will not be affected. situations, apply the brakes while in Safety valves in each circuit will protect motion, to dry the brake surfaces. the other circuits in the event that a circuit loses air.

(04/13) Y53-1200-1B1 4-21 OPERATING THE BRAKE SYSTEM

WARNING! WARNING! WARNING! The Anti-Lock Brake System is a crit- Do not drive through water deep Do not rely on an anti-lock brake sys- ical vehicle safety system. For the enough to wet brake components, as tem that is functioning improperly. You safety of you and others around you, it may cause the brakes to work less could lose control of the vehicle re- have the vehicle submitted for peri- efficiently than normal. The vehicle's sulting in a severe accident, causing odic preventive maintenance checks stopping distance may be longer than death or personal injury. If your ABS as well as having any suspected prob- expected, and the vehicle may pull lamp goes on while you are driving lems immediately checked by an au- to the left or right when brakes are or stays on after the self-check, your thorized dealer. Failure to properly applied, which could contribute to an anti-lock system might not be work- maintain your brake system can lead accident involving death or personal ing. The ABS may not function in an to serious accidents. Failure to com- injury. emergency. You will still have conven- 4 ply may result in death, personal injury, tional brakes, but not anti-lock brakes. equipment or property damage. If the lamp indicates a problem, have the ABS checked.

Vehicles without anti-lock brake systems (ABS) are typically equipped with a bobtail brake proportioning system. When a trailer is not connected, the drive axle brake application pressure will automatically be limited by the proportioning system. When driven in a bobtail mode, these tractors will require greater

4-22 Y53-1200-1B1 (04/13) OPERATING THE BRAKE SYSTEM brake pedal application to provide the Parking Brake equivalent braking to a bobtail tractor Parking brakes work in reverse action not equipped with a proportioning of the regular brakes. When the system. parking brakes are engaged, air is exhausted from the spring chambers, which allows the spring to engage the brakes. This design also provides a safety function if a brake circuit has a leak and loses air. In such a scenario, the parking brakes will apply.

The vehicle’s parking brake controls are the yellow diamond shaped knob on your dash board. If the vehicle is 4 equipped to tow a trailer, then there will be an additional red octagon shaped knob for the trailer parking brakes. Parking brakes will be engaged when either of these knobs are pulled OUT. (If one knob is pulled out, the other knob will automatically pop out.) 1. Normal Run Position 2. Trailer Park with Vehicle Pushing IN a knob will disengage Released the respective parking brakes. If you 3. System Park or Trailer push in the yellow knob only, you Charge with Vehicle Parked will disengage the vehicle’s parking

(04/13) Y53-1200-1B1 4-23 OPERATING THE BRAKE SYSTEM

brakes but will not disengage the trailer Trailer ABS parking brakes (if applicable). Either Power Line Communication (PLC) CAUTION knob will pop back out if the system Do not splice into the non-switchable pressure is not above 60 psi (414 kPa). North American on-highway vehicles Auxiliary circuit on the primary 7-way are equipped with a separate electrical trailer light line. Doing so may cause The instrument panel display will circuit to power the anti-lock brake the trailer ABS to malfunction. This cir- provide a message any time the system (ABS) on towed vehicle(s). cuit is dedicated for trailer ABS power. parking brakes (vehicle or the trailer) In most cases, the ABS power will To add a switchable auxiliary circuit, are set and the vehicle is put into be supplied through the Auxiliary contact a dealership. motion. circuit on the primary 7-way trailer light line connector. If the vehicle Vehicles and trailers built after was manufactured with a switchable 3/1/01 must be able to turn on an Auxiliary circuit for trailer accessories, In-Cab Trailer ABS Warning Lamp 4 an additional 7-way connector would (per Federal Motor Vehicle Safety have been provided for trailer ABS Standards (FMVSS) 121). The industry power. In either case, the ABS chose Power Line Communication power line on the vehicle will be PLC (PLC) as the standard method to turn equipped. it on.

NOTE Trailers not equipped with PLC can not turn on the In-Cab Trailer ABS Warn- ing Lamp.

4-24 Y53-1200-1B1 (04/13) OPERATING THE BRAKE SYSTEM

Special Trailer ABS (Without PLC) NOTE CAUTION Option For doubles or triples, the lamp does The center pin of the 7-way trailer light If a trailer does not have PLC, but not distinguish between trailers. An line may be constantly powered for it does have ABS that is powered ABS problem in any of the trailers ABS. Make sure it will not accidently through an optional second trailer will activate the Trailer ABS Warning turn on trailer equipment. connector (ISO 3731) and that trailer Lamp. ABS is designed to control the Trailer ABS Warning Lamp in the cab and NOTE the vehicle has been ordered with the If you change the intended service in option to turn on this lamp for these any way (i.e. number of axles, multiple types of trailers, then this lamp will turn on when that trailer ABS has a system trailers, add switchable trailer acces- 4 sories, etc.) from the date the vehicle problem. This should be checked by a was manufactured, you should con- dealer as soon as possible. The Trailer tact your trailer manufacturer and/or ABS Warning Lamp will not turn on for trailer anti-lock brake manufacturer the power-on test when connected to to determine if the power available at these types of trailers. the 7-way trailer light line is adequate. Failure to do so might result in insuffi- NOTE cient power to the trailer ABS system, Very few trailers built before 3/1/01 which may affect its operation. have this option. Trailers built after 3/1/01 are built with PLC technology.

(04/13) Y53-1200-1B1 4-25 OPERATING THE BRAKE SYSTEM

Advanced ABS with Stability Roll Stability Program thereby reducing the tendency to roll Control over. Bendix® Roll Stability Program (RSP), This vehicle may be equipped an element of the overall ESP system, with an optional Electronic Stability addresses rollover conditions. In the Program (ESP). ESP is a feature for case of a potential roll event, the ECU ABS-equipped vehicles that reduces will override the throttle and quickly the risk of rollovers, jackknifing, and apply brake pressure at all wheel ends other loss of control situations. ESP to slow the vehicle combination. The features include Roll Stability Program level of braking application during an (RSP) and Yaw Control. RSP event will be proportional to roll risk. During operation, the ECU of the 4 Bendix® Advanced ABS system A Real World Example of How the constantly compares performance RSP System Operates models to the vehicle’s actual movement, using the wheel speed Excessive speed for road conditions sensors of the ABS system, as well creates forces that exceed the as lateral, yaw, and steering angle threshold at which a vehicle is likely to sensors. If the vehicle shows a rollover on a higher-friction surface. tendency to leave an appropriate travel RSP Example path, or if critical threshold values are The system automatically reduces approached, the system will intervene engine torque and applies the service to assist the driver. brakes (based on the projected rollover risk) to reduce the vehicle speed,

4-26 Y53-1200-1B1 (04/13) OPERATING THE BRAKE SYSTEM

Yaw Stability Yaw Control The Bendix® Yaw Control system Yaw stability counteracts the tendency Yaw Control responds to a wide reduces engine throttle and selectively of a vehicle to spin about its vertical range of low- to high-friction surface applies brakes to reduce the vehicle axis. During operation, if the friction scenarios including rollover, jackknife speed, thereby reducing the tendency between the road surface and the tires and loss of control. In the case of to jackknife. is not sufficient to oppose lateral (side) vehicle slide (over-steer or understeer forces, one or more of the tires can situations), the system will reduce the slide, causing the truck/tractor to spin. throttle and then brake one or more of the “four corners” of the vehicle These yaw events are referred to as (in addition to potentially applying either “under-steer” (where there is a the trailer brakes), thus applying a lack of vehicle response to steering counter-force to better align the vehicle input due to tire slide on the steer axle) with an appropriate path of travel. For 4 or “over-steer” (where the tractor's example, in an over-steer situation, rear end slides out due to tire slide the system applies the “outside” on the rear axle) situation. Generally, front brake; while in an under-steer shorter wheelbase vehicles (tractors, condition, the “inside” rear brake is for instance) have less natural yaw applied. stability, while longer wheelbase vehicles (straight trucks, for instance) A Real World Example of How Yaw have greater natural yaw stability. Control Operates Factors that influence yaw stability are: wheelbase, suspension, steering Excessive speed exceeds the geometry, weight distribution front to threshold, creating a situation where a rear, and vehicle track width. vehicle is likely to spin and jackknife. Yaw Control Example

(04/13) Y53-1200-1B1 4-27 OPERATING THE BRAKE SYSTEM

ESP May Reduce the Vehicle Speed Towing Doubles or Triples May Limitations of Stability Systems Automatically Reduce the Effectiveness of Stability Systems The ESP stability system’s To minimize unexpected deceleration effectiveness may be greatly reduced and reduce the risk of a collision the ESP is designed and optimized for if: operator must: trucks and for tractors that tow single trailers. If a tractor equipped with • The load shifts due to improper • Avoid aggressive driving ESP is used to power multiple trailer retention, accident damage or the maneuvers, such as sharp combinations (known as “doubles” or inherently mobile nature of some turns or abrupt lane changes at “triples”) the effectiveness of the ESP loads (for example, hanging meat, high speeds, which might trigger system may be greatly reduced. live animals or partially laden the stability system. tankers). WARNING! 4 • Always operate the vehicle safely, • The vehicle has an unusually high drive defensively, anticipate Exercise extreme care when tow- or off-set center of gravity (CG). obstacles and pay attention ing doubles or triples with a vehicle to road, weather, and traffic equipped with Electronic Stability Pro- • One side of the vehicle drops off conditions. ABS, ATC, and ESP gram. Excessive speed and aggres- the pavement at an angle that is stability systems are no substitute sive maneuvers, such as sharp turns, too large to be counteracted by a for prudent, careful driving. sudden steering inputs or abrupt lane reduction in speed. changes should be avoided because • The vehicle is used to haul double these maneuvers could cause loss of or triple trailer combinations. vehicle control possibly resulting in an accident involving death or personal • If very rapidly winding steering injury. inputs are inputted at high speeds.

4-28 Y53-1200-1B1 (04/13) OPERATING THE BRAKE SYSTEM

• There are mechanical problems To Maximize the Effectiveness of Truck Chassis Modifications with suspension leveling of the ESP The ESP system was specifically tractor or trailer resulting in uneven • Loads must be properly secured calibrated and validated only for loads. and evenly distributed at all times. your vehicle’s original factory-built configuration. If your vehicle’s chassis • The vehicle is maneuvering on a • Drivers need to exercise extreme components are altered (for example; high banked road creating either caution at all times, and avoid a wheelbase extension or reduction, additional side forces due to the sharp turns, sudden steering tag axle addition or removal, tractor to weight (mass) of the vehicle or a inputs or abrupt lane changes at truck conversion or steering system deviation between expected and high speeds, particularly if: actual yaw rates. component change) the ESP system a. the vehicle hauls loads that must be disabled immediately by a • Gusty winds are strong enough could shift, qualified mechanic. to cause significant side forces 4 b. the vehicle or load has a high on the vehicle and any towed WARNING! vehicles. or off-set center of gravity (CG) when loaded, or Failure to disable ESP “Electronic Sta- bility Program” when modifying a vehi- c. the vehicle tows doubles or cle could result in a loss of vehicle con- triples. trol possibly resulting in an accident in- volving death or personal injury.

(04/13) Y53-1200-1B1 4-29 OPERATING THE BRAKE SYSTEM

Steering Angle Sensor Optional ATC Functions WARNING! Re-Calibration Wheel Spin Control (option) For vehicles equipped with ESP “Elec- Whenever maintenance or repair Your truck/tractor ABS may have an tronic Stability Program” do not re- work is performed to the steering acceleration slip regulation (ASR) place the vehicle’s steering wheel with mechanism, linkage, gear, adjustment or automatic traction control (ATC) an aftermarket or different part num- of the wheel track, or if the steering feature. This feature is controlled by a ber than originally supplied. Using a angle sensor is replaced or the steering switch as shown in the next illustration. different steering wheel could cause wheel is changed or re-centered, the Either of these features is monitored by ESP to malfunction causing a loss of Steering Angle Sensor must be a warning lamp located on the switch. vehicle control possibly resulting in an re-calibrated. accident involving death or personal injury. WARNING! 4 If the Steering Angle Sensor is not re-calibrated, the Yaw Control system will not function properly. A uncali- brated sensor could result in a loss of Wheel Spin Control Warning Lamp control of your vehicle which can lead to an accident involving death or per- The Traction Control warning lamp on sonal injury. page 3-37 will briefly illuminate and then go out when the ignition switch is first turned on. The traction control warning lamp will illuminate whenever the ASR or ATC system detects drive wheel spin. The lamp will remain illuminated as long as wheel spin is

4-30 Y53-1200-1B1 (04/13) OPERATING THE BRAKE SYSTEM detected and the ASR or ATC system transfers engine torque to the increases available traction on extra is applying the drive wheel brakes or wheels with better traction. soft surfaces like snow, mud or gravel, reducing engine torque. Engine torque by slightly increasing the permissible or vehicle speed should be reduced • If all drive wheels spin, wheel spin wheel spin. When this function is in to eliminate wheel spin and prevent control reduces engine torque to use, the ASR Warning Lamp blinks excessive application of the ASR/ATC provide improved traction. continuously. system. Except for checking for proper Wheel spin control turns itself on and illumination of the ABS and traction Off-Road ABS Function Switch off, you do not have to select this control warning lamps when first (option) feature. If drive wheels spin during starting the vehicle, and for monitoring acceleration, the ASR Warning Lamp these lamps while driving, no special Your vehicle may be equipped with comes on, indicating wheel spin control operating procedures are required. a separate switch to activate an is active. For detailed system description, see Off-Road ABS function. This function is NOT to be used for On-Highway 4 literature for your specific ABS that Do not allow the ASR Warning Lamp was provided with your vehicle. driving but is intended to be used to remain on continuously for an to improve stopping performance in extended length of time. Extended, This feature helps improve traction Off-Highway conditions (e.g. loose continuous use of the ASR/ATC can when vehicles are on slippery surfaces gravel and mud). The Off-Road ABS cause overheating of the drive wheel or surfaces with poor traction (i.e. function is accomplished by allowing a brakes. mud or snow) by reducing drive wheel “wedge” of material to build-up in front of momentarily locked wheels. overspin. Wheel spin control works Deep Snow and Mud Switch (option) automatically in two different ways: Features and Benefits • If a drive wheel starts to spin, A deep snow and mud switch is wheel spin control applies air included with Wheel Spin Control. The • Changes the ABS control limits to pressure to brake the wheel. This Deep Snow and Mud feature is helpful allow for a more aggressive ABS during acceleration. This function function while off-road.

(04/13) Y53-1200-1B1 4-31 OPERATING THE BRAKE SYSTEM

• Improves vehicle control and • At speeds between 10 and 25 WARNING! helps reduce stopping distances mph, the ABS control software is in off-road conditions or on poor While the off-road mode can improve modified to allow short periods traction surfaces such as loose vehicle control and shorten stopping (0.25 seconds) of locked-wheel gravel, sand, and dirt. distances, some steering ability may cycles. be reduced on certain surfaces result- • Allows retarders to function ing from the momentarily sliding tires. • At speeds below 10 mph, the ABS independently of the ABS function. Always operate your vehicle at safe control software is turned off to operating speeds. Failure to do so allow locked wheels. • If your vehicle does not have an may cause you to lose control of the engine retarder, the Off- Road • When the Off-Road ABS function vehicle and could result in an accident ABS switch will function the same. is enabled, the Retarder Disable or personal injury. output is turned off. That is, 4 CAUTION the engine retarders are left to How the Off-Road ABS Function function without ABS intervention. Never drive your vehicle on improved Works For additional information, see the roads/highways with the Off-Road Off-Road ABS pamphlet in your ABS function turned on. When you The ABS lamp flashes slowly • vehicle’s glove box. drive your vehicle onto an improved during off-road mode engagement. road surface or highway, immediately This is done to alert you of a turn off the Off-Road ABS switch. modification to the ABS control Failure to do so will cause the ABS software. system to not function properly in an ABS event under 25 mph and could • At speeds above 25 mph, the ABS result in an accident or personal injury. controller operates in the normal on-highway mode.

4-32 Y53-1200-1B1 (04/13) OPERATING THE BRAKE SYSTEM

Retarders pressure to slow the drivetrain. Use WARNING! the service brakes for quick stops. Various retarders are available, which Do not use any of the vehicle’s re- function against the engine, driveline, tarders in any situation that requires an Do not use the retarder when operating or transmission. These are devices immediate stop and/or in situations of on road surfaces with poor traction that use your engine’s power to slow poor traction (such as wet, icy or snow (such as wet, icy, or snow covered down your vehicle. They save wear covered roads). Trying to use the re- roads or gravel). Retarders can and tear on your service brakes and tarder instead of the service brakes cause the wheels to skid on a slippery can be a safety feature, too, because may cause a loss of vehicle control, surface. they can keep your brakes from which may result in an accident involv- overheating. ing death or personal injury. Ideally, you should always slow your vehicle with your retarder (where WARNING! 4 permitted by law) and use your service The service brakes must be used in an brakes only for stopping completely. emergency. The retarder alone might Operating this way will greatly prolong not stop you fast enough to prevent an the life of your brakes. accident. Failure to comply may result in death, personal injury, equipment or property damage.

The retarder is NOT intended as the primary brake for the vehicle, nor is it an emergency brake. The retarder only helps the service brakes by using

(04/13) Y53-1200-1B1 4-33 OPERATING THE BRAKE SYSTEM

Driving Bobtail or with an Unloaded Transmission Retarder Trailer WARNING! Do not rely on your automatic trans- We recommend that you do not use mission hydraulic retarder to stop your your engine retarder to slow down vehicle. If your engine shuts down, the when you are bobtailing or pulling an If you have this option, it will act vehicle’s retarder will cease to operate empty trailer. like a brake to slow your vehicle which, may lead to an accident involv- without using the brakes. Take your ing death or personal injury. Always WARNING! foot off the throttle and operate the be ready to suddenly apply the service Using an engine retarder can cause a retarder switch. When you do not brakes. wheel lockup. The trailer is not load- need full retarder effect, you can ing the tires enough to give the traction apply it intermittently (off and on) 4 you may need. When you are bobtail to cause gradual or partial slowing. or unloaded, you can have a serious Continuous application of your retarder accident if your wheels lock suddenly will cause your hydraulic fluid to get during braking. You could be killed or hotter. Intermittent application will help injured. Don’t use your retarder when prevent overheating. you are driving bobtail or with an un- loaded trailer.

4-34 Y53-1200-1B1 (04/13) CRUISE CONTROL CRUISE CONTROL Using Cruise Control While Driving Changing the Cruise Set Speed Cruise Control Switch Setting Cruise Speed For vehicles with cruise control buttons on the steering wheel, the cruise This vehicle may have cruise control 1. Ensure that the vehicle speed is speed may be changed by using the switches located on the steering wheel above the minimum cruise control +/- button. The pressing and holding instead of the switches on the dash speed (19 mph (30 km/h) for the + button will increase speed while board. The instructions are still the PACCAR MX engine and 30 mph pressing and holding the - button will same. See Steering Wheel Controls (48 km/h) for Cummins engines) decrease speed. For vehicles with on page 3-73 to determine where the and the engine speed is above dash mounted cruise control switches, cruise control switches are located. 1100 rpm. changing the speed is done through 2. Press the "ON/OFF" button. the "Set/Resume" button. To increase For information about the Adaptive 4 Cruise Control, see Adaptive Cruise 3. Accelerate the vehicle to the the speed, press and hold the Set Control on page 4-37. desired cruise speed. button. To decrease the speed, press and hold the "Resume" button. • To Turn On: 4. Press the "SET" button to set the cruise speed. Cancelling Cruise Control Press the ON/OFF button. NOTE You can cancel cruise control in any • To Turn Off: of these ways: Cruise Control may not hold the set Press the ON/OFF button. Any speed going down hills. If the speed • Tap the brake pedal. previous speed settings are cleared. increases going down a hill, use the brakes to slow down. This will cancel • Tap the clutch pedal. Cruise Control.

(04/13) Y53-1200-1B1 4-35 CRUISE CONTROL

• Press the ON/OFF button if the Using Cruise Control for Stationary • Press the "OFF" button (or vehicle has dash board mounted PTO Operation the steering wheel mounted cruise control switches or the "CANCEL" button). CANCEL button if the vehicle has Setting Idle Speed cruise control switches on the NOTE 1. Ensure parking brakes are applied. steering wheel. Cruise control functions and features 2. Ensure transmission is in Neutral. may vary depending upon which en- Resuming Cruise Control 3. Engage PTO per the gine you have. For specific expla- 1. If you tapped the brake or manufacturer's operating nation of your cruise control, see the clutch pedal, the cruise control instructions. cruise control or engine manual in- remembered the previously set cluded with your vehicle. cruise speed. To resume that 4. Press the "ON" button. 4 set speed, accelerate above the 5. Press the "SET" button to obtain This vehicles electronic system will minimum cruise control speed and the desired engine rpm. perform a ‘rationality check’ every time press the "RESUME" button. the vehicle is started. This check is 2. If you pressed the "OFF" button Cancelling Cruise Control to ensure that the service brakes are (or the steering wheel mounted working before allowing cruise control "CANCEL" button) or turned the You can cancel cruise control in any to function. This safety feature is ignition key OFF, this cleared the of these ways: designed to ensure that a driver is able to cancel the cruise set speed by using system memory and you will need • Tap the brake pedal. to set a new cruise speed. the service brake pedal. The system • Tap the clutch pedal. will not allow cruise control operation if it does not pass the ‘rationality check.’ The instrument cluster will prompt you to press the service brake pedal if it

4-36 Y53-1200-1B1 (04/13) CRUISE CONTROL has not been pressed since the vehicle Adaptive Cruise Control has been started. (Optional)

In vehicles with Eaton transmissions, This vehicle may have an Adaptive the cruise control switches may be Cruise Control with Braking (ACB) located on the shift control knob. system that enhances the cruise The information in the instrument control function. The adaptive cruise cluster will provide various visual control system uses a radar sensor to and audible information. The audible detect the following distance to vehicles sounds may be a steady beep or in front. The system will attempt to a repeating beep depending on the maintain either a safe distance or the situation. The following illustrations vehicle speed depending on what is are provided with the beeping selected by the driver. If a following characteristics. 4 distance conflict occurs the system will alter the vehicles throttle position, Level 3 (Green) Following Distance apply engine braking, and even apply Alert vehicle foundation brakes in attempt to maintain the following distance. The driver should always remain alert and ultimately is the one still responsible for safe vehicle control. This warning is active when the When the system is active and following distance is less than what controlling the speed and distance, the is set in the system. This is the screen will show the following display. least severe of all the warning tones. The system will emit a single beep

(04/13) Y53-1200-1B1 4-37 CRUISE CONTROL

repeating at a rate of 42 tones per applying more braking power and/or minute. This warning is active when the steering clear of the vehicle ahead to following distance is less than what avoid a potential collision. The system Level 2 (Amber) Following Distance is set in the system. This warning will emit a solid beep for a 3 second Alert tone is the most severe following duration. distance alert. The system will emit a continuous beep repeating at a Stationary Object Alert rate of 188 tones per minute and a popup “WARNING Following Distance: Increase Gap to Vehicle Ahead.” This warning is active when the Brake Command Warning following distance is less than what is 4 set in the system. This warning is more The system can also detect stationary severe than the Level 3 Following objects in the vehicles path. The Distance Alert. The system will emit a operator needs to take control of the double beep repeating at a rate of 80 vehicle to avoid the stationary object. tones per minute (40 double beeps per The icon will be accompanied with a minute). pop-up message but no audible sound.

Level 1 (Red) Following Distance This is the most severe warning issued. Alert When the system uses the foundation brakes the level 1 warning will appear on the screen accompanied with a "Collision Alert BRAKE" message. The warning is active when the driver must take immediate evasive action by

4-38 Y53-1200-1B1 (04/13) CRUISE CONTROL

WARNING! The Wingman® ACB sensor may not be able to detect vehicles and objects with limited metal surfaces (such as recreational vehicles, horse-drawn buggies, motorcycles, logging trail- ers, etc.). Failure to understand the system limitation may result in death, serious injury, and/or property dam- age.

Fault Alert 4

This warning is presented to alert the operator that the ACB system is malfunctioning and will be disabled. The operator will need to resume control of the vehicle’s throttle and brakes. The system will remain disabled until the fault is corrected.

(04/13) Y53-1200-1B1 4-39 AXLE AXLE In the LOCK position, continuous WARNING! operation on paved, dry surfaces, put Do not put the differential lock in the Differential Lock stress on the axles, and can possibly LOCK position while the wheels are damage the internal gears. The switch spinning freely (slipping), you could has a guard to prevent accidental lose control of the vehicle or cause operation of the switch. axle damage. Switch to LOCK only Locking the differentials is typically when the wheels are not spinning. The vehicle may be equipped with used during ice or snow conditions Failure to comply may result in death, switches to lock the either of the rear and without tire chains, unpaved roads personal injury, equipment or property axle differentials. Depending on how that have loose sand, mud or uneven damage. the vehicle is specified, a combination surfaces. Look ahead and predict individual switches may be available 4 when the differential needs to be that can lock the interaxle driveline locked. Stop the vehicle and lock the and/or any combination of the forward differentials before approaching. rear or rear-rear driving axles. While using the differential in the The interaxle differential switch allows locked position, do not exceed 25 mph each axle to turn independently. (40 km/h). When disengaging the In certain situations, engaging the differential lock, reduce the throttle to interaxle differential lock relieves prevent drivetrain damage. stress on the rear axles and reduces tire wear. Engaging this switch will also provide better traction in slippery or loose gravel conditions.

4-40 Y53-1200-1B1 (04/13) AXLE

Dual Range (Two-Speed) Dual Range Axle Operation Rear Axle CAUTION Important tips on operating a Dual If you shift the axle range with the in- Range Axle with Interaxle Differential: ter-axle differential in LOCK, you could • Shift the axle with the inter-axle seriously damage the axles. Never differential in the unlocked position shift the axle range with the differen- Your vehicle may be equipped with a only. tial locked. two-speed or dual range axle (option). You can select two rear axle ratios for • When you are driving with poor operating under heavy loads or rough traction, lock the differential. When terrain as well as for over the road you have the differential locked, hauling. drive with the axle in LOW range only. The Low Range provides maximum 4 torque for hauling heavy loads or • When you are driving on a surface traveling over rough terrain. The High with good traction, keep the Range is a faster ratio for highway interaxle differential unlocked. You speeds and general over the road can drive with the axle in the LOW conditions. A switch on the accessory or HIGH range. switch panel controls the Dual Range Rear Axle. You will notice that the • Always UNLOCK the inter-axle switch has a guard to protect you from differential before shifting the axle activating it accidentally. Always park speed range. your vehicle with the range selector in LOW.

(04/13) Y53-1200-1B1 4-41 AXLE

Starting-Up Proper shifting of the axle depends on CAUTION 1. Unlock the inter-axle differential the synchronization of engine/driveline before starting. To avoid damaging your vehicle shift and wheel speed. When you shift the axle at slower travel speeds until 2. Put the Range Selector in the the axle, the connection between the you are used to driving with a dual LOW range. Shift the transmission engine and wheels is momentarily range axle. to start the vehicle moving. disengaged while the gearing is synchronized. Normally when the axle 3. When you are driving on rough is shifted the speed of the engine, axle, terrain and secondary roads, or and wheels adjust, allowing for proper under a very heavy load, keep the gear engagement. axle in the LOW range. Shift the transmission to maintain proper When going downhill the wheels will 4 road speed. not slow down, but will tend to speed up, which makes gear synchronization WARNING! almost impossible. As a result, the Never shift the axle when moving axle is neither in HIGH nor LOW range downhill. Engine driveline disengage- and all engine/driveline retardation is ment may occur, eliminating engine lost. Without engine retardation it is retardation and allowing the wheels to more difficult to slow the vehicle down spin faster than the current speed of and greater stress is put on the brake the engine. This may require severe system. braking to slow the vehicle down and can result in an accident. Failure to comply may result in death, personal injury, equipment or property damage.

4-42 Y53-1200-1B1 (04/13) AXLE

LOW to HIGH (Cruising) HIGH to LOW (Rough Terrain) Auxiliary Axles - Pusher or Tag When you go from rough terrain to If you need to downshift the axle for highway driving, shift the axle to the more power or you are driving on HIGH range following this procedure: rough terrain: 1. Be sure the differential is 1. Maintain your vehicle speed UNLOCKED. (accelerator depressed) and move Adjustable auxiliary axles (commonly the Range Selector lever to LOW. 2. Maintain your vehicle speed known as Pusher or Tag axles) can (accelerator depressed) and move 2. Keep driving with the accelerator add to the productivity of the vehicle by the Range Selector lever to HIGH. depressed until you want the axle increasing the load capabilities of the to downshift. vehicle when they are in the deployed 3. Keep driving with the accelerator (down) position. There are different depressed until you want the axle 3. To make the axle downshift, configurations of axles with different 4 to shift. release and depress the functionality (liftable versus steerable). accelerator quickly to increase the 4. To make the axle shift, release the Without the extra axle, the excessive engine RPM. The axle will shift to accelerator until the axle shifts. weight can reduce the service life LOW range. You are now in the HIGH axle of vehicle components such as, but range for highway speeds. Shift 4. You are now in the LOW axle not limited to, the frame rail, axles, the transmission normally to reach range for rough terrain and heavy suspension and brakes. your desired cruising speed. loads. Shift the transmission normally to maintain the desired Operation of the auxiliary axles speed. includes the proper maintenance of the system and calibration of its controls. Operating the auxiliary axles will also require a firm understanding of the

(04/13) Y53-1200-1B1 4-43 AXLE

Gross Axle Weight Rating (GAWR) creep ratings are assigned by the and the load that is being carried. See axle manufacturer and are based on WARNING! Vehicle Loading on page 1-34. axle model and intended service of Do not operate or park the vehicle the vehicle. Contact an authorized with auxiliary axles in the down/loaded The vehicle will have switches on the dealership if you are unable to identify position when vehicle is unladen, or dash to control the position of the the axle creep rating of this vehicle. is being unloaded. Raise or dump air auxiliary axles. In certain situations, into driver-controlled auxiliary axle(s) • Liftable/steerable (axle lift however, the system will override the prior to unloading vehicle. Failure calibration required) controls to protect the axle system. to do so can result in loss of vehicle Any liftable and steerable auxiliary • Liftable/non-steerable (axle lift control or rollaway that may result in axles will rise off of the ground when calibration required) death, personal injury, equipment or the parking brakes are engaged or property damage. when the vehicle is put in reverse. • Non-liftable (some suspensions 4 If the liftable auxiliary axle is not a require dump valve calibration) steerable axle, then it will remain in the down position when activated by the dash mounted switch.

Operating the auxiliary liftable axles must be performed in a manner that does not exceed the axle creep rating. Axle creep ratings are weight and speed limits that are allowed while the vehicle is fully loaded (in excess of the vehicle’s standard GAWR) and the axle is in its up position. Axle

4-44 Y53-1200-1B1 (04/13) AXLE

Axle Creep Rating Definition ratings are generally limited to the Creep Ratings following: WARNING! Never operate the vehicle with more Low speed, off-highway (work site) • Tandem rear axles only pressure in the lift axles than is nec- axle loads, which exceed the standard • Straight trucks only essary to carry the load, as deter- gross axle weight rating (GAWR) of a mined by the calibration procedure particular axle. • Maximum spring mount described. Failure to do so can result centers per axle manufacturers in loss of traction and stability at the Operator's using vehicles equipped specifications with liftable auxiliary axles must steer and/or drive axles and can result consider creep ratings when any • Maximum tire static loaded radius in increased braking distance, which liftable axle is unloaded or in the raised (SLR) per axle manufacturers could cause loss of vehicle control position. Liftable auxiliary axles should specifications resulting in an accident. Failure to only be raised (or unloaded) to improve comply may result in death, personal 4 maneuverability in an off-road use or CAUTION injury, equipment or property damage. when vehicle is unloaded. Always lower the axles as soon as possible after receiving a load. Never CAUTION NOTE exceed 5 miles per hour when driving Do not modify the air system and/or Axle Creep ratings MUST NOT be ex- with a load with the auxiliary axle(s) control functionality on a factory in- ceeded. raised/unloaded. Failure to lower the stalled auxiliary axle(s). Modifying the axle(s) can overload the frame and re- factory operation of the pusher and/or Contact your dealer or axle maining axles, and could cause equip- tag axle(s) will void your warranty, and manufacturer to determine what ment damage. can cause equipment damage. the creep rating is for your particular axle(s) and configuration. Creep

(04/13) Y53-1200-1B1 4-45 AXLE

Liftable/Steerable or Setting the Pressure-to-Load Ratio CAUTION Liftable/Non-Steerable Pusher To obtain the desired axle load A change in tire size on either the aux- and/or Tag Axle Calibration distribution, you must correlate the iliary axles or the drive/steer axles can Procedure suspension air gauge pressure to the change the calibration of the auxiliary Below are some general instructions actual axle load by scaling the axle axles. If tires are installed with a differ- on how to adjust and calibrate the air weight(s) and adjusting the pressure ent loaded radius, the calibration pro- control valve for the auxiliary axles to to obtain the desired load. Once the cedure must be repeated. Failure to obtain the proper load distribution of desired load or load range is achieved, do so can cause equipment damage. the axle(s). For additional operating document the pressure-to-load ratio or and maintenance instructions, see the setting for future use. pusher or tag suspension manufacturer literature in the glove box or contact 4 them directly.

NOTE This procedure must be performed prior to placing the vehicle into ser- vice.

4-46 Y53-1200-1B1 (04/13) AXLE

General Calibration Guidelines 4. Adjust the amount of load on Operation guidelines each axle by turning the pressure These instructions are general in regulator clockwise to increase nature. For more specific instructions, NOTE the load or counterclockwise review the pusher or tag suspension to decrease the load. (The Steerable-pusher and/or tag axle(s) manufacturers maintenance manual or suspension manufacturer will raise when the transmission is contact the nearest authorized dealer. may publish pre-established shifted into reverse or when the park- Pressure-to-Load Ratio Pressure ing brakes are applied. NOTE Settings to assist you in achieving Perform this procedure at or near a an estimated ground load). Maximizing Drive Axle Traction weight scale. Procedure can be per- formed while parked on the weight 5. After setting the pressure to obtain Adjust the pressure regulator control scale if scale is available. the desired axle load, verify proper knob to a lower pressure until desired 4 ground loading with the weight traction is obtained. By reducing air 1. Park loaded vehicle on level scale. pressure at pusher or tag axle, load surface with wheels blocked. will be transferred to drive axles. Do NOTE 2. Release vehicles spring not overload drive axles. brakes. (Do not release for Exceeding local, state or federal Coupling to a Loaded Trailer Liftable/Non-Steerable pusher or weight limits may result in citations. tag axles). Contact your local commercial weight enforcement office for limits in your Inflate air springs of the auxiliary axles 3. Lower the pusher/tag axles with area. to the desired pressure after coupling the axle lift control flip valve. (For to a loaded trailer while still maintaining some non-liftable axles, inflate air proper traction of the drive axles. suspension). Unloading Operation

(04/13) Y53-1200-1B1 4-47 AXLE

Always deflate air springs of the auxiliary axles before attempting to unload vehicle. This allows maximum traction of the drive axles to control the vehicle.

Non-liftable (Non-steerable) Axles

Some suspensions require dump valve calibration.

Example: Neway dead axles do not 4 lift, but the air can be dumped out of them to unload them when empty. Air pressure is controlled via an adjustable regulator. These axles need to be calibrated for load.

Contact your authorized dealer or axle/suspension manufacturer for dump valve calibration procedures.

4-48 Y53-1200-1B1 (04/13) SUSPENSION

SUSPENSION Suspension Air Pressure Gauge CAUTION Air Suspension Height/Air Operating a vehicle with air suspen- The Suspension Air Pressure gauge (option), see Optional Gauges on page Pressure sion bags either overinflated or under- inflated may cause damage to drive- 3-43, which indicates the amount of air line components. If a vehicle must pressure in the air suspension springs be operated under such conditions, do in pounds per square inch (psi). Air not exceed 5 mph (8 km/h). Failure to pressure in the spring is related to comply may result in equipment dam- the rear axle load. The greater the age. rear axle load, the greater the air pressure in the air bags. Therefore, Your vehicle may have an air the air pressure displayed will vary, depending upon the rear axle load. suspension and a deflation switch 4 which allows the air in the suspension to be exhausted from a switch on the dash. The normal purpose of this feature is to allow you to lower the vehicle for loading.

A guard on the switch prevents you from accidentally deflating the suspension.

(04/13) Y53-1200-1B1 4-49 SUSPENSION

Driving with Deflated Air control arm to center in the closed Springs position. 2. The air system can then be If an air spring is ruptured, there will pumped up to normal pressure for be enough air pressure to drive the continued operation. vehicle to a safe stop off the highway to investigate the problem. WARNING! WARNING! Do not drive the vehicle if the air pres- sure is less than 100 psi (690 kPa). Do not continue to drive with ruptured Driving the vehicle with less than 100 air springs. The air loss can cause the psi (690 kPa) could make the brakes spring brakes to apply allowing your unsafe to use which could cause an brakes to drag and burn up the linings, 4 accident involving death or personal which could lead to an accident caus- injury. ing death or personal injury. Do not continue to operate the vehicle in this condition. CAUTION Operating a vehicle with air suspen- You can get to a repair facility if you do sion bags either overinflated or under- the following: inflated may cause damage to drive- line components. If a vehicle must 1. Remove the height control link be operated under such conditions, do connected to the axle and to not exceed 5 mph (8 km/h). the suspension air valve control arm. This will cause the air valve

4-50 Y53-1200-1B1 (04/13) AFTER-TREATMENT SYSTEM AFTER-TREATMENT SYSTEM

Introduction

This vehicle will has an exhaust After-Treatment System (ATS), to control vehicle exhaust emissions, which consist of a Diesel Particulate Filter (DPF), Selective Catalyst Reduction (SCR), Regeneration Switch and warning lights. The DPF will trap soot from the engine exhaust 4 gases. The SCR uses Diesel Exhaust Fluid to reduce the levels of NOx in the engine exhaust. The ATS will periodically clean (regenerate) the DPF. Please refer to the Exhaust Aftertreatment System Supplement provided with the vehicle for more detailed description of functionality and warnings.

(04/13) Y53-1200-1B1 4-51 DRIVING TIPS AND TECHNIQUES

DRIVING TIPS AND Coasting TECHNIQUES Coasting with the transmission WARNING! in neutral also prevents proper transmission component lubrication. Introduction Do not coast with the transmission in During coasting the transmission is neutral or with the clutch pedal de- driven by the rear wheels, and the This section covers additional driving pressed - it is a dangerous practice. countershaft gear (which lubricates tips and techniques on how to drive Coasting in neutral may result in dam- the transmission components by oil your vehicle more efficiently. age to your drivetrain when you try splash) will only be turning at idle to re-engage the transmission. You speed. could lose control of the vehicle which can lead to an accident involving death or personal injury. 4 Do not coast with the transmission in neutral or with the clutch pedal depressed. Besides being illegal and dangerous, coasting is also expensive. It causes premature failure or damage to the clutch and transmission and overloads the brake system.

4-52 Y53-1200-1B1 (04/13) DRIVING TIPS AND TECHNIQUES

Descending a Grade Engine Overspeed Under normal load and road conditions WARNING! CAUTION operate the engine in the lower end of the range. Do not hold the brake pedal down too To avoid engine damage, do not let the long or too often while going down a engine rpm go beyond the maximum steep or long grade. This could cause governed rpm—valve damage could the brakes to overheat and reduce result if overspeed conditions occur. their effectiveness. As a result, the vehicle will not slow down at the usual NOTE rate. To reduce the risk of an accident which could cause death or personal Often these recommendations are injury, before going down a steep or secondary to maintaining an adequate long grade, reduce speed and shift the and safe speed relative to the sur- 4 transmission into a lower gear to help rounding traffic and road conditions. control your vehicle speed. Failure to follow procedures for proper downhill Operate the engine within the optimum operation could result in loss of vehi- engine rpm range and do not allow cle control. the rpm's to exceed the maximum governed speed. See your Engine Operation and Maintenance manual for information regarding engine rpm. When the engine is used as a brake to control vehicle speed (e.g., while driving down a grade), do not allow the engine rpm to exceed maximum governed speed.

(04/13) Y53-1200-1B1 4-53 DRIVING TIPS AND TECHNIQUES

Use of Tachometer to the engine. However, the governor Optimal Engine Speed has no control over the engine rpm The tachometer is an instrument that when it is being driven by the vehicle's WARNING! aids in obtaining the best performance transmission, for example, on steep Do not look at the Instrument Clus- of the engine and manual transmission, downgrades. Apply service brakes or ter Display for prolonged periods or at serving as a guide for shifting gears. shift to a higher gear. it repeatedly in a short period of time while the vehicle is moving. Extended Refer to the Engine Operation and Fuel economy and engine performance glance durations to instrument cluster Maintenance manual for optimum are also directly related to driving and or overly frequent glances inside engine rpm. habits: the vehicle can cause a loss of at- • If the engine rpm moves beyond • The best results in trip time and tention to the situations on the road- the maximum governed speed, fuel economy are obtained while way and vehicle’s road position, which 4 indicating an overspeed condition, driving the vehicle at a steady could lead to an accident and possible apply the service brake or shift to speed. death or personal injury or equipment a higher gear to bring engine rpm damage. within the optimum speed range. • Shift into higher or lower gears (or apply the service brake) to keep The tachometer displays a green bar • When driving downhill: shift to a engine rpm near the lower end of just below the most efficient engine lower gear, use the engine brake the optimum operating range. speed for the vehicle. The placement (if so equipped), and use the and size of this bar is dependent on service brake, keeping the engine • Avoid rapid acceleration and the engine as installed at the factory. speed below 2,100 rpm. braking. The driver’s general goal should When the engine speed reaches be to select a gear that keeps the its maximum governed speed, the tachometer needle positioned over injection pump governor cuts off fuel the green light as much as possible

4-54 Y53-1200-1B1 (04/13) DRIVING TIPS AND TECHNIQUES during steady state driving. In addition Use of Instrument Cluster Display Fuel - Excess Consumption to proper maintenance and good driving habits, this visual cue can help The Instrument cluster display The vehicle's fuel consumption is minimize the fuel consumption. provides information to help the driver connected to three important factors: optimize vehicle efficiency. Refer to maintenance, driving habits, and Instrumentation Cluster Information on general condition of the road, traffic page 3-14 for details. A driver will find conditions, and vehicle load. the section describing Trip Information and the RPM Detail useful.

4

1. Optimal Engine Speed Indicator

(04/13) Y53-1200-1B1 4-55 DRIVING TIPS AND TECHNIQUES

Maintenance Maintenance factors affecting fuel Driving Habits consumption: Proper maintenance will keep the Wrong driving habits must be vehicle running like new even after • air and/or fuel filters partially corrected and the recommendations long periods of use. The driver must clogged on economic driving should be perform the daily and weekly checks followed. • engine valves out of adjustment of the vehicle. • injection pump improperly Driving factors affecting fuel synchronized consumption: • injection nozzles defective or • excessive speed and unnecessary uncalibrated fast acceleration 4 • improperly inflated tires • long periods of idling • wheel bearings improperly • driving with foot resting on the adjusted (manual transmission) clutch pedal • clutch improperly adjusted or worn (slipping) • fuel leaks

4-56 Y53-1200-1B1 (04/13) DRIVING TIPS AND TECHNIQUES

General Condition

Other factors affecting fuel consumption are related to loads and type of roads on which the vehicle operates. It is not always possible to choose the most adequate road, but it must be kept in mind that the ideal road is the one that allows a steady speed in high gear, without requiring frequent braking and acceleration.

The following general conditions can affect fuel consumption: 4 • overload • unbalanced load • very high load • inadequate roads • traffic conditions

(04/13) Y53-1200-1B1 4-57 SLEEPER BUNKS SLEEPER BUNKS WARNING! WARNING! Sleeper Bunk Always keep the lower bunk in its down Be sure the latch that holds the upper (latched) position while the vehicle is bunk in the folded position is working If your vehicle has an upper and lower moving. If left open, stored items could properly so the bunk will not fall down. bunk, the upper bunk can be folded up become loose during an accident and If the bunk falls, you could be injured. out of the way to provide you with more strike you. Before you move the vehi- dressing area in the sleeper cab. The cle, check to be sure the lower bunk WARNING! lower bunk has storage underneath is latched securely. Failure to comply Be sure to stow away all loose belong- it to stow your luggage and other may result in death or personal injury. belongings. The upper bunk weight ings before you move your vehicle. Do limit is 320 lb. (145 kg). • Before you move the vehicle, not store objects on the bunks, they 4 check to be sure the lower could cause damage or injury in an ac- WARNING! bunk is latched securely. cident. Failure to comply may result in death, personal injury, equipment or Be sure the restraint system is used To Lower Upper Bunk: pull on the property damage. when anyone is occupying the sleeper lanyard in the upper left corner of the while the vehicle is moving. In an ac- bunk to release the bunk. This will free cident, an unrestrained person lying in it from the anchored position and allow a sleeper bunk could be injured. He or you to lower the bunk. she could be thrown from the bunk. To Raise Upper Bunk: fold the upper bunk up and push it against the retaining latch until you hear a click. Pull on the bunk to be sure it is latched securely.

4-58 Y53-1200-1B1 (04/13) SLEEPER BUNKS

Sleeper Occupant Restraint WARNING! The sleeper restraint is stored in a Be sure the restraint system is used compartment on the rear sleeper cab when anyone is occupying the sleeper wall. while the vehicle is moving. In an ac- cident, an unrestrained person lying in WARNING! a sleeper bunk could be injured. He or she could be thrown from the bunk. Failure to properly use the sleeper re- Failure to comply may result in death straint when an individual is located or personal injury. in the sleeper bunk and the vehicle is moving can result in death or personal injury. WARNING! 4 Be sure no one ever rides unsecured See Sleeper Bunks and Restraints on in the upper bunk. That person could page 1-29, for more information on be thrown out in an accident and could cab/seat restraint systems. be injured. Do not use the upper bunk while you are moving. Failure to com- ply may result in death or personal in- jury.

(04/13) Y53-1200-1B1 4-59 STOPPING THE ENGINE

STOPPING THE ENGINE Turbochargers Refueling

Before Stopping the Engine This cooling-down practice is Air inside the fuel tanks allows water especially important on a turbocharged to condense in the tank. To prevent A hot engine stores a great amount of engine. The turbocharger contains this condensation while the vehicle is heat. It doesn’t cool down immediately bearings and seals that are subjected parked for extended periods of time, after you shut it off. Always cool your to hot exhaust gases. While the fill the tanks to 95 percent of capacity. engine down before shutting it off. You engine is operating, heat is carried Never fill to more than 95 percent will greatly increase its service life. away by circulating oil. If you stop the capacity as this provides room for engine suddenly, the temperature of expansion resulting from temperature Idle the engine at 1000 RPM for the turbocharger could rise as much as extremes. When refueling, add five minutes. Then low idle for thirty 100°F (55°C) above the temperature approximately the same amount to seconds before shutdown. This will reached during operation. A sudden each fuel tank on vehicles with more 4 allow circulating coolant and lubricating rise in temperature like this could than one tank. oil to carry away heat from the cylinder cause the bearings to seize or the oil head, valves, pistons, cylinder liners, seals to loosen. WARNING! turbocharger, and bearings. This Do not carry additional fuel containers way you can prevent serious engine in your vehicle. Fuel containers, either damage that may result from uneven full or empty, may leak, explode, and cooling. cause or feed a fire. Do not carry ex- tra fuel containers, even empty ones are dangerous. Failure to comply may result in death, personal injury, equip- ment or property damage.

4-60 Y53-1200-1B1 (04/13) STOPPING THE ENGINE

Location of Fuel Shut-Off Valves Refuel Before the Final Stop WARNING! If your vehicle is equipped with shut-off Air space in your fuel tanks allows Diesel fuel in the presence of an ig- valves for the take-off and return lines, water to condense there. To prevent nition source (such as a cigarette) they are located on the fuel lines this condensation while you are could cause an explosion. A mixture entering the top of the fuel tank. Fuel stopped, fill your tanks to 95% of of gasoline or alcohol with diesel fuel shut-off valves for the fuel crossover capacity. increases this risk of explosion. Do line are on the bottom of the fuel tank, not remove a fuel tank cap near an at the crossover line connection. open flame. Use only the fuel and/or additives recommended for your en- gine. Failure to comply may result in death, personal injury, equipment or property damage. 4

Specification: Use only Ultra Low Sulfur Diesel (ULSD) Fuel, as recommended by engine manufacturers. If you need further information on fuel specifications, consult the Engine Operation and Maintenance Manual.

(04/13) Y53-1200-1B1 4-61 STOPPING THE ENGINE

Final Stop Final Stopping Procedures 2. If you are parked on a steep grade, To make sure your vehicle is ready 1. Set the parking brake before leaving block the wheels. to go after a long stop (such as over the driver’s seat. To hold your vehicle night), please follow the suggestions while it is parked, don’t rely on: Suitable wheel chocks are at a below. Your vehicle will be easier to minimum an 18-inch (46 cm) long 4x4. get going when you are ready, and • Air Brakes it will be safer for anyone who might • Hand Control Valve for Trailer be around it. Please remember, too, Brakes that in some states it is illegal to leave the engine running and the vehicle • Engine Compression unattended. WARNING! 4 Using the trailer hand brake or air brakes to hold a parked vehicle is dangerous. Because they work with air pressure, these brakes could come loose. Your vehicle could roll, causing Blocked Wheels an accident involving death or per- sonal injury. Always set the parking 3. Drain water from the air reservoirs. brakes. Never rely on the trailer hand While the engine and air supply brake or truck air brakes to hold a system are still warm, drain moisture parked vehicle. from the air reservoirs. Open the reservoir drains just enough to drain the moisture. Don’t deplete the entire

4-62 Y53-1200-1B1 (04/13) STOPPING THE ENGINE air supply. Be sure to close the drains before leaving the vehicle.

4 Opening Drains

4. Secure the vehicle. Close all the windows and lock all the doors.

(04/13) Y53-1200-1B1 4-63

MAINTENANCE

PREVENTIVE MAINTENANCE SCHEDULE Introduction ...... 5-9 Maintenance Schedule ...... 5-12 LUBRICANT SPECIFICATIONS Introduction ...... 5-35 Engine ...... 5-35 Master Lubrication Index ...... 5-38 Fuller Transmission Lubrication ...... 5-41 Allison Transmission Lubrication ...... 5-43 Spicer Transmission Lubrication ...... 5-43 Oil Changes ...... 5-44 5 Meritor Axle Lubrication ...... 5-45 Eaton/Dana Axle Lubrication ...... 5-46 Wheel Bearing Lubrication ...... 5-47 Universal Joint Lubrication ...... 5-47 Steering Gear Lubrication ...... 5-48

(04/13) Y53-1200-1B1 5-1 MAINTENANCE

AIR SYSTEM Introduction ...... 5-49 Air Dryer ...... 5-52 Air Tanks ...... 5-54 Air Gauges and Air Leaks ...... 5-55 Air Compressor ...... 5-56 BRAKE SYSTEM Brake Adjustment ...... 5-58 CAB Exterior Maintenance ...... 5-63 Cleaning, Protecting and Weather Stripping . . . 5-64 5 Safety Restraint System - Inspection ...... 5-68 Windshield Wiper/Washer ...... 5-71 COOLING SYSTEM Cooling system maintenance ...... 5-72 Engine (Block) Heater ...... 5-75

5-2 Y53-1200-1B1 (04/13) MAINTENANCE

ELECTRICAL Electrical System ...... 5-77 Light Bulbs ...... 5-78 Bulb Specifications ...... 5-79 Fuses, Circuit Breakers and Relays ...... 5-80 Fuse Inspection and Replacement ...... 5-84 Adding Electrical Options ...... 5-84 Batteries ...... 5-85 Battery Care ...... 5-89 Battery Charging ...... 5-89 Electrical and Alternator Precautions ...... 5-91 Remote Keyless Entry ...... 5-92 5 ENGINE Engine Maintenance ...... 5-93 Engine Lubrication ...... 5-94 Accessory Drive Belts ...... 5-97 Engine Fan ...... 5-98 Air Intake System ...... 5-99

(04/13) Y53-1200-1B1 5-3 MAINTENANCE

Turbocharger ...... 5-99 Air Cleaners ...... 5-100 ServiSignal™ Mini Indicator ...... 5-101 Exhaust System ...... 5-101 Engine Mounting ...... 5-101 FUEL SYSTEM Location of Fuel Shut-off Valves...... 5-103 Specification ...... 5-103 Fuel Filters ...... 5-103 FRAME Introduction ...... 5-104 5 FRONT AXLE AND SUSPENSION Axle Lubrication ...... 5-108 Inspection ...... 5-109 Wheel Alignment ...... 5-109 U-Bolt Torque ...... 5-110

5-4 Y53-1200-1B1 (04/13) MAINTENANCE

HEATER AND AIR CONDITIONER Introduction ...... 5-112 Air Filters ...... 5-113 Heater...... 5-115 Air Conditioner ...... 5-116 NOISE AND EMISSION CONTROL Noise Emission Warranty ...... 5-117 Inspection and Maintenance Instructions . . . . . 5-118 Noise Control System - Maintenance Log . . . . 5-124 REAR AXLE AND SUSPENSION General Maintenance ...... 5-125 Visual Inspection ...... 5-126 5 Rear Suspension Fasteners ...... 5-127 Rear Axle Lubrication ...... 5-128 Rear Axle Alignment ...... 5-130 STEERING SYSTEM Power Steering ...... 5-131

(04/13) Y53-1200-1B1 5-5 MAINTENANCE

Fluid Level and Refill ...... 5-132 Steering Shaft ...... 5-133 DRIVELINE Driveshaft Maintenance ...... 5-135 U-Joints ...... 5-135 TIRES AND WHEEL Tires ...... 5-136 Wheel Mounting and Fastening ...... 5-142 Wheel Replacement with Disc Brake Option . . . 5-144 Disc Wheels ...... 5-145 WHEEL BEARING 5 Wheel Bearing Adjustment ...... 5-146 TRANSMISSION MAINTENANCE Introduction ...... 5-147 Transmission Lubricants ...... 5-148 Automatic Transmissions ...... 5-149

5-6 Y53-1200-1B1 (04/13) MAINTENANCE

CLUTCH Introduction ...... 5-150 Clutch Hydraulic Fluid ...... 5-150 Clutch Adjustment ...... 5-151 Clutch Adjustment – Normal Wear ...... 5-151

5

(04/13) Y53-1200-1B1 5-7

PREVENTIVE MAINTENANCE SCHEDULE PREVENTIVE MAINTENANCE WARNING! WARNING! SCHEDULE Before attempting any procedures If work has to be done with the en- in the engine compartment, stop the gine running, always (1) set the park- engine and let it cool down. Hot com- ing brake, (2) block the wheels, and (3) Introduction ponents can burn skin on contact. ensure that the shift lever or selector Failure to comply may result in death, is in Neutral. Failure to comply may Preventive maintenance program personal injury, equipment or property result in death, personal injury, equip- begins with the daily checks. See damage. ment or property damage. Driver’s Check List on page 1-36 for these routine checks. Routine vehicle checks can help avoid many WARNING! WARNING! large, expensive, and time consuming If the engine must be operating to in- Exercise extreme caution to prevent repairs. The vehicle will operate better, spect, be alert and cautious around the neckties, jewelry, long hair, or loose be safer, and last longer. Neglect engine at all times. Failure to com- clothing from getting caught in the fan of recommended maintenance can ply may result in death, personal injury, blades or any other moving engine void your vehicle’s warranty. Some equipment or property damage. parts. Failure to comply may result 5 maintenance operations demand in death, personal injury, equipment or skills and equipment you may not property damage. have. For such situations, please take your vehicle to an authorized Service Center.

(04/13) Y53-1200-1B1 5-9 PREVENTIVE MAINTENANCE SCHEDULE

WARNING! WARNING! The following pages contain a table of maintenance tasks with the related Disconnect the battery ground strap When working underneath the vehi- intervals for each task on the right whenever you work on the fuel sys- cle without appropriate safety stands side of the table. The top of the table tem or the electrical system. When but with the wheels on the ground (not displays a guide to a maintenance you work around fuel, do not smoke supported), make sure that (1) the ve- interval and its schedule. Some or work near heaters or other fire haz- hicle is on hard level ground, (2) the tasks are dependent on the vehicle ards. Keep an approved fire extin- parking brake is applied, (3) all wheels application. These tasks will be guisher handy. Failure to comply may are blocked (front and rear) and (4) re- shown as separate tasks and will have result in death, personal injury, equip- move the ignition key so that the en- the words “ON HIGHWAY”, “CITY ment or property damage. gine cannot be started. Failure to com- DELIVERY” or “OFF-HIGHWAY” ply may result in death, personal injury, after the description. These tasks equipment or property damage. WARNING! are differentiated because they are Always support the vehicle with ap- dependent on the vehicle’s operating propriate safety stands if it is neces- WARNING! environment. 5 sary to work underneath the vehicle. A Never start or let the engine run in an jack is not adequate for this purpose. enclosed, unventilated area. Exhaust On highway is defined for applications Failure to comply may result in death, fumes from the engine contain carbon where the vehicle is NOT used off of a personal injury, equipment or property monoxide, a colorless and odorless paved road during normal operation. damage. gas. Carbon monoxide can be fatal if City Delivery is defined for applications inhaled. Failure to comply may result where frequent start and stopping is in death, personal injury, equipment or required during normal operation and property damage. the highway is used infrequently and for short periods of time.

5-10 Y53-1200-1B1 (04/13) PREVENTIVE MAINTENANCE SCHEDULE

interval. Refer to Oil Changes on Off highway is defined for applications page 5-44 before you put a new where the vehicle may be driven off vehicle into service. the pavement on a regular basis, even if it is an infrequent basis and/or for a • The initial fill of lubricant in brief time period. manual transmissions must be changed before the end of the first Please contact an authorized maintenance interval. See Fuller service dealership if there are Transmission Lubrication on page questions regarding which interval 5-41 for specific information. to follow. Consult the supplier for specific recommendations where • If your vehicle is equipped with an discrepancies develop between these automatic transmission, consult recommendations in this table and the owner’s manual for it that came component supplier recommendations. with your vehicle to obtain lubricant check and change intervals. • Engine lubricating oil change intervals aren’t listed here. Refer 5 to your engine’s operating manual for recommendations. For specific information on maintenance procedures consult your vehicle maintenance manual. • The initial fill of drive axle lubricant must be changed before the end of the first scheduled maintenance

(04/13) Y53-1200-1B1 5-11 PREVENTIVE MAINTENANCE SCHEDULE

Maintenance Schedule

New Vehicle Maintenance Schedule

New Vehicle Maintenance Schedule After First Miles (km) 50 – 100 500 (800) 2,000 3,000 Operation\Frequency First Day (80 – 160) (3218) –5,000 (4800 –8000) Steering Shaft U-Bolts. (OFF-HIGHWAY) See Steering System on page 5-131. X Wheel Mounting. See Wheel Mounting and Fastening on page 5-142. X Front Axle U-Bolt Torque. See Front Spring Suspension U-Bolts on page 5-110. X Charge Air Cooler and Air Intake Pipe Clamps, re- torque fasteners. X Rear Suspension Fasteners. See Rear Suspension Fasteners on page 5-127. X Transmission Lubrication. X 1. For Fuller transmission, see Fuller Transmission Lubrication on page 5-41. 2. For Allison transmission, see Allison Transmission Lubrication on page 5-43. 3. For Spicer transmission, see Spicer Transmission Lubrication on page 5-43. Axle Lubrication. 5 1. For Meritor axle, see Meritor Axle Lubrication on page 5-45. X 2. For Eaton/Dana axle, see Eaton/Dana Axle Lubrication on page 5-46.

5-12 Y53-1200-1B1 (04/13) PREVENTIVE MAINTENANCE SCHEDULE

PREVENTIVE MAINTENANCE (PM) INTERVALS

Recommended PM Interval SYSTEM COMPONENT MAINTENANCE TASK I A B C D E Frame Fifth Wheel Check the kingpin lock and plate for wear and function; X lubricate (NLGI #2 grease). Inspect fifth wheel operation (shown on page 5-127) X Frame Fasteners Check for tightness; tighten to the specified torque value as X required (shown on page 5-104). Crossmembers and Inspect for cracks and loose fasteners. Replace or tighten to X Mounting Brackets the specified torque value as required (shown on page 5-104). Engine Mounting Inspect engine mounts every 60,000 miles (96,560 km) (shown X on page 5-101). Contact an authorized vehicle OEM dealership if engine mounts need servicing. 5

(04/13) Y53-1200-1B1 5-13 PREVENTIVE MAINTENANCE SCHEDULE

PREVENTIVE MAINTENANCE (PM) INTERVALS

Recommended PM Interval SYSTEM COMPONENT MAINTENANCE TASK I A B C D E Front Axle Total Vehicle Alignment Check and adjust as required. X X (Meritor) Steering knuckle spindles, Inspect for wear and damage and endplay. Shim or replace as X thrust bearings, kingpins, required (shown on page 5-131). drawkeys, tie rod ends, steering stops, and bushings Kingpin bushings, thrust Lubricate with approved grease. X bearings, and tie rod ball ends

5 Drawkeys Tighten nuts X X

5-14 Y53-1200-1B1 (04/13) PREVENTIVE MAINTENANCE SCHEDULE

PREVENTIVE MAINTENANCE (PM) INTERVALS

Recommended PM Interval SYSTEM COMPONENT MAINTENANCE TASK I A B C D E Front Axle Total Vehicle Alignment Check and adjust as required. X X (Dana) Kingpin bushings, thrust Lubricate with approved grease. X bearings, and tie rod ball ends (ON HIGHWAY) Kingpin bushings, thrust Lubricate with approved grease. X bearings, and tie rod ball ends (OFF-HIGHWAY) Steering knuckle spindles, Inspect for wear and damage and for endplay. Shim or replace X thrust bearings, kingpins, as required. drawkeys, tie rod ends, steering stops, and bushings (ON HIGHWAY) 5 Steering knuckle spindles, Inspect for wear and damage and for endplay. Shim or replace X thrust bearings, kingpins, as required. drawkeys, tie rod ends, steering stops, and bushings (OFF-HIGHWAY)

(04/13) Y53-1200-1B1 5-15 PREVENTIVE MAINTENANCE SCHEDULE

PREVENTIVE MAINTENANCE (PM) INTERVALS

Recommended PM Interval SYSTEM COMPONENT MAINTENANCE TASK I A B C D E Front Front Spring Inspect for cracked leaves, worn bushings, and excessive X Suspension corrosion. Spring Pins and Shackles Inspect for worn parts and excessive joint clearance. Shim X or replace as required. Shock Absorbers Inspect for leaking, body damage, and damaged or worn X bushings. Replace as required. Check the shock mounting stud torque. Spring Pins Lubricate with approved grease. X Check for proper function. X U-bolts (ON HIGHWAY) Check the general condition and the tightness of the nuts. X X Tighten the nuts to the specified torque value as required 5 (shown on page 5-111). U-bolts (OFF HIGHWAY) Check the general condition and the tightness of the nuts. X Tighten the U-bolts after the first day or two of operation. Then tighten the nuts to the specified torque value as required (shown on page 5-111).

5-16 Y53-1200-1B1 (04/13) PREVENTIVE MAINTENANCE SCHEDULE

PREVENTIVE MAINTENANCE (PM) INTERVALS

Recommended PM Interval SYSTEM COMPONENT MAINTENANCE TASK I A B C D E Drive Axle Axle Housing Visually inspect for damage or leaks. X (Dana) Check oil level. Check “cold.” Torque the drain plug. X Drain the lubricant while warm. Flush each unit with clean See information on page 5-45 flushing oil. Change the lubricant. Air Shift Unit Check the lubricant level. X Remove the housing cover and drain the lubricant. Wash the X parts thoroughly and dry in air. Breather Clean or replace. X Lube Pump (ON HIGHWAY) Remove the magnetic strainer and inspect for wear particles. X Wash in solvent and dry in air. Lube Pump (OFF Remove the magnetic strainer and inspect for wear particles. X HIGHWAY) Wash in solvent and dry in air. 5 Lube Filter (ON HIGHWAY) Change. X Lube Filter (OFF Change. X HIGHWAY) Magnetic drain plug and Clean or replace. X breather (ON HIGHWAY) Magnetic drain plug and Clean or replace. X breather (OFF HIGHWAY)

(04/13) Y53-1200-1B1 5-17 PREVENTIVE MAINTENANCE SCHEDULE

PREVENTIVE MAINTENANCE (PM) INTERVALS

Recommended PM Interval SYSTEM COMPONENT MAINTENANCE TASK I A B C D E Drive Axle Axle Housing Check the “cold” fill level at the differential carrier plug for a X (Meritor) pinion angle of less than 7 degrees, or at the axle bowl plug for a pinion angle of greater than 7 degrees. Tighten the plug to 35-50 Lb. ft. (47-68 N.m.) Visually inspect for damage or leaks. X Drain and replace the lubricant. See information on page 5-44 Lubricant filter Change the filter. X Breather Check the operation. If the cap doesn’t rotate freely, replace. X Input shaft and pinion shaft Check and adjust the endplay. X Axle shaft Tighten the rear axle flange nuts to the specified torque value. X Interaxle differential Check the operation. X 5 Drive Axle Axle Housing Change the oil in the differential carrier and the hubs, and clean X X (SISU) the magnetic oil drain plugs. Check the wheel bearing hubs and adjust if necessary. X X Visually inspect for damage or leaks. X X Check the oil level in the differential carrier and hubs. X Breather Check the breather for proper operation. X Lube Filter Clean the suction filter for the optional pressure lubrication X system. S-cam brakes Overhaul the brakes; degrease all moving parts; check the X bushings and seals for wear.

5-18 Y53-1200-1B1 (04/13) PREVENTIVE MAINTENANCE SCHEDULE

PREVENTIVE MAINTENANCE (PM) INTERVALS

Recommended PM Interval SYSTEM COMPONENT MAINTENANCE TASK I A B C D E Rear U-bolts Check the torque. Tighten to specified torque value as required X X Suspension (shown on page 5-128). Frame and crossmember Check the torque. Tighten to specified torque value as required X bolts (shown on page 5-106).

Mounting brackets and Check the condition and the fastener torque. Tighten to the X X fasteners specified torque value as required (shown on page 5-106).

5

(04/13) Y53-1200-1B1 5-19 PREVENTIVE MAINTENANCE SCHEDULE

PREVENTIVE MAINTENANCE (PM) INTERVALS

Recommended PM Interval SYSTEM COMPONENT MAINTENANCE TASK I A B C D E Drum Brakes Slack adjusters Check the push rod travel and check the control arm for cracks. X (All) Adjust at reline (shown on page 5-61). Lubricate (NLGI #2 grease). X Brake camshaft bearing Check for excessive camshaft paly in the axial and radial X directions. Max allowable play is 0.003 in. Lubricate (NLGI #2 grease). Brake treadle valve Clean the area around the treadle, boot, and mounting plate. X Check the pivot and mounting plate for integrity. Check the plunger boot for cracks. Lubricate roller pin, pivot pin, and plunger (NLGI #2 grease). Brake air system Check air lines and fittings for leaks (shown on page 5-49). X 5 Adjust routing as required to prevent chafing. Check tank mounting and condition. Clean or replace the inline filters. X Brake lining Inspect; replace as required. X

5-20 Y53-1200-1B1 (04/13) PREVENTIVE MAINTENANCE SCHEDULE

PREVENTIVE MAINTENANCE (PM) INTERVALS

Recommended PM Interval SYSTEM COMPONENT MAINTENANCE TASK I A B C D E Disc Brakes Brake pads Inspect; replace as required. X (Bendix®) Brake disc/rotor Inspect for visible cracks, heat checking, galling, or scoring of X surface. Check for runout (max allowable is 0.002 in.). Caliper sliding function Ensure caliper slides freely with no obstructions or excessive X play. Caliper slide pins Inspect protective caps of the guide pins for damage or X cracking. System operation Check operation; inspect as per manufacturer’s service X literature.

5

(04/13) Y53-1200-1B1 5-21 PREVENTIVE MAINTENANCE SCHEDULE

PREVENTIVE MAINTENANCE (PM) INTERVALS

Recommended PM Interval SYSTEM COMPONENT MAINTENANCE TASK I A B C D E Hub, Drum, Hubs (non-LMS) Check the bearing endplay and adjust as required (shown on X and Hubcap page 5-47). Hubs (non-LMS) with Clean the components and check for excessive wear or X outrunner seals damage. Change the oil and seal (shown on page 5-47). Hubs (non-LMS) with Clean the components and check for excessive wear or X standard seals damage. Change the oil and seal (shown on page 5-47). Hub seals (all) Check for leaks; replace as required. X LMS Hubs (Dana) Inspect for leaks. Check the bearing endplay and adjust as X required (shown on page 5-47). LMS Hubs (Dana) with Service the bearings, seals and oil. This interval may be 500,000 miles/ 800,000 km Synthetic Lubricant different depending on the results of the regular inspection. 5 (shown on page 5-47). LMS Hubs (Dana) with Service the bearings, seals and oil. This interval may be 350,000 miles/ 560,000 km Mineral Lubricant different depending on the results of the regular inspection. (shown on page 5-47). Brake drums Inspect for visible cracks, heat checking, galling or scoring of X the braking surface, and for severe corrosion on the outside surface. Check for out-of-round or oversize condition [0.080 in. (2 mm) more than the original diameter]. Replace as required. Hubcaps Clean the sight window. Check the center plug, mounting X flange, and fill plug for leaks and for proper installation. Replace broken or damaged parts. Check the lubricant level and add as required.

5-22 Y53-1200-1B1 (04/13) PREVENTIVE MAINTENANCE SCHEDULE

PREVENTIVE MAINTENANCE (PM) INTERVALS

Recommended PM Interval SYSTEM COMPONENT MAINTENANCE TASK I A B C D E Main and Main and auxiliary Inspect for visible damage, signs of overheating, and leaks. X X auxiliary transmission and transfer Check the drain plugs for tightness. X transmission case Mounting Brackets and Check the condition of the fasteners and their torque. Tighten X Fasteners to the specified torque value as required. Oil cooler Clean the fins (air-to-oil type) and body. Check the hose X condition and for leaks; replace as required. Main and aux. transmission Check the oil level; refill as required. X Main and auxiliary Drain lubricant while warm. Flush each unit with clean flushing 500,000 miles/ 800,000 km transmission (ON oil. HIGHWAY) Main and auxiliary Drain lubricant while warm. Flush each unit with clean flushing X X 5 transmission (OFF oil. HIGHWAY) Auxiliary Cotta Transfer Case Inspect: Check oil level; inspect for leaks and any visible X transmission TR2205 damage. Fabco Transfer Case Initial oil change: Drain oil while warm; flush case with gear X X TC142/TC143/TC170/ oil-compatible fluid; clean magnetic drain plug; refill. Do not TC270 flush the case with any solvent. Marmon-Harrington Change oil. X Transfer Case MVG2000/MVG2000SD

(04/13) Y53-1200-1B1 5-23 PREVENTIVE MAINTENANCE SCHEDULE

PREVENTIVE MAINTENANCE (PM) INTERVALS

Recommended PM Interval SYSTEM COMPONENT MAINTENANCE TASK I A B C D E Air Intake Air intake piping, mounting, Check the system for broken pipes, leaks, joint integrity, X and charge air cooler cleanliness, and proper support (shown on page 5-99). Cold starting aids Check for leaks and proper operation (shown on page 4-10). X Air cleaner Replace the engine intake air cleaner element (shown on page When required by air restriction 5-100). indicator or required by the engine manufacturers operator manual. Clutch Clutch hydraulic fluid Replace fluid and bleed system. X Clutch release bearing Lubricate. X Inspect and adjust when necessary (no adjustment required X for SOLO type clutches) 5

5-24 Y53-1200-1B1 (04/13) PREVENTIVE MAINTENANCE SCHEDULE

PREVENTIVE MAINTENANCE (PM) INTERVALS

Recommended PM Interval SYSTEM COMPONENT MAINTENANCE TASK I A B C D E Cooling Hoses Check the radiator and heater hoses for leaks. X X Extended Life Coolant Check the freeze point (shown on page 5-73). X (ELC) Check for contamination using test strips (shown on page 5-72). X Replace blank water filter if applicable. X Perform lab analysis (shown on page 5-72). X If lab analysis shows coolant is unsuitable for continued use: Flush, drain, and refill (shown on page 5-72). Add ELC Extender (shown on page 5-72). Flush, drain, and refill with new coolant (shown on page 5-72). X Fan clutch Check for air leaks. (shown on page 5-98). X X Check the fan drive bearings (turn the sheave in both directions to check for worn hub bearings). 5 Solenoid valve Check the fan drive for proper engagement and disengagement. X X

(04/13) Y53-1200-1B1 5-25 PREVENTIVE MAINTENANCE SCHEDULE

PREVENTIVE MAINTENANCE (PM) INTERVALS

Recommended PM Interval SYSTEM COMPONENT MAINTENANCE TASK I A B C D E Tires and Tires Check inflation pressure (shown on page 5-136). Weekly “cold” using calibrated gauge Wheels Inspect for cuts, irregular wear, missing lugs, sidewall damage, X etc. Disc wheels Inspect the wheel disc for any cracks or surface irregularities. X Inspect the rim edge and bead seat area for damage. Replace any damaged wheels - DO NOT ATTEMPT TO REPAIR. Demountable rims Inspect the mounting ring, rim gutter, side ring, and lock ring for X damage; replace as required. Wheel nuts and studs Check the tightness of the fasteners and tighten the fasteners X to the specified torque as required (shown on page 5-142). Inspect for damaged hex corners, stripped or damaged X 5 threads, and excessive corrosion; clean or replace as required.

5-26 Y53-1200-1B1 (04/13) PREVENTIVE MAINTENANCE SCHEDULE

PREVENTIVE MAINTENANCE (PM) INTERVALS

Recommended PM Interval SYSTEM COMPONENT MAINTENANCE TASK I A B C D E Power Reservoir Check the fluid level (shown on page 5-48). X Steering Reservoir (ON HIGHWAY) Drain, replace the filter, and refill (shown on page 5-48). X X Reservoir (OFF HIGHWAY) Drain, replace the filter, and refill (shown on page 5-48). X X Steering gear Check the lash of the sector shaft; adjust as required. X Grease the trunnion bearing (EP NLGI #2 lithium-based, X moly-filled, HD grease). Grease the input shaft seal (EP NLGI #2 lithium-based, X moly-filled, HD grease). Power assist cylinder Lubricate the ball joints. Inspect for leaking rod seals, damaged X ball joint boots, and damage to cylinder rod or barrel. Hoses and tubes Check for leaks and chafing. X Steering linkage Check all joints for excessive lash; replace as required (shown X 5 on page 5-131). Draglink tube clamp and Check the torque; tighten to specified torque value as required. X X ball socket Pitman arm clamp bolt and Check the torque; tighten to specified torque value as required. X X nut Steering intermediate shaft Check the torque on the pinch bolt and nut. X X

(04/13) Y53-1200-1B1 5-27 PREVENTIVE MAINTENANCE SCHEDULE

PREVENTIVE MAINTENANCE (PM) INTERVALS

Recommended PM Interval SYSTEM COMPONENT MAINTENANCE TASK I A B C D E Power Steering intermediate shaft Lubricate [EP NLGI #2 HD grease, +325° F to -10° F (+163° C X X Steering U-joints (ON HIGHWAY) to -23° C) range]. Steering intermediate shaft Lubricate [EP NLGI #2 HD grease, +325° F to -10° F (+163° C X X U-joints (OFF HIGHWAY or to -23° C) range]. CITY DELIVERY) Draglink and tie rod arm ball Lubricate (EP NLGI #2 lithium-based, moly-filled, HD grease). X X sockets (ON HIGHWAY) Draglink and tie rod arm ball Lubricate (EP NLGI #2 lithium-based, moly-filled, HD grease). X X sockets (OFF HIGHWAY or CITY DELIVERY) Fuel and Tanks Fuel tanks Inspect tanks, brackets, hoses, and fittings for correct location, X 5 tightness, abrasion damage, and leaks; repair or replace as required. Fuel tank breathers Check for proper function; clean the drain hoses. X Fuel tank straps Check the strap tightness; tighten to proper torque value as X X required: Aluminum tank: 30 Lb. ft. (41 N.m.) Cylindrical Steel tank: 8 Lb. ft. (11 N.m.)

5-28 Y53-1200-1B1 (04/13) PREVENTIVE MAINTENANCE SCHEDULE

PREVENTIVE MAINTENANCE (PM) INTERVALS

Recommended PM Interval SYSTEM COMPONENT MAINTENANCE TASK I A B C D E Driveshafts Models SPL-90, 1710 and Lubricate*. X X 1810 slip member and Inspect. U-joint inspections should be U-joints performed every time a vehicle comes in for scheduled maintenance.** Model SPL-100 slip Lubricate*. X member and U-joints Inspect. U-joint inspections should be performed every time a vehicle comes in for scheduled maintenance.** Models Lubricate*. X SPL-140/140HD/170/ Inspect. U-joint inspections should be 170HD/250/250HD slip performed every time a vehicle comes members and U-joints (ON in for scheduled maintenance.** 5 HIGHWAY and LINEHAUL)

(04/13) Y53-1200-1B1 5-29 PREVENTIVE MAINTENANCE SCHEDULE

PREVENTIVE MAINTENANCE (PM) INTERVALS

Recommended PM Interval SYSTEM COMPONENT MAINTENANCE TASK I A B C D E Driveshafts Models Lubricate*. X SPL-140/140HD/170/ Inspect. U-joint inspections should be 170HD/250/250HD slip performed every time a vehicle comes members and U-joints (OFF in for scheduled maintenance.** HIGHWAY) Models Lubricate*. 350,000 mi (560,000 km) 1st interval SPL-140XL/170XL/250XL and then every 100,000 mi (160,00 slip members and U-joints km) after that. (ON HIGHWAY and LINE Inspect. U-joint inspections should be HAUL) performed every time a vehicle comes in for scheduled maintenance.** 5 Models Lubricate*. X SPL-140XL/170XL/250XL Inspect. U-joint inspections should be slip members and U-joints performed every time a vehicle comes (OFF HIGHWAY and CITY) in for scheduled maintenance.** *Use only Spicer Driveshaft approved lubricants when greasing Spicer U-joints. **Refer to Spicer Driveshaft service manual DSSM-0100 (3264-SPL) for detailed instructions.

5-30 Y53-1200-1B1 (04/13) PREVENTIVE MAINTENANCE SCHEDULE

PREVENTIVE MAINTENANCE (PM) INTERVALS

Recommended PM Interval SYSTEM COMPONENT MAINTENANCE TASK I A B C D E Battery Boxes, Battery cables Check the condition of the cables, cushion clamps, nylon tie X Tool Boxes, straps, and routing. Replace a cushion clamp if the rubber has and Steps deteriorated. Repair or tighten terminals, and secure cables to prevent chafing. Replace damaged cables (cuts, cracks, or excessive wear) (shown on page 5-77). Batteries (ON HIGHWAY Check for cracks and damage, electrolyte level, condition of X and LINE HAUL) terminals, and tightness of holddowns (shown on page 5-77). Batteries (OFF-HIGHWAY) Check for cracks and damage, electrolyte level, condition of X terminals, and tightness of holddowns (shown on page 5-77). Battery box and tray (ON Check the box integrity. Clean the drain tube and check for acid X HIGHWAY and LINE HAUL) leaks. Check condition of all equipment mounted under the box. Battery box and tray Check the box integrity. Clean the drain tube and check for acid X 5 (OFF-HIGHWAY) leaks. Check condition of all equipment mounted under the box. Battery Cable Fasteners Check battery cable fasteners and tighten as necessary to X 10-15 Lb. ft. (13.6-20.3 N.m.) as specified on the battery label.

(04/13) Y53-1200-1B1 5-31 PREVENTIVE MAINTENANCE SCHEDULE

PREVENTIVE MAINTENANCE (PM) INTERVALS

Recommended PM Interval SYSTEM COMPONENT MAINTENANCE TASK I A B C D E Electrical and Headlamps Check the aim and adjust as required. X lights Warning lights in light bar Check at the ignition start position to verify bulbs and driver X information display function (shown on page 3-30). Turn, Stop, Reverse lights Visual check. X and signals Alternator Check operation and output. X Check tightness of the pulley nut. X Check the tension of the drive belt (shown on page 5-97). X Check tightness of the terminal hex nuts. X Starter Check torque on hex nuts. X ECM connector Check the tightness of the ECM connector. X 5 Wheel sensors Check for damaged sensors and connectors, and worn or X frayed wires. Fuel and diesel exhaust Check the mounting screws and electrical connections for worn X X fluid tank sending unit or damaged wires and connectors. Power supply harnesses Check for worn or damaged insulation, corroded terminals, X (engine, transmission, etc.) frayed wires, and oil or fluid leaks on the connectors or wiring. Wash to remove excess grease. X Cab structure, Hood Lubricate the lower hood pivot (only if lube fittings are present). X doors and Hinges and latch Lubricate with silicone spray. X hoods Body and cab holddown Check the condition and tightness. X bolts

5-32 Y53-1200-1B1 (04/13) PREVENTIVE MAINTENANCE SCHEDULE

PREVENTIVE MAINTENANCE (PM) INTERVALS

Recommended PM Interval SYSTEM COMPONENT MAINTENANCE TASK I A B C D E Heating Air conditioner Operate the system. X and Air Heater and air conditioner Perform the checks listed shown on page 5-112. X Conditioning Full operational and diagnostic check. X Cabin fresh air filter (ON Inspect and clean, replace if necessary, as shown on page X HIGHWAY) 5-113. Cabin fresh air filter Inspect and clean, replace if necessary, as shown on page X (OFF-HIGHWAY) 5-113. Condenser Clear any debris from the front of the condenser. X Sleeper air filter Inspect and clean, replace if necessary, as shown on page X 5-114. Recirc cab air filter (ON Please contact an authorized dealer when the service interval X HIGHWAY) is required to inspect the cabin recirculation air filter. 5 Recirc cab air filter Please contact an authorized dealer when the service interval X (OFF-HIGHWAY) is required to inspect the cabin recirculation air filter. Aftertreatment System Check for leaks and proper support (shown on page 5-117). X System Diesel particulate filter Clean filter. Refer to the Engine Maintenance Manual. Diesel exhaust fluid tank Inspect the tank, straps, brackets, hoses and fittings for X abrasion damage, leaks, tightness and fully engaged connectors. Diesel exhaust fluid supply Replace filter. Refer to the Engine Maintenance module Manual.

(04/13) Y53-1200-1B1 5-33 PREVENTIVE MAINTENANCE SCHEDULE

PREVENTIVE MAINTENANCE (PM) INTERVALS

Recommended PM Interval SYSTEM COMPONENT MAINTENANCE TASK I A B C D E Air Air compressor governor Replace air strainer. X Air lines Check condition and routing to prevent chafing. X System Lubricate (shown on page 5-49). X Inline filters Replace elements or clean with solvent. X Air dryer Perform the checks listed (shown on page 5-49). X Air dryer (ON HIGHWAY) Overhaul. 360,000 miles/576,000 km Air dryer (OFF HIGHWAY) Overhaul. X Engine Basic Engine Maintenance and service interval recommendations are detailed in the engine manufacturer’s Operations and Maintenance Manual included with the vehicle. The engine manufacturer’s recommendations vary depending engine model. Information is also available from authorized dealers, the engine manufacturer’s authorized service centers, and the engine manufacturer’s web site. 5 Safety Three-point Safety Belt Inspect. 20,000 miles/32,000km System If the vehicle is exposed to severe environmental or working conditions, more frequent inspections may be necessary.

5-34 Y53-1200-1B1 (04/13) LUBRICANT SPECIFICATIONS

LUBRICANT its life is proper lubrication servicing. Engine SPECIFICATIONS Neglecting this essential aspect of vehicle care can cost time and money Proper engine lubrication depends in the long run. on the outside temperatures where Introduction you will be driving. Use the oil CAUTION recommended for the conditions you WARNING! are most likely to be operating in. You Do not mix different types of lubricants. will find a complete engine lubrication Handle lubricants carefully. Vehicle lu- Mixing lubricants (oil and grease) of service guide in the Engine Operation bricants (oil and grease) can be poi- different brands or types could dam- Manual that came with your vehicle. sonous and cause death, personal in- age vehicle components; therefore, The engine operator manual contains jury or sickness. They can also dam- drain (or remove) old lubricants from specific maintenance tasks that you or age the paint on the vehicle. the unit before refilling it. a qualified service technician need to In this section you will find the basic perform to maintain the engine. information you need to do the routine lubrication your vehicle requires. Of course you will want to schedule 5 service more frequently if you are operating under severe conditions such as extreme heat or cold, with very heavy loads, off-road, etc. For any special service requirements, consult your service manuals and your lubricant supplier. Please remember: one key to keeping your truck running at top economy and in prolonging

(04/13) Y53-1200-1B1 5-35 LUBRICANT SPECIFICATIONS

WARNING! NOTE Exhaust fumes from the engine con- Keep the engine exhaust system and tain carbon monoxide, a colorless and the vehicle’s cab ventilation system odorless gas. A poorly maintained, properly maintained. It is recom- damaged, or corroded exhaust system mended that the vehicle’s exhaust can allow carbon monoxide to enter system and cab be inspected: the cab or sleeper. Failure to prop- erly maintain your vehicle could cause • By a competent technician every carbon monoxide to enter the cab and 15,000 miles/ 24,000 km, cause death, personal injury or serious • Whenever a change is noticed in illness. the sound of the exhaust system, • Whenever the exhaust system, WARNING! underbody, cab or sleeper is Never idle your vehicle for prolonged damaged. 5 periods of time if you sense that ex- haust fumes are entering the cab. In- NOTE vestigate the cause of the fumes and correct it as soon as possible. If the ve- Use only an exact replacement parts hicle must be driven under these con- in Aftertreatment exhaust system. Us- ditions, drive only with the windows ing a noncompliant replacement part slightly open. Failure to repair the could violate emissions requirements source of the exhaust fumes may lead and also void the emission system’s to death, personal injury or serious ill- warranty. ness.

5-36 Y53-1200-1B1 (04/13) LUBRICANT SPECIFICATIONS

Pipe and Hose Clamps

Use the following table for torque specifications to check pipe and hose clamps.

Pipe and Hose Clamp Torque Values

APPLICATION APPROVED CLAMP TORQUE Nm Lb-In Radiator and Heat Exchanger Hoses Constant-Torque CT-L 10.2-12.5 90-110 Heater Hoses Constant Tension not required not required Air Intake Pipes Hi-Torque HTM-L 11.3-14.2 100-125 Plastic Air Intake Pipes Constant- Torque CT-L 4.5 40 (maximum) Charge Air Intake Hoses Flex Seal 667 7.9-11.3 70-100 B9296 6-7 50-60 Fuel, Oil and Water Heat Exchangers (for Miniature 3600L 1.1-1.7 10-15 hoses less than 9/16 diameter) 5

(04/13) Y53-1200-1B1 5-37 LUBRICANT SPECIFICATIONS

Master Lubrication Index

Lubricant Symbol Key ATF MD3 or MERCON®-approved automatic transmission fluid BB High temperature ball bearing grease. Chevron SRI Mobile Grease HP, Texaco Multifax 2 or equivalent CB Engine oil for mild to moderate requirements CC/CD Engine oil for severe requirements (MIL-L-2104B /MIL-L-45199B w/ 1.85% max. sulfated ash content) CD Engine oil meeting API “Five engine test sequence” CD50 SAE50W synthetic transmission fluid CE Engine oil meeting severe duty service requirements for direct-injection turbocharged engines CJ-4 Engine oil for PACCAR MX and Cummins EGR engines CL Multipurpose chassis grease EP Extreme Pressure Lubricant (Lithium 12-hydroxystearate base NGLI 2) GL Straight mineral gear lubricant HD Hypoid Gear Oil, A.P.I. - GL-5, SAE 75W-90FE synthetic gear lubricant HT High Temperature grease (Timken Spec. 0-616) MP Multipurpose gear lubricant (MIL-L-2105B) DOT3 or DOT4 Brake Fluid

5 NOTE boxes, transfer cases, etc.) the oil must be level with the filler opening. Use care when checking the oil level The responsibility for meeting these with a finger. Just because you can specifications, the quality of the prod- reach the oil level with a finger, does uct, and its performance in service not mean the oil level is correct. rests with the lubricant supplier.

For oil reservoir with side filler plugs 1 Improper Oil Level (transmission, axles, steering gear 2 Proper Oil Level

5-38 Y53-1200-1B1 (04/13) LUBRICANT SPECIFICATIONS

Component Lubrication Index Universal Joints EP* Drive Shaft Splines CL* Steering Column CL Alternator Bearing BB* Fan Hub BB* Power Steering Reservoir ATF Steering Drag Link CL Steering Knuckles CL Spring Pins CL Clutch Release Bearings BB Brake Shoe Anchor Pins HT Brake Cam Bearings HT Slack Adjusters CL Starter Bearings CC Turbocharger Aneroid CC Water Pump BB* Suspension Fittings (other than threaded pins and bushings) EP Steering Axle: Grease Fittings on Steering Arm; Tie Rod Ends; Drag EP Link; King Pins 5 Steering Shaft Grease Fittings EP Brake Treadle Hinge and Roller Engine oil Lock Cylinders Lock lubricant Door Hinges Not required - Teflon bushings Door Latches and Striker Plates Polyethylene grease stick Door Weatherstrip Silicone lubricant Hub-piloted Aluminum Wheels Coat the wheel pilot or hub pads with Freylube #3 lubricant (light colored) or Chevron Zinc lube. Do not get lubricant on the face of the wheel or the hub.

(04/13) Y53-1200-1B1 5-39 LUBRICANT SPECIFICATIONS

Component Lubrication Index Manual Transmission Hydraulic Clutch DOT3 or DOT4 (Brake Fluid) *Consult manufacturer or lubricant supplier for special details.

5

5-40 Y53-1200-1B1 (04/13) LUBRICANT SPECIFICATIONS

Fuller Transmission Lubrication Change and Inspection Lubrication Off-Highway Use

Fuller transmissions are designed so Refer to the Eaton Fuller transmission that the internal parts operate in a manual for servicing information. bath of oil circulated by the motion of gears and shafts. Grey iron parts have Highway Use built-in channels where needed to • Refer to the Eaton Fuller help lubricate bearings and shafts. All transmission manual for servicing parts will be amply lubricated if these information. procedures are closely followed: • Refer to the oil change vs. 1. Maintain oil level; check it temperature chart that follows for regularly. special oil change information. The CAUTION 2. Change oil regularly. “intermittent peak temperature” Exceeding the recommended oil is the maximum temperature 3. Use the correct grade and type of change intervals may be harmful to observed for a short time in a oil. the life of the transmission and the 5 fully loaded vehicle performing transmission oil cooler. 4. Buy oil from a reputable dealer. normally.

(04/13) Y53-1200-1B1 5-41 LUBRICANT SPECIFICATIONS

Recommended Lubricants

Type Grade (SAE) Ambient Temperature Heavy Duty Engine Oil MIL-L-2104B, C, or D; 50 Above 10° F (-12° C) API - SF, or API-CD 40 Above 10° F (-12° C) 30 Below 10° F (-12° C) Mineral gear oil with rust and oxidation inhibitor 90 Above 10° F (-12° C) API-GL-1 80W Below 10° F (-12° C) Synthetic Lubricant* 50 All *See your dealer for approved brands.

5

5-42 Y53-1200-1B1 (04/13) LUBRICANT SPECIFICATIONS

Allison Transmission Spicer Transmission Recommended Lubricants Lubrication Lubrication Lubrication Change and Inspection The lubricants listed below are It is extremely important to use the recommended, in order of preference, • Refer to your transmission proper lubricants and maintain the for use in all Spicer mechanical manual (furnished separately) for correct oil levels in Spicer units. This transmissions, auxiliaries, and lubrication information. will ensure proper lubrication and transfer cases. Do not use extreme operating temperatures in these units. pressure additives such as those • Refer to the Allison Transmission found in multipurpose or rear axle-type manual for servicing information. lubricants. These additives are not required in Spicer transmissions, and may in some cases create transmission problems. Multipurpose oils, as a group, have relatively poor oxidation stability, a high rate of sludge formation, and a greater tendency to react with or corrode the steel and bronze parts. 5

Type Grade (SAE) Ambient Temperature Heavy Duty Engine Oil MIL-L-2104D or 30, 40, or 50 Above 0° F (-18° C) MIL-L-46152B, API-SF or API-CD (MIL-L-2104B 30 Below 0° F (-18° C) or C or MIL-L-46152 designations are acceptable) Mineral gear oil (R and O type) API-GL-1 90 Above 0° F (-18° C) 80 Below 0° F (-18° C) Synthetic Engine Oil meeting MIL-L-2104D or CD50 All MIL-L-46152B, API-SF or API-CD CD30

(04/13) Y53-1200-1B1 5-43 LUBRICANT SPECIFICATIONS

Type Grade (SAE) Ambient Temperature *Synthetic Gear Oil Meeting MIL-2105C or EP75W90 All API-GL5 EP75W140 *EP Gear Oils are not recommended when lubricant operating temperatures are above 230° F (110° C). Oil Changes Refilling

CAUTION Remove all dirt around filler plug. Refill with new oil of the grade recommended When adding oil, types and brands of for the existing season and prevailing oil should not be intermixed because service. Fill to the bottom of the of possible incompatibility, which could level testing plug positioned on the decrease the effectiveness of the lubri- side of the transmission. Do not cation or cause component failure. overfill the transmission. Overfilling usually results in oil breakdown due An initial oil change and flush should to excessive heat and aeration from be performed after the transmission the churning action of the gears. Early has been placed in actual service. breakdown of the oil will result in heavy 5 This change should be made any time varnish and sludge deposits that plug after 3000 miles (4800 km) but never up oil ports and build up on the splines longer than 5000 miles (8000 km) of and bearings. Overflow of oil can also over-the-road service. In off-highway escape onto clutch or parking brakes. use, the change should be made after When adding oil, do not mix different 24 hours but before 100 hours of types of oil. service have elapsed.

5-44 Y53-1200-1B1 (04/13) LUBRICANT SPECIFICATIONS

Meritor Axle Lubrication Under Meritor’s Advanced Lube Rear NOTE Drive Axle program, the axles listed below are exempt from an initial Axles utilized in 100% off-highway use lubricant change: are not eligible for Meritor’s Advanced Lube Rear Drive Axle program.

AVAILABLE ADVANCED LUBE AXLES RS-17-145 RS-23-180 RT-40-145 RT-44-145P RS-19-145 RS-26-180 RT-40-145P RT-46-160 RS-21-145 RS-30-180 SQ-100A RT-46-160P RS-23-160 RT-34-145 SQ-100AP RT-52-160 RS-23-161 RT-34-145P RT-44-145 RT-52-160P

Meritor rear axles that do not appear particular axle for lubricant • Refer to the following chart for on the list above will continue to specifications. lubricant change intervals: require an initial drain at 3000-5000 miles (4800-8000 km). • See your dealer for 5 Meritor-approved lubricant • Refer to the Meritor Field brands. Maintenance Manual for a

Application Type Of Lubricant Mileage Interval On Highway Synthetic 240,000 mi. (384,000 km) Synthetic with Pump and Filter 500,000 mi. (800,000 km) Mineral Base 120,000 mi. (192,000 km)

(04/13) Y53-1200-1B1 5-45 LUBRICANT SPECIFICATIONS

Application Type Of Lubricant Mileage Interval City Delivery Synthetic 120,000 mi. (192,000 km) Synthetic with Pump and Filter 240,000 mi. (384,000 km) Mineral Base 120,000 mi. (192,000 km) Off Highway Synthetic 120,000 mi. (192,000 km) Synthetic with Pump and Filter 120,000 mi. (192,000 km) Mineral Base 120,000 mi. (192,000 km)

• Change the lubricant filter every Eaton/Dana Axle Lubrication • Change the lubricant within the 120,000 miles (192,000 km). Top • The original mineral-based first 5000 miles (8000 km) of off the lubricant level with a similar operation after a carrier head lubricant. lubricant must be drained within 3000-5000 miles (4800-8000 replacement, regardless of the km) on all Eaton axles. This lubricant type. initial change is very important • Refer to the Eaton Field because it flushes out break-in Maintenance Manual for a contaminants that might otherwise particular axle for lubricant cause premature wear. specifications. 5 • No initial drain is required on • See your dealer for Eaton axles that are factory filled Eaton-approved lubricant brands. with an Eaton-approved synthetic lubricant. • Refer to the chart below for lubricant change interval. • Mineral-based lubes must be drained within the first 5000 miles (8000 km) if converting to an Eaton-approved synthetic lube.

5-46 Y53-1200-1B1 (04/13) LUBRICANT SPECIFICATIONS

Type of Lubricant On-Highway Mi. (km) Maximum Change Interval On/Off Highway Severe Maximum Change Interval Service Mi. (km) Mineral-Based 120,000 (192,000) Yearly 60,000 (96,000) Yearly Eaton-Approved Synthetic 240,000 (384,000) 2 Years 120,000 (192,000) Yearly Eaton-Approved Synthetic 350,000 (560,000) in axle with extended drain interval option Wheel Bearing Lubrication Oil-lubricated Nondriven Hubs Universal Joint Lubrication Oil-lubricated Driven Hubs Use CD50 synthetic transmission fluid Refer to the Spicer Universal Joints Use hypoid oil, A.P.I.-GL-5 SAE SAE 50W or equivalent. A minimum of and Driveshafts service manual and 75W-90FE synthetic gear lubricant 9 oz. (270 ml) of lubricant is required lubrication specifications. or equivalent. A minimum of 1 quart for proper lubrication of an LMS™ hub; (921 ml) of oil is required for proper 10-13 oz. (295-400 ml) is required for lubrication of each drive hub. Add oil a non-LMS hub, depending on wheel through the filler hole in the hub; if design. Allow time for the fluid to seep none, add oil through the differential through the bearings when initially filler hole. (Note: Remember to replace filling a hub. When properly filled, the 5 vent plug or threaded filler plug when fluid level will lie between the fluid level done.) Allow time for the oil to seep line and 1/4” above the line. through the bearings when initially filling a hub. Maintain the differential NOTE oil level by adding oil until its surface is Remember to replace vent plug when even with the bottom of the filler hole done. (see illustration on page 5-38).

(04/13) Y53-1200-1B1 5-47 LUBRICANT SPECIFICATIONS

Steering Gear Lubrication Inspection Fluid Refill If incompatible (insoluble) fluids are NOTE mixed in a power steering system, The following recommendations are air bubbles can be produced at the Before removing reservoir cover, wipe for general purpose steering systems interface of the two fluids. This can outside of cover so that no dirt can fall (both TRW and Sheppard). cause cavitation, which reduces the into the reservoir. lubrication between moving parts in • For normal temperatures, use 1. Check the fluid level; add fluid if the gear. This could result in worn Automatic Transmission Fluid components. (ATF) Type E or F or Dexron® III. required. 2. Check fluid for contamination, The mixture of two different fluids, • For cold temperatures of -22º F discoloration, or burnt smell; although harmless to individual (-30º C) and above use ATF Type correct source of such problems internal components, may initiate a A. before replacing fluid and filter. chemical reaction that produces a new • For extremely cold temperatures compound that will attack seals and between -22º F (-30º C) and -40º CAUTION other internal components. F (-40º C) use ATF Type B. When adding fluid, be sure to use fluid 5 Do not mix different fluids. of the same type. While many flu- ids have the same description and in- tended purpose, they should not be mixed due to incompatible additives. Mixing incompatible fluids may lead to equipment damage.

5-48 Y53-1200-1B1 (04/13) AIR SYSTEM AIR SYSTEM WARNING! WARNING! Introduction Prior to the removal of any air system Never connect or disconnect a hose component, always block and hold the or line containing air pressure. It may WARNING! vehicle by a secure means other than whip as air escapes. Never remove a the vehicle's own brakes. Depleting component or pipe plug unless you are Do not attempt to modify, alter, repair air system pressure may cause the certain all system pressure has been or disconnect any component of the vehicle to roll unexpectedly result- depleted. Failure to comply may result air system. Repairs or modifications ing in an accident causing death or in death, personal injury, equipment or to the air system, other than what is personal injuries. Keep hands away property damage. described in this section, should only from chamber push rods and slack be performed by an authorized dealer. adjusters, they may apply as system Failure to comply may result in death WARNING! pressure drops. or personal injury. Never exceed recommended air pres- sure and always wear safety glasses WARNING! when working with air pressure. Never After completing any repairs to the air look into air jets or direct them at any- system, always test for air leaks, and one. Failure to comply may result in 5 check the brakes for safe operation death, personal injury, equipment or before putting the vehicle in service. property damage. Failure to comply may result in death, personal injury, equipment or property damage.

(04/13) Y53-1200-1B1 5-49 AIR SYSTEM

reservoirs to be stored until needed. WARNING! WARNING! When you operate your air brakes, the Never attempt to disassemble a com- Completely bypassing a Bendix® stored compressed air flows into the ponent until you have read and un- AD-IS air dryer will bypass the sys- chambers where it is used to apply derstood recommended procedures. tem’s pressure protection valves. This your truck and trailer brakes. That is Some components contain power- could lead to loss of air pressure or why, when you push down on your ful springs and injury can result if damage to the vehicle’s air system, brake pedal, you don’t feel the same not properly disassembled. Use only which could cause an accident involv- amount of pressure on the pedal that proper tools and observe all precau- ing death or personal injury. Always you do when you apply the brakes on tions pertaining to use of those tools. adhere to the manufacturer’s proce- your car. All you are doing on your Failure to comply may result in death, dure if it is necessary in an emergency truck is opening an air valve to allow personal injury, equipment or property to temporarily bypass an AD-IS-series air to flow into the brake chambers. damage. air dryer. Failure to comply may result in death, personal injury, equipment or Contamination of the air supply system property damage. is the major cause of problems in air-operated components such as brake valves, and suspension height The operation of the vehicle’s braking 5 control valves. To keep contaminants system and many vehicle accessories to the lowest possible level, follow depends upon the storage and these maintenance procedures. application of a high-pressure air supply.

Your vehicle’s compressor takes outside air and compresses it, usually to 100-120 psi (689-827 kPa). The compressed air then goes to the

5-50 Y53-1200-1B1 (04/13) AIR SYSTEM

Daily Periodically WARNING! • Drain moisture from the supply • Clean filter screens ahead of the If the supply and service tanks are and service air tanks. valves by removing the screens not drained at the recommended fre- and soaking them in solvent. Blow quency, water could enter the air lines • Operate air devices to circulate them dry with pressurized air and valves. This could cause corro- lubricants within the unit. before reinstalling them. sion or blockage, which could compro- mise the brake system safety and po- tentially cause an accident involving death or personal injury.

5

(04/13) Y53-1200-1B1 5-51 AIR SYSTEM

Twice a Year Air Dryer NOTE • Maintain the air compressor to The function of the air dryer is to collect A small amount of oil in the system prevent excessive oil by-pass. and remove air system contaminants in may be normal and should not, in it- See your maintenance manual for solid, liquid and vapor form before they self, be considered a reason to replace details. enter the brake system. It provides the desiccant cartridge. Oil stained clean, dry air to the components of • Replace worn seals in valves and desiccant can function adequately. the brake system, which increases air motors as they are needed. the life of the system and reduces A tablespoon of water found in the maintenance costs. air tank would point to the need for a desiccant cartridge change. However, NOTE the following conditions can also Because no two vehicles operate un- cause water accumulation and should der identical conditions, maintenance be considered before replacing the and maintenance intervals will vary. desiccant cartridge. Experience is a valuable guide in de- 5 termining the best maintenance inter- • Air usage is exceptionally high val for any one particular operation. and not normal for a highway vehicle. This may be due to Every 900 operating hours or 25,000 accessory air demands or some miles (40,200 km) or every three (3) unusual air requirement that months check for moisture in the air does not allow the compressor brake system by opening air tanks, to load and unload (compressing drain cocks, or valves and checking for and non-compressing cycle) in a presence of water. normal fashion or it may be due to excessive leaks in the air system.

5-52 Y53-1200-1B1 (04/13) AIR SYSTEM

• In areas where more than a 30° Overhaul Bendix® AD-IS Series Air Dryer F (17° C) range of temperature Maintenance intervals typical for Your vehicle may be equipped with a occurs in one day, small amounts on-highway operation would be 2 - 3 Bendix® AD-IS series air dryer. Any of water can accumulate in years, 350,000 miles or 10,800 hours. air dryer replacement should be made the air brake system due to with an identical component. condensation. Under these Maintenance intervals typical for high conditions, the presence of small duty cycle usage such as transit bus, WARNING! amounts of moisture is normal refuse hauler, dump truck, cement If a different air dryer brand or model is and should not be considered as mixers and off-highway operation installed on the vehicle other than what an indication that the dryer is not would be 1 year, 100,000 miles or was originally installed, it could cause performing properly. 3,600 hours. the air system to not perform correctly • An outside air source has been unless the full air system design is NOTE used to charge the air system. reviewed and modifications made to This air did not pass through the Review the warranty policy before per- comply with Federal Motor Vehicle drying bed. forming any maintenance procedures. Safety Standards (FMVSS) 121 - Air An extended warranty may be voided Brake Systems. Failure to abide by 5 if unauthorized maintenance is per- this warning and maintain compliance formed during this period. to FMVSS 121 could cause loss of vehicle control and may lead to death or serious personal injury.

The AD-IS Series air dryer has incorporated into its design various components that have typically been

(04/13) Y53-1200-1B1 5-53 AIR SYSTEM

installed separately on the vehicle (see Air Tanks below for components/areas affected): WARNING! If the supply and service air tanks are • Pressure protection valves not drained at the recommended fre- • Safety valve quency, water could enter the air lines and valves. This could cause corro- • Governor and plumbing sion or blockage, which could compro- mise the brake system safety and po- • Plumbing of the front and rear To eject moisture from the air system tentially cause an accident. Failure to service air tanks tanks, pull the line that is connected to comply may result in death, personal • Plumbing to accessory systems the moisture ejection valve. Continue injury, equipment or property damage. pulling until the air comes out free of water. These components are required to CAUTION meet the Federal Motor Vehicle Safety Standards (FMVSS 121 - Air Brake Daily: The supply and service air Do not use penetrating oil, brake fluid, Systems). As the Warning above tanks, must be drained on a daily or wax-based oils in the air system. 5 states, any other type of air dryer basis. Operate air devices daily to These fluids may cause severe dam- installed in the place of an AD-IS Series circulate lubricants within the unit. age to air system components. will require changes, modifications and/or additions to your vehicle’s air Periodically: Clean filter screens • Maintain the air compressor to system to maintain compliance with ahead of the valves by removing the prevent excessive oil bypass. FMVSS 121. screens and soaking them in solvent. Blow them dry with pressurized air • Replace worn seals in valves and before reinstalling them. air motors as they are needed. Your authorized dealer carries rebuild kits for most units.

5-54 Y53-1200-1B1 (04/13) AIR SYSTEM

Air Gauges and Air Leaks If the light and alarm do not turn off at Your vehicle comes with air pressure start-up, do not try to drive the vehicle gauges for two separate systems, until the problem is found and fixed. If Primary and Secondary: the Primary the pressure in either or both systems gauge indicates pressure in the rear is too low for normal brake operation, braking system; the Secondary gauge i.e., the pointer of one gauge falls Secondary Air Pressure Gauge indicates pressure in the front braking below 65 psi (448 kPa), a warning light system. Each gauge indicates the on the gauge will glow and the audible Follow the procedure below to amount of air pressure in pounds per alarm will sound. check the compressed air system square inch (psi). for leaks: NOTE 1. Periodically, or after maintenance WARNING! Park brakes lock up at 60 psi (414 or replacement of air system Do not operate the vehicle if leakage kPa), the audible alarm will sound at components: in the air system is detected. Con- 65 psi (448 kPa). 2. Build up air pressure in the system duct the following procedure and con- to the governor cutout point or until tact an authorized dealer (or any other 120 psi (827 kPa) is reached. 5 properly equipped service center) if a leak is detected. Failure to check 3. Stop the engine and release the the brakes or follow these procedures service brakes. could cause a system failure, increas- 4. Without applying the brake pedal, ing the risk of an accident and may Primary Air Pressure Gauge observe the rate of air pressure result in death, personal injury, equip- drop. This rate should not exceed ment or property damage. 2.0 psi (14 kPa) per minute.

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Preventive Maintenance 5. Start the engine and build up the Air Compressor Operation air pressure again. The following service checks are 6. Stop the engine, and apply the All compressors, regardless of make provided for your information only and brakes fully. Apply the brake pedal or model, run continuously while the should be performed by a certified and hold it down for five minutes. engine is running. System pressure mechanic. Contact your dealer or the The pressure drop should not is controlled by the governor. The engine manufacturer's Maintenance exceed 3.0 psi (21 kPa) per governor acts in conjunction with Manual for further information on minute. the unloading mechanism in the servicing air compressors. compressor cylinder block to start 7. If you detect excessive leakage and stop compression of air. The After completing any repairs to the air (air pressure loss greater than 3.0 compressor is unloaded when the system, always test for air leaks, and psi (21 kPa) after five minutes of system pressure reaches 120 psi (827 check the brakes for safe operation brake application), a leakage test kPa) and compression is reestablished before putting the vehicle in service. should be made at the air line when system pressure falls to 100 psi connections and at all air brake (690 kPa). Below is a list of areas to maintain for control units. These tests should the air compressor: 5 determine where air is escaping. • Inspect compressor air filter element, if so equipped, and replace element if clogged. Check compressor mounting and drive for alignment and belt tension. Adjust if necessary. • Remove compressor discharge valve cap nuts and check for

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presence of excessive carbon. If excessive carbon is found, clean or replace the compressor cylinder head. Also, check compressor discharge line for carbon, and clean or replace the discharge line if necessary. • Disassemble compressor and thoroughly clean and inspect all parts. Repair or replace all worn or damaged parts, or replace compressor with a factory exchange unit.

CAUTION When draining the engine cooling sys- tem is required, to prevent damage 5 from freezing, the compressor must also be drained at the cylinder head and block. Engine damage could oc- cur if the cooling system is not peri- odically drained and maintained. See Cooling System on page 5-72 for fur- ther information.

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BRAKE SYSTEM system. All of the following areas CAUTION are interrelated and must conform to Brake Adjustment The air brake system of this vehicle original specifications: was configured for ONE of the follow- • Tire Size WARNING! ing operations: tractor or truck, and complies with the respective portions Do not work on the brake system with- • Drum brakes of FMVSS 121. A tractor shall not be out the parking brake set and wheels operated or configured as a truck, nor a. Cam Radius chocked securely. If the vehicle is not shall a truck be operated or configured secured to prevent uncontrolled vehi- b. Wedge Angle as a tractor, without significant modifi- cle movement, it could roll and cause cations to the air brake system in order c. Drum Radius death, serious personal injury or dam- to retain compliance with FMVSS 121. age to the vehicle. d. Brake Linings Contact your dealer for instructions. e. Brake Chambers To operate your vehicle safely Once a brake system is set to and profitably, you need some f. Slack Adjusters specifications, changing any one of understanding of its brake systems. its components or any combination of • Disc Brakes 5 For more on brakes, see the Index, components may cause the system under Brakes. a. Disc Rotors to not work as well. All parts have Brake adjustment and brake balance to work together to perform as they must be set carefully to (1) make should. Any replacement components the most efficient use of the forces in your brake system should be exactly available for braking and (2) allow equal to the original components. equal stopping forces at all wheels. Any changes from the original specifications can affect the whole

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Air Disc Brakes WARNING! WARNING! Have brake pads inspected by a Do not use any replacement part in the Do not use brake linings with a thick- qualified mechanic for wear at regular brake system unless it conforms ex- ness below the specified minimum. intervals according to the Preventive actly to original specifications. A non- Such linings will have lining rivets Maintenance Schedule on page 5-12. conforming part in your vehicle's brake exposed that can damage the brake In severe service or off-highway system could cause a malfunction re- drum and reduce brake efficiency, applications inspect the linings more sulting in an accident causing death which could cause death, personal frequently. or personal injury. Sizes and types injury or system failure. are so related to one another that a Regularly inspect for pad/rotor wear: seemingly unimportant change in one may result in a change in how well • Park on level ground and chock the brakes work for you on the road. the wheels. If parts do not work together properly, you could lose control of your vehicle, • Temporarily release the parking which could cause a serious accident. brakes. • Compare the relative position 5 All vehicle operators should check of two notches; one located on their brakes regularly. the caliper and the other on the carrier. See the illustration below to determine if the brakes require a detailed inspection by a qualified mechanic.

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• Have a qualified mechanic • Chock the wheels. perform a detailed inspection if the notches are not found. • Temporarily release the parking The pads and rotors should brakes. be measured and compared • Grab the caliper and move it. This against the manufacturers movement is Running Clearance. specifications located in the brake manufacturer’s service manual. • Proper Running Clearance is 0.08 inch (2 mm) of movement of Caliper Detail the brake caliper (approximately 1. Brake Caliper Assembly the thickness of a nickel) in the 2. Location of Inspection inboard/outboard direction. Grooves • Have a qualified mechanic provide 3. Notches Line-Up (Time to further inspection if the caliper schedule inspection of Pads does not move or appears to move and Rotors) more than the specified clearance. 5 4. Brake Rotor 5. Brake Carrier Assembly

Regularly inspect caliper for Running Clearance: • Stop the vehicle on level ground and let the brakes cool down. Hot brake calipers can burn skin on contact.

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Drum Brakes Automatic Slack Adjusters Chamber Type Stroke 36 (rear brakes) 1-1/2" - 2-1/4" Have brake drum linings and disc Periodically check the Brake Chamber (38 - 57 mm) brake pads inspected by a qualified Stroke. Replace the slack adjuster if 30 (rear brakes) 1-1/2" - 2" mechanic for wear at regular intervals proper stroke cannot be maintained. (38 - 51 mm) according to the maintenance 16, 20 and 24 (front 1" - 1-3/4" brakes) schedule. In severe service or Operational checks of automatic (25.4 - 44.4 mm) off-highway applications inspect the slack adjusters linings more frequently. • Measure brake chamber stroke with the spring brake released and the air pressure no less than 100 psi (690 kPa). • Brake Chamber Stroke is the difference between the applied and the retracted position of the air chamber pushrod. 5 • A correctly installed and functioning auto slack adjuster will produce the following strokes: Brake Chamber Stroke

(04/13) Y53-1200-1B1 5-61 BRAKE SYSTEM

WARNING! Manual adjustment of automatic slack adjusters is a dangerous practice that could have serious consequences. It gives the operator a false sense of se- curity about the effectiveness of the brakes. Contact the Service Depart- ment at your dealership if the stroke exceeds the above specifications. A stroke exceeding these values may in- dicate a problem with the slack ad- juster or the brake foundation.

5

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CAB Chrome and Aluminum Surfaces • Under corrosive conditions, such as driving on salted roads, clean To prevent rust, keep chromed parts Exterior Maintenance aluminum parts with steam or high clean and protected with wax at all Painted Surfaces pressure water from a hose. A times, especially in winter conditions mild soap solution will help. Rinse where the roads are salted. Wash painted surfaces frequently to thoroughly. remove grime and caustic deposits • If necessary, use a commercial which may stain the finish. See chrome cleaner to remove light Cleaning, Protecting, and Weather rust. Stripping on page 5-64. • Chrome surfaces are best cleaned with fresh water. Wipe dry to preserve their luster. A commercial chrome cleaner will remove light rust. After cleaning, wax flat surfaces and apply a thin coat of rust preventive lubricant 5 around bolts or other fasteners. • Clean aluminum wheels and bumpers with warm water. Tar remover will get rid of heavy deposits of road grime. To prevent spotting, wipe aluminum surfaces dry after washing.

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Tail Pipe Surface Cleaning Stainless Steel Cleaning, Protecting and Weather Stripping WARNING! Even high quality stainless steel parts can rust under prolonged exposure Always allow hot surfaces to cool Frequent washings of the vehicle to salt water, especially when the down before attempting to work near are required to remove grime and salt-laden moisture is held against them. Failure to comply may result in contaminants that can stain and the metal surface by road grime. It death or personal injury. oxidize paint and accelerate corrosion is, therefore, important to frequently of plated and polished metal surfaces. clean salty moisture and grime from To maintain your quality finish, wash stainless steel surfaces. Waxing offers added protection against with a soft cloth, mild soap and water staining and oxidation. But to allow If surface rust is encountered, or glass cleaner. A non-abrasive • enough time for your truck's finish to wash the surface and use a chrome polish can be used sparingly cure, wait about 30 days after the date commercial polishing compound on hard to clean areas. Do Not clean of manufacture before waxing. Do not to clean off the rust, followed by a your high heat chrome using scouring apply wax in the hot sun and do not coating of wax. pads, abrasive chrome polish, highly friction burn the paint with a buffing acidic chemical cleaners or any other machine. 5 abrasive cleaners. • Never use steel wool when cleaning stainless steel because minute particles of the steel wool Occasionally spray weather-stripping can embed in the surface of the on doors and windows with silicone stainless steel and cause rust compound to help preserve resiliency. staining. This is especially useful in freezing weather to prevent doors and windows from sticking shut with ice.

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Vehicle Cleaning • Do not use any solution that can WARNING! damage the body paint. Precautions Do not clean the underside of chas- sis, fenders wheel covers, etc. with- • Most chemical cleaners are WARNING! out protecting your hands and arms. concentrates that require dilution. Handle cleaning agents carefully. You may cut yourself on sharp-edged • Only use spot removing fluids in Cleaning agents may be poisonous. metal parts. Failure to comply may re- well ventilated areas. Keep them out of the reach of children. sult in death, personal injury, equip- Failure to comply may result in death, ment or property damage. • Any vehicle is subjected to personal injury, equipment or property deterioration from industrial damage. WARNING! fumes, ice, snow, corrosive road salt, etc., to name just a few Moisture, ice, and road salt on brakes WARNING! causes. A well-cared-for vehicle may affect braking efficiency. Test can look like new many years Do not use gasoline, kerosene, naph- the brakes carefully after each vehicle later. Regular and correct care tha, nail polish remover or other wash. Failure to comply may result in will contribute to maintaining the volatile cleaning fluids. They may be death, personal injury, equipment or beauty and the value of your 5 toxic, flammable or hazardous in other property damage. vehicle. ways. Failure to comply may result in death, personal injury, equipment or • Observe all caution labels. Your dealer has a number of property damage. vehicle-care products and can advise Always read directions on the • you on which ones to use for cleaning container before using any the exterior and interior of your vehicle. product.

(04/13) Y53-1200-1B1 5-65 CAB

Washing the Exterior plated, and polished metal CAUTION surfaces. 1. Begin by spraying water over the Do not aim the water jet directly at door dry surface to remove all loose dirt 3. Rinse surfaces frequently while locks or latch. Tape the key holes to before applying the car wash and washing to flush away dirt that prevent water from seeping into the wax solution. might scratch the finishes during lock cylinders. Water in lock cylinders the washing operation. should be removed with compressed ° Do not wash the vehicle in air. To prevent locks from freezing in direct sunshine. 4. Wipe everything dry with a the winter, squirt glycerin or lock deicer chamois to avoid water spots. into the lock cylinders. ° Do not spray water directly into the cab vents. ° To prevent water spotting, dry off the cosmetic surfaces with 2. Using soapy water, wash the a clean cloth or chamois. vehicle with a clean soft cloth or a soft brush made for automotive 5. Remove road tar with an cleaning. automotive type tar remover or mineral spirits. ° Use cool or warm water and 5 a mild, household type soap. 6. After cleaning and drying, apply a Strong industrial detergents quality automotive wax. and cleaning agents are not recommended. ° Do not use stiff brushes, paper towels, steel wool, or abrasive cleaning compounds because they will scratch painted,

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Cleaning the Chassis Cleaning Interior Vinyl and NOTE Upholstery • Hose dirt and grime from the To allow enough time for your truck's entire chassis. Then, if an oil • Wipe vinyl upholstery and lining finish to cure, wait at least thirty days leak develops, you will be able to with a good commercial upholstery after the date of manufacture before detect it easier. cleaner. Do not use acetone or waxing. lacquer thinner. • Do not apply wax in the hot sun. • Corrosive materials used for ice and snow removal and dust control • Clean fabric upholstery with • Never dust off dry surfaces with a can collect on the underbody. If upholstery shampoo specially cloth because it will scratch the these materials are not removed, formulated for this purpose. Follow finishes. accelerated corrosion (rust) can instructions on the container. occur on underbody parts such as fuel lines, frames, floor pan, and exhaust system, even though they have been provided with corrosion protection. 5 At least every spring, flush these materials from the under body with plain water. Be sure to clean any area where mud and other debris can collect. Sediment packed in closed areas of the frame should be loosened before being flushed. If desired, your dealer can do this service for you.

(04/13) Y53-1200-1B1 5-67 CAB

Safety Restraint System - Factors contributing to reduced seat Inspection belt life: Due to these factors, the three-point safety belt system installed in your Factors contributing to reduced seat The seat belt system, including vehicle requires thorough inspection belt life: webbing, buckles, latches, and every 20,000 miles (32,000 km). If the vehicle is exposed to severe mounting hardware, endures heavy • Heavy trucks typically accumulate environmental or working conditions, use in heavy-duty vehicles, much more twice as many miles as the more frequent inspections may be than seat belt systems in passenger average passenger car in a given necessary. cars. All users should be aware of the time period. factors contributing to this heavy use Any seat belt system that shows cuts, and reduced belt life. • Seat and cab movement in trucks causes constant movement of the fraying, extreme or unusual wear, significant discoloration due to UV WARNING! belt due to ride characteristics and seat design. The constant (ultraviolet) exposure, abrasion to the Failure to properly inspect and main- movement of the belt inside seat belt webbing, or damage to the tain restraint systems can lead to injury the restraint hardware and the buckle, latch plate, retractor hardware or loss of life. Without periodic inspec- potential for the belt to come in or any other obvious problem should 5 tion and maintenance to detect unsafe contact with the cab and other be replaced immediately, regardless conditions, seat restraint components vehicle parts, contributes to the of mileage. can wear out or not protect you in an wear of the entire system. accident. • Environmental conditions, such as dirt and ultraviolet rays from the sun, will reduce the life of the seat belt system.

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Inspection Guidelines These areas are typical places WARNING! where the web will experience It is important to remember that any Follow these guidelines when cutting or abrasion. Cuts, fraying, time a vehicle is involved in an acci- inspecting for cuts, fraying, extreme or excessive wear would indicate dent, the entire seat belt system must or unusual wear of the webbing, the need for replacement of the be replaced. Unexposed damage and damage to the buckle, retractor, seat belt system. hardware, or other factors. Damage to caused by the stress of an accident 2. The pillar web guide (D-loop) is could prevent the system from func- these areas indicates that belt system replacement is necessary. the area where almost constant tioning properly the next time it is movement of the seat belt needed. Failure to comply may result WARNING! webbing occurs because of in death or personal injury. relative movement between the Replace the entire belt system (retrac- seat and cab. tor and buckle side) if replacement of any one part is necessary. Unexposed 3. Check the Komfort-Latch for damage to one or more components cracks or possible damage and could prevent the system from func- check for proper operation. tioning properly the next time it is 4. Check buckle and latch for proper 5 needed. Failure to comply may result operation and to determine if in death or personal injury. latch plate is worn, deformed, or damaged. 1. Check the web wear in the system. The webbing must be closely 5. Inspect the retractor web storage examined to determine if it is device, which is mounted on the coming into contact with any sharp floor of the vehicle, for damage. or rough surfaces on the seat or The retractor is the heart of the other parts of the cab interior. occupant restraint system and can

(04/13) Y53-1200-1B1 5-69 CAB

often be damaged if abused, even 5 Retractor Web Storage for unintentionally. Check operation damage. (located behind to ensure that it is not locked up trim panel) and that it spools out and retracts 6 Tethers for web wear and webbing properly. proper tightness of mounting hardware. 6. If tethers are used, be sure they 7 Mounting hardware for are properly attached to the corrosion, proper tightness seat and, if adjustable, that they of bolts and nuts. are adjusted in accordance with 8 Web for deterioration, due installation instructions. Tethers to exposure to the sun must also be inspected for web wear and proper tightness of WARNING! mounting hardware. Failure to adjust tether belts properly 7. Mounting hardware should be can cause excessive movement of evaluated for corrosion, and for Seat Belt Inspection Points the seat in an accident. Tether belts tightness of bolts and nuts. should be adjusted so that they are 5 1 Web cut or frayed or taut when the seat is in its most up- 8. Check web in areas exposed to extremely worn at latch ward and forward position. Failure to ultraviolet rays from the sun. If the area. comply may result in death or personal color of the web in these areas is 2 Web cut or frayed at D-loop injury. gray to light brown, the physical web guide. strength of the web may have 3 Comfort Clip cracked or deteriorated due to exposure to damaged. Once the need for replacement of the sun's ultraviolet rays. Replace 4 Buckle casting broken. the seat belt has been determined, the system. be certain it is only replaced with

5-70 Y53-1200-1B1 (04/13) CAB an authorized PACCAR Parts Windshield Wiper/Washer Washer Reservoir replacement seat belt. The windshield wiper system is CAUTION If the inspection indicates that any maintenance free. Check wiper blades Do not use antifreeze or engine part of the seat belt system requires annually or every 60,000 miles (96,000 coolant in the windshield washer replacement, the entire system must km). reservoir, damage to seals and other be replaced. An installation guide is components will result. attached to every replacement belt. Utilize the proper guide for your type of seat, and follow the instructions very Daily: Check reservoir water level, closely. It is vitally important that all located in the engine compartment. If components be reinstalled in the same necessary, refill to the proper level. position as the original components that were removed and that the fasteners be torqued to specification. This will maintain the design integrity of the mounting points for the seat belt assembly. Contact your dealer if you 5 have any questions concerning seat belt replacement.

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COOLING SYSTEM What to Check in an ELC-filled CAUTION Cooling System Cooling system The engine cooling system has very ELC Concentration maintenance specific maintenance and inspection requirements. Failure to follow re- Check the level of freeze/boilover protection, which is determined by Your engine’s cooling system is quirements can damage the engine. the ELC concentration. Use a glycol standard with Extended Life Coolant Engine damage can include but is not refractometer to determine glycol level. (ELC). ELC consists of a mixture of limited to: Add ELC to obtain the ELC to water ethylene glycol, water, and organic • Freezing ratio required to provide the protection acid technology chemical inhibitors. you need. Use the chart below to help ELC prevents corrosion and scale • Boiling determine how much ELC you need formation as well as provides freezing • Corrosion to add. and boiling point protection. • Pitted cylinder liners NOTE This information is found in the engine Maximum recommended ELC con- manufacturers owner’s manual. It is centration is 60% ELC and 40% water 5 the owner’s responsibility to follow all by volume (a 60/40 coolant mixture). requirements listed in the engine man- The minimum recommended concen- ufacturers owner’s manual. tration is 40%.

In an ELC-filled cooling system, the freeze point should be maintained between -30° F and -45° F (-34° C and -43° C).

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Desired ELC/ 0% 10% 15% 20% 25% 30% 35% 40% 45% 50% 55% 60% 65% 70% 75% 80% 85% 90% 100% Water ratio: Freeze +32 +25 +20 +15 +10 +5 -5 -12 -23 -34 -50 -65 -75 -84 -70 -55 -43 -30 -5 point °F (°C) (0) (-4) (-7) (-9) (-12) (-15) (-21) (-24) (-31) (-37) (-46) (-54) (-59) (-64) (-57) (-48) (-42) (-34) (-21) Items in bold are the recommended levels of concentration. ELC Condition (Contamination and test kits, test strips, and laboratory Topping Off Inhibitor Concentration) sample procedures. WARNING! Perform a visual inspection of the ELC Extender Removing the fill cap on a hot engine ELC. It should have no cloudiness can cause scalding coolant to spray or floating debris. Determine the Add ELC extender if necessary at the out and burn you badly. If the en- chemical inhibitor concentration level maintenance interval under “Cooling”. gine has been in operation within the by using an ELC-specific test kit or previous 30 minutes, be very care- test strips. Inhibitor concentration level Coolant Filter ful in removing the fill cap. Protect determines corrosion protection. If you face, hands, and arms against escap- 5 are concerned about possible coolant If your vehicle came with a ing fluid and steam by covering the quality, contamination, or mechanical non-chemical filter (“blank filter”), cap with a large, thick rag. Do not problems, submit a coolant sample for replace it only with a blank filter at the try to remove it until the surge tank analysis. Improper maintenance may interval specified in the Preventive cools down or if you see any steam cause coolant degradation and could Maintenance Schedule on page 5-12. or coolant escaping. In any situation, result in damage to the cooling system Never use filters that contain SCAs in remove the cap very slowly and care- and engine components. Consult an ELC-filled system. fully. Be ready to back off if any steam your dealer or the ELC manufacturer’s or coolant begins to escape. representative for recommended ELC

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• The minimum fluid level is NOTE determined by the line on the If frequent topping off is necessary and surge tank indicated by the letters there are no visible signs of coolant “MIN”. This indicator is located leaks when the engine is cold, check below the fill cap. for leaks with the engine operating at normal temperature. • The cooling system will need fluid if the surge tank level does not rise to the “MIN” line regardless if the Top off the cooling system when system is hot or cold. coolant does not rise to the level Surge Tank indicated as ‘MIN’ on the surge tank. Refilling Your Radiator The surge tank is translucent which allows the coolant level to be seen. NOTE 1. If your cooling system is built with Add coolant through the surge tank fill Do not use the pressure cap to fill the drain valves in the upper engine cap. Do not remove the pressure cap surge tank with fluid. coolant pipe, open them before to fill the cooling system. filling the surge tank. 5 Proper Coolant Level 2. Close any open coolant drains in the system. NOTE 3. Remove the surge tank fill cap Do not overfill a cooling system. Ex- (do not remove the surge tank cess coolant may result in overflow, pressure cap). loss of antifreeze, and reduced corro- sion protection. 4. Fill the system with premixed coolant through the surge tank fill cap. Pour coolant at a steady flow

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rate until the surge tank is full (to 9. Fill the surge tank as necessary Engine (Block) Heater the base of the fill neck). It may be to raise the coolant level to ½ in. necessary to pause for 1 minute WARNING! above the “MIN” level. and then re-fill if the fluid level Do not use the heater if there are 10. Operate the engine at high idle for dropped. any signs of problems. Engine block another 10 minutes and then fill 5. Close any drain valves that were heaters can cause fires resulting in the surge tank again to ½" above opened in Step 1. death, personal injury, equipment the “MIN” level. or property damage if not properly 6. Start the engine and idle at low 11. Replace the surge tank fill cap. maintained and operated. Regularly RPM. inspect the engine block heater wiring 7. During low rpm idle, air will purge Check the coolant level after each trip. and connector for damaged or frayed from the cooling system which will Add coolant as necessary. You may wires. Contact your authorized dealer lower the coolant level in the surge find your coolant level is not up to the or the manufacturer of the heater if tank. Continue to fill the surge correct level soon after you have filled you are in need of repairs or informa- tank until the coolant level remains the radiator. This may be because all tion. Failure to comply may result in approximately ½ in. above the of the trapped air in the system has not death, personal injury, equipment or "MIN" line. This may take up to 2 yet been purged. It takes a little time property damage. 5 minutes, depending on the outside for all the air to leave the system after temperature. you fill your radiator. CAUTION 8. Operate the engine throttle Always unplug the block heater be- until the operating temperature fore starting your engine. Damage to stabilizes (when the thermostat the cooling system could occur if not opens). turned OFF (unplugged).

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Use a solution of half ethylene glycol antifreeze and half water for best heater performance. Do not use more than 65 percent concentration of antifreeze, as a shortened heater life will result.

After servicing the cooling system, operate the vehicle for a day or two before using the heater. Trapped air inside the engine needs time to escape.

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5-76 Y53-1200-1B1 (04/13) ELECTRICAL

ELECTRICAL Low Voltage Disconnect (LVD) See an authorized dealer if the LVD Electrical System Purpose fails to reconnect loads during normal operation. The LVD may increase battery life WARNING! and prevent unnecessary jump Circuits Disconnected By LVD Battery posts, terminals and related start conditions by ensuring that an accessories contain lead and lead unattended load does not deplete • Cab Dome Lamps compounds, chemicals known to the the battery charge to a level that will • Cab Accessories State of California to cause cancer prevent you from starting your vehicle. and reproductive harm. Wash hands • Spare Battery A and B after handling. Operation NOTE The LVD will disconnect non-vital CAUTION battery loads when battery voltage All LVD circuits are color-coded blue Do not modify or improperly repair the drops below 12.3V for 3 minutes and on the central electrical panel cover vehicles electrical system or power the key switch is in the ACC or OFF label. distribution box. All electrical repairs position. During the last 2 minutes the 5 should be performed by an authorized LVD will emit a slow audible beep. 30 dealer. Improper repair or modifica- seconds before disconnecting loads tions will void your warranty and/or the alarm will change to a fast beep. cause serious damage to your vehicle. The battery voltage must come back up above a certain voltage before the LVD will reset.

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Light Bulbs WARNING! Headlight Replacement Do not use the Spare Battery A and Replacing a headlight bulb is B circuits or other circuits that are accomplished by accessing the rear controlled by the LVD to power elec- of the headlight via a access panel in tronic engine controls, ABS circuits, the front fender. Open the hood to get or safety/work-related lighting. Before access to this panel. adding any device to the vehicle's electrical system, consult your nearest Once the panel is open, the headlight authorized dealer or read the contents bulb socket may be removed to replace of TMC RP-136. Failure to do so may the bulb. cause equipment damage or lead to personal injury. WARNING! Access door Optional HID headlights have high NOTE voltage circuits and should only be 5 The determination of what cir- serviced by a trained technician. At- cuits/loads that were connected to tempting to service the HID ballast the LVD was based upon the rec- without proper training may result in ommendation from Technology and severe electrical shock which could Maintenance Council (TMC) of the lead to death or personal injury. American Trucking Association. To re- view the recommended practice, see TMC RP-136.

5-78 Y53-1200-1B1 (04/13) ELECTRICAL

Headlight Aiming Bulb Specifications

The headlights were properly Bulb Location Type of Bulb Low Beam Halogen H11-LL (SAE), H7 aimed at the factory to meet safety (ECE) (long life specifications. If the headlights need to version not required) be adjusted, please have an authorized Low Beam HID D1-S dealership aim the headlights. High Beam Halogen HB3A – LL (long life version not required) Turn Signal/ Daytime 4157 NAK (SAE), Running Lamp PY27/7W (ECE) Side Marker/Position 168(SAE), W5W Lamp/Park Lamp (ECE) Rear tail light/ Turn Not applicable – LED 1. Adjustment knob Signal lighting Interior Not applicable – LED 2. Park/turn lamp map/dome/indirect lighting light 3. Low beam 4. High beam 5

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Fuses, Circuit Breakers and Relays

Fuses, circuit breakers, and relays are located in the Power Distribution Box to the left of the steering column behind the clutch pedal. Additional fuses are located in the engine compartment (drivers side bulkhead) and also in the sleeper under bunk storage compartment.

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5-80 Y53-1200-1B1 (04/13) ELECTRICAL

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Engine Area Fuse Label

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In-Cab Fuse Label

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Sleeper Fuse Label

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Fuse Inspection and Adding Electrical Options Replacement WARNING! If a fuse is blown, see What to do if Do not add a fuse with a rating higher fuse or relay blows on page 2-6 for than 30 amps. Follow the circuit pro- more information. tection size/type recommended by the component manufacturer. Installing a fuse or circuit breaker greater than designated may damage the electrical system which could lead to equipment damage and/or personal injury.

CAUTION Follow all manufacturers' circuit pro- tection recommendations for the com- 5 ponents and wires being added. Fail- ure to comply may result in equipment damage. Fuse Puller

5-84 Y53-1200-1B1 (04/13) ELECTRICAL

Batteries NOTE WARNING! If you are unfamiliar with proper elec- Never install a circuit breaker in a Battery Access trical repair practices and procedures, circuit that is designated as “fuse- see your authorized dealer for assis- only” circuit(s). Fuse-only circuits are The vehicle is originally equipped with tance. marked with an * on the reverse side of three or four batteries. Replacement the Power Distribution Box cover. Us- batteries must meet the following specifications: maintenance-free, NOTE ing a circuit breaker in those fuse-only circuits may cause the circuit to over- group 31 size, threaded stud, 12V/ 650 Easy addition of circuits is provided by heat when a short exists which could cold cranking ampere (CCA), and 160 plug-in connectors that have a ground lead to equipment damage and/or per- minutes of reserve capacity. and a power wire. sonal injury. The battery compartment is located on For proper electrical system the left side of the vehicle, under the performance, refer to a wiring cab access steps. diagram for your chassis before adding 1. Remove the 6 bolts that are electrical options. located in the 2 cab access step 5 plate. 2. Remove battery cover for access.

(04/13) Y53-1200-1B1 5-85 ELECTRICAL

In-Cab Battery Box WARNING! WARNING! Your vehicle may be equipped Replace only with AGM (Group 31) Electrical damage or battery explosion with Absorbed Glass Mat (AGM) batteries. Use of other batteries could can occur when improperly charg- batteries located in the cab under the result in acid leaks causing personal ing batteries. Refer to the Charging passenger’s seat. The glass mat in injury in the event of a vehicle acci- System on page 5-89 for appropri- AGM batteries are designed to absorb dent. Failure to comply may result in ate charging instructions. Failure to the battery acid inside the battery that death, personal injury, equipment or comply may result in death, personal can leak or spill out in conventional property damage. injury, equipment or property damage. batteries. This design feature allows batteries to be positioned in any orientation without risk of leaking. WARNING! Battery cables and air/electrical har- To access the batteries: nesses are mounted to the bottom of 1. Remove 6 fasteners securing the the floor. Do not drill or screw into floor passenger side seat base to the pan without first checking the location 5 battery box assembly. of the cables, harnesses or any other component that might be damaged. 2. Remove the seat and seat base Damaging any component could result as one unit to gain access to the in electrical shock which could cause batteries. personal injury and/or loss of a critical truck system. Failure to comply may result in death, personal injury, equip- ment or property damage.

5-86 Y53-1200-1B1 (04/13) ELECTRICAL

Removing and Installing Batteries: WARNING! CAUTION 1. Be sure all switches on the vehicle Batteries release gases that are Properly secure battery tie downs and are turned OFF. flammable. Batteries are equipped battery box cover when reinstalling with vent tubes and flash arrestors batteries after service. Do not over 2. Wait 2 minutes after turning which vent battery gases out of the tighten. Over tightening can crack the ignition off then disconnect cab. Ensure all vent tubes, flash ar- battery case which can lead to equip- negative ground cable first. restors and grommets are properly ment damage. 3. Disconnect positive cable. installed and ensure they are clear 4. Unscrew bolt of holding plate with and functioning properly. Failure to CAUTION reinstall or keep the vent tubes and open end wrench. grommets clear or ensure the flash The Diesel Exhaust Fluid (DEF) sys- arrestor(s) are functioning properly tem purges to prevent damage from NOTE could result in personal injury or equip- freezing. If your vehicle is equipped Always dispose of automotive batter- ment damage. Failure to comply may with battery disconnect switches, do ies in a safe and responsible manner. result in death, personal injury, equip- NOT disconnect battery power within Contact your authorized dealer for dis- ment or property damage. two minutes of switching the ignition posal standards. Call your local au- 5 key off. Failure to comply may result thorized recycling center for informa- in vehicle or property damage. CAUTION tion on recycling automotive batteries. Do not store other items in this battery box. Failure to comply could result in damage to the truck and/or batteries.

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Replacing Parts Removed for Follow the procedure below to reinstall Access WARNING! batteries on the vehicle: 1. Replace battery cover. Fairings not installed properly could come loose and cause other motorists NOTE 2. Install 2 bolts in step strut. Torque to have an injury accident. It is impor- Make sure to reconnect the ground to 24-32 lb-ft (33-43 Nm). tant that fairings be installed properly. (negative) cable last. 3. Install fairing and install 4 bolts. Failure to comply may result in death, Torque to 6-7 lb-ft (8-9 Nm). personal injury, equipment or property 1. Place batteries in vehicle and damage. tighten bolt of holding plate. 4. Install steps by installing 2 bolts in each step. Torque to 24-32 lb-ft 2. Reconnect positive cable. (33-43 Nm). WARNING! 3. Reconnect ground (negative) Before attempting any work on the bat- ground cable. WARNING! teries or electrical system, remove all Always reinstall the steps before en- jewelry. If metal jewelry or other metal WARNING! tering the cab. Without the steps you comes in contact with electrical cir- cuits, a short circuit may occur causing 5 Battery replacement may alter or dis- could slip and fall, resulting in possible you to be injured, as well as electrical turb battery cable routing. Check to in- injury to yourself. system failure and damage. sure battery cables are free from any point of chaffing. Failure to comply may result in death, personal injury, equipment or property damage.

5-88 Y53-1200-1B1 (04/13) ELECTRICAL

Battery Care Battery Charging Dirty or Loose Connections: Regular attention to the charging improper connections may stop the Except for using small trickle charges system will help prolong the service flow of electrical power to and from the to maintain battery condition, you life of the batteries. Here are some battery. should have your vehicle's batteries common causes of battery failure: charged by a qualified service facility.

Overcharge: this condition results WARNING! from improper voltage regulator Batteries can injure you severely. adjustment. It results in overheating They contain acid, produce poisonous of the battery, warped plates, and and explosive gases, and supply lev- evaporation of electrolyte. els of electric current high enough to Undercharge: the voltage regulator cause burns. A spark or flame near is malfunctioning, the drive belt is a battery on charge may cause it to slipping, or your vehicle has undergone explode with great force. Never re- long periods of standing idle or short move or tamper with the battery caps. distance driving. These conditions Failure to comply may result in death, 5 result in battery plates becoming personal injury, equipment or property covered with a hard coating. damage.

Vibration: loose battery hold-downs To help reduce the risk of personal may cause battery plate failure. injuries, follow these guidelines carefully when recharging a battery: Short Circuits: these discharge the battery by draining electricity. • Before attempting any service in the electrical installation,

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disconnect the battery negative positive terminal), could cause a can seriously damage sensitive cable. short circuit or an explosion. electronic components such as relays, radio, etc., as well • Allow no sparks or open flame Charging Reminders as the battery charger. Fast anywhere near the charging area. charging a battery is dangerous • Use protective eyewear. • Charge a battery only in a and should only be attempted by well-ventilated area, such as • Keep all batteries away from a competent mechanic with the outdoors or in a fully open garage children. proper equipment. which contains no pilot lights or • Never reverse battery poles. other flames. Gases generated during the charging process must • Never attempt to place the vehicle be allowed to escape. in motion, or run the engine with batteries disconnected. • Always make sure the battery charger is OFF before connecting • Keep the battery clean and dry. or disconnecting the cable clamps. • Look for any signs of damage. 5 • To avoid short circuits, damage to the vehicle, or personal injury, • Battery terminals should not never place metal tools or jumper be coated with improper cables on the battery or nearby. grease. Use petroleum jelly Metal that accidentally comes in or commercially available, contact with the positive battery noncorrosive, nonconductive terminal or any other metal on the terminal coatings. vehicle (that is in contact with the • Never use a fast charger as a booster to start the engine. This

5-90 Y53-1200-1B1 (04/13) ELECTRICAL

Slow Battery Charging Electrical and Alternator WARNING! Precautions NOTE Always make sure the battery charger Follow the instructions that come with is OFF before connecting or discon- Take the following precautions to your battery charger. necting the cable clamps. To reduce avoid burning out alternator diodes: the danger of explosions and result- • Do not start the engine • It is not necessary to remove the ing death or personal injury, do not with alternator disconnected battery from the compartment. connect or disconnect charger cables (connections removed) from the while the charger is operating. circuit. WARNING! 1. Disconnect the battery cables. Charger cables must be connected • Before welding, disconnect all positive to positive (+ to +) and nega- 2. Connect charger cables. electronic connections to the tive to negative (- to -). If connected vehicle batteries. 3. Start charging the battery at a rate improperly, batteries could explode. not over 6 amperes. Normally, a • Remove battery power cable and Failure to comply may result in death, battery should be charged at no insulate it from the vehicle. personal injury, equipment or property more than 10 percent of its rated damage. • Do not run the engine with the 5 capacity. batteries disconnected. 4. After charging, turn OFF charger and disconnect charger cables. • Do not disconnect the battery cables or alternator connection cables with the engine running. • Never turn the ignition switch from the ON position to the START position with the engine running.

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• When charging the battery Remote Keyless Entry (installed in the vehicle) disconnect The remote keyless entry system may the battery cables. become inoperational due to a key • Do not reverse the cables of the fob battery. If you have issues with alternator, starter motor, or battery. a key fob, replace the battery and re-synchronize the key fob. In some • Do not polarize the alternator. The situations, the key fob may need to alternator should not be polarized be replaced and in others, a fuse may like a generator. To ensure correct have failed and may render both key polarity, use a test lamp or a fobs inoperative. voltmeter. Contact your dealer for more help if a key fob does not work and it is not because of a bad battery.

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5-92 Y53-1200-1B1 (04/13) ENGINE ENGINE WARNING! NOTE Engine Maintenance Never idle your vehicle for prolonged Keep the engine exhaust system and periods of time if you sense that ex- the vehicles cab ventilation system WARNING! haust fumes are entering the cab. In- properly maintained. It is recom- vestigate the cause of the fumes and mended that the vehicles exhaust Exhaust fumes from the engine con- correct it as soon as possible. If the ve- system and cab be inspected: tain carbon monoxide, a colorless and hicle must be driven under these con- odor less gas. Do not breathe the • By a competent technician every ditions, drive only with the windows engine exhaust gas. A poorly main- 15,000 miles, open. Failure to repair the source of tained, damaged or corroded exhaust the exhaust fumes may result in death, • Whenever a change is noticed in system can allow carbon monoxide to personal injury, equipment or property the sound of the exhaust system, enter the cab. Entry of carbon monox- damage. ide into the cab is also possible from • Whenever the exhaust system, other vehicles nearby. Failure to prop- underbody or cab is damaged. erly maintain your vehicle could cause carbon monoxide to enter the cab and cause death or personal injury. 5

(04/13) Y53-1200-1B1 5-93 ENGINE

Engine Lubrication Inspection of the Engine Oil Level 1. Make sure that the vehicle frame rail is standing on a flat and level Refer to the engine manufacturer's NOTE Engine Operation and Maintenance surface. It takes approximately 15 minutes for Manual supplied with your vehicle for all the oil to run into the sump when the 2. Make sure that the vehicle is information about draining and refilling engine is ‘warm.’ If the level is checked horizontal, both lengthwise and engine oil, engine crank case capacity, immediately after switching off the en- crosswise. Check this carefully engine oil type, and changing oil filters, gine, the dipstick will show a low oil on a vehicle with air suspension. etc. level. Note that the engine may be inclined up to 4° depending on the WARNING! vehicle model and wheelbase. Hot engine oil can be dangerous. You 3. Twist the dipstick handle to unlock could be burned. Let the engine oil it, then pull the dipstick out of the cool down before changing it. Failure holder. to comply may result in death, per- sonal injury, equipment or property 4. Wipe the dipstick clean with a 5 damage. lint-free cloth. 5. Place the dipstick back into the holder. 6. Pull the dipstick out again and check the oil level. The oil level should always be between the 2 marks on the dipstick.

5-94 Y53-1200-1B1 (04/13) ENGINE

Topping Up the Engine Oil Pipe and Hose Clamps 7. Reinstall the dipstick and twist to lock it in place. 1. Top up with oil, if necessary, via Use the following table for torque the filler opening. Use the correct specifications to check pipe and hose grade in the correct quantity. For clamps. oil replacement, please see engine Operator’s Manual included with this chassis. 2. After topping up, wait 1 minute and check the oil level again. 3. Reinstall the oil fill cap and twist to lock it in place.

1. Engine Oil High Level 5 2. Engine Oil Low Level

(04/13) Y53-1200-1B1 5-95 ENGINE

Pipe and Hose Clamp Torque Values

APPLICATION APPROVED CLAMP TORQUE Nm Lb-In Radiator and Heat Exchanger Hoses Constant-Torque CT-L 10.2-12.5 90-110 Heater Hoses Constant Tension not required not required Air Intake Pipes Hi-Torque HTM-L 11.3-14.2 100-125 Charge Air Intake Hoses Flex Seal 667 7.9-11.3 70-100 B9296 6-7 50-60 Fuel, Oil and Water Heat Exchangers (for Miniature 3600L 1.1-1.7 10-15 hoses less than 9/16 diameter) Exhaust Clamps Breeze V-Band 54 480

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5-96 Y53-1200-1B1 (04/13) ENGINE

Accessory Drive Belts 2. Slip the belt around the idler You can extend the reliability and pulley attached to the automatic service life of your vehicle's drive belts tensioner. with proper attention to installation, 3. Release the automatic tensioner. and maintenance. Neglect could cause belt failure. The result could be 4. Check the belt alignment on each the loss of the electrical or air system pulley. The belt must fall between as well as possible engine damage the flanges of each pulley. from overheating. So it's a very good idea to check your belts frequently and replace them as soon as you detect trouble. PACCAR MX Belt Routing

Follow this procedure to install an NOTE accessory drive belt: See the engine manufacturer's opera- 1. Route the new belt around the tor's manual for further information on 5 pulleys, and then rotate the replacing engine drive belts. automatic tensioner so that the idler pulley swings toward the belt routing. The following figure shows an example of the rotation direction to release the tensioner. Cummins Belt Routing

(04/13) Y53-1200-1B1 5-97 ENGINE

Engine Fan Fan Drive and Blade • With the engine idling and the hood open, stand at the front of WARNING! WARNING! the vehicle. Listen for any noises Do not work on the fan with the engine coming from the fan hub. Bearings Do not work on the fan with the engine running. The engine fan can engage that have lost lubricant, and are running. The engine fan can engage at any time without warning. Before dry, will typically emit a squeal at any time without warning. Before turning on the ignition, be sure that no or a growl when the engine is at turning on the ignition be sure that no one is near the fan. Failure to comply operating temperature and the one is near the fan. Failure to comply may result in death or personal injury. fan clutch is engaged. If noise is may result in death or personal injury. detected, have the fan bearings Your truck may be equipped with an inspected by an authorized Fan Blade Clearance: Around the fan On/Off or Viscous Fan Drive. Follow dealership. shroud, the recommended distance these guidelines to check your engine is 1 in. (25 mm) from front edge of fan: any fan blade-to-radiator side member. Minimum clearance is 3/4 in. (19 mm). • Check the fan bearings for fan 5 hub bearing looseness, loss • Rear edge of any blade must be of lubricant and any abnormal no closer than 3/8 in. (9 mm) to conditions. (For example, fan the nearest engine component. If belt misaligned or excessive this cannot be obtained, the fan wear/damage.) Before starting the spacer or fan is not correct. engine and with the engine off, look and feel for looseness in the • The leading edge of any fan blade fan hub. must be 1 in. (25 mm) from the inside edge of the shroud.

5-98 Y53-1200-1B1 (04/13) ENGINE

Air Intake System Turbocharger High Frequency Vibration: Vibration Engine heat, vibration, and age When servicing the air intake and may indicate turbo rotor imbalance. combine to loosen air intake exhaust systems on a turbocharged Have your dealer investigate this connections and cause cracks in engine, check the items listed below. immediately. If you detect any the tubing and elbows. Leaks in the deficiencies, take the vehicle to an intake system allow abrasive dust to WARNING! authorized dealer for servicing. Delay could lead to severe and expensive enter the engine and quickly cause Do not operate engine with tur- damage to your vehicle. expensive damage. During your daily bocharger intake piping disconnected. walk-around inspection, carefully A suction is created when the engine check all tubing, elbows, clamps, is running. This suction could draw supports and fasteners for condition your hand or anything else near it into and tightness. the impeller fan. You could be injured. • Check the Charge-Air-Cooler for Always keep the intake piping con- air leaks annually. The air leaks nected when you will be running the can be caused by cracked tubes engine. or header. For service see your 5 authorized dealer. Lubricating System: Check the oil lines, housing, and connections. Look CAUTION for leaks, damage, or deterioration. Leaks could mean you have damaged Do not use air intake pipes and con- oil lines or oil seals. nections as a step or to pull yourself up. This could loosen the connections Manifold: With the engine operating, and open the system to unfiltered air check for leaking manifold or flange which could damage the engine. gaskets.

(04/13) Y53-1200-1B1 5-99 ENGINE

Air Cleaners mirrors, the mirror must be pivoted to Replacing the Engine Air Intake provide access for servicing the filter Filter The following service information is element. basic to all air cleaner makes and 1. Open hood. models. 2. Loosen a total of 4 screws. (screws will not come out of the CAUTION housing) Failure to replace air filter at proper 3. Remove lid. intervals may result in passage of dirt/debris into the engine or the “dust- 4. Remove filter. ing” of an engine resulting in significant engine damage.

Service the air cleaner filter elements as specified in the Preventive Maintenance Schedule on page 5-12. 5 Your vehicle is equipped with an air inlet restriction indicator. Service the filter elements when the air inlet restriction indicator locks in the extreme Up position. Paper elements require care and proper handling because they are critical to engine service life. If your vehicle has an external air cleaner and cab-mounted

5-100 Y53-1200-1B1 (04/13) ENGINE

ServiSignal™ Mini Indicator Exhaust System Engine Mounting

The ServiSignal™ Mini Indicator is The exhaust system is part of the Periodic Inspection: Inspect engine installed on the air cleaner or air noise and emission control system. mounts every 60,000 miles (96,560 induction piping so it has access to Periodically check the exhaust for km). Check for the following: clean filtered air. As the filter plugs wear, exhaust leaks, and loose or and restriction increases, a red flag missing parts. For details see Noise • Inspect both mount and leg appears in the window. When it and Emission Control on page 5-117. fasteners. Check for loose reaches the red zone, the air filter or broken bolts. Replace as should be replaced. The indicator can Please refer to the Engine Operator's necessary. Manual for more details on how to be reset by pressing the button at the • Check mount and leg for fractures, maintain the emission's components in end of the indicator. breaks or deformation. Replace the exhaust system. as necessary. • Check for complete insertion of motor mount. Replace as necessary. 5 • New leg to mount flange head bolts should be torqued to 210-230 Lb-Ft (284-311 Nm).

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CAUTION Do not re-torque or reuse existing flange head bolts. These bolts are factory set to the specified torque. If bolts are loose or damaged, they must be replaced with the new bolts. Fail- ure to comply may result in equipment or property damage.

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5-102 Y53-1200-1B1 (04/13) FUEL SYSTEM

FUEL SYSTEM Specification Fuel Filters

Location of Fuel Shut-off Use only diesel fuel as recommended See Engine Manufacturer’s Operator by engine manufacturers. Manual provided with this chassis Valves or the instructions provided with a WARNING! Fleetguard filter. Fuel shut-off valves for the fuel crossover line are on the bottom of the A mixture of gasoline or alcohol with secondary fuel tank, at the crossover diesel fuel in the presence of an igni- line connection. They are optional on tion source (such as a cigarette) could the primary fuel tank. cause an explosion resulting in death or personal injury. Use only the recom- mended diesel fuel.

CAUTION If anyone ever pours gasoline into your fuel tank, drain the entire system. Oth- erwise, the pump and engine will be 5 damaged. Don’t try to dilute the gaso- line by adding diesel fuel (See Warning above).

(04/13) Y53-1200-1B1 5-103 FRAME

FRAME Emergency Welding Welding Precautions

Introduction WARNING! In the event of emergency welding of a frame rail and when welding any other Frame welding is NOT recommended. part of your truck or any component WARNING! The high heat of welding nullifies the attached to your truck, observe the special heat treatment of the rails, Do not cut, splice or weld frame rails or following precautions before welding: drill through the top or bottom flanges greatly reducing the tensile strength of the rails. These operations could af- of the frame rail. If a frame member • Disconnect all electronic devices. fect frame rail strength leading to a fail- becomes cracked from overloading, It is not possible to list all of the ure resulting in an accident. Rail fail- fatigue, surface damage or a collision, electronics that could be affected, ures resulting from such modifications the only permanent repair is to replace but a few examples include the are not warrantable. Failure to com- the damaged frame member with a following: alternator, engine ply may result in death, personal injury, new part. Electronic Control Unit (ECU), equipment or property damage. transmission ECU, ABS ECU, In an emergency, a temporary repair navigation devices, diagnostic may be performed. Observe the devices, and monitoring devices. 5 following precautions to protect electronic systems during welding • Disconnect battery cables and operations. Emergency welding insulate them from the vehicle. procedures are further explained in the • Do not use the ECU or engine maintenance manuals. Please refer to ground stud for the ground of the the ordering information on the back welding probe. cover to obtain a maintenance manual. • Ensure that the ground connection for the welder is as close to the

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weld point as possible. This Painting Fifth Wheel Maintenance ensures maximum weld current and minimum risk to damage Do not electrostatically paint your Proper preventive maintenance is of electrical components on the truck or any component on your essential to trouble-free service and vehicle. truck without first removing all of safe operation of the fifth wheel. the electronic components from the truck. It is not possible to list all of Every 15,000 miles or monthly: the electronics that could be affected, • Refer to specific manufacturer's but a few examples include the literature for any special alternator, engine Electronic Control instructions. Unit (ECU), transmission ECU, ABS ECU, navigation devices, diagnostic • Steam clean the fifth wheel. devices, and monitoring devices. • Check lock guard operation using a commercial lock tester. • Clean and oil all moving parts. 5 • Lubricate the lock mechanism with a lithium-base grease. • All grease fittings (especially those which grease the top surface of the fifth wheel).

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Frame Fastener Torque Every 60,000 miles or 6 months: Requirements Standard Grade 8 UNF or UNC and Metric • Refer to specific manufacturer's TORQUE * Tighten all frame fasteners with a FASTENER literature for any special SIZE Nm Lb-Ft torque wrench. Torque specifications instructions. 5/16 22-30 16-22 apply to the following fasteners with 3/8 41-54 30-40 • Remove fifth wheel from vehicle. lightly lubricated threads. 7/16 75-88 55-65 Refer to the Shop Manual, “Fifth 1/2 109-122 80-90 NOTE 9/16 156-190 115-140 Wheel Removal.” 5/8 224-265 165-195 Whenever possible, torque all frame 3/4 394-462 290-340 • Steam clean the fifth wheel and fasteners on the nut end, not the bolt 7/8 517-626 380-460 mounting brackets. head. 1 952-1,129 700-830 1-1/8 1,346-1,591 990-1,170 • Check all moving parts for 1-1/4 1,877-2,217 1,380-1,630 excessive wear or damage. METRIC WITH NYLON INSERT NUTS Replace all worn or broken parts. M5 8-12 6-9 M6 9-15 7-11 • Complete two-month service M8 23-31 17-23 5 procedure. M10 33-43 24-32 M12 75-101 55-75 • Install fifth wheel. Refer to M16 163-217 120-160 the Shop Manual, “Fifth Wheel M20 352-460 260-340 Installation.” * ESNA Style Lock Nut, with nylon insert. Lubricate nylon insert nut lightly with SAE 20/30 oil.

5-106 Y53-1200-1B1 (04/13) FRAME

Sliding Fifth Wheels

Lubricate bearing surface of support bracket through the grease fittings on the side of the fifth wheel plate. Use a water resistant lithium-base grease.

NOTE The plate must be lifted up slightly to relieve the weight of the bracket while applying grease.

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(04/13) Y53-1200-1B1 5-107 FRONT AXLE AND SUSPENSION

FRONT AXLE AND Kingpin Lubrication Suspension Lubrication SUSPENSION Lubricate with approved lubricant. Each standard spring anchor pin Lubricate knuckle thrust bearings, has a grease fitting. Pressure Axle Lubrication knuckle pins, and tie rod ends. See lubricate spring pins as specified. See Preventive Maintenance Schedule Preventive Maintenance Schedule on Change bearing lubrication when seals on page 5-12. Lack of lubrication page 5-12. are replaced, or brakes are relined. causes premature wear and hard See Preventive Maintenance Schedule steering. Lubrication schedule may be At regular intervals, the spring leaves on page 5-12. shortened if necessary. may be lubricated with a rust-inhibiting oil applied with a spray gun or brush. Thoroughly clean hubs and bearings with solvent and a stiff bristle brush, Depending on your suspension, then dry and inspect components for lubricate all spring pins until grease wear or damage. Re-lubricate with flows out of both ends of the bushing. approved axle lubricant. Look for signs of rust or water in the flushed grease. If a pin will not accept 5 grease, it should be removed, cleaned, and inspected.

CAUTION Do not spray the suspension with chemical products or mineral oil; it can cause damage to the bushings.

5-108 Y53-1200-1B1 (04/13) FRONT AXLE AND SUSPENSION

Inspection Wheel Alignment

For all vehicles, mandatory For driving safety and comfort, and maintenance procedures include to prolong the life of your vehicle, it retightening all U-bolts and inspecting is important to have wheels correctly the suspension for loose fasteners, aligned. Check tire wear frequently. abnormal wear, or damage. However, Uneven tire wear is a sign that the even with proper maintenance, the wheels may be misaligned. service life of leaf springs is affected by many factors, such as: fatigue, If you see uneven wear, take your vehicle gross weight, type of load, road vehicle to an authorized dealer familiar conditions, and vehicle speed. with aligning wheels on your vehicle.

Check for cracks, wear marks, splits, or other defects on the surface of the spring. Defective parts must be replaced. Because repaired springs cannot be fully restored to their original 5 service life, replace the complete assembly if cracks or other defects are detected.

Visually inspect shock absorbers and rubber bushings.

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U-Bolt Torque Chevron zinc lubricant (SAE 20 or 30 WARNING! oils acceptable but not preferred). It is important that U-bolts remain tight. Do not operate the vehicle if the Severe use of your vehicle will cause U-bolts are not properly tightened. WARNING! them to loosen faster. But all vehicles Loose U-bolts will cause the axle to Do not replace U-bolts and nuts with need to have their U-bolts checked and not be properly secured to the sus- common U-bolts or standard nuts. tightened regularly. Be sure someone pension, which could cause loss of These parts are critical to vehicle with the proper training and the right vehicle control and an accident. Loose safety. If the wrong U-bolts or nuts tools checks and tightens the U-bolts U-bolts can also cause uneven tire are used, the axle could loosen or on your vehicle. wear and poor alignment. Failure to separate from the vehicle and cause comply may result in death, personal New springs can settle in after service, a serious accident. Use only U-bolts injury, equipment or property damage. relieving the tension on the U-bolts. and nuts of SAE Grade 8 specification Loose U-bolts can cause leaf spring or better. Failure to comply may result breakage, axle misalignment, hard U-bolts are difficult to tighten unless in death, personal injury, equipment or steering and abnormal tire wear. you have the right equipment. If you property damage. cannot tighten them correctly yourself, 5 All vehicles should have suspension be sure to have them checked and U-bolts tightened after the first 500 tightened regularly by an authorized miles (800 km) of operation. Re-torque mechanic. the front spring pinch bolts and shackle pinch bolts. Tighten U-bolt nuts to the specified torque value with the vehicle loaded to its normal gross weight. The following torque values apply to U-bolts and nuts with clean threads lubricated with

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Front Spring Suspension U-Bolts, Grade 8

U-BOLT SIZE TORQUE DIAMETER Nm Lb-Ft (Inch Dimensions) 3/4 333-408 245-300 7/8 598-734 440-540 1 925-1,060 680-780 1-1/8 1,470-1,660 1,080-1,220 1-1/4 1,890-2,120 1,390-1,560 1-1/2 3,130-3,860 2,300-2,840

5

(04/13) Y53-1200-1B1 5-111 HEATER AND AIR CONDITIONER

HEATER AND AIR • Whenever the exhaust system, Special Precautions CONDITIONER underbody or cab is damaged WARNING! Introduction To allow for proper operation of the Excessive heat may cause the pres- vehicle ventilation system, proceed as surized components of the air con- The combination heater-air conditioner follows: ditioning system to explode. Never provides comfort for those in the cab weld, solder, steam clean, or use a • Keep the inlet grille at the base of through accurate control of the cab blow torch near any part of the air con- the windshield clear of snow, ice, environment in all weather conditions. ditioning system. Failure to comply leaves and other obstructions at Regular attention to the items below may result in death, personal injury, all times. will help you keep the heater-air equipment or property damage. conditioner unit running well. • Keep the exhaust pipe area clear to help reduce the buildup of WARNING! Keep the vehicle's ventilation system, exhaust gas under the vehicle. engine exhaust system and cab Air conditioning refrigerant can be haz- joints properly maintained. It is • Check the drain tube of the fresh ardous to your health. Do not expose 5 recommended that the vehicle's air inlet for trapped water before yourself to leaking refrigerant for pro- exhaust system and cab be serviced assuming that there is a leak in the longed periods near excessive heat, as follows: heating system. open flames, or without proper venti- lation. Failure to do so may result in • Inspected by a competent death or personal injury. technician every 15,000 miles • Whenever a change is noticed in If a refrigerant leak develops in the the sound of the exhaust system presence of excessive heat or an open flame, hazardous gases may be generated. If you become aware of a

5-112 Y53-1200-1B1 (04/13) HEATER AND AIR CONDITIONER refrigerant leak on your vehicle have Air Filters Cabin Fresh Air Filter your system serviced immediately and Cab Recirculation Air Filter observe the following precautions: The fresh air filter for the cab HVAC is Please contact an authorized dealer located in the air intake housing that is Stay away from the hot engine until the when the service interval is required to located in the passenger rear corner of exhaust manifold has cooled. inspect the cabin recirculation air filter. the engine compartment. The filter can be replaced without using any tools. Do not permit any open flame in the area. Even a match or a cigarette Inspect and clean cab air filter lighter may generate a hazardous element every 3 - 6 months of quantity of poisonous gas. service. Depending on the operating environment, if air flow from the air Do not smoke in the area. Inhaling conditioner and heater is less efficient gaseous refrigerant through a cigarette or windows fog easier, you may need may cause violent illness. to replace the cab air filter. 1. Tilt the hood open. 2. Locate air intake housing at 5 passenger rear corner of vehicle under the rain tray.

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the side of the filter element with Sleeper HVAC Air Filter the airflow direction that is clearly marked on the air intake housing. The sleeper recirculation filter is located under the sleeper bunk on the passenger side of the vehicle. Lift the bottom bunk to access the unit. The filter can be replaced without using any tools.

6. Replace the filter cover on the air 3. Locate filter cover labeled “OPEN” intake housing and slide the cover 5 with an arrow pointing rearward in forward in vehicle. An audible vehicle. Slide filter cover rearward snap sound can be heard when in vehicle until you are able to the cover is correctly in place. If remove the cover. the snap feature is damaged there are two screw features that may 4. Remove and inspect filter referring 1. Lift the sleeper bunk to expose the be utilized to retain the cover in to maintenance interval schedule. sleeper HVAC module. place. 5. Replace filter in housing taking 2. Find the retention tab at the side 7. Close and secure hood of vehicle. care to align the airflow direction of the filter element and move it to that is indicated on the side of release the filter. Moving this tab

5-114 Y53-1200-1B1 (04/13) HEATER AND AIR CONDITIONER

will allow the filter to be removed element such that it points into the Heater in an upward direction. HVAC housing. • Check all heater controls for 4. Insert the filter and make sure the full-range operation. retention tab has re-engaged to secure the filter. • Check hoses, connections, and heater core for condition and 5. Close the bunk. leaks.

CAUTION During extreme cold weather, do not blow hot defroster air onto cold wind- shields. This could crack the glass. Turn the air direction lever to Defrost and adjust the fan speed accordingly while the engine warms. If the en- gine is already warm, move the tem- perature selector to Cool, then grad- 5 ually increase the temperature when you see that the windshield is starting to warm-up.

3. Align the airflow direction that is indicated on the side of the filter

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Air Conditioner be removed with compressed to worsen. Have a qualified air blown through the core in the technician correct the problem. WARNING! opposite direction of normal air The air conditioning system is under flow. NOTE pressure. If not handled properly dur- A leaking evaporator or condenser ing servicing, it could explode. Any WARNING! core cannot be repaired; it must be servicing that requires depressurizing Wear eye protection any time you blow replaced. and recharging the air conditioning compressed air. Small particles blown system must be conducted by a qual- by compressed air could injure your Have the air conditioning system fully ified technician with the right facilities eyes. serviced annually by your authorized to do the job. Failure to comply may dealer. Qualified service technicians result in death, personal injury, equip- • Check the engine belt for condition will have to evacuate and recharge the ment or property damage. and proper tension. system.

• Listen to the compressor and drive • Check all hoses for kinks, clutch for noise and vibration. deterioration, chafing, and leaks. 5 If you find problems, have the Adjust kinked or chafing hoses to system checked thoroughly. A eliminate restrictions and prevent malfunctioning clutch usually further wear. indicates trouble elsewhere in the • Check all components and system. connections for refrigerant leaks. • Check the evaporator core, filter, If you discover a leak, do not try to and condenser core for debris tighten a connection. Tightening restricting air flow. Clean if a connection may cause a leak necessary. Small particles may

5-116 Y53-1200-1B1 (04/13) NOISE AND EMISSION CONTROL

NOISE AND EMISSION Tampering with Noise Control Air Intake System System CONTROL • Removing or rendering inoperative Federal law prohibits the following the air cleaner/silencers or intake Noise Emission Warranty acts or the causing thereof: piping. Engine Cooling System There are specific components on (1) The removal or rendering the vehicle that are designed to meet inoperative by any person other than • Removing or rendering inoperative certain Environmental Protection for purposes of maintenance, repair, or the fan clutch. Agency (EPA) emissions and noise replacement, of any device or element regulations. To maintain conformance of design incorporated into any new • Removing the fan shroud. with the regulations, these components vehicle for the purpose of noise control Engine need to be functional and properly prior to its sale or delivery to the maintained. ultimate purchaser or while it is in use, • Removing or rendering engine or (2) the use of the vehicle after such speed governor inoperative so as device or element of design has been to allow engine speed to exceed removed or rendered inoperative by manufacturer's specifications. any person. 5 • Modifying ECU parameters. Among those acts presumed to Exhaust System constitute tampering are the acts listed below: • Removing or rendering inoperative exhaust system components.

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Fuel System • Cutting holes in, or cutting away Inspection and Maintenance Instructions • Removing or rendering engine part of noise insulators. speed governor inoperative, • Removing hood-mounted noise The following instructions are based on allowing engine speed to exceed insulation. inspection of the noise control system manufacturer's specifications. at regular intervals as indicated in the • Removing of air signal attenuator Noise Control System Maintenance on engines equipped with this Log on page 5-124. device. If, during periodic inspection and • Removing of diesel exhaust fluid maintenance of other systems and tank and system. components, it is found that parts of the noise control system require attention, Inner Fender Shields and Cab Skirts we recommend that those parts be • Removing shield or skirts. inspected at more frequent intervals to assure adequate maintenance and • Cutting away parts of shields, performance. 5 skirts or damaged or loose portions of shields or skirts. Noise Insulating Blankets • Removing noise insulators from engine block or from around the oil pan.

5-118 Y53-1200-1B1 (04/13) NOISE AND EMISSION CONTROL

Air Intake System Engine Mounted Noise Insulators Exhaust System • Do all checks and maintenance • Check condition. Is the insulator • Check for exhaust leaks, procedures listed in this manual secure? How you do this will which would indicate a leaking under Engine Air Intake System depend on the method of attaching manifold gasket; replace gasket if and Air Cleaner. See Air Dryer on the noise insulators on the engine necessary. page 5-52. and around the oil pan (bolts, snap fasteners, or straps). Tighten • Check cap screws for tightness, • Check the induction tubing, elbow loose fasteners and repair or including those at the flanges. connections, clamps, brackets, replace any worn or damaged Refer to the engine manufacturer's and fasteners for deterioration, fasteners. service manual for proper cracks, and security. tightening sequence and torque • Check insulators around fasteners values. • If you find an air leak anywhere and stress points, especially between the air cleaner and where they may be affected by the engine, repair that leak engine vibration. Repair any immediately. cracked or damaged mounting points. Use suitable reinforcing 5 CAUTION plates to ensure that the insulators Air leaks cause excessive noise and will remain in position. may result in serious damage to the engine. If you do not repair them the engine damage will not be covered by your warranty. Repair all air leaks as soon as you find them.

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Joints and Clamps Selective Catalyst Reduction (SCR) Piping • Check for leaks, and tighten as • Check SCR canister filter, clamps • Check exhaust piping for rust, necessary. Check for deterioration and mounting brackets. Tighten if corrosion, or damage. Replace or dents in pipes and clamps which necessary. Inspect SCR canister deteriorated piping before holes could allow exhaust to escape. for signs of rust or corrosion. appear. If piping is perforated at any point, temporary patching or • Replace any serviceable joints, lagging is acceptable until you can flexible pipes and gaskets at the have permanent repairs made. service intervals. On turbocharged engines, check joints at flanges and mounting brackets for tightness.

5

5-120 Y53-1200-1B1 (04/13) NOISE AND EMISSION CONTROL

Diesel Particulate Filters (DPF) Diesel Exhaust Fluid Tank CAUTION • Check diesel particulate filter (DPF), clamps, and mounting The Diesel Exhaust Fluid (DEF) sys- brackets. Tighten if necessary. tem purges to prevent damage from Inspect diesel particulate filter freezing. If your vehicle is equipped (DPF) for signs of rust or corrosion. with battery disconnect switches, do NOT disconnect battery power within • Check internal baffling. You can two minutes of switching the ignition do this by listening for rattling key off. Failure to comply may result sounds while tapping on the diesel in vehicle or property damage. particulate filter (DPF) with a rubber mallet or revving the engine DEF Filter up and down through its normal operating range. The DEF system has a supply Vehicles that comply with 2013 EPA pump filter and this filter should be emission requirements will have a serviced according to the preventive Diesel Exhaust Fluid (DEF) tank maintenance schedule. Follow these 5 mounted to the vehicle frame. steps to replace the DEF supply pump filter: 1. Turn off the vehicle and allow the vehicle to cool down. Take special precaution with hot exhaust piping.

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Exhaust Tail Pipe WARNING! 3. Using a 27 mm socket wrench (DIN3124), remove the filter cap • Check the mounting. Tighten as The exhaust piping can become ex- that is screwed to the DEF Supply necessary. The miter cut at the tip tremely hot during engine operation pump. of the pipe must be facing the rear and can cause personal injury includ- of the vehicle. Do not modify the ing serious burns to the skin. Allow end of the pipe in any way. adequate cooling time before working near any part of the exhaust system.

2. Remove the pump protective plate mounted on the bottom of the DEF tank.

5

5-122 Y53-1200-1B1 (04/13) NOISE AND EMISSION CONTROL

Engine Fan and Shroud Hood Insulation Blanket Inner Fender Shields and Cab Skirts

WARNING! • Check all fasteners for condition • Check all fasteners that hold the and security. Repair or replace fender shields in place. Do not work on the fan with the engine any broken or defective fasteners. running. The engine fan can engage • Check fender shields for tire at any time without warning. Anyone • Check for chafing or tears. Patch marks, worn spots, or damage near the fan when it turns on could be it if necessary. Find the cause of from objects thrown from tire injured. Before turning on the ignition, the damage. If any component treads. be sure that no one is near the fan. or accessory is causing wear or damage and cannot be relocated, • Check cab skirts, sills, and • Check all fasteners for tightness. put reinforcing pads on the blanket brackets for overall condition Check for stress cracks in the at the site of wear. and repair them as necessary. shroud. Make sure the shroud is Damaged rubber fender shields adjusted so that it does not touch or cab skirting cannot be repaired. the fan blades. You will need to replace it. • Check to verify that the fan is disengaged (not turning) with 5 the engine running at normal operating temperatures (from cold to the point that the fan engages). • Check fan blade mounting bolts. Inspect fan blades to be sure they are not cracked or bent.

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Noise Control System - maintenance checks. Use the Maintenance Log following log sheet and retain copies of documents regarding maintenance To ensure your vehicles noise control services performed and parts replaced requirements are maintained, record on the vehicle.

Noise Control System - Maintenance Log

Recommended Repair Facility Work Repair Facility & Work Component Date & R.O. No. Date & R.O. No. Interval (Miles) & Location Performed Location Performed Exhaust System 25,000 Routing Integrity Shutters 25,000 Shrouds Hood Insulation 10,000 Blanket Engine Mounted 10,000 Hose Insulators Fasteners Inner Fender 50,000 5 Shields Cab Skirts 50,000 Fasteners Air Intake 5,000 System Integrity Element Clutch Type Fan 10,000 Drive

5-124 Y53-1200-1B1 (04/13) REAR AXLE AND SUSPENSION REAR AXLE AND SUSPENSION WARNING! WARNING! Do not operate the vehicle if the Failure to maintain the specified General Maintenance U-bolts are not properly tightened. torque values or to replace worn parts Loose U-bolts will cause the axle to can cause component system failure, WARNING! not be properly secured to the sus- possibly resulting in an accident. Im- pension, which could cause loss of properly tightened (loose) suspension Do not work on the vehicle without the vehicle control and an accident. Loose U-bolts can lead to unsafe vehicle parking brake set and wheels blocked U-bolts can also cause uneven tire conditions, including: hard steering, securely. If the vehicle is not secured wear and poor alignment. Failure to axle misalignment, spring breakage or to prevent uncontrolled vehicle move- comply may result in death, personal abnormal tire wear. See Front Spring ment, it could roll and may result in injury, equipment or property damage. Suspension U-bolts on page 5-111 for death, personal injury, equipment or proper torque specifications. Failure property damage. to comply may result in death, per- sonal injury, equipment or property Your vehicle's suspension, by damage. design, requires a minimal amount of 5 maintenance. However, suspensions CAUTION in over-the-road operations require periodic inspection to ensure trouble- Do not spray the suspension with free performance. chemical products or mineral oil; it can cause damage to the bushings.

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Visual Inspection • Visually check for loose or missing NOTE fasteners, cracks in hanger, or For all vehicles, mandatory Failure to follow these recommenda- axle connection brackets. maintenance procedures include tions could void warranty. retightening of U-bolts and complete • Check that springs are centered in inspection. However, even with proper hangers and in good condition. maintenance, many factors affect the service life of springs and suspension • Check for cracks, wear marks, components, such as: fatigue, vehicle splits, or other defects on the gross weight, type of load, road surface of the spring. conditions, and vehicle speed. • Replace defective parts. Because It is important that U-bolts remain tight. repaired springs cannot be Severe use of your vehicle can cause fully restored to their original them to loosen faster. But all vehicles service life, replace the complete need to have their U-bolts checked and assembly if cracks or other defects tightened regularly. Be sure someone are detected. 5 with the proper training and the right • After replacement of any part or tools checks and tightens the U-bolts discovery of loose components, on your vehicle. check the torque of all fasteners. • After the first 500 miles (800 km) of • New springs settle-in after the operation, inspect the suspension vehicle's initial service, causing periodically, as noted below: the U-bolts to become loose.

5-126 Y53-1200-1B1 (04/13) REAR AXLE AND SUSPENSION

Rear Suspension Fasteners U-Bolt Torque Rear Suspension Fasteners (Metric and To maintain the performance of the NOTE Standard) air suspension, check fastener torque To ensure an accurate torque read- SIZE/TYPE TORQUE * values after the first 2,000 miles (3,218 ing, use properly maintained and cal- Nm Lb-Ft km) of service and every 60,000 miles M16 163-217 120-160 ibrated torque wrenches. (96,000 km) thereafter. nylon-insert Clean the nut and bolt. No dirt, grit, or nuts rust should be present. M20 352-460 260-340 Torque recommendations apply to nylon-insert fasteners supplied and installed by nuts vehicle manufacture. The values listed WARNING! M20 all-metal 427-475 315-350 in the tables below, are for cadmium lock nuts Do not operate the vehicle if the 1/2 in. nut 109-122 80-90 plated or phosphate and oil fasteners U-bolts are not properly tightened. 3/4 in. nut 394-462 290-340 only. Loose U-bolts will cause the axle to 1-1/4 in. nut 1,877-2,217 1,380-1,630 not be properly secured to the sus- * Torque requirements apply to manufacturer U-bolts are difficult to tighten unless proprietary suspensions. All other pension, which could cause loss of you have the right equipment. If you suspensions must refer and adhere to vehicle control and an accident. Loose original manufacturers shop manual. cannot tighten them correctly yourself, 5 U-bolts can also cause uneven tire be sure to have them checked and wear and poor alignment. Failure to tightened regularly by an authorized comply may result in death, personal mechanic. injury, equipment or property damage.

NOTE Whenever possible, torque all fasten- ers on the nut end, not the bolt head.

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Rear Axle Lubrication Rear Suspension U-Bolts, Grade 8 WARNING! (lubricated*) Do not replace U-bolts and nuts with Check oil level with the vehicle parked U-BOLT SIZE TORQUE** common U-bolts or standard nuts. on level ground and the fluid warm. DIAMETER The level should be even with the Nm Lb-Ft These parts are critical to vehicle THREAD safety. If the wrong U-bolts or nuts bottom of the filler hole. 3/4 333-408 245-300 are used, the axle could loosen or 7/8 598-734 440-540 1 925-1,060 680-780 separate from the vehicle and cause 1-1/8 1,470-1,660 1,080-1,220 a serious accident. Use only U-bolts 1-1/4 1,890-2,120 1,390-1,560 and nuts of SAE Grade 8 specification 1-1/2 3,130-3,860 2,300-2,840 or better. Failure to comply may result *Chevron Zinc Lubricant or SAE 20/30 oil in death, personal injury, equipment or should be used on U-Bolt threads **Torque requirements apply to manufacturer property damage. proprietary suspensions. All other suspensions must refer and adhere to original manufacturers shop manual.

5 • Load the vehicle to its normal gross weight before tightening U-bolts. Loading the vehicle ensures proper adjustment of the U-bolt and spring assembly.

5-128 Y53-1200-1B1 (04/13) REAR AXLE AND SUSPENSION

Dana Spicer and Fabco CAUTION All Vehicles with Dana Spicer Do not mix lubricants of different No initial drain is required on Dana and Fabco Axles: See Preventive grades; although, mixing different Spicer axles that are factory filled with Maintenance Schedule on page 5-12. brands of the same grade lubricant an Dana Spicer-approved synthetic Contact your dealer for approved (meeting MIL L2105C), is acceptable. lubricant. synthetic lubricant brands. Lubricants of different grades are not • Petroleum-based lubricants must • Dana Spicer Axles with synthetic compatible and could damage the be drained within the first 5,000 lubrication and Out Runner Seals: axle. miles (8,000 km) if converting to drain, flush, and refill at 500,000 an approved synthetic lubricant. miles (804,000 km). NOTE Initial Change: See Preventive Axle Housing Breather Vent: In all cases, lubricant supplier as- Maintenance Schedule on page 5-12 sumes full responsibility for the per- for standard rear axle service intervals. • Check and clean the axle housing formance of their product, and for Change mineral-based lubricant in breather vent at each oil level product and patent liability. other Dana Spicer and Fabco axle check. assemblies (new or rebuilt) within the Meritor: 5 For recommended types and brands of first 3,000 to 5,000 miles (4,800 to lubricants, contact your dealer. 8,000 km). • See Meritor Lubrication Maintenance Manual (MM1). • For petroleum-based axles, use lubricants meeting MIL L2105C/D grade specifications or approved synthetic lubrication. Do not use oil additives.

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Rear Axle Alignment

Continual road shock and load stresses may force the rear axles out of alignment. If you detect rapid tire wear on the rear axles, you may have misaligned axles. If you suspect rapid tire wear, have your rear axle alignment checked and adjusted by an authorized dealer.

In addition to pre-delivery inspections, suspension alignment should be checked when any one of the following conditions exist: • Discovery of loose suspension 5 fasteners. (Loose, defined as any torque below the recommended torque value.) • Discovery of elongated holes in a suspension component. • Bushing replacement. • Excessive or abnormal tire wear.

5-130 Y53-1200-1B1 (04/13) STEERING SYSTEM

STEERING SYSTEM any reason, the power assist system If the steering feels unbalanced from goes out, steering the vehicle is still Power Steering side-to-side while turning, check for possible, yet it will require much the following possible causes: greater effort. Oil (under low pressure) provides the • unequal tire pressures power to operate the steering gear. It Visually check the following parts: also serves to lubricate moving parts • vehicle overloaded or unevenly • Crosstube: Is it straight? and remove heat. A loss of steering distributed load efficiency will occur if too much heat • Draglink tube clamp: Check for builds up in the system. • wheels out of alignment looseness or interference. • wheel bearings improperly WARNING! • Ball joints and steering U-joints: adjusted. Check for looseness. Do not operate the vehicle if the steer- ing system is not working properly. If you cannot correct the problem, • Steering wheel for excessive You could lose control of your vehicle check with an authorized dealer. free-play. Check the simplest if the steering system is not in good probable causes first: working condition, which could re- Your vehicle is equipped with integral a. unequal tire pressures 5 sult in a serious accident. For driving power steering. The system includes safety, visually check the steering gear an engine-driven fluid pump, a fluid b. loose cap nuts and components. Frequent checks reservoir, the steering gear, and c. bent crosstube are important for driving safety, espe- connecting hoses. Because of the cially after traveling over rough roads. hydraulic power assist, little effort is d. lack of lubrication. Failure to comply may result in death, required to turn the steering wheel. personal injury, equipment or property When no input is applied through the • If these checks do not reveal the damage. steering wheel, the steering gear will problem, or if you correct them return to the neutral position. If, for and still have a steering problem,

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take your truck to an authorized Fluid Level and Refill • Maximum/Minimum level is dealer for evaluation. Have the power steering fluid and indicated on the reservoir. These filters changed at an authorized dealer. same levels are also indicated by two lines on the dipstick in the CAUTION reservoir. When adding fluid, be sure to use fluid • There are two ways to check of the same type. While many flu- whether the power steering fluid ids have the same description and in- is at its proper level. Both checks tended purpose, they should not be are with the engine NOT running. mixed due to incompatible additives. 1. If you check the fluid with the Mixing incompatible fluids may lead to engine and steering system equipment damage. COLD, the fluid level should be at/or above the Minimum indicator Check and completely change the • level and should generally not fluid level according to Preventive exceed the middle point between Maintenance Schedule on page 5 Maximum and Minimum level 5-12. Use the following procedure: indicators. NOTE 2. If you check the fluid with the engine and steering system Before removing reservoir cover, wipe WARM, the fluid should NOT outside of cover so that no dirt can fall exceed the Maximum level into the reservoir. indicator and should generally not drop below the middle point

5-132 Y53-1200-1B1 (04/13) STEERING SYSTEM

between the Maximum and 2. Bleed the system if necessary. Steering Shaft Minimum level indicators. The following are common torque Fluid Filter Replacement specifications for most steering shafts. • Torque on U–joint pinch bolt and nut (7/16 in) 74–81 Nm (55 to 60 lb-ft), lubricated. • Torque on Pitman arm clamp bolt and nut (3/4 in): 406–433 Nm (300 to 320 lb-ft), lubricated. • For off–highway vehicles, tighten the U–bolts after the first day or two of operation. Then check weekly. 5

CAUTION Servicing the power steering system without bleeding it of trapped air may cause damage to the power steering pump.

1. Replace both fluid and filter.

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WARNING! If this chassis is equipped with an elec- tronic stability system (ESP) and any part of the steering system (e.g. link- age, steering driveline, column, front- end alignment, etc) is repaired, re- moved, or disassembled in any way, or if the steering angle sensor is re- placed, the steering angle sensor must be recalibrated. Any repairs or adjust- ments to any part of the steering sys- tem must be performed by an autho- rized dealer. Failure to comply may result in death, personal injury, equip- ment or property damage. 5

5-134 Y53-1200-1B1 (04/13) DRIVELINE

DRIVELINE U-Joints For SPL170XL and SPL250XL, the U-joint lube interval changes after the Driveshaft Maintenance initial lube at 350,000 miles. After the first lube interval, the U-joint The slip joints and universal joints of needs lubrication every 150,000 miles. the driveshaft should be lubricated Inspection of the U-joints is the same periodically. regardless of when the U-joint grease Use a good quality lithium-soap-base interval occurs. or equivalent extreme pressure (E.P.) grease: NLGI Grade 2. WARNING! Improper lubrication of U-joints can Dana SPL U-joints and driveshafts cause them to fail prematurely. The The slip joints and universal joints of should be inspected every time driveshaft could separate from the ve- the drive shaft should be lubricated a vehicle comes in for scheduled hicle and result in an accident. Make according to Preventive Maintenance maintenance (Refer to Spicer sure lubricant is purged at all four ends Schedule on page 5-12. Driveshaft service manual DSSM-0100 of each U-joint and loosen caps if nec- (3264-SPL) for detailed instructions). 5 Use a good quality lithium-soap-base essary. Also, regularly inspect U-joints for excessive wear or movement, and Use only Spicer Driveshaft approved or equivalent extreme pressure (E.P.) grease: NLGI Grade 2. repair or replace as necessary. Fail- lubricants when greasing Spicer SPL ure to comply may result in death, U-joints. Use only Spicer Driveshaft approved personal injury, equipment or property lubricants when greasing Spicer SPL damage. U-joints.

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TIRES AND WHEEL right care will give you the assurance Checking Inflation Pressure of safe and reliable tire operation. Tires Here are some tips on maintaining Give your tires a visual test every day, your tires. and check inflation with a gauge every WARNING! week: Do not repair damaged tires unless • When checking tire pressure, you are fully qualified and equipped to inspect each tire for damage to do so. Wheel and tire assemblies can- sidewalls, cuts, cracks, uneven not be worked on without proper tools wear, rocks between duals, etc. If and equipment, such as: safety cages a tire appears underinflated, check or restraining devices. Have all tire re- for damage to the wheel assembly. pairs performed by an expert. Stand Don’t forget to check between dual away from the tire assembly while the wheels. If you find wheel damage, expert is working. Failure to do this have an expert tire service repair may result in death or injury. it. 5 • Maximum tire pressure will be Your tires are a very important part of indicated on the sidewall of a tire. your vehicle’s whole braking system. How fast you can stop depends in • Check pressure only when the large measure on how much friction tires are cool. Warm or hot tires you get between the road and your cause pressure buildup and will tires. In addition, keeping your tires in give you an inaccurate reading. good condition is essential to the safe, So never deflate a warm tire to the efficient operation of your vehicle. specified pressure. Regular, frequent inspection and the

5-136 Y53-1200-1B1 (04/13) TIRES AND WHEEL

Underinflated Tires WARNING! WARNING! Low pressure is a tire’s worst enemy. Do not operate a vehicle with underin- Do not attempt to raise the vehicle to Underinflation allows tires to flex flated tires. The extra heat caused by remove or install a damaged tire and improperly, causing high temperatures underinflation can cause sudden tire wheel assembly if you are not fully to build up. Heat causes early tire failure such as a tire fire or blow out, qualified and not equipped with the damage such as flex break, radial which can cause an accident result- proper tools and equipment. Do not at- cracks, and ply separation. Low ing in death or personal injury. Low tempt to re-inflate a tire that has been pressure may affect control of your pressure may affect control at the front run flat. Obtain expert help. A person vehicle, especially at the front wheels. wheels, which could result in an acci- can be seriously injured or killed if us- Most tire wear problems are caused dent involving death or personal injury. ing the wrong service methods. Truck by underinflation as the result of slow Keep your tires inflated to the manu- tires and wheels should be serviced leaks, so you’ll want to check tire facturer's recommended air pressure. only by trained personnel using proper pressure regularly. Lower tire pressure equipment. Follow OSHA regulations does not provide better traction on ice per section 1910.177. or snow.

NOTE 5 Follow all warnings and cautions con- tained within the tire and wheel manu- facturers literature.

(04/13) Y53-1200-1B1 5-137 TIRES AND WHEEL

Overloaded Tires 1 3 Overloading your truck is as damaging Proper-Inflation: the Over-Inflation: correct profile for full reduces the tread to your tires as underinflation. The contact with the road. contact area with following chart shows how neglect or the road surface, deliberate abuse can affect the life of TREAD CONTACT concentrating all of your tires. TREAD CONTACT WITH ROAD the vehicle weight WITH ROAD on the center of the tread. This causes premature wear of the 2 tire.

Under-Inflation: causes abnormal tire deflection, which builds up excessive heat, running the risk of TREAD CONTACT failure. It also causes WITH ROAD irregular wear.

5 EFFECT OF LOAD PRESSURE ON TIRE LIFE Vehicle Load Normal 20% Over 40% Over 60% Over 80% Over 100% Over Tire Pressure Normal 20% Low 30% Low 35% Low 45% Low 55% Low Expected Total Tire Normal 70% 50% 40% 30% 25% Mileage Overinflated Tires

Too much air pressure reduces the tire tread contact area and results in rapid wear in the center of the tread.

5-138 Y53-1200-1B1 (04/13) TIRES AND WHEEL

Matching Tires WARNING! WARNING! Be sure to buy matched tires for Overinflated tires can cause acci- Do not install regrooved or reinforce- your vehicle, especially on the rear dents. They wear more quickly than ment-repaired tires on steering axles. axles. Mismatched tires can cause properly inflated tires and are more They could fail unexpectedly and stress between axles and cause the subject to punctures, cracks, and cause you to lose control of your ve- temperature of your axle lubricant to other damage. They could fail and hicle resulting in an accident causing get too hot. Matched tires will help cause you to lose control of your ve- death or personal injury. your driveline last longer and will give hicle resulting in an accident causing you better tire mileage. death or personal injury. Be sure all tires are inflated correctly according to WARNING! the manufacturer's recommendations. Do not mismatch tires, it can be dan- gerous. Never mix tires of different de- sign such as steel belted radials and bias ply tires, etc. Mixing tire types and sizes will adversely affect the road- 5 holding ability of both types of tires and can lead to loss of vehicle control and causing death or personal injury.

(04/13) Y53-1200-1B1 5-139 TIRES AND WHEEL

Replacing Tires Greenhouse Gas Certified Tires WARNING! Front: Replace front tires when less Do not replace original equipment Replacing a tire that is greenhouse than 4/32 in. of tread remains. Check tires with load ratings less than the gas certified. at three places equally spaced around original tires. Doing so could lead to the tire. unintentional overloading of the tire, NOTE which could cause a failure resulting The tires installed on this vehicle at the Drive Axles or Trailers: Replace tires in loss of vehicle control and an acci- factory as original equipment may be on drive axles or trailers when less than dent. Failure to comply may result in certified for Greenhouse Gas and Fuel 2/32 in. of tread depth remains in any death, personal injury, equipment or Efficiency regulations. Replacement major groove. Check at three places property damage. tires must be of equal or lower rolling equally spaced around the tire. See resistance level (TRRL or C ). Consult the next illustration for recommended rr with your tire supplier(s) for appropri- measuring points for tread depth. NOTE ate replacement tires. To prolong your tires’ life and make them safer, have their radial and lateral Verify if your vehicle is equipped with run-out checked at your dealer. And Greenhouse Gas certified tires by 5 of course, you should have your tires checking the Vehicle Emission Control balanced anytime you change a tire. label on the driver's side door frame. If these tires were installed at the factory, Lower Rolling Resistance codes (LRR) identify which tires are certified. Steer Tire Points (left), Drive Tire Points (right)

5-140 Y53-1200-1B1 (04/13) TIRES AND WHEEL

Tire Chains Speed Restricted Tires Maintaining a greenhouse gas certified tire. If you need tire chains, install them on WARNING! both sides of each driving axle. In order to limit the rolling resistance of This vehicle may be equipped with speed restricted tires. Check each the tires and optimize fuel economy, CAUTION the maintenance procedures specified tire’s sidewall for maximum rated by the tire manufacture must be Chains on the tires of only one tandem speed. The vehicle should not be op- followed. axle can damage the driveline U-joints erated at sustained speed in excess and the interaxle differential. Your re- of maximum rated speed. Failure to For warranty information, See pairs could be costly and time-con- comply with these speed restrictions Greenhouse Gas Tires on page 6-9. suming. could cause sudden tire failure which can result in death, personal injury or property damage.

5

(04/13) Y53-1200-1B1 5-141 TIRES AND WHEEL

Wheel Mounting and Wheel Cap Nut Torque Fastening WARNING! Never use oil or grease on studs or At the first scheduled lube interval, After the vehicle travels about 50 to 100 nuts; improper torque readings will have all wheel cap nuts torqued to miles (80 to 160 km), wheel mountings result, which could cause improper their specified value listed in Wheel seat in and will lose some initial torque. wheel clamping and could lead to a Cap Nut Torque on page 5-142. After Check hub/wheel mountings after this wheel failure resulting in an accident. that, check wheel cap nuts at least initial period and retighten. Failure to comply may result in death, once a week. Contact an authorized personal injury, equipment or property dealer for information on the proper damage. installation procedure for the wheels on your truck. This is a job you may not be able to do yourself. You need the right torquing equipment to do it.

Wheel Cap Nut Torque

WHEEL and NUT STUD SIZE TORQUE FOR INNER and OUTER CAP NUTS and RIM CLAMP NUTS CONFIGURATION Nm Lb-Ft 5 Steel or Aluminum Disc-Type 3/4-16 610-680 450-500 Wheel; Double Cap Nut Mounting; 1-1/8-16 610-680 450-500 Standard 7/8 Radius Ball Seat Heavy-Duty Steel Disc-Type Wheel; 15/16-12 1,020-1,220 750-900 Double Cap Nut Mounting; 1-1/8-16 1,020-1,220 750-900 1-3/16 Radius Ball Seat: 1-15/16-12 1,020-1,220 750-900 Hub-Piloted Disc-Type Wheel M22-1.5 610-680 450-500 w/Two Piece Flanged Cap Nuts: Steel or Aluminum Wheel PHP-10; Budd Uni-Mount-10; WDH-8

5-142 Y53-1200-1B1 (04/13) TIRES AND WHEEL

WHEEL and NUT STUD SIZE TORQUE FOR INNER and OUTER CAP NUTS and RIM CLAMP NUTS CONFIGURATION Nm Lb-Ft Stud Backnuts (when used) 3/4-16 240-270 175-200 1-14 240-410 175-300 Rim Clamp Nut Torque 1/2” Dia. 110-120 80-90 Cast Spoke Wheel Assembly 5/8” Dia. 220-250 160-185 3/4” Dia. 305-335 225-245

Threads should be clean and dry. Do Proper Torque and Sequence not lubricate wheel nuts or studs. WARNING! Proper wheel torque can best be Tighten wheel cap nuts properly. If obtained on level ground. Install lug they are not tightened properly, wheel nuts and finger-tighten in the numerical nuts could eventually cause the wheel sequence as shown below, see Nut to become loose, to fail, and/or to Tightening Sequence for Hub Piloted come off while the vehicle is moving, Disc Wheels on page 5-143 or Nut possibly causing loss of control and Tightening Sequence for Stud Piloted may result in death, personal injury, Disc Wheels on page 5-144. This equipment or property damage. 5 procedure will ensure that the wheel is drawn evenly against the hub. Torque each nut to the torque value listed in Wheel Cap Nut Torque on page 5-142.

Nut Tightening Sequence for Hub Piloted Disc Wheels

(04/13) Y53-1200-1B1 5-143 TIRES AND WHEEL

Wheel Replacement with installing any replacement wheel, Disc Brake Option always inspect the tires/wheels to ensure there is adequate clearance WARNING! between other vehicle components.

Use only the wheel brand, size and With the hood open, check for Nut Tightening Sequence for Stud part number originally installed. Use clearance between the wheel and disc Piloted Disc Wheels of a different wheel brand or size could brake assembly. Use a hydraulic jack cause valve stem to interfere with a to raise the front of the vehicle off brake component which could lead to the ground to allow the wheel to spin loss of vehicle control. Failure to com- freely. While rotating the wheel, check ply may result in death, personal injury, to ensure there is adequate clearance equipment or property damage. between the wheel and disc brake assembly. Vehicles equipped with front disc brakes are fitted with wheels designed specifically for disc brake applications. 5 If it ever becomes necessary to replace an original equipment wheel, the replacement wheel must be the same brand and size as the take-off wheel. On vehicles equipped with 22.5 in. disc wheels, installing the wrong replacement wheel could result in the wheel valve stem making contact with the disc brake assembly. When

5-144 Y53-1200-1B1 (04/13) TIRES AND WHEEL

Disc Wheels WARNING! WARNING! If the hood falls, anyone under it could Improperly mounting and demounting WARNING! be injured. Always make sure that the tire and rim assemblies is dangerous. Use the correct components and tools hood hold open device engages when Failure to observe proper precautions when working on wheels. Grooves in the hood is in its open position any could cause the tire-rim assembly to the wheel disc or other damage to the time anyone gets under the hood for burst explosively, causing death or disc can weaken the wheel and cause any reason. personal injury. See the wheel manu- it to eventually come off. This could • The hood could hurt someone facturer's literature for the proper way cause you to lose control of your ve- that is in the way of its descent. to mount and demount your tires and hicle, and may result in an accident. Before lowering the hood, be sure rims. Follow their precautions exactly. Failure to comply may result in death, no objects or people are in the personal injury, equipment or property way. damage.

The end of the wheel wrench must WARNING! be smooth. Burrs on the end of the Always support the vehicle with appro- wrench can tear grooves in the disc. 5 priate safety stands if it is necessary to These grooves may lead to cracks in work underneath the vehicle. A jack is the disc, and can cause it to fail. not adequate for this purpose.

(04/13) Y53-1200-1B1 5-145 WHEEL BEARING WHEEL BEARING

Wheel Bearing Adjustment

For safe, reliable operation and adequate service life, your wheel bearings must be adjusted properly at the recommended intervals. Contact your authorized dealer to make sure the wheel bearings are properly adjusted.

5

5-146 Y53-1200-1B1 (04/13) TRANSMISSION MAINTENANCE

TRANSMISSION Oil Change MAINTENANCE For more details, please refer to the maintenance section in the Change fluid according to change transmission manufacturer’s manual procedures specified in the Introduction or service literature. Transmission Service Manual. Use the recommended types of oil Proper maintenance of the CAUTION as specified in the Operation and transmission will ensure that the Service Manual (included with vehicle). vehicle will operate efficiently. When adding oil, types and brands of oil should not be intermixed because Select from the appropriate lubricant for varying ambient (outside air) To check the transmission fluid level, of possible incompatibility, which could temperatures. park the vehicle on level ground. For decrease the effectiveness of the lubri- an automatic transmission the oil level cation or cause component failure. should be checked with the engine idling and the transmission fluid at Initial Change: drain and replace operating temperature. Checking the according to Preventive Maintenance fluid of a manual transmission may be Schedule on page 5-12; for some done with the engine off. transmissions this may not be required. 5 The recommended fluid replacement intervals contain an initial change and a separate interval for the changes after the initial drain. When the oil needs to be replaced, be sure to refer to the manufacturer’s literature on the correct grade and type of oil to purchase.

(04/13) Y53-1200-1B1 5-147 TRANSMISSION MAINTENANCE

Transmission Lubricants Service Intervals Standard Transmission Oil Level Manual Transmission For recommended types and brands NOTE Manual transmissions are designed so of all lubricants, see the transmission The vehicle must be parked on level that the internal parts operate in a bath manufacturer's Service Manual and ground. of oil circulated by the motion of gears Preventive Maintenance Schedule on and shafts. page 5-12. See the Transmission Operator's Check all hoses for kinks, deterioration, Manual for information on checking the chafing, and leaks. Adjust kinked or transmission oil level. chafing hoses to eliminate restrictions and prevent further wear. To ensure proper inspection, it may be necessary to inspect under and inside frame rails and unclip harnesses, hoses and cable bundles. 5

5-148 Y53-1200-1B1 (04/13) TRANSMISSION MAINTENANCE

Automatic Transmissions Automatic Transmission Oil Level Service Intervals NOTE Check daily with engine idling. See The vehicle must be parked on level Preventive Maintenance Schedule on ground. page 5-12 for service intervals.

See the Transmission Operator's Manual for information on checking the transmission oil level.

5

(04/13) Y53-1200-1B1 5-149 CLUTCH

CLUTCH Clutch Hydraulic Fluid air to escape. Close the fitting when fluid starts coming out. Then refill the Introduction Visually inspect the clutch fluid from the reservoir. Repeat this until all air has reservoir. There are molded lines with been purged from the system. The clutch pedal transmits force from the letters MIN to indicate minimum the operator to the clutch via hydraulic fluid level and MAX to indicate the Replace with the recommended fluid and air assist action. The clutch pedal maximum fluid level recommended for Component Lubrication Index on page position is factory set and does not proper operation. Be sure to maintain 5-39. require adjustment. the fluid between the MIN and MAX levels indicated on the plastic reservoir. If the fluid level repeatedly goes below the MIN line, then it is time to have your clutch adjusted or the hydraulic system inspected for service.

To replace the fluid, locate the drain fitting on the air solenoid mounted to 5 the transmission housing. Open this fitting and allow fluid to drain out of the system. Once all the fluid is drained out, close the fitting and fill the system through the master cylinder reservoir in the engine compartment. Once the system is full, then purge the system of air by simultaneously pressing on the pedal and opening the fitting to allow

5-150 Y53-1200-1B1 (04/13) CLUTCH

Clutch Adjustment Clutch Adjustment – Normal Wear Some clutches are self-adjusting, however; there are manually adjusted See the clutch manufacturer's Service clutches that will require the operator Manual for the proper adjustment to know when to adjust the clutch. The procedures. clutch will need adjustment when your clutch pedal stroke seems to get longer and its effectiveness at a seamless shift becomes less.

Another sign of the clutch needing adjustment is the level of the fluid in the reservoir. If the hydraulic fluid is not leaking, but the fluid level is getting lower, then the clutch may need to be adjusted. Please take the vehicle to an authorized dealership to have the 5 clutch adjusted.

(04/13) Y53-1200-1B1 5-151

INFORMATION

CONSUMER INFORMATION AND VEHICLE IDENTIFICATION Vehicle Identification ...... 6-3 General VIN Information ...... 6-4 Component Identification...... 6-7 CONSUMER INFORMATION Federal Safety Standard Certification Label . . . . 6-8 How to Order Parts ...... 6-8 NHTSA Consumer Information ...... 6-8 Canadian Consumer Information ...... 6-9 Warranty...... 6-9

6

(04/13) Y53-1200-1B1 6-1

CONSUMER INFORMATION AND VEHICLE IDENTIFICATION

CONSUMER Assembly Plant Code INFORMATION Model Year Designations F = KENMEX CODE YEAR AND VEHICLE 9 2009 IDENTIFICATION A 2010 M = Ste. Therese B 2011 C 2012 R = Renton Vehicle Identification D 2013 E 2014 J = Chillicothe The 17-digit Vehicle Identification F 2015 Number (VIN) is used to register G 2016 your vehicle for warranty, license and H 2017 insurance. I 2018

1 Manufacturer Identifier 2 Vehicle Attributes 3 Reserved Space 4 Model Year 5 Assembly Plant 6 6 Serial Number (Chassis Number)

(04/13) Y53-1200-1B1 6-3 CONSUMER INFORMATION AND VEHICLE IDENTIFICATION

General VIN Information Chassis Number Certification Labels VIN Locations The Chassis Number refers to the last Your vehicle information and The full, 17-digit VIN is located on the six characters of the VIN. This number specifications are documented on Weight Rating Data Label. The label is will allow your dealer to identify your labels. As noted below, each label located on the driver's side door edge vehicle. You will be asked for this contains specific information pertaining or on the driver's side door frame. number when you bring it in for service. to vehicle capacities and specifications that you should be aware of. Chassis Number Locations • Right frame rail, top flange, about 3 ft. from the front end • Cab back, left-hand rear panel, lower edge • Tire, Rim, and Weight Rating Data label (truck) • Components and Weights label • Noise Emission label 6 • Paint Identification label

6-4 Y53-1200-1B1 (04/13) CONSUMER INFORMATION AND VEHICLE IDENTIFICATION

Components and Weights Label Tire and Rim Data Label WARNING! The Components and Chassis Weight The Tire, Rim and Weight Rating Do not exceed the specified load rat- Label is located on either the driver’s Data Label is located on the driver’s ing. Overloading can result in loss of side door edge or on the driver’s side door edge or on the driver’s side vehicle control and personal injury, ei- side door frame. It includes chassis door frame. It contains the following ther by causing component failures or number, chassis weight and gross information: by affecting vehicle handling. Exceed- weight, plus model information for the • GVWR - Gross Vehicle Weight ing load ratings can also shorten the vehicle, engine, transmission, and service life of the vehicle. axles. Rating • GAWR FRONT, INTERMEDIATE The components of your vehicle and REAR - Gross Axle Weight are designed to provide satisfactory Ratings for Front, Intermediate service, if the vehicle is not loaded and Rear Axle in excess of either the gross vehicle weight rating (GVWR), or the maximum • TIRE/RIM SIZES AND INFLATION front and rear gross axle weight ratings PRESSURES - Tire/Rim Sizes (GAWRs). and Cold Pressure Minimums • VIN including CHASSIS NUMBER NOTE GVW is the TOTAL SCALE WEIGHT the vehicle is designed to carry. This 6 includes the weight of the empty vehi- cle, loading platform, occupants, fuel, and any load.

(04/13) Y53-1200-1B1 6-5 CONSUMER INFORMATION AND VEHICLE IDENTIFICATION

Noise Emission Label Paint Identification Label Federal Safety Standard Certification Label The Noise Emission Label is located The Paint Identification Label contains in the driver's side door frame. It the paint colors used by the factory The NHTSA regulations require a label contains information regarding U.S. to paint your vehicle. It lists frame, certifying compliance with Federal noise emission regulations, chassis wheels, cab interior and exterior Safety Standards, for United States number, and date of manufacture. colors. This label is located inside the and U.S. Territories, be affixed to glove box. each motor vehicle and prescribe where such label may be located. This certification label, which indicates the date of manufacture and other pertinent information, is located on the driver’s side door edge or on the driver’s side door frame.

6

6-6 Y53-1200-1B1 (04/13) CONSUMER INFORMATION AND VEHICLE IDENTIFICATION

Component Identification 1. Axle Specification Number, usually stamped on the right rear side of Each of the major components on the axle housing. This number your vehicle has an identification label identifies the complete axle. or tag. For easy reference, record component numbers such as, model, 2. Axle Housing Number Tag, usually serial, and assembly number. located on the left forward side of the housing arm. This tag Engine: For further information, identifies the axle housing. please refer to the Engine Operation and Maintenance Manual. 3. Axle Differential Carrier Identification, usually located Transmission: For both manual on the top side of the differential and automatic transmissions, the carrier. The following information identification number is stamped on a is either stamped, or marked with a tag affixed to the right rear side of the metal tag: Model No., Production transmission case. Assembly No., Serial No., Gear Ratio, and Part Number. Clutch: Enclosed in clutch housing. Location depends on manufacturer. Steer Axle: The front axle serial 6 number is stamped on a plate located on the center of the axle beam.

Drive Axles: The drive axle numbering system includes three labels or stamps:

(04/13) Y53-1200-1B1 6-7 CONSUMER INFORMATION

CONSUMER How to Order Parts NHTSA Consumer INFORMATION Information Replacement parts may be obtained from an authorized dealership. Federal Safety Standard If you believe that your vehicle has a defect, which could cause a crash Certification Label When you order, it is IMPORTANT or could cause death or personal that you have the following information injury, you should immediately inform The National Highway Traffic Safety ready: the National Highway Traffic Safety Administration regulations require • Your name and address. Administration (NHTSA) in addition to a label certifying compliance with notifying the vehicle manufacturer. Federal Safety Standards, for United • Serial number of the truck. States and U.S. Territories, be affixed If NHTSA receives similar complaints, to each motor vehicle and prescribe • The name of the part you need. it may open an investigation, and where such label may be located. if it finds that a safety defect exists • The name and number of the This certification label, which indicates in a group of vehicles, it may order component for which the part is the date of manufacture and other a recall and remedy campaign. required. pertinent information, is located on the However, NHTSA cannot get involved left hand cab door post. • The quantity of parts you need. in individual problems between you, your dealer, and vehicle manufacturer. • How you want your order shipped. Contacting NHTSA is possible through 6 telephone, written mail and email. NHTSA also has a website where you can input your comments directly to them on the web. Please use any of the four ways to contact NHTSA:

6-8 Y53-1200-1B1 (04/13) CONSUMER INFORMATION

Toll Free 888-327-4236 Canadian Consumer Warranty (800-4249153 TTY) Information Greenhouse Gas Tires 8:00 am to 10:00 pm ET Monday-Friday Canadian customers who wish to report The following warranty is for vehicles Office of Defects equipped with Greenhouse Gas Investigations/CRD a safety-related defect to Transport NVS-216 Canada, Defect Investigations and certified tires: 1200 New Jersey Ave SE. Recalls, may telephone the toll free Washington, D.C. 20590 hotline 1-800-333-0510, or contact VEHICLE EMISSIONS LIMITED www www.safercar.gov Transport Canada by mail at: EXPRESS WARRANTY RELATED @ [email protected] TO ORIGINAL EQUIPMENT TIRES Transport Canada, ASFAD Place de Ville Tower C PACCAR Inc warrants the tires 330 Sparks Street installed as original equipment on Ottawa ON K1A 0N5 this vehicle only against defects in materials and workmanship which For additional road safety information, cause the vehicle to fail to comply please visit the Road Safety website with applicable U.S. and Canadian at: greenhouse gas emission limits (“Warrantable Emissions Failures”). http://www.tc.gc.ca This vehicle emissions limited express warranty relating to original equipment tires is valid for two (2) years or 24,000 6 miles, whichever occurs first.

(04/13) Y53-1200-1B1 6-9 CONSUMER INFORMATION

BY LAW, PACCAR EXPRESSLY The tires are separately warranted YOUR SOLE AND EXCLUSIVE DISCLAIMS ANY WARRANTY OF by their manufacturer for defects in REMEDY AGAINST PACCAR MERCHANTABILITY OR FITNESS materials and workmanship other than Inc IS LIMITED TO THE FOR A PARTICULAR PURPOSE those which cause non-compliance REPAIR OR REPLACEMENT RELATING TO VEHICLE EMISSIONS. with U.S. and Canadian GHG OF ORIGINAL EQUIPMENT TIRES IT IS AGREED THAT PACCAR regulations, subject to limitations and AT AUTHORIZED UNITED STATES SHALL NOT BE LIABLE FOR conditions contained within the tire AND CANADIAN PACCAR DEALERS, INCIDENTAL OR CONSEQUENTIAL manufacturer’s warranty agreement. SUBJECT TO PACCAR’S TIME AND DAMAGES INCLUDING, BUT NOT You are responsible for the safe MILEAGE LIMITATIONS LISTED LIMITED TO: LOSS OF INCOME operation and maintenance of the ABOVE. This Vehicle Emissions OR LOST PROFITS; VEHICLE vehicle and its tires. PACCAR does Limited Express Warranty relating to DOWNTIME; COMMUNICATION not warrant wear and tear of the tires. original equipment tires begins on EXPENSES; LODGING AND/OR the date of delivery of the vehicle MEAL EXPENSES; FINES; to the first purchaser or lessee and APPLICABLE TAXES OR BUSINESS accrued time and mileage is calculated COSTS OR LOSSES; ATTORNEY’S when the vehicle is brought into an FEES; AND ANY LIABILITY YOU MAY authorized dealer for correction of HAVE IN RESPECT TO ANY OTHER the Warrantable Emissions Failures PERSON OR ENTITY RELATING relating to the original equipment tires. TO WARRANTABLE EMISSIONS FAILURES. 6 PACCAR MAKES NO OTHER VEHICLE EMISSIONS WARRANTIES This Vehicle Emissions Limited RELATING TO THE ORIGINAL Express Warranty relating to EQUIPMENT TIRES, EXPRESS original equipment tires is limited OR IMPLIED. WHERE PERMITTED to emissions compliance only.

6-10 Y53-1200-1B1 (04/13) Index Index

5th wheel liftable/non-steerable pusher tractor air brake pressure...... 3-47 maintenance ...... 5-105 calibration...... 4-46 tractor air brake pressure - liftable/steerable calibration .... 4-46 primary/secondary ...... 3-12 A tag axle calibration ...... 4-46 trailer air brake pressure...... 3-48 After-treatment system trailer air tank pressure ...... 3-48 About the Manual ...... 1-3 introduction ...... 4-51 Air intake system...... 5-99 ABS off-road switch...... 3-60 Air cleaners...... 5-100 Air suspension height/air pressure 4-49 Accessories Air compressor ...... 5-56 Air system cigarette lighter ...... 3-94 Air conditioner button ...... 3-86 air cleaners ...... 5-100 radio ...... 3-94 Air dehumidification...... 3-88 air compressor...... 5-56 sleeper alarm clock ...... 3-91 Air disc brakes air dryer ...... 5-52 Accessory drive belts ...... 5-97 maintenance ...... 5-59 air filter restriction gauge ...... 3-44 Active warnings ...... 3-17 Air distribution dial ...... 3-85 air gauges and air leaks ...... 5-55 Adaptive cruise control ...... 4-37 Air dryer...... 5-52 air intake system ...... 5-99 Adding electrical options ...... 5-84 Air dryer (Bendix® AD-IS series) . 5-53 draining air tanks ...... 5-54 Additional sources of information...1-8 Air dryer overhaul ...... 5-53 primary air pressure gauge..... 5-55 California proposition 65 warning 1-6 Air filter restriction gauge...... 3-44 secondary air pressure gauge . 5-55 data recorder ...... 1-6 Air gauges turbocharger ...... 5-99 installed equipment - operator's air pressure - air suspension air Air system maintenance...... 5-49 manuals...... 1-8 bags #1 & #2 ...... 3-47 Air tanks ...... 5-54 other sources ...... 1-9 tag axle air pressure ...... 3-43 Alarms 7 Adjustable auxiliary axles ...... 4-43

(04/13) Y53-1200-1B1 Index-1 Index

engine overspeed air shutdown Automated transmission and shift removing and installing alarm ...... 3-40 indicator area ...... 3-18 batteries...... 5-87 headlight on alarm ...... 3-41 Automatic and automated Battery access ...... 5-85 low coolant level alarm...... 3-40 transmissions ...... 4-19 Battery care ...... 5-89 stop engine alarm ...... 3-40 Automatic Slack Adjusters ...... 5-61 Battery chargning ...... 5-89 Alert screens Automatic transmissions Beacon lights switch ...... 3-63 fault alert ...... 4-39 oil level ...... 5-149 Belt damage and repair ...... 1-28 impact alert ...... 4-38 service intervals ...... 5-149 Bendix® AD-IS series air dryer ... 5-53 level 1 following distance alert . 4-38 Auxiliary axles...... 4-43 Brake adjustment ...... 5-58 level 2 following distance alert . 4-38 Auxiliary lights switch ...... 3-63 Brake gauges level 3 following distance alert . 4-38 Auxiliary transmission ...... 4-20 tractor air brake pressure...... 3-47 stationary object alert ...... 4-38 Auxiliary transmission oil temperature tractor primary/secondary air brake Allison transmission lubrication... 5-43 gauge ...... 3-49 pressure...... 3-12 Anti-lock brake system warning Auxiliary transmission warning trailer air brake pressure...... 3-48 light ...... 3-37 light ...... 3-42 trailer air tank pressure ...... 3-48 Anti-lock brakes Axle creep rating ...... 4-45 Brake Level Switch ...... 3-61 trailer ABS ...... 4-24 Axle lubrication...... 5-108 Brake system trailer ABS (without PLC) ...... 4-25 adjustment ...... 5-58 wheel spin control ...... 4-30 retarders ...... 4-33 Anti-lock brakes (ABS) B roll stability program (RSP)..... 4-26 electronic stability program Back up alarm mute switch ...... 3-60 spring brakes ...... 2-20 (ESP)...... 4-26 Batteries yaw control...... 4-27 roll stability program (RSP)..... 4-26 battery access ...... 5-85 Bulb replacement Appliances...... 3-95 battery care ...... 5-89 headlight ...... 5-78 7 Assembly plant code ...... 6-3 battery charging ...... 5-89 Bulb specifications ...... 5-79 Audible alarm...... 3-8 jump starting vehicles...... 2-8

Index-2 Y53-1200-1B1 (04/13) Index

C Cleaning, protecting and weather Controls...... 3-94 Cab air distribution...... 3-89 stripping ...... 5-64 Coolant Level...... 5-74 Cab and frame access ...... 1-10 Climbing onto the deck plate...... 1-13 Cooling system Cab dimmer switch ...... 3-60 Clock ...... 3-17 adding coolant ...... 5-73 Cab recirculation air filter...... 5-113 to set alarm time...... 3-28 fan ...... 5-98 Cab storage ...... 3-95 to set clock display ...... 3-28 fan clutch...... 5-98 glove box...... 3-95 to set home/local time...... 3-28 maintenance ...... 5-72 Cabin fresh air filter ...... 5-113 to turn alarm ON/OFF...... 3-28 Cooling system maintenance ..... 5-72 California Proposition 65 Warning..1-6 Clutch Cruise control indicator...... 3-18 Canadian consumer information....6-9 clutch brake...... 4-16 Cruise control on/off switch ...... 3-61 Certification labels ...... 6-4 clutch linkage adjustment...... 5-151 Cruise control set/resume switch. 3-61 components and weights label...6-5 clutch travel ...... 4-16 double clutching ...... 4-18 federal safety standard certification D label ...... 6-6 identification ...... 6-7 noise emission label ...... 6-6 riding the clutch...... 4-20 Daily checks ...... 1-37 paint identification label...... 6-6 Clutch adjustment...... 5-151 Dash switches...... 3-50 tire and rim data label...... 6-5 Clutch brake ...... 4-17 Data recorder...... 1-6 Chassis number...... 6-4 Clutch hydraulic fluid ...... 5-150 Daytime running light (DRL) ...... 3-63 Chassis number locations...... 6-4 Clutch maintenance ...... 5-150 Deck plate access ...... 1-13 Check engine warning light ...... 3-40 Clutch travel ...... 4-17 Deep snow and mud switch...... 4-31 Check messages ...... 3-9 Coasting ...... 4-52 DEF filter...... 5-121 Check transmission warning light 3-42 Component identification reference 6-7 Defrost vents ...... 3-85 Checking tire inflation pressure..5-136 Components and weights label.....6-5 Defrosting and defogging the Chrome and aluminum surfaces.. 5-63 Consumer information windshield ...... 3-86 Cigarette lighter ...... 3-94 Federal safety standards ...... 6-8 Descending a grade ...... 4-53 7 Cleaning vinyl and upholstery .... 5-67 how to order parts ...... 6-8 Diesel exhaust fluid gauge ...... 3-14

(04/13) Y53-1200-1B1 Index-3 Index

Diesel Exhaust Fluid Tank ...... 5-121 Door mounted controls ...... 3-75 engine RPM...... 4-53 Diesel particulate filter (DPF) Double clutching ...... 4-18 fuel economy ...... 4-55 regeneration switch...... 3-62 Drive axle temperature gauge .... 3-46 optimal engine speed ...... 4-54 Diesel particulate filter (DPF) warning Drive axles using the driver information light ...... 3-38 identification ...... 6-7 display...... 4-55 Differential lock...... 4-40 Driver controlled main differential 2-16 using the driver performance Dim Control Operation...... 3-93 Driver information display center ...... 3-14 Disc wheels...... 5-145 tire pressure monitoring system using the tachometer...... 4-54 Displays/menu screens (TPMS)...... 3-23 Driving with deflated air springs .. 4-50 clock display ...... 3-28 Driver performance center ..3-12, 3-14 Drum brakes driver performance center ...... 3-19 fuel economy ...... 3-24 maintenance ...... 5-61 fuel economy ...... 3-24 ignition timer ...... 3-24 Dual Axle Diff-Lock Switch ...... 3-60 ignition timer ...... 3-24 menu screens...... 3-19 Dual range (two-speed) rear axle 4-41 settings ...... 3-27 settings ...... 3-27 Dump truck gate switch ...... 3-60 tire pressure monitoring system trip information...... 3-24 Dump truck, body up warning light 3-38 (TPMS)...... 3-23 truck information...... 3-25 Dump truck, gate warning light ... 3-38 to set time ...... 3-28 virtual gauges...... 3-23 Dump truck, trailer body up warning trip information...... 3-24 warning and faults...... 3-26 light ...... 3-38 truck information...... 3-25 Driver's virtual gauges...... 3-23 daily checks...... 1-37 warning and faults...... 3-26 weekly checks ...... 1-40 E Dome lights switch...... 3-64 Driver's check list ...... 1-36 Eaton/Dana axle lubrication...... 5-46 Door lock ...... 1-11 Driveshaft Maintenance ...... 5-135 Electrical and alternator key fob synchronization...... 1-13 Driving tips precautions...... 5-91 7 remote keyless entry (RKE) coasting ...... 4-52 Electrical system system ...... 1-12 descending a grade ...... 4-53 adding electrical options ...... 5-84

Index-4 Y53-1200-1B1 (04/13) Index

batteries ...... 5-85 pipe and hose clamp torque winterfronts ...... 4-13 battery care ...... 5-89 values ...... 5-37, 5-95 Engine overspeed ...... 4-53 battery charging ...... 5-89 Engine (block) heater...... 5-75 Engine overspeed air shutdown electrical and alternator Engine block heater ...... 4-6 (manual) ...... 3-62 precautions ...... 5-91 Engine brake on/off switch ...... 3-61 Engine overspeed air shutdown fuses, circuit breakers and Engine control display ...... 4-14 (test) ...... 3-62 relays...... 5-80 Engine cool down ...... 4-60 Engine overspeed air shutdown jump starting vehicles...... 2-8 Engine fan ...... 5-98 alarm...... 3-40 removing and installing Engine fan control ...... 4-12 Engine retarder warning light ..... 3-40 batteries...... 5-87 Engine fan override switch ...... 3-61 Engine warm-up...... 4-7 Electrical system maintenance ... 5-77 Engine fan warning light...... 3-40 Environmental Protection ...... 1-7 Electronic stability program (ESP) 4-26 Engine heater switch ...... 3-62 Ether metering equipment ...... 4-10 Emergency Engine heater warning light ...... 3-40 Ether start switch ...... 3-61 battery connections ...... 2-10 Engine is overheating ...... 2-5 Ether start warning light ...... 3-40 emergency equipment kit...... 1-36 Engine lubrication...... 5-94 Exhaust system ...... 5-101 jump starting vehicles...... 2-8 Engine maintenance...... 5-93 Extended life coolant (ELC) Emergency equipment ...... 1-36 Engine mounted noise insulators 5-119 What to Check in an ELC-filled Emergency welding...... 5-104 Engine Mounting ...... 5-101 Cooling System ...... 5-72 Engine Engine oil pressure gauge ...... 3-45 Exterior lights self test ...... 3-64, 3-77 air cleaners ...... 5-100 Engine oil pressure lamp turns on..2-4 Exterior maintenance ...... 5-63 air intake system ...... 5-99 Engine oil temperature gauge .... 3-45 Exterior washing ...... 5-66 drive belts ...... 5-97 Engine operation engine mounting...... 5-101 engine block heater ...... 4-6 exhaust system...... 5-101 engine control display...... 4-14 F identification ...... 6-7 engine cool down...... 4-60 Fan control dial...... 3-85 7 lubrication ...... 5-94 engine fan control ...... 4-12 Fasten seat belt warning indicator 3-41

(04/13) Y53-1200-1B1 Index-5 Index

Federal safety standard certification Fuel heater ...... 3-63 fuel filter restriction pressure ... 3-44 label...... 6-6, 6-8 Fuel pressure gauge...... 3-46 fuel tank(s) level ...... 3-9 Fifth wheel Fuel shut-off valve ...... 4-61 primary air pressure...... 5-55 maintenance ...... 5-105 Fuel shut-off valves ...... 5-103 pusher axle(s) air pressure ..... 3-43 Fifth wheel slide switch...... 3-62 Fuel specification ...... 4-60 secondary air pressure ...... 5-55 Final stopping procedures ...... 4-62 Fuel system speedometer...... 3-9 Flood lights switch ...... 3-64 fuel filters...... 5-103 suspension load air pressure Floor and defrost vents...... 3-85 shut-off valves ...... 5-103 #1...... 3-47 Floor vents...... 3-85 Fuller transmission lubrication .... 5-41 suspension load air pressure Fog lights switch ...... 3-64 Fuse inspection and replacement . 2-7, #2...... 3-47 Forward PTO switch...... 3-66 5-84 tachometer ...... 3-10 Forward pusher axle switch...... 3-66 Fuse or relay blows ...... 2-6 tag axle air pressure ...... 3-43 Forward Rear Axle Diff-Lock Fuses, circuit breakers and relays 5-80 tractor brake application air Switch...... 3-60 pressure...... 3-47 Forward trailer axle lift switch ..... 3-66 trailer air tank air pressure...... 3-48 Frame fastener torque G trailer brake application air requirements ...... 5-106 Gauges pressure...... 3-48 Front axle and suspension air pressure - primary ...... 3-12 transfer case oil temperature... 3-48 maintenance ...... 5-108 air pressure - secondary...... 3-12 transmission retarder oil Fuel economy ...... 3-24, 4-55 auxiliary transmission oil temperature...... 3-49 Fuel filter restriction pressure temperature...... 3-49 Gauges (optional) gauge ...... 3-44 diesel exhaust fluid (DEF) ...... 3-14 air filter restriction ...... 3-44 Fuel filters ...... 5-103 engine coolant (water) drive axle temperature (forward and Fuel gauges temperature...... 3-11 rear) ...... 3-46 7 fuel filter restriction pressure ... 3-44 engine oil pressure ...... 3-11, 3-45 fuel pressure...... 3-46 fuel tank(s) level ...... 3-9 engine oil temperature ...... 3-45 manifold pressure ...... 3-45

Index-6 Y53-1200-1B1 (04/13) Index

transmission temperature ...... 3-46 air conditioner...... 5-116 Hill hold ...... 4-19 Gauges (standard) heater ...... 5-115 Hood hold downs ...... 1-15 tachometer...... 4-54 Heater and air conditioner Hood hold-open device...... 1-17 GAWR - Gross Axle Weight Rating 6-5, maintenance ...... 5-112 Hood latch ...... 1-16 1-35 Heating and air conditioning Hood tilting GCW - Gross Combination air conditioner button...... 3-86 hood hold downs ...... 1-15 Weight ...... 1-35 defrost vents ...... 3-85 hood hold-open device ...... 1-17 Generic air accessory switch ..... 3-63 fan control dial ...... 3-85 hood latch ...... 1-16 Generic spare switch ...... 3-63 floor and defrost vents ...... 3-85 How to order parts ...... 6-8 Glove box...... 3-95 floor vents ...... 3-85 Greenhouse gas certified tires...5-140 outside air/recirculation air Greenhouse Gas Tires button ...... 3-85 I warranty ...... 6-9 panel and floor vents...... 3-85 Idling the engine ...... 4-9 Guide to the Warning Symbols ... 3-29 panel vents...... 3-85 Ignition key switch ...... 3-96 GVWR - Gross Vehicle Weight sleeper heater - A/C controls... 3-89 Ignition timer...... 3-24 Rating...... 6-5, 1-35 sleeper override ...... 3-85 In-cab battery box...... 5-86 temperature control set point... 3-86 Inspection of the engine oil level . 5-94 Heating and Air Conditioning H Installed Equipment - Operator's automatic control mode...... 3-83 Manuals ...... 1-8 Hazard lights switch ...... 3-64 buttons and dials ...... 3-85 Instrument cluster...... 3-7 Header ...... 3-18 cab controls...... 3-79 Instrument panel ...... 3-5 Headlight aiming ...... 5-79 introduction ...... 3-80 Instrument system self test ...... 3-8 Headlight on alarm...... 3-41 manual control mode...... 3-82 Instrumentation Headlight replacement ...... 5-78 max defrost mode ...... 3-84 driver performance center ...... 3-12 Headlight switch...... 3-64 High exhaust system temperature instrument cluster ...... 3-7 7 Heater and air conditioner ...... 5-112 (HEST) warning light ...... 3-39 instrument panel...... 3-5

(04/13) Y53-1200-1B1 Index-7 Index

instrument system self test ...... 3-8 Low voltage disconnect (LVD) ....3-60, exterior ...... 5-63 menu control switch (MCS)..... 3-19 5-77 frame fastener torque Inter axle diff lock warning light ... 3-38 Lubricant specifications ...... 5-35 requirements ...... 5-106 Inter-Axle Differential Lock Switch 3-60 Lubrication...... 5-38 frame fastener torque table....5-106 front axle and suspension J lubrication...... 5-108 M fuel system...... 5-103 Jump starting vehicles...... 2-8 Main content area...... 3-19 Fuller transmission lubrication . 5-41 Maintenance heater ...... 5-115 K 5th wheel...... 5-105 inspection ...... 5-109 lubricant specifications...... 5-35 Key fob operation ...... 1-12 air cleaners ...... 5-100 maintenance schedule...... 5-12 Key fob synchronization...... 1-13 air conditioner...... 5-116 Meritor axle lubrication...... 5-45 Keys air intake system ...... 5-99 noise and emission control remote keyless entry (RKE) .... 1-11 air system ...... 5-49 standards ...... 5-117 Kingpin lubrication ...... 5-108 Allison transmission lubrication 5-43 oil changes...... 5-44 Komfort-Latch® Feature ...... 1-26 brake adjustment ...... 5-58 brake inspection ...... 5-59 painted surfaces...... 5-63 chrome and aluminum surfaces 5-63 preventive maintenance ...... 5-9 L cleaning vinyl and upholstery .. 5-67 rear axle alignment...... 5-130 Lane departure warning (LDW) clutch ...... 5-150 rear axle and suspension...... 5-125 light ...... 3-41 cooling system...... 5-72 rear axle lubrication ...... 5-128 Lap/shoulder belt ...... 1-23 driver's check list ...... 1-36 rear suspension fasteners torque Left turn signal light indicator ..... 3-42 Eaton/Dana axle lubrication .... 5-46 table ...... 5-127 Load distribution ...... 1-35 electrical system...... 5-77 rear suspension U-bolt torque 7 Low air alarm turns on...... 2-3 emergency welding ...... 5-104 table ...... 5-128 Low coolant level warning light ... 3-40 engine ...... 5-93

Index-8 Y53-1200-1B1 (04/13) Index

safety restraint system - Malfunction Indicator Lamp (MIL) 3-39 N inspection ...... 5-68 Manifold pressure gauge...... 3-45 NHTSA consumer information ...... 6-8 safety restraint system - inspection Manual transmission...... 4-15 Noise and emission control guidelines ...... 5-69 clutch brake...... 4-17 maintenance ...... 5-117 sliding fifth wheel ...... 5-107 clutch travel ...... 4-17 Noise control inspections ...... 5-118 Spicer transmission lubrication. 5-43 double clutching ...... 4-18 air intake system ...... 5-119 stainless steel...... 5-64 release bearing wear...... 4-20 diesel particulate filters ...... 5-121 steering and driveline ...... 5-131 riding the clutch...... 4-20 engine fan and shroud ...... 5-123 steering gear lubrication ...... 5-48 shifting gears ...... 4-17 engine mounted noise tail pipe surface cleaning ...... 5-64 Manual windshield insulators...... 5-119 tires ...... 5-136 defrosting/defogging...... 3-87 exhaust system...... 5-119 transmission ...... 5-147 Marker/clearance light switch ..... 3-65 exhaust tail pipe ...... 5-122 U-bolt torque...... 5-110 Marker/Clearance/Cab light hood insulation blanket ...... 5-123 U-bolt torque table ...... 5-111 switch ...... 3-65 inner fender shields and cab universal joint lubrication ...... 5-47 Marker/Clearance/Trailer light skirt ...... 5-123 vehicle cleaning ...... 5-65 switch ...... 3-65 joints and clamps...... 5-120 washing chassis ...... 5-67 Master lubrication index ...... 5-38 maintenance log...... 5-124 washing exterior ...... 5-66 Matching tires ...... 5-139 piping ...... 5-120 wheel alignment ...... 5-109 MCS knob cue ...... 3-19 Noise emission label...... 6-6 wheel bearing lubrication ...... 5-47 Menu control switch (MCS) ...... 3-19 windshield wiper/washer...... 5-71 Meritor axle lubrication ...... 5-45 Maintenance Procedures Mirror heat switch ...... 3-76 O inspection of the engine oil level 5-94 Mirrors ...... 3-75 Odometer/trip odometer...... 3-16 topping up the engine oil ...... 5-95 mirror heat switch ...... 3-76 Off-road ABS function switch ..... 4-31 Maintenance schedule ...... 5-9 power mirror switch ...... 3-76 Oil changes...... 5-44 7 Oil gauges

(04/13) Y53-1200-1B1 Index-9 Index

auxiliary transmission oil Painting ...... 5-105 Rear axle - dual range temperature...... 3-49 Panel and floor vents ...... 3-85 (two-speed)...... 4-41 engine oil pressure ...... 3-11, 3-45 Panel vents ...... 3-85 Rear axle alignment ...... 5-130 engine oil temperature ...... 3-45 Park brake warning light...... 3-37 Rear axle and suspension transfer case oil temperature... 3-48 Parking brake ...... 4-23 maintenance ...... 5-125 transmission retarder oil Parking brake valve...... 3-60 rear suspension fasteners .....5-127 temperature...... 3-49 Passenger seat swivel...... 1-22 visual inspection...... 5-126 Oil pressure gauge ...... 3-11 Passenger side 'down' mirror ..... 3-99 Rear axle lubrication...... 5-128 Operating hydraulic clutch ...... 4-15 Pintle hook switch...... 3-66 Rear PTO switch...... 3-66 Operating procedure Pipe and hose clamp torque Rear Rear Axle Diff-Lock Switch . 3-60 automatic and automated values...... 5-37, 5-95 Rear suspension fasteners ...... 5-127 transmissions...... 4-19 Power door lock...... 3-77 Rear suspension fasteners torque refueling ...... 4-61 Power line communication (PLC). 4-24 table...... 5-127 stopping procedures ...... 4-62 Power mirror switch...... 3-76 Rear suspension U-bolt torque transmission retarder ...... 4-34 Power Take-off (PTO) switch ..... 3-65 table...... 5-128 Optimal engine speed ...... 4-54 Power take-off (PTO) warning Rear trailer axle lift switch...... 3-67 Outside air / recirculation air ...... 3-89 light ...... 3-41 Recovery hitch capacities ...... 2-18 Outside air temperature ...... 3-16 Power window...... 3-77 Recovery hitch connection ...... 2-14 Outside air/recirculation air button 3-85 Pressure gauges Recovery hitch installation ...... 2-15 Overinflated tires...... 5-138 engine oil pressure ...... 3-11, 3-45 Recovery procedure ...... 2-13 Overloaded tires ...... 5-138 Pump mode warning light ...... 3-41 Recovery rigging ...... 2-19 Pusher axle(s) air pressure gauge 3-43 Refilling your radiator ...... 5-74 Refrigerator warning light ...... 3-41 P Refueling ...... 4-60 R 7 Paint identification label ...... 6-6 fuel specification...... 4-61 Painted surfaces ...... 5-63 Radio...... 3-94 Release bearing wear ...... 4-20

Index-10 Y53-1200-1B1 (04/13) Index

Remote keyless entry (RKE)...... 1-12 emergency equipment kit...... 1-36 Komfort-Latch feature...... 1-26 Remote Keyless Entry (RKE) ..... 5-92 introduction ...... 1-3 tether belts ...... 1-25 batteries ...... 1-13 safe vehicle operation...... 1-33 To adjust an external tether belt 1-26 key fob operation ...... 1-12 safety alerts...... 1-3 Seats and restraints ...... 1-19 key fob synchronization...... 1-13 suspension air pressure gauge 4-49 Service brake warning light ...... 3-38 Remote throttle control switch .... 3-62 vehicle loading...... 1-34 Service transmission warning light 3-42 removing and installing batteries . 5-87 vehicle safety ...... 1-5 ServiSignal Mini Indicator ...... 5-101 Replacing tires ...... 5-140 Safety alerts ...... 1-3 Setting System Alarm ...... 3-92 Returning vehicle to service ...... 2-20 Safety restraint belts...... 1-22 Setting System Time...... 3-92 Riding the clutch ...... 4-20 belt damage and repair ...... 1-28 Shut-down Right turn signal light indicator.... 3-42 during pregnancy...... 1-28 fuel specification...... 4-61 Roll stability program (RSP) ...... 4-26 inspection ...... 5-68 location of fuel shut-off valves.. 4-61 Roof mounted condenser fan safety restraint tips ...... 1-31 refueling ...... 4-60 switch ...... 3-66 Safety restraint system sleeper bunk ...... 4-58 inspection ...... 5-68 Single Rear Axle Diff Lock Switch 3-60 Seat adjustment...... 1-19 Sleeper Alarm Clock...... 3-91 S passenger seat swivel ...... 1-22 dim control operation...... 3-93 Safe vehicle operation...... 1-33 Seat belts ...... 1-19 setting system alarm ...... 3-92 Safety adjustments...... 1-19 setting system time...... 3-92 about the manual...... 1-3 belt damage and repair ...... 1-28 snooze operation ...... 3-93 air suspension height/air during pregnancy...... 1-28 turning the alarm on/off ...... 3-93 pressure...... 4-49 Komfort-Latch feature...... 1-26 Sleeper bunk ...... 4-58 cab and frame access ...... 1-10 lap/shoulder belt...... 1-23 sleeper restraint ...... 4-59 deck plate access ...... 1-13 safety restraint tips ...... 1-31 Sleeper bunks and restraints ..... 1-29 deflated air springs ...... 4-50 Seats Sleeper heater - A/C controls ..... 3-89 7 driver's check list ...... 1-36 adjustments...... 1-19 Sleeper HVAC air filter ...... 5-114

(04/13) Y53-1200-1B1 Index-11 Index

Sleeper occupant restraint ...... 4-59 trailer brake hand valve...... 3-72 axle switch, diff-lock - single Sliding 5th wheel turn signal/high beam switch ... 3-69 rear ...... 3-51 maintenance ...... 5-107 Steering gear lubrication ...... 5-48 axle switch, diff-lock - steer..... 3-51 Sliding Fifth wheel Steering system maintenance axle switch, inter axle differential maintenance ...... 5-107 steering shaft ...... 5-133 locked (tandem) ...... 3-51 Snooze Operation ...... 3-93 Steering wheel controls ...... 3-73 axle switch, pusher...... 3-57 Speed restricted tires ...... 5-141 Stop engine lamp turns on ...... 2-4 axle switch, tag ...... 3-57 Speedometer ...... 3-9 Stop engine warning light ...... 3-40 axle switch, two speed...... 3-51 Spicer transmission lubrication ... 5-43 Suspension air pressure gauge .. 4-49 back up alarm mute switch ..... 3-51 Spot light. switch...... 3-65 Suspension dump switch...... 3-66 beacon light switch ...... 3-55 Spring brakes—manual release .. 2-20 Suspension dump warning light .. 3-41 brake level switch ...... 3-52 Stainless steel...... 5-64 Suspension lift switch...... 3-66 brake on/off switch ...... 3-52 Starting procedure Suspension load air pressure cab dimmer ...... 3-52 cold temperature ...... 4-6 gauges...... 3-47 cruise control ...... 4-35 engine warm-up ...... 4-7 Suspension lubrication ...... 5-108 cruise control on/off switch ..... 3-52 ether metering ...... 4-10 Switches cruise control set/resume normal temperature ...... 4-5 2 speed transfer case...... 3-59 switch ...... 3-53 Stationary PTO operation ...... 4-12 ABS off-road switch ...... 3-52 dash switches...... 3-50 Steer axle accessory air switch...... 3-54 daytime running light switch .... 3-55 identification ...... 6-7 air conditioner button...... 3-86 diesel particulate filter (DPF) Steer Axle Diff Lock Switch ...... 3-60 auxiliary light switch...... 3-54 regeneration switch ...... 3-54 Steering and driveline axle switch, diff-lock - dual ..... 3-50 dome light switch ...... 3-55 maintenance ...... 5-131 axle switch, diff-lock - forward dual range rear axle switch..... 4-41 fluid level and refill ...... 5-132 rear ...... 3-50 dump truck gate switch ...... 3-52 Steering column...... 3-67 axle switch, diff-lock - rear rear 3-51 engine fan override switch...... 3-53 7 tilt/telescoping ...... 3-68 engine fan switch...... 4-12

Index-12 Y53-1200-1B1 (04/13) Index

engine heater switch ...... 3-53 optional deep snow and mud trailer dump gate switch ...... 3-59 ether start switch ...... 3-53 switch ...... 4-31 trailer hotline switch ...... 3-59 exterior lights self test...... 3-77 outside air/recirculation air trailer marker light interrupter exterior lights self test switch... 3-55 button ...... 3-85 switch ...... 3-69 fifth wheel slide switch ...... 3-54 overspeed air shutdown trailer suspension air dump..... 3-59 flood light switch...... 3-55 (manual) ...... 3-53 transfer case...... 3-59 fog light switch...... 3-55 overspeed air shutdown (test).. 3-53 turn signal/high beam switch ... 3-69 forward power take-off (PTO) parking brake valve ...... 3-52 under hood air intake ...... 3-54 switch ...... 3-57 pintle hook switch ...... 3-58 winch clutch switch...... 3-59 forward trailer axle lift switch ... 3-58 power door lock ...... 3-77 windshield wipers/washer ...... 3-71 fuel heater switch...... 3-54 power take-off (PTO) switch.... 3-57 hazard light switch ...... 3-56 power window ...... 3-77 headlight switch ...... 3-64 rear power take-off (PTO) T headlight switch and parking switch ...... 3-57 Tachometer ...... 3-10 lights...... 3-56 rear trailer axle lift switch ...... 3-58 Tag axle air pressure gauge ...... 3-43 low voltage disconnect (LVD) ..3-51, remote throttle switch ...... 3-53 Tag axle switch...... 3-66 3-60 roofdenser switch ...... 3-57 Tail pipe surface cleaning ...... 5-64 marker light switch ...... 3-56 sleeper override ...... 3-85 Telematic system marker/clearance/cab light spare switch ...... 3-54 care and operation ...... 3-98 switch ...... 3-56 spot light switch ...... 3-56 disclaimer ...... 3-99 marker/clearance/trailer light suspension dump switch ...... 3-57 Temperature control dial...... 3-86 switch ...... 3-56 suspension lift switch ...... 3-58 Temperature gauges mud and snow traction control . 3-56 temperature control set point... 3-86 engine oil temperature ...... 3-45 off-road ABS function switch third axle lift switch ...... 3-58 transmission retarder oil (option)...... 4-31 trailer axle (3rd axle) lift switch. 3-58 temperature...... 3-49 trailer belly dump switch ...... 3-58 7

(04/13) Y53-1200-1B1 Index-13 Index

water temperature (engine Traction control switch...... 3-65 Transmission retarder ...... 4-34 coolant) ...... 3-11 Traction control warning light ..... 3-37 Transmission retarder oil temperature Tether belts ...... 1-25 Tractor brake application air pressure gauge ...... 3-49 Third axle lift switch...... 3-66 gauge ...... 3-47 Transmission retarder warning Third trailer axle lift switch ...... 3-66 Trailer ABS ...... 4-24 light ...... 3-42 Tilt/telescoping steering column .. 3-68 Trailer air suspension switch...... 3-67 Transmission temperature gauge 3-46 Tire and rim data label...... 6-5 Trailer air tank air pressure gauge 3-48 Transmission temperature gauges GAWR ...... 6-5 Trailer anti-lock brake system warning auxiliary transmission oil Tire chains...... 5-141 light ...... 3-38 temperature...... 3-49 Tire Chains ...... 2-22 Trailer belly dump switch ...... 3-67 Transmissions Tire inflation warning light ...... 3-42 Trailer brake application air pressure automatic and automated ...... 4-19 Tire Pressure Monitoring System gauge ...... 3-48 auxiliary transmission ...... 4-20 (TPMS) ...... 3-23 Trailer brake hand valve...... 3-72 transmission retarder ...... 4-34 Tires...... 5-136 Trailer dump gate switch ...... 3-67 Trip information ...... 3-24 greenhouse gas certified tires.5-140 Trailer hotline switch...... 3-67 Trip reset...... 3-14 inflation check ...... 5-136 Transfer case oil temperature Truck information ...... 3-25 replacement...... 5-140 gauge ...... 3-48 Turbocharger ...... 5-99 tire chains ...... 5-141 Transfer case switch...... 3-67 Turn signal/high beam switch..... 3-69 Tires and wheels Transmission Turning the Alarm On/Off ...... 3-93 wheel cap nut torque identification ...... 6-7 Two speed axle switch ...... 3-60 sequence ...... 5-143 lubricants...... 5-148 Two speed transfer case switch .. 3-67 wheel cap nut torque table ....5-142 maintenance ...... 5-147 wheel mounting and fastening 5-142 oil change ...... 5-147 To jump start your vehicle ...... 2-9 shifting gears in a new vehicle . 4-17 U 7 Topping up the engine oil ...... 5-95 transmission tips ...... 4-20 U-bolt torque ...... 5-110 Towing the vehicle ...... 2-23 Transmission maintenance ...... 5-147 U-Joints ...... 5-135

Index-14 Y53-1200-1B1 (04/13) Index

Under hood air intake switch...... 3-62 recovery hitch connection ...... 2-14 dump truck, body up ...... 3-38 Underinflated tires ...... 5-137 recovery hitch installation...... 2-15 dump truck, gate ...... 3-38 Universal joint lubrication...... 5-47 recovery procedure ...... 2-13 dump truck, trailer body up ..... 3-38 Use of instrument cluster display . 4-55 recovery rigging ...... 2-19 emissions, diesel particulate filter Using the tachometer...... 4-54 returning vehicle to service ..... 2-20 (DPF)...... 3-38 sand, mud, snow and ice ...... 2-22 emissions, high exhaust system spring brakes ...... 2-20 temperature (HEST) ...... 3-39 V towing the vehicle ...... 2-23 engine brakesaver or transmission Vehicle cleaning...... 5-65 Vehicle safety ...... 1-5 retarder...... 3-42 Vehicle identification Vehicle telematic system ...... 3-97 engine, check engine ...... 3-40 assembly plant code ...... 6-3 VIN number location ...... 6-4 engine, engine fan ...... 3-40 chassis number...... 6-4 Vinyl and upholstery engine, ether start ...... 3-40 chassis number locations...... 6-4 cleaning ...... 5-67 engine, heater ...... 3-40 model year designations table ...6-3 Virtual gauges ...... 3-23 engine, low coolant level ...... 3-40 VIN number ...... 6-3 engine, overspeed air shutdown...... 3-40 VIN number locations ...... 6-4 W Vehicle loading ...... 1-34 engine, retarder (brake) ...... 3-40 GAWR ...... 1-35 Wait to start warning light ...... 3-41 engine, stop engine ...... 3-40 GCW...... 1-35 Warning and faults ...... 3-26 engine, wait to start ...... 3-41 GVWR...... 1-35 Warning light/indicator symbols .. 3-30 lane departure warning (LDW) . 3-41 load distribution...... 1-35 anti-lock brake system (ABS) .. 3-37 lights, high beam ...... 3-41 Vehicle recovery anti-lock brake system (ABS), malfunction indicator lamp...... 3-39 driver controlled main trailer ...... 3-38 park brake...... 3-37 differential...... 2-16 axle, inter-axle differential locked power take-off (PTO)...... 3-41 recovery guidelines ...... 2-12 (tandem axles) ...... 3-38 power take-off (PTO), pump 7 recovery hitch capacities ...... 2-18 axle, traction control...... 3-37 mode ...... 3-41

(04/13) Y53-1200-1B1 Index-15 Index

rationality check ...... 3-38 stop engine lamp turns on ...... 2-4 refrigerator ...... 3-41 you need roadside assistance ...2-3 seat belt, fasten ...... 3-41 Wheel alignment ...... 5-109 service transmission ...... 3-42 Wheel bearing adjustment ...... 5-146 suspension dump ...... 3-41 Wheel bearing lubrication ...... 5-47 tire inflation...... 3-42 Wheel cap nut torque...... 5-142 transmission, auxiliary ...... 3-42 Wheel mounting and fastening ..5-142 transmission, check ...... 3-42 Wheel replacement with disc brake turn signal, left ...... 3-42 option ...... 5-144 turn signal, right ...... 3-42 Wheel spin control ...... 4-30 water in fuel (WIF)...... 3-41 Wheel spin control warning lamp. 4-30 wheel spin control ...... 4-30 Winch clutch switch...... 3-67 Warning/informational screen..... 3-99 Windshield wiper/washer...... 5-71 Warranty ...... 6-9 maintenance ...... 5-71 greenhouse gas tires...... 6-9 Windshield wipers/washer ...... 3-71 Washing chassis ...... 5-67 Winterfronts ...... 4-13 Water in fuel (WIF) warning light . 3-41 Water temperature gauge ...... 3-11 Weekly checks ...... 1-40 Y Welding (emergency)...... 5-104 Yaw control ...... 4-27 What to do if...... 2-3 Yaw stability ...... 4-27 engine is overheating ...... 2-5 engine oil pressure lamp turns on...... 2-4 fuse or relay blows ...... 2-6 7 low air alarm turns on ...... 2-3

Index-16 Y53-1200-1B1 (04/13)

Your Servicing Dealer Is:

Need Help? Give Us A Call - 24 Hours a Day 1-800-KW-ASSIST 1-800-592-7747

KENWORTH TRUCK COMPANY P.O. Box 1000 Kirkland, Washington 98083-1000 (425) 828-5000

CANADIAN KENWORTH COMPANY 6711 Mississauga Road N. Mississauga, Ontario L5N 4J8 (905) 858-7000 Do not remove the manual from vehicle. Before operating vehicle study the manual carefully. Read and understand all Warnings, Cautions and Notes. Y53-1200-1B1 © 2013 Kenworth Truck Company