Contents
Safety 1
Emergency 2
Controls 3
Driving 4
Maintenance 5
Information 6
Index 7 Contents
©2017 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
MAINTENANCE
PREVENTIVE MAINTENANCE SCHEDULE Introduction ...... 5-9 Maintenance Schedule ...... 5-12 LUBRICANT SPECIFICATIONS Introduction ...... 5-41 Engine ...... 5-41 Master Lubrication Index ...... 5-44 Fuller Transmission Lubrication ...... 5-48 Allison Transmission Lubrication ...... 5-50 Spicer Transmission Lubrication ...... 5-50 Oil Changes ...... 5-51 5 Meritor Axle Lubrication ...... 5-52 Eaton/Dana Axle Lubrication ...... 5-53 Wheel Bearing Lubrication ...... 5-54 Universal Joint Lubrication ...... 5-55 Steering Gear Lubrication ...... 5-55
(03/17) Y53-6077-1B1 5-1 MAINTENANCE
AIR SYSTEM Introduction ...... 5-57 Air Dryer ...... 5-60 Air Tanks ...... 5-62 Air Gauges and Air Leaks ...... 5-63 Air Compressor ...... 5-64 BRAKE SYSTEM Brake Adjustment ...... 5-66 CAB Exterior Maintenance ...... 5-71 Cleaning, Protecting and Weather Stripping . . . 5-72 5 Safety Restraint System - Inspection ...... 5-78 Windshield Wiper/Washer ...... 5-81 COOLING SYSTEM Cooling system maintenance ...... 5-82 Engine (Block) Heater ...... 5-86
5-2 Y53-6077-1B1 (03/17) MAINTENANCE
ELECTRICAL Electrical System ...... 5-87 Light Bulbs ...... 5-88 Bulb Specifications ...... 5-89 Fuses, Circuit Breakers and Relays ...... 5-89 Fuse Inspection and Replacement ...... 5-92 Adding Electrical Options ...... 5-92 Batteries ...... 5-93 Battery Care ...... 5-97 Battery Charging ...... 5-97 Electrical and Alternator Precautions ...... 5-99 Remote Keyless Entry ...... 5-100 5 ENGINE Engine Maintenance ...... 5-101 Engine Lubrication ...... 5-102 Accessory Drive Belts ...... 5-105 Engine Fan ...... 5-106 Air Intake System ...... 5-107
(03/17) Y53-6077-1B1 5-3 MAINTENANCE
Turbocharger...... 5-107 Air Cleaners ...... 5-108 ServiSignal™ Mini Indicator ...... 5-109 Exhaust System ...... 5-110 Engine Mounting ...... 5-110 FUEL SYSTEM Location of Fuel Shut-off Valves...... 5-111 Specification ...... 5-111 Fuel Filters ...... 5-111 FRAME Introduction ...... 5-112 5 FRONT AXLE AND SUSPENSION Axle Lubrication ...... 5-116 Inspection ...... 5-117 Wheel Alignment ...... 5-117 U-Bolt Torque ...... 5-118
5-4 Y53-6077-1B1 (03/17) MAINTENANCE
HEATER AND AIR CONDITIONER Introduction ...... 5-120 Heater...... 5-121 Air Conditioner ...... 5-121 NOISE EMISSION CONTROL Noise Emission Warranty ...... 5-123 Inspection and Maintenance Instructions . . . . . 5-124 Noise Control System - Maintenance Log . . . . 5-128 REAR AXLE AND SUSPENSION General Maintenance ...... 5-131 Visual Inspection ...... 5-132 Rear Suspension Fasteners ...... 5-132 5 Rear Axle Lubrication ...... 5-134 Rear Axle Alignment ...... 5-135 STEERING SYSTEM Power Steering ...... 5-136 Fluid Level and Refill ...... 5-137
(03/17) Y53-6077-1B1 5-5 MAINTENANCE
Steering Shaft ...... 5-138 DRIVELINE Driveshaft Maintenance ...... 5-139 U-Joints ...... 5-139 TIRES AND WHEEL Tires ...... 5-140 Wheel Mounting and Fastening ...... 5-146 Wheel Replacement with Disc Brake Option . . . 5-148 Disc Wheels ...... 5-150 WHEEL BEARING Wheel Bearing Adjustment ...... 5-151 5 TRANSMISSION MAINTENANCE Introduction ...... 5-152 Transmission Lubricants ...... 5-153 Automatic Transmissions ...... 5-154
5-6 Y53-6077-1B1 (03/17) MAINTENANCE
CLUTCH Introduction ...... 5-155 Clutch Adjustment - Normal Wear ...... 5-155
5
(03/17) Y53-6077-1B1 5-7
PREVENTIVE MAINTENANCE SCHEDULE PREVENTIVE MAINTENANCE WARNING! WARNING! SCHEDULE Before attempting any procedures in If work has to be done with the the engine compartment, stop the engine running, always (1) set the engine and let it cool down. Hot parking brake, (2) block the wheels, Introduction components can burn skin on con- and (3) ensure that the shift lever tact. Failure to comply may result in or selector is in Neutral. Failure to Preventive maintenance program death, personal injury, equipment or comply may result in death, per- begins with the daily checks. See property damage. sonal injury, equipment or property Driver’s Check List for these routine damage. checks. Routine vehicle checks can help avoid many large, expensive, WARNING! and time consuming repairs. The If the engine must be operating to in- WARNING! vehicle will operate better, be spect, be alert and cautious around Exercise extreme caution to prevent safer, and last longer. Neglect of the engine at all times. Failure to neckties, jewelry, long hair, or loose recommended maintenance can comply may result in death, personal clothing from getting caught in the void your vehicle’s warranty. Some injury, equipment or property dam- fan blades or any other moving en- 5 maintenance operations demand age. gine parts. Failure to comply may re- skills and equipment you may not sult in death, personal injury, equip- have. For such situations, please take ment or property damage. your vehicle to an authorized Service Center.
(03/17) Y53-6077-1B1 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 displays a guide to a maintenance you work around fuel, do not smoke (not supported), make sure that (1) interval and its schedule. Some or work near heaters or other fire the vehicle is on hard level ground, tasks are dependent on the vehicle hazards. Keep an approved fire ex- (2) the parking brake is applied, (3) application. These tasks will be tinguisher handy. Failure to comply all wheels are blocked (front and shown as separate tasks and will have may result in death, personal injury, rear) and (4) remove the ignition the words “ON HIGHWAY”, “CITY equipment or property damage. key so that the engine cannot be DELIVERY” or “OFF-HIGHWAY” started. Failure to comply may result after the description. These tasks in death, personal injury, equipment WARNING! are differentiated because they are or property damage. Always support the vehicle with ap- dependent on the vehicle’s operating propriate safety stands if it is neces- environment. WARNING! 5 sary to work underneath the vehicle. A jack is not adequate for this pur- Never start or let the engine run in On highway is defined for applications pose. Failure to comply may result an enclosed, unventilated area. Ex- where the vehicle is NOT used off of a in death, personal injury, equipment haust fumes from the engine contain paved road during normal operation. or property damage. carbon monoxide, a colorless and City Delivery is defined for applications odorless gas. Carbon monoxide can where frequent start and stopping is be fatal if inhaled. Failure to comply required during normal operation and may result in death, personal injury, the highway is used infrequently and equipment or property damage. for short periods of time.
5-10 Y53-6077-1B1 (03/17) PREVENTIVE MAINTENANCE SCHEDULE
interval. Refer to Oil Changes on Off highway is defined for applications page 5-51 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 5-48 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
(03/17) Y53-6077-1B1 5-11 PREVENTIVE MAINTENANCE SCHEDULE
Maintenance Schedule
New Vehicle Maintenance Schedule
New Vehicle Maintenance Schedule After First Miles (km)
First 3,000 Operation\Frequency 50 – 100 2,000 –5,000 Day 500 (800) (80 – 160) (3218) (4800 –8000) Steering Shaft U-Bolts. (OFF-HIGHWAY) See Steering System on page X 5-136. Wheel Mounting. See Wheel Mounting and Fastening on page 5-146. X Front Axle U-Bolt Torque. See Front Spring Suspension U-Bolts on page X 5-118. Charge Air Cooler and Air Intake Pipe Clamps, re- torque fasteners. X 5 Rear Suspension Fasteners. See Rear Suspension Fasteners on page 5-132. X Transmission Lubrication. 1. For Fuller transmission, see Fuller Transmission Lubrication on page 5-48. 2. For Allison transmission, see Allison Transmission Lubrication on page X 5-50. 3. For Spicer transmission, see Spicer Transmission Lubrication on page 5-50. Axle Lubrication. 1. For Meritor axle, see Meritor Axle Lubrication on page 5-52. X 2. For Eaton/Dana axle, see Eaton/Dana Axle Lubrication on page 5-53.
5-12 Y53-6077-1B1 (03/17) PREVENTIVE MAINTENANCE SCHEDULE
PREVENTIVE MAINTENANCE (PM) INTERVALS
Recommended PM Interval SYSTEM COMPONENT MAINTENANCE TASK IAB C DE 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 5-113) X Frame Fasteners Check for tightness; tighten to the specified torque value as X required (shown on page 5-114). Crossmembers and Inspect for cracks and loose fasteners. Replace or tighten X Mounting Brackets to the specified torque value as required (shown onpage 5-114). 5 Engine Mounting Inspect engine mounts every 60,000 miles (96,560 km) X (shown on page 5-110). Contact an authorized vehicle OEM dealership if engine mounts need servicing.
(03/17) Y53-6077-1B1 5-13 PREVENTIVE MAINTENANCE SCHEDULE
PREVENTIVE MAINTENANCE (PM) INTERVALS
Recommended PM Interval SYSTEM COMPONENT MAINTENANCE TASK IAB C DE Front Axle Total Vehicle Alignment Check and adjust as required. X X (Meritor) Steering knuckle Inspect for wear and damage and endplay. Shim or replace X spindles, thrust bearings, as required (shown on page 5-136). kingpins, drawkeys, tie rod ends, steering stops, and bushings Kingpin bushings, thrust Lubricate with approved grease. X bearings, and tie rod ball 5 ends
Drawkeys Tighten nuts XX
5-14 Y53-6077-1B1 (03/17) PREVENTIVE MAINTENANCE SCHEDULE
PREVENTIVE MAINTENANCE (PM) INTERVALS
Recommended PM Interval SYSTEM COMPONENT MAINTENANCE TASK IAB C DE 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 Inspect for wear and damage and for endplay. Shim or X spindles, thrust bearings, replace as required. 5 kingpins, drawkeys, tie rod ends, steering stops, and bushings (ON HIGHWAY) Steering knuckle Inspect for wear and damage and for endplay. Shim or X spindles, thrust bearings, replace as required. kingpins, drawkeys, tie rod ends, steering stops, and bushings (OFF-HIGHWAY)
(03/17) Y53-6077-1B1 5-15 PREVENTIVE MAINTENANCE SCHEDULE
PREVENTIVE MAINTENANCE (PM) INTERVALS
Recommended PM Interval SYSTEM COMPONENT MAINTENANCE TASK IAB C DE Front Front Spring Inspect for cracked leaves, worn bushings, and excessive X Suspension corrosion. Spring Pins and Inspect for worn parts and excessive joint clearance. Shim X Shackles 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 5 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 (shown on page 5-118). 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 5-118).
5-16 Y53-6077-1B1 (03/17) PREVENTIVE MAINTENANCE SCHEDULE
PREVENTIVE MAINTENANCE (PM) INTERVALS
Recommended PM Interval SYSTEM COMPONENT MAINTENANCE TASK IAB C DE 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 5-53 flushing oil. Change the lubricant. Air Shift Unit Check the lubricant level. X Remove the housing cover and drain the lubricant. Wash X the parts thoroughly and dry in air. Breather Clean or replace. X 5 Lube Pump (ON Remove the magnetic strainer and inspect for wear particles. X HIGHWAY) 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. Lube Filter (ON Change. X HIGHWAY) Lube Filter (OFF Change. X HIGHWAY)
(03/17) Y53-6077-1B1 5-17 PREVENTIVE MAINTENANCE SCHEDULE
PREVENTIVE MAINTENANCE (PM) INTERVALS
Recommended PM Interval SYSTEM COMPONENT MAINTENANCE TASK IAB C DE Drive Axle Magnetic drain plug and Clean or replace. X (Dana) breather (ON HIGHWAY) Magnetic drain plug Clean or replace. X and breather (OFF HIGHWAY)
5
5-18 Y53-6077-1B1 (03/17) PREVENTIVE MAINTENANCE SCHEDULE
PREVENTIVE MAINTENANCE (PM) INTERVALS
Recommended PM Interval SYSTEM COMPONENT MAINTENANCE TASK IAB C DE Drive Axle Axle Housing Check the “cold” fill level at the differential carrier plug fora 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 5-51 Lubricant filter Change the filter. X Breather Check the operation. If the cap doesn’t rotate freely, replace. X 5 Input shaft and pinion Check and adjust the endplay. X shaft Axle shaft Tighten the rear axle flange nuts to the specified torque X value. Interaxle differential Check the operation. X
(03/17) Y53-6077-1B1 5-19 PREVENTIVE MAINTENANCE SCHEDULE
PREVENTIVE MAINTENANCE (PM) INTERVALS
Recommended PM Interval SYSTEM COMPONENT MAINTENANCE TASK IAB C DE Drive Axle Axle Housing Change the oil in the differential carrier and the hubs, and X X (SISU) clean 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 5 system. S-cam brakes Overhaul the brakes; degrease all moving parts; check the X bushings and seals for wear.
5-20 Y53-6077-1B1 (03/17) PREVENTIVE MAINTENANCE SCHEDULE
PREVENTIVE MAINTENANCE (PM) INTERVALS
Recommended PM Interval SYSTEM COMPONENT MAINTENANCE TASK IAB C DE Rear U-bolts Check the torque. Tighten to specified torque value as X X Suspension required (shown on page 5-133). Frame and crossmember Check the torque. Tighten to specified torque value as X bolts required (shown on page 5-114).
Mounting brackets and Check the condition and the fastener torque. Tighten to the X X fasteners specified torque value as required (shown on page 5-114). 5
(03/17) Y53-6077-1B1 5-21 PREVENTIVE MAINTENANCE SCHEDULE
PREVENTIVE MAINTENANCE (PM) INTERVALS
Recommended PM Interval SYSTEM COMPONENT MAINTENANCE TASK IAB C DE Drum Slack adjusters Check the push rod travel and check the control arm for X Brakes (All) cracks. Adjust at reline (shown on page 5-69). 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 5 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 5-57). X 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
5-22 Y53-6077-1B1 (03/17) PREVENTIVE MAINTENANCE SCHEDULE
PREVENTIVE MAINTENANCE (PM) INTERVALS
Recommended PM Interval SYSTEM COMPONENT MAINTENANCE TASK IAB C DE Disc Brakes Brake pads Inspect; replace as required. X (Bendix®) Brake disc/rotor Inspect for visible cracks, heat checking, galling, or scoring X of 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
(03/17) Y53-6077-1B1 5-23 PREVENTIVE MAINTENANCE SCHEDULE
PREVENTIVE MAINTENANCE (PM) INTERVALS
Recommended PM Interval SYSTEM COMPONENT MAINTENANCE TASK IAB C DE Hub, Drum, Hubs (non-LMS) Check the bearing endplay and adjust as required (shown X and Hubcap on page 5-54). 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 5-54). 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 5-54). Hub seals (all) Check for leaks; replace as required. X 5 LMS Hubs (Dana) Inspect for leaks. Check the bearing endplay and adjust as X required (shown on page 5-54). 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. (shown on page 5-54). 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 5-54).
5-24 Y53-6077-1B1 (03/17) PREVENTIVE MAINTENANCE SCHEDULE
PREVENTIVE MAINTENANCE (PM) INTERVALS
Recommended PM Interval SYSTEM COMPONENT MAINTENANCE TASK IAB C DE Hub, Drum, Brake drums Inspect for visible cracks, heat checking, galling or scoring of X and Hubcap 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
(03/17) Y53-6077-1B1 5-25 PREVENTIVE MAINTENANCE SCHEDULE
PREVENTIVE MAINTENANCE (PM) INTERVALS
Recommended PM Interval SYSTEM COMPONENT MAINTENANCE TASK IAB C DE Main and Main and auxiliary Inspect for visible damage, signs of overheating, and leaks. XX auxiliary transmission and transfer transmis- case Check the drain plugs for tightness. X sion Mounting Brackets and Check the condition of the fasteners and their torque. X Fasteners Tighten 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. Check the oil level; refill as required. X 5 transmission Main and auxiliary Drain lubricant while warm. Flush each unit with clean 500,000 miles/ 800,000 km transmission (ON flushing oil. HIGHWAY) Main and auxiliary Drain lubricant while warm. Flush each unit with clean X X transmission (OFF flushing oil. HIGHWAY)
5-26 Y53-6077-1B1 (03/17) PREVENTIVE MAINTENANCE SCHEDULE
PREVENTIVE MAINTENANCE (PM) INTERVALS
Recommended PM Interval SYSTEM COMPONENT MAINTENANCE TASK IAB C DE Auxiliary Cotta Transfer Case Inspect: Check oil level; inspect for leaks and any visible X transmis- TR2205 damage. sion 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. Donot TC270 flush the case with any solvent. Marmon-Harrington Transfer Case Change oil. X MVG2000/MVG2000SD Air Intake Air intake piping, Check the system for broken pipes, leaks, joint integrity, X mounting, and charge air cleanliness, and proper support (shown on page 5-109). 5 cooler Air cleaner Replace the engine intake air cleaner element (shown on When required by air restriction page 5-108). indicator or required by the engine manufacturer's operator manual. Clutch Clutch linkage Lubricate. X Clutch release bearing Lubricate. X Inspect and adjust when necessary (no adjustment required X for SOLO type clutches)
(03/17) Y53-6077-1B1 5-27 PREVENTIVE MAINTENANCE SCHEDULE
PREVENTIVE MAINTENANCE (PM) INTERVALS
Recommended PM Interval SYSTEM COMPONENT MAINTENANCE TASK IAB C DE Cooling Hoses Check the radiator and heater hoses for leaks. X X Extended Life Coolant Check the freeze point (shown on page 5-83). X (ELC) Check for contamination using test strips (shown on page X 5-82). Replace blank water filter if applicable. X Perform lab analysis (shown on page 5-82). X If lab analysis shows coolant is unsuitable for continued use: 5 Flush, drain, and refill (shown on page 5-82). Add ELC Extender (shown on page 5-82). Flush, drain, and refill with new coolant (shown on page X 5-82). Fan clutch Check for air leaks. (shown on page 5-106). X X Check the fan drive bearings (turn the sheave in both directions to check for worn hub bearings). Solenoid valve Check the fan drive for proper engagement and X X disengagement.
5-28 Y53-6077-1B1 (03/17) PREVENTIVE MAINTENANCE SCHEDULE
PREVENTIVE MAINTENANCE (PM) INTERVALS
Recommended PM Interval SYSTEM COMPONENT MAINTENANCE TASK IAB C DE Tires and Tires Check inflation pressure (shown on page 5-140). Weekly “cold” using calibrated Wheels gauge Inspect for cuts, irregular wear, missing lugs, sidewall X damage, 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 X 5 for damage; replace as required. Wheel nuts and studs Check the tightness of the fasteners and tighten the X fasteners to the specified torque as required (shown on page 5-146). Inspect for damaged hex corners, stripped or damaged X threads, and excessive corrosion; clean or replace as required.
(03/17) Y53-6077-1B1 5-29 PREVENTIVE MAINTENANCE SCHEDULE
PREVENTIVE MAINTENANCE (PM) INTERVALS
Recommended PM Interval SYSTEM COMPONENT MAINTENANCE TASK IAB C DE Power Reservoir Check the fluid level (shown on page 5-55). X Steering Reservoir (ON Drain, replace the filter, and refill (shown on page 5-55). X X HIGHWAY) Reservoir (OFF Drain, replace the filter, and refill (shown on page 5-55). X X HIGHWAY) Steering gear Check the lash of the sector shaft; adjust as required. X Grease the trunnion bearing (EP NLGI #2 lithium-based, X 5 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, X damaged 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 X (shown on page 5-136).
5-30 Y53-6077-1B1 (03/17) PREVENTIVE MAINTENANCE SCHEDULE
PREVENTIVE MAINTENANCE (PM) INTERVALS
Recommended PM Interval SYSTEM COMPONENT MAINTENANCE TASK IAB C DE Power Draglink tube clamp and Check the torque; tighten to specified torque value as X X Steering ball socket required. Pitman arm clamp bolt Check the torque; tighten to specified torque value as X X and nut required. Steering intermediate Check the torque on the pinch bolt and nut. X X shaft Steering intermediate Lubricate [EP NLGI #2 HD grease, +325° F to -10° F (+163° X X shaft U-joints (ON C to -23° C) range]. HIGHWAY) 5 Steering intermediate Lubricate [EP NLGI #2 HD grease, +325° F to -10° F (+163° XX shaft U-joints (OFF C to -23° C) range]. HIGHWAY or CITY DELIVERY) Draglink and tie rod Lubricate (EP NLGI #2 lithium-based, moly-filled, HD XX arm ball sockets (ON grease). HIGHWAY) Draglink and tie rod Lubricate (EP NLGI #2 lithium-based, moly-filled, HD XX arm ball sockets (OFF grease). HIGHWAY or CITY DELIVERY) (03/17) Y53-6077-1B1 5-31 PREVENTIVE MAINTENANCE SCHEDULE
PREVENTIVE MAINTENANCE (PM) INTERVALS
Recommended PM Interval SYSTEM COMPONENT MAINTENANCE TASK IAB C DE Fuel and Fuel tanks Inspect tanks, brackets, hoses, and fittings for correct X Tanks location, 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 XX as required: Aluminum tank: 30 Lb. ft. (41 N.m.) Cylindrical Steel tank: 8 Lb. ft. (11 N.m.) 5
5-32 Y53-6077-1B1 (03/17) PREVENTIVE MAINTENANCE SCHEDULE
PREVENTIVE MAINTENANCE (PM) INTERVALS
Recommended PM Interval SYSTEM COMPONENT MAINTENANCE TASK IAB C DE Driveshafts Models SPL-90, 1710 Lubricate*. XX and 1810 slip member and U-joints Inspect. U-joint inspections should be 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 5 maintenance.** Models SPL- Lubricate*. X 140/140HD/170/ 170HD/250/250HD slip Inspect. U-joint inspections should members and U-joints be performed every time a (ON HIGHWAY and vehicle comes in for scheduled LINEHAUL) maintenance.**
(03/17) Y53-6077-1B1 5-33 PREVENTIVE MAINTENANCE SCHEDULE
PREVENTIVE MAINTENANCE (PM) INTERVALS
Recommended PM Interval SYSTEM COMPONENT MAINTENANCE TASK IAB C DE Driveshafts Models SPL- Lubricate*. X 140/140HD/170/ 170HD/250/250HD slip Inspect. U-joint inspections should members and U-joints be performed every time a (OFF HIGHWAY) vehicle comes in for scheduled maintenance.** Models SPL-140XL/ Lubricate*. 350,000 mi (560,000 km) 1st 170XL/250XL slip interval and then every 100,000 mi members and U-joints (160,00 km) after that. (ON HIGHWAY and LINE 5 HAUL) Inspect. U-joint inspections should be performed every time a vehicle comes in for scheduled maintenance.** Models SPL-140XL/ Lubricate*. X 170XL/250XL slip members and U-joints Inspect. U-joint inspections should (OFF HIGHWAY and be performed every time a CITY) vehicle comes 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.
5-34 Y53-6077-1B1 (03/17) PREVENTIVE MAINTENANCE SCHEDULE
PREVENTIVE MAINTENANCE (PM) INTERVALS
Recommended PM Interval SYSTEM COMPONENT MAINTENANCE TASK IAB C DE Battery Battery cables Check the condition of the cables, cushion clamps, nylon tie X Boxes, Tool straps, and routing. Replace a cushion clamp if the rubber Boxes, and has deteriorated. Repair or tighten terminals, and secure Steps cables to prevent chafing. Replace damaged cables (cuts, cracks, or excessive wear) (shown on page 5-87). Batteries (ON HIGHWAY Check for cracks and damage, electrolyte level, condition of X and LINE HAUL) terminals, and tightness of holddowns (shown on page 5-87). Batteries (OFF- Check for cracks and damage, electrolyte level, condition of X HIGHWAY) terminals, and tightness of holddowns (shown on page 5-87). 5 Battery box and tray (ON Check the box integrity. Clean the drain tube and check for X HIGHWAY and LINE acid leaks. Check condition of all equipment mounted under HAUL) the box. Battery box and tray Check the box integrity. Clean the drain tube and check for X (OFF-HIGHWAY) acid 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.
(03/17) Y53-6077-1B1 5-35 PREVENTIVE MAINTENANCE SCHEDULE
PREVENTIVE MAINTENANCE (PM) INTERVALS
Recommended PM Interval SYSTEM COMPONENT MAINTENANCE TASK IAB C DE Electrical Headlamps Check the aim and adjust as required. X and lights Warning lights in light bar Check at the ignition start position to verify bulbs and driver X information display function. Turn, Stop, Reverse Visual check. X lights and signals Alternator Check operation and output. X Check tightness of the pulley nut. X 5 Check the tension of the drive belt (shown on page 5-105). 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 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 XX fluid tank sending unit worn or damaged wires and connectors.
5-36 Y53-6077-1B1 (03/17) PREVENTIVE MAINTENANCE SCHEDULE
PREVENTIVE MAINTENANCE (PM) INTERVALS
Recommended PM Interval SYSTEM COMPONENT MAINTENANCE TASK IAB C DE Electrical Power supply harnesses Check for worn or damaged insulation, corroded terminals, X and lights (engine, transmission, frayed wires, and oil or fluid leaks on the connectors or etc.) wiring. Wash to remove excess grease. X Cab Hood Lubricate the lower hood pivot (only if lube fittings are X structure, present). doors and hoods Hinges and latch Lubricate with silicone spray. X Body and cab holddown Check the condition and tightness. X bolts 5 Heating and Air conditioner Operate the system. X Air Condi- tioning Heater and air Perform the checks listed shown on page 5-120. X conditioner Full operational and diagnostic check. X Condenser Clear any debris from the front of the condenser. X
(03/17) Y53-6077-1B1 5-37 PREVENTIVE MAINTENANCE SCHEDULE
PREVENTIVE MAINTENANCE (PM) INTERVALS
Recommended PM Interval SYSTEM COMPONENT MAINTENANCE TASK IAB C DE Aftertreat- System Check for leaks and proper support (shown on page 5-123). X ment Sys- tem 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 Replace filter. Refer to the Engine Maintenance 5 supply module Manual.
5-38 Y53-6077-1B1 (03/17) PREVENTIVE MAINTENANCE SCHEDULE
PREVENTIVE MAINTENANCE (PM) INTERVALS
Recommended PM Interval SYSTEM COMPONENT MAINTENANCE TASK IAB C DE Air Air compressor governor Replace air strainer. X Air lines Check condition and routing to prevent chafing. X System Lubricate (shown on page 5-60). X Inline filters Replace elements or clean with solvent. X Air dryer Perform the checks listed (shown on page 5-57). X Air dryer (ON HIGHWAY) Overhaul. 360,000 miles/576,000 km Air dryer (OFF Overhaul. X 5 HIGHWAY)
(03/17) Y53-6077-1B1 5-39 PREVENTIVE MAINTENANCE SCHEDULE
PREVENTIVE MAINTENANCE (PM) INTERVALS
Recommended PM Interval SYSTEM COMPONENT MAINTENANCE TASK IAB C DE 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. 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 5 inspections may be necessary.
5-40 Y53-6077-1B1 (03/17) LUBRICANT SPECIFICATIONS
LUBRICANT at top economy and in prolonging Engine SPECIFICATIONS its life is proper lubrication servicing. Neglecting this essential aspect of Proper engine lubrication depends vehicle care can cost time and money on the outside temperatures where Introduction in the long run. you will be driving. Use the oil recommended for the conditions you WARNING! CAUTION are most likely to be operating in. You will find a complete engine lubrication Handle lubricants carefully. Vehi- Do not mix different types of lubri- service guide in the Engine Operation cle lubricants (oil and grease) can cants. Mixing lubricants (oil and Manual that came with your vehicle. be poisonous and cause death, per- grease) of different brands or types The engine operator manual contains sonal injury or sickness. They can could damage vehicle components; specific maintenance tasks that you or also damage the paint on the vehi- therefore, drain (or remove) old lu- a qualified service technician need to cle. bricants from the unit before refilling perform to maintain the engine. it. In this section you will find the basic information you need to do the routine lubrication your vehicle requires. Of 5 course you will want to schedule 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
(03/17) Y53-6077-1B1 5-41 LUBRICANT SPECIFICATIONS
WARNING! WARNING! NOTE Exhaust fumes from the engine Never idle your vehicle for prolonged Keep the engine exhaust system contain carbon monoxide, a color- periods of time if you sense that ex- and the vehicle’s cab ventilation less and odorless gas. A poorly haust fumes are entering the cab. system properly maintained. It is maintained, damaged, or corroded Investigate the cause of the fumes recommended that the vehicle’s ex- exhaust system can allow car- and correct it as soon as possible. haust system and cab be inspected: bon monoxide to enter the cab or If the vehicle must be driven under • By a competent technician every sleeper. Failure to properly main- these conditions, drive only with the 15,000 miles/ 24,000 km, tain your vehicle could cause car- windows slightly open. Failure to re- bon monoxide to enter the cab and pair the source of the exhaust fumes • Whenever a change is noticed in cause death, personal injury or seri- may lead to death, personal injury or the sound of the exhaust system, ous illness. serious illness. • Whenever the exhaust system, underbody, cab or sleeper is damaged. 5 NOTE Use only an exact replacement parts in Aftertreatment exhaust system. Using a noncompliant replacement part could violate emissions require- ments and also void the emission system’s warranty.
5-42 Y53-6077-1B1 (03/17) 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 & Water Heat Exchangers Miniature 3600L 1.1-1.7 10-15 5 (for hoses less than 9/16 diameter)
(03/17) Y53-6077-1B1 5-43 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 5 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
5-44 Y53-6077-1B1 (03/17) LUBRICANT SPECIFICATIONS
NOTE The responsibility for meeting these specifications, the quality of the product, and its performance in ser- vice rests with the lubricant supplier.
For oil reservoir with side filler plugs (transmission, axles, steering gear boxes, transfer cases, etc.) the oil must be level with the filler opening.
1 Improper Oil Level 5 2 Proper Oil Level
Use care when checking the oil level with a finger. Just because you can reach the oil level with a finger, does not mean the oil level is correct.
(03/17) Y53-6077-1B1 5-45 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 5 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 Steering Shaft Grease Fittings EP
5-46 Y53-6077-1B1 (03/17) LUBRICANT SPECIFICATIONS
Component Lubrication Index 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. Manual Transmission Hydraulic Clutch DOT3 or DOT4 (Brake Fluid) *Consult manufacturer or lubricant supplier for special details.
5
(03/17) Y53-6077-1B1 5-47 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 5 oil. the life of the transmission and the fully loaded vehicle performing transmission oil cooler. 4. Buy oil from a reputable dealer. normally.
5-48 Y53-6077-1B1 (03/17) 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 90 Above 10° F (-12° C) inhibitor API-GL-1 80W Below 10° F (-12° C) Synthetic Lubricant* 50 All *See your dealer for approved brands.
5
(03/17) Y53-6077-1B1 5-49 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 5 bronze parts.
Type Grade (SAE) Ambient Temperature Heavy Duty Engine Oil MIL-L-2104D 30, 40, or 50 Above 0° F (-18° C) or MIL-L-46152B, API-SF or API-CD (MIL-L-2104B or C or MIL-L-46152 30 Below 0° F (-18° C) 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)
5-50 Y53-6077-1B1 (03/17) LUBRICANT SPECIFICATIONS
Type Grade (SAE) Ambient Temperature Synthetic Engine Oil meeting MIL-L-2104D or CD50 All MIL-L-46152B, API-SF or API-CD CD30 *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 24 hours but before 100 hours of Refilling service have elapsed. CAUTION Remove all dirt around filler plug. Refill with new oil of the grade recommended When adding oil, types and brands for the existing season and prevailing of oil should not be intermixed be- service. Fill to the bottom of the cause of possible incompatibility, level testing plug positioned on the which could decrease the effec- side of the transmission. Do not tiveness of the lubrication or cause overfill the transmission. Overfilling component failure. usually results in oil breakdown due to excessive heat and aeration from 5 An initial oil change and flush should the churning action of the gears. Early be performed after the transmission breakdown of the oil will result in heavy has been placed in actual service. varnish and sludge deposits that plug This change should be made any time up oil ports and build up on the splines after 3000 miles (4800 km) but never and bearings. Overflow of oil can also longer than 5000 miles (8000 km) of escape onto clutch or parking brakes. over-the-road service. In off-highway When adding oil, do not mix different use, the change should be made after types of oil.
(03/17) Y53-6077-1B1 5-51 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 lubricant change: use are not eligible for Meritor’s Ad- vanced Lube Rear Drive Axle pro- gram.
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
5 Meritor rear axles that do not appear • See your dealer for on the list above will continue to Meritor-approved lubricant require an initial drain at 3000-5000 brands. miles (4800-8000 km). • Refer to the following chart for • Refer to the Meritor Field lubricant change intervals: Maintenance Manual for a particular axle for lubricant specifications.
5-52 Y53-6077-1B1 (03/17) LUBRICANT SPECIFICATIONS
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) 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 with an Eaton-approved synthetic 120,000 miles (192,000 km). Top lubricant. off the lubricant level with a similar • The original mineral-based lubricant. lubricant must be drained within • Mineral-based lubes must be 5 3000-5000 miles (4800-8000 drained within the first 5000 miles km) on all Eaton axles. This (8000 km) if converting to an initial change is very important Eaton-approved synthetic lube. because it flushes out break-in contaminants that might otherwise • Change the lubricant within the cause premature wear. first 5000 miles (8000 km) of operation after a carrier head • No initial drain is required on replacement, regardless of the Eaton axles that are factory filled lubricant type.
(03/17) Y53-6077-1B1 5-53 LUBRICANT SPECIFICATIONS
• Refer to the Eaton Field • See your dealer for • Refer to the chart below for Maintenance Manual for a Eaton-approved lubricant brands. lubricant change interval. particular axle for lubricant specifications.
Type of Lubricant On-Highway Mi. (km) Maximum Change On/Off Highway Severe Maximum Change Interval Service Mi. (km) Interval Mineral-Based 120,000 (192,000) Yearly 60,000 (96,000) Yearly Eaton-Approved 240,000 (384,000) 2 Years 120,000 (192,000) Yearly Synthetic Eaton-Approved 350,000 (560,000) Synthetic in axle with extended drain interval option Wheel Bearing Lubrication done.) Allow time for the oil to seep Oil-lubricated Nondriven Hubs Oil-lubricated Driven Hubs through the bearings when initially filling a hub. Maintain the differential Use CD50 synthetic transmission fluid 5 Use hypoid oil, A.P.I.-GL-5 SAE oil level by adding oil until its surface is SAE 50W or equivalent. A minimum of 75W-90FE synthetic gear lubricant even with the bottom of the filler hole 9 oz. (270 ml) of lubricant is required or equivalent. A minimum of 1 quart (see illustration on page 5-45). 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 vent plug or threaded filler plug when
5-54 Y53-6077-1B1 (03/17) LUBRICANT SPECIFICATIONS fluid level will lie between the fluid level Universal Joint Lubrication Steering Gear Lubrication line and 1/4” above the line. Fluid Refill Refer to the Spicer Universal Joints NOTE and Driveshafts service manual and The following recommendations are lubrication specifications. for general purpose steering systems Remember to replace vent plug (both TRW and Sheppard). when done. • For normal temperatures, use Automatic Transmission Fluid (ATF) Type E or F or Dexron® III. • For cold temperatures of -22º F (-30º C) and above use ATF Type A. • For extremely cold temperatures between -22º F (-30º C) and -40º F (-40º C) use ATF Type B. 5
(03/17) Y53-6077-1B1 5-55 LUBRICANT SPECIFICATIONS
Inspection If incompatible (insoluble) fluids are NOTE mixed in a power steering system, air bubbles can be produced at the Before removing reservoir cover, interface of the two fluids. This can wipe outside of cover so that no dirt cause cavitation, which reduces the can fall into the reservoir. lubrication between moving parts in 1. Check the fluid level; add fluid if the gear. This could result in worn required. components. 2. Check fluid for contamination, The mixture of two different fluids, discoloration, or burnt smell; although harmless to individual correct source of such problems internal components, may initiate a before replacing fluid and filter. chemical reaction that produces a new compound that will attack seals and CAUTION other internal components. When adding fluid, be sure to use 5 Do not mix different fluids. fluid of the same type. While many fluids have the same description and intended purpose, they should not be mixed due to incompatible ad- ditives. Mixing incompatible fluids may lead to equipment damage.
5-56 Y53-6077-1B1 (03/17) AIR SYSTEM AIR SYSTEM WARNING! WARNING! Introduction Prior to the removal of any air sys- Never connect or disconnect a hose tem component, always block and or line containing air pressure. It WARNING! hold the vehicle by a secure means may whip as air escapes. Never re- other than the vehicle's own brakes. move a component or pipe plug un- Do not attempt to modify, alter, repair Depleting air system pressure may less you are certain all system pres- or disconnect any component of the cause the vehicle to roll unexpect- sure has been depleted. Failure to air system. Repairs or modifications edly resulting in an accident causing comply may result in death, personal to the air system, other than what death or personal injuries. Keep injury, equipment or property dam- is described in this section, should hands away from chamber push age. only be performed by an authorized rods and slack adjusters, they may dealer. Failure to comply may result apply as system pressure drops. in death or personal injury. WARNING! Never exceed recommended air WARNING! pressure and always wear safety After completing any repairs to the glasses when working with air pres- air system, always test for air leaks, sure. Never look into air jets or direct 5 and check the brakes for safe opera- them at anyone. Failure to comply tion before putting the vehicle in ser- may result in death, personal injury, vice. Failure to comply may result in equipment or property damage. death, personal injury, equipment or property damage.
(03/17) Y53-6077-1B1 5-57 AIR SYSTEM
compressed air then goes to the WARNING! WARNING! reservoirs to be stored until needed. Never attempt to disassemble a Completely bypassing a Bendix® When you operate your air brakes, the component until you have read and AD-IS air dryer will bypass the sys- stored compressed air flows into the understood recommended proce- tem’s pressure protection valves. chambers where it is used to apply dures. Some components contain This could lead to loss of air pres- your truck and trailer brakes. That is powerful springs and injury can re- sure or damage to the vehicle’s why, when you push down on your sult if not properly disassembled. air system, which could cause an brake pedal, you don’t feel the same Use only proper tools and observe accident involving death or per- amount of pressure on the pedal that all precautions pertaining to use sonal injury. Always adhere to the you do when you apply the brakes on of those tools. Failure to comply manufacturer’s procedure if it is your car. All you are doing on your may result in death, personal injury, necessary in an emergency to tem- truck is opening an air valve to allow equipment or property damage. porarily bypass an AD-IS-series air air to flow into the brake chambers. dryer. Failure to comply may result in death, personal injury, equipment Contamination of the air supply system or property damage. is the major cause of problems in air-operated components such as 5 brake valves, and suspension height The operation of the vehicle’s braking 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
5-58 Y53-6077-1B1 (03/17) 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 and soaking them in solvent. Blow frequency, water could enter the • Operate air devices to circulate them dry with pressurized air air lines and valves. This could lubricants within the unit. before reinstalling them. cause corrosion or blockage, which could compromise the brake system safety and potentially cause an ac- cident involving death or personal injury.
5
(03/17) Y53-6077-1B1 5-59 AIR SYSTEM
Twice a Year Air Dryer drain cocks, or valves and checking for presence of water. • Maintain the air compressor to The function of the air dryer is to collect prevent excessive oil by-pass. and remove air system contaminants in NOTE See your maintenance manual for solid, liquid and vapor form before they A small amount of oil in the system details. enter the brake system. It provides may be normal and should not, in it- clean, dry air to the components of • Replace worn seals in valves and self, be considered a reason to re- the brake system, which increases air motors as they are needed. place the desiccant cartridge. Oil the life of the system and reduces stained desiccant can function ade- maintenance costs. quately. NOTE A tablespoon of water found in the Because no two vehicles operate air tank would point to the need for a under identical conditions, mainte- desiccant cartridge change. However, nance and maintenance intervals the following conditions can also will vary. Experience is a valuable cause water accumulation and should 5 guide in determining the best main- be considered before replacing the tenance interval for any one partic- desiccant cartridge. ular operation. • Air usage is exceptionally high Every 900 operating hours or 25,000 and not normal for a highway miles (40,200 km) or every three (3) vehicle. This may be due to months check for moisture in the air accessory air demands or some brake system by opening air tanks, unusual air requirement that does not allow the compressor to load and unload (compressing
5-60 Y53-6077-1B1 (03/17) AIR SYSTEM
and non-compressing cycle) in a Overhaul Bendix® AD-IS Series Air Dryer normal fashion or it may be due to excessive leaks in the air system. Maintenance intervals typical for Your vehicle may be equipped with a on-highway operation would be 2 - 3 Bendix® AD-IS series air dryer. Any • In areas where more than a 30° years, 350,000 miles or 10,800 hours. air dryer replacement should be made F (17° C) range of temperature with an identical component. occurs in one day, small amounts Maintenance intervals typical for high of water can accumulate in duty cycle usage such as transit bus, WARNING! the air brake system due to refuse hauler, dump truck, cement If a different air dryer brand or model condensation. Under these mixers and off-highway operation is installed on the vehicle other than conditions, the presence of small would be 1 year, 100,000 miles or what was originally installed, it could amounts of moisture is normal 3,600 hours. cause the air system to not perform and should not be considered as correctly unless the full air system an indication that the dryer is not NOTE design is reviewed and modifica- performing properly. Review the warranty policy before tions made to comply with Federal • An outside air source has been performing any maintenance proce- Motor Vehicle Safety Standards used to charge the air system. dures. An extended warranty may (FMVSS) 121 - Air Brake Systems. 5 This air did not pass through the be voided if unauthorized mainte- Failure to abide by this warning and drying bed. nance is performed during this pe- maintain compliance to FMVSS 121 riod. 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
(03/17) Y53-6077-1B1 5-61 AIR SYSTEM
components that have typically been Air Tanks basis. Operate air devices daily to installed separately on the vehicle (see circulate lubricants within the unit. below for components/areas affected): Periodically: Clean filter screens • Pressure protection valves ahead of the valves by removing the screens and soaking them in solvent. • Safety valve Blow them dry with pressurized air • Governor and plumbing before reinstalling them.
• Plumbing of the front and rear WARNING! service air tanks If the supply and service air tanks • Plumbing to accessory systems are not drained at the recommended frequency, water could enter the These components are required to air lines and valves. This could meet the Federal Motor Vehicle Safety cause corrosion or blockage, which Standards (FMVSS 121 - Air Brake could compromise the brake system 5 Systems). As the Warning above safety and potentially cause an ac- states, any other type of air dryer To eject moisture from the air system cident. Failure to comply may result installed in the place of an AD-IS Series tanks, pull the line that is connected to in death, personal injury, equipment will require changes, modifications the moisture ejection valve. Continue or property damage. and/or additions to your vehicle’s air pulling until the air comes out free of system to maintain compliance with water. FMVSS 121. Daily: The supply and service air tanks, must be drained on a daily
5-62 Y53-6077-1B1 (03/17) AIR SYSTEM
Air Gauges and Air Leaks CAUTION 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 Do not use penetrating oil, brake gauges for two separate systems, until the problem is found and fixed. If fluid, or wax-based oils in the air sys- Primary and Secondary: the Primary the pressure in either or both systems tem. These fluids may cause severe gauge indicates pressure in the rear is too low for normal brake operation, damage to air system components. braking system; the Secondary gauge i.e., the pointer of one gauge falls indicates pressure in the front braking below 65 psi (448 kPa), a warning light • Maintain the air compressor to system. Each gauge indicates the on the gauge will glow and the audible prevent excessive oil bypass. amount of air pressure in pounds per alarm will sound. • Replace worn seals in valves and square inch (psi). air motors as they are needed. NOTE Your authorized dealer carries WARNING! Park brakes lock up at 60 psi (414 rebuild kits for most units. Do not operate the vehicle if leak- kPa), the audible alarm will sound at age in the air system is detected. 65 psi (448 kPa). Conduct the following procedure and contact an authorized dealer (or 5 any other properly equipped service center) if a leak is detected. Failure to check the brakes or follow these procedures could cause a system failure, increasing the risk of an Primary Air Pressure Gauge accident and may result in death, personal injury, equipment or prop- erty damage.
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5. Start the engine and build up the Air Compressor Operation air pressure again. 6. Stop the engine, and apply the All compressors, regardless of make brakes fully. Apply the brake pedal or model, run continuously while the and hold it down for five minutes. engine is running. System pressure Secondary Air Pressure Gauge The pressure drop should not is controlled by the governor. The exceed 3.0 psi (21 kPa) per governor acts in conjunction with Follow the procedure below to minute. the unloading mechanism in the check the compressed air system compressor cylinder block to start for leaks: 7. If you detect excessive leakage and stop compression of air. The (air pressure loss greater than 3.0 1. Periodically, or after maintenance compressor is unloaded when the psi (21 kPa) after five minutes of system pressure reaches 120 psi (827 or replacement of air system brake application), a leakage test components: kPa) and compression is reestablished should be made at the air line when system pressure falls to 100 psi 2. Build up air pressure in the system connections and at all air brake (690 kPa). to the governor cutout point or until control units. These tests should 5 120 psi (827 kPa) is reached. determine where air is escaping. 3. Stop the engine and release the service brakes. 4. Without applying the brake pedal, observe the rate of air pressure drop. This rate should not exceed 2.0 psi (14 kPa) per minute.
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Preventive Maintenance presence of excessive carbon. If excessive carbon is found, clean The following service checks are or replace the compressor cylinder provided for your information only and head. Also, check compressor should be performed by a certified discharge line for carbon, and mechanic. Contact your dealer or the clean or replace the discharge line engine manufacturer's Maintenance if necessary. Manual for further information on servicing air compressors. • Disassemble compressor and thoroughly clean and inspect After completing any repairs to the air all parts. Repair or replace system, always test for air leaks, and all worn or damaged parts, or check the brakes for safe operation replace compressor with a factory before putting the vehicle in service. exchange unit.
Below is a list of areas to maintain for CAUTION the air compressor: When draining the engine cooling 5 • Inspect compressor air filter system is required, to prevent dam- element, if so equipped, and age from freezing, the compressor replace element if clogged. Check must also be drained at the cylinder compressor mounting and drive head and block. Engine damage for alignment and belt tension. could occur if the cooling system is Adjust if necessary. not periodically drained and main- tained. See Cooling System on page • Remove compressor discharge 5-82 for further information. valve cap nuts and check for
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BRAKE SYSTEM specifications can affect the whole CAUTION system. All of the following areas Brake Adjustment The air brake system of this vehicle are interrelated and must conform to was configured for ONE of the fol- original specifications: WARNING! lowing operations: tractor or truck, • Tire Size and complies with the respective Do not work on the brake system portions of FMVSS 121. A tractor without the parking brake set and • Drum brakes shall not be operated or configured wheels chocked securely. If the as a truck, nor shall a truck be op- a. Cam Radius vehicle is not secured to prevent erated or configured as a tractor, uncontrolled vehicle movement, it b. Wedge Angle without significant modifications to could roll and cause death, serious the air brake system in order to re- c. Drum Radius personal injury or damage to the tain compliance with FMVSS 121. 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 5 understanding of its brake systems. its components or any combination of • Disc Brakes 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
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Air Disc Brakes WARNING! WARNING! Have brake pads inspected by a Do not use any replacement part in Do not use brake linings with a thick- qualified mechanic for wear at regular the brake system unless it conforms ness below the specified minimum. intervals according to the Preventive exactly to original specifications. A Such linings will have lining rivets Maintenance Schedule on page 5-12. nonconforming part in your vehi- exposed that can damage the brake In severe service or off-highway cle's brake system could cause a drum and reduce brake efficiency, applications inspect the linings more malfunction resulting in an accident which could cause death, personal frequently. causing death or personal injury. injury or system failure. Sizes and types are so related to Regularly inspect for pad/rotor wear: one another that a seemingly unim- portant change in one may result • Park on level ground and chock in a change in how well the brakes the wheels. work for you on the road. If parts do not work together properly, you • Temporarily release the parking could lose control of your vehicle, brakes. which could cause a serious acci- • Compare the relative position 5 dent. of two notches; one located on the caliper and the other on the All vehicle operators should check carrier. See the illustration below their brakes regularly. 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 manufacturer's 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 Have brake drum linings and disc Periodically check the Brake Chamber 36 (rear brakes) 1-1/2" - 2-1/4" brake pads inspected by a qualified Stroke. Replace the slack adjuster if (38 - 57 mm) mechanic for wear at regular intervals proper stroke cannot be maintained. 30 (rear brakes) 1-1/2" - 2" according to the maintenance (38 - 51 mm) schedule. In severe service or Operational checks of automatic 16, 20 and 24 (front 1" - 1-3/4" off-highway applications inspect the slack adjusters brakes) (25.4 - 44.4 mm) 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
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WARNING! Manual adjustment of automatic slack adjusters is a dangerous prac- tice that could have serious con- sequences. It gives the operator a false sense of security about the effectiveness of the brakes. Con- tact the Service Department at your dealership if the stroke exceeds the above specifications. A stroke ex- ceeding these values may indicate a problem with the slack adjuster 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 5-72. • 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 contaminants that can stain and the metal surface by road grime. It in 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. • Most chemical cleaners are WARNING! without protecting your hands and concentrates that require dilution. Handle cleaning agents carefully. arms. You may cut yourself on • Only use spot removing fluids in Cleaning agents may be poisonous. sharp-edged metal parts. Failure well ventilated areas. Keep them out of the reach of chil- to comply may result in death, per- dren. Failure to comply may result sonal injury, equipment or property • Any vehicle is subjected to in death, personal injury, equipment damage. deterioration from industrial or property damage. fumes, ice, snow, corrosive road WARNING! salt, etc., to name just a few WARNING! causes. A well-cared-for vehicle Moisture, ice, and road salt on can look like new many years Do not use gasoline, kerosene, brakes may affect braking efficiency. later. Regular and correct care naphtha, nail polish remover or other Test the brakes carefully after each will contribute to maintaining the volatile cleaning fluids. They may vehicle wash. Failure to comply beauty and the value of your 5 be toxic, flammable or hazardous may result in death, personal injury, vehicle. in other ways. Failure to comply equipment or property damage. may result in death, personal injury, Your dealer has a number of equipment or property damage. • Observe all caution labels. vehicle-care products and can advise you on which ones to use for cleaning Always read directions on the • the exterior and interior of your vehicle. container before using any product.
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Washing the Exterior plated, and polished metal CAUTION surfaces. 1. Begin by spraying water over the Do not aim the water jet directly at dry surface to remove all loose dirt 3. Rinse surfaces frequently while door locks or latch. Tape the key before applying the car wash and washing to flush away dirt that holes to prevent water from seeping wax solution. might scratch the finishes during into the lock cylinders. Water in lock the washing operation. cylinders should be removed with ° Do not wash the vehicle in compressed air. To prevent locks direct sunshine. 4. Wipe everything dry with a from freezing in the winter, squirt chamois to avoid water spots. glycerin or lock deicer into the lock ° Do not spray water directly ° To prevent water spotting, dry cylinders. into the cab vents. 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 can collect on the underbody. If upholstery shampoo specially a cloth because it will scratch these materials are not removed, formulated for this purpose. Follow the 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.
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Passenger Door Lower View Window NOTE Always make sure that a gasket is There may be occasions when the installed properly so the weep slots inner view window must be removed will be indexed correctly. The notch for maintenance cleaning and/or in the gasket is to face forward on damage. Follow this procedure when the RH side. This places the weep installing and removing an inner view slots at the bottom of the window window. The recommended tool for opening (see next illustration).There To install a window, slide the glass removal of the glass is a glass stick, is a ridge on the bottom surface of from the rear of the door toward the although other tools may be used the gasket (see next illustration). removal slot until the forward edge of provided proper caution is observed. Install the glass outboard of this the glass is against the inside edge of ridge. The polished satin finish on the seal (see next illustration; arrow CAUTION the glass, which leaves a rounded indicates forward). The use of screwdrivers, gasket edge, rests against the edge of the tools, knives or other similar in- ridge.The installation and removal 5 struments may damage the seal or will be easier by using water or soap break the glass. Use a glass stick as a lubricant on the edge of the as a tool whenever possible when glass. removing or installing a window. If another tool must be used, exercise extreme care when performing this procedure with such a tool.
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Use the glass stick to leverage the glass out of the seal.
Continue this process along the entire front edge of the seal until the glass is free.
Press and slide the glass into the aft 5 When the forward edge of the glass portion of the seal to seat it. reaches the forward inside edge of the seal, the glass should pivot outboard To remove an inner view window, into the remaining seal (see arrow in insert the glass stick into the removal next illustration). slot, then use the glass stick to push the glass as far aft as possible.
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Safety Restraint System - vehicle requires thorough inspection Inspection Factors contributing to reduced seat every 20,000 miles (32,000 km). If belt life: the vehicle is exposed to severe The seat belt system, including environmental or working conditions, • Heavy trucks typically accumulate webbing, buckles, latches, and more frequent inspections may be twice as many miles as the mounting hardware, endures heavy necessary. average passenger car in a given use in heavy-duty vehicles, much more time period. than seat belt systems in passenger Any seat belt system that shows cuts, cars. All users should be aware of the • Seat and cab movement in fraying, extreme or unusual wear, factors contributing to this heavy use trucks causes almost constant significant discoloration due to UV and reduced belt life. movement of the belt due to ride (ultraviolet) exposure, abrasion to the characteristics and seat design. seat belt webbing, or damage to the WARNING! The constant movement of the belt buckle, latch plate, retractor hardware or any other obvious problem should Failure to properly inspect and main- inside the restraint hardware and the potential for the belt to come be replaced immediately, regardless tain restraint systems can lead to in- of mileage. jury or loss of life. Without periodic in contact with the cab and other 5 inspection and maintenance to de- vehicle parts, contributes to the tect unsafe conditions, seat restraint wear of the entire system. components can wear out or not pro- • Environmental conditions, such as tect you in an accident. dirt and ultraviolet rays from the sun, will reduce the life of the seat belt system.
Due to these factors, the three-point safety belt system installed in your
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Inspection Guidelines other parts of the cab interior. WARNING! These areas are typical places It is important to remember that any Follow these guidelines when where the web will experience time a vehicle is involved in an ac- inspecting for cuts, fraying, extreme cutting or abrasion. Cuts, fraying, cident, the entire seat belt system or unusual wear of the webbing, or excessive wear would indicate must be replaced. Unexposed dam- and damage to the buckle, retractor, the need for replacement of the age caused by the stress of an acci- hardware, or other factors. Damage to seat belt system. dent could prevent the system from these areas indicates that belt system replacement is necessary. 2. The pillar web guide (D-loop) is functioning properly the next time it the area where almost constant is needed. Failure to comply may re- WARNING! movement of the seat belt sult in death or personal injury. webbing occurs because of Replace the entire belt system (re- relative movement between the tractor and buckle side) if replace- seat and cab. ment of any one part is necessary. Unexposed damage to one or more 3. Check the Komfort-Latch for components could prevent the sys- cracks or possible damage and tem from functioning properly the check for proper operation. 5 next time it is needed. Failure to 4. Check buckle and latch for proper comply may result in death or per- operation and to determine if sonal 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
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occupant restraint system and can the sun's ultraviolet rays. Replace 4 Buckle casting broken. often be damaged if abused, even the system. 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 the seat in an accident. Tether belts 5 tightness of bolts and nuts. Seat Belt Inspection Points should be adjusted so that they are 8. Check web in areas exposed to taut when the seat is in its most up- ultraviolet rays from the sun. If the 1 Web cut or frayed or ward and forward position. Failure color of the web in these areas is extremely worn at latch to comply may result in death or per- gray to light brown, the physical area. sonal injury. strength of the web may have 2 Web cut or frayed at D-loop deteriorated due to exposure to web guide. Once the need for replacement of 3 Comfort Clip cracked or the seat belt has been determined, damaged.
5-80 Y53-6077-1B1 (03/17) CAB be certain it is only replaced with Windshield Wiper/Washer Washer Reservoir an authorized PACCAR Parts replacement seat belt. The windshield wiper system is CAUTION maintenance free. Check wiper blades Do not use antifreeze or engine If the inspection indicates that any annually or every 60,000 miles (96,000 coolant in the windshield washer part of the seat belt system requires km). reservoir, damage to seals and other replacement, the entire system must components will result. be replaced. An installation guide is attached to every replacement belt. Utilize the proper guide for your type of Daily: Check reservoir water level, seat, and follow the instructions very located in the engine compartment. If closely. It is vitally important that all necessary, refill to the proper level. components be reinstalled in the same 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 5 assembly. Contact your dealer if you 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 refractometer to determine glycol level. (ELC). ELC consists of a mixture of not 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 en- Maximum recommended ELC con- gine manufacturer's owner’s man- centration is 60% ELC and 40% wa- 5 ual. It is the owner’s responsibil- ter by volume (a 60/40 coolant mix- ity to follow all requirements listed in ture). The minimum recommended the engine manufacturer's owner’s concentration is 40%. manual.
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/Water ratio: 10% 15% 20% 25% 30% 35% 40% 45% 50% 55% 60% 65% 70% 75% 80% 85% 90% Freeze point °F (°C) +25 +20 +15 +10 +5 -5 -12 -23 -34 -50 -65 -75 -84 -70 -55 -43 -30 (-4) (-7) (-9) (-12) (-15) (-21) (-24) (-31) (-37) (-46) (-54) (-59) (-64) (-57) (-48) (-42) (-34) Items in bold are the recommended levels of concentration. ELC Condition (Contamination and representative for recommended ELC Inhibitor Concentration) test kits, test strips, and laboratory sample procedures. Perform a visual inspection of the ELC. It should have no cloudiness ELC Extender or floating debris. Determine the chemical inhibitor concentration level Add ELC extender if necessary at the by using an ELC-specific test kit or maintenance interval under “Cooling”. test strips. Inhibitor concentration level determines corrosion protection. If you Coolant Filter 5 are concerned about possible coolant quality, contamination, or mechanical If your vehicle came with a problems, submit a coolant sample for non-chemical filter (“blank filter”), analysis. Improper maintenance may replace it only with a blank filter at the cause coolant degradation and could interval specified in the Preventive result in damage to the cooling system Maintenance Schedule on page 5-12. and engine components. Consult Never use filters that contain SCAs in your dealer or the ELC manufacturer’s an ELC-filled system.
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Topping Off NOTE WARNING! If frequent topping off is necessary Removing the fill cap on a hot en- and there are no visible signs of gine can cause scalding coolant coolant leaks when the engine is to spray out and burn you badly. cold, check for leaks with the engine If the engine has been in opera- operating at normal temperature. tion within the previous 30 minutes, be very careful in removing the fill Top off the cooling system when cap. Protect face, hands, and arms coolant does not rise to the level Surge Tank against escaping fluid and steam by indicated as ‘MIN’ on the surge tank. covering the cap with a large, thick The surge tank is translucent which rag. Do not try to remove it until the allows the coolant level to be seen. NOTE surge tank cools down or if you see Add coolant through the surge tank fill Do not use the pressure cap to fill the any steam or coolant escaping. In cap. Do not remove the pressure cap surge tank with fluid. any situation, remove the cap very to fill the cooling system. 5 slowly and carefully. Be ready to Proper Coolant Level back off if any steam or coolant be- gins to escape. NOTE Do not overfill a cooling system. Ex- cess coolant may result in overflow, loss of antifreeze, and reduced cor- rosion protection.
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rate until the surge tank is full (to • The minimum fluid level is 9. Fill the surge tank as necessary the base of the fill neck). It may be determined by the line on the to raise the coolant level to ½ in. necessary to pause for 1 minute surge tank indicated by the letters above the “MIN” level. and then re-fill if the fluid level “MIN”. This indicator is located dropped. 10. Operate the engine at high idle below the fill cap. for another 10 minutes and then 5. Close any drain valves that were fill the surge tank again to ½in. • The cooling system will need fluid opened in Step 1. if the surge tank level does not rise above the “MIN” level. 6. Start the engine and idle at low to the “MIN” line regardless if the 11. Replace the surge tank fill cap. system is hot or cold. RPM. Refilling Your Radiator 7. During low rpm idle, air will purge Check the coolant level after each trip. from the cooling system which will Add coolant as necessary. You may 1. If your cooling system is built with lower the coolant level in the surge find your coolant level is not up tothe drain valves in the upper engine tank. Continue to fill the surge correct level soon after you have filled coolant pipe, open them before tank until the coolant level remains the radiator. This may be because all filling the surge tank. approximately ½ in. above the the trapped air in the system has not 2. Close any open coolant drains in "MIN" line. This may take up to 2 yet been purged. It takes a little time 5 the system. minutes, depending on the outside for all of the air to leave the system temperature. after you fill your radiator. 3. Remove the surge tank fill cap (do not remove the surge tank 8. Operate the engine throttle pressure cap). until the operating temperature stabilizes (when the thermostat 4. Fill the system with premixed opens). coolant through the surge tank fill cap. Pour coolant at a steady flow
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Engine (Block) Heater Use a solution of half ethylene glycol WARNING! antifreeze and half water for best heater performance. Do not use Do not use the heater if there are more than 65 percent concentration of any signs of problems. Engine block antifreeze, as a shortened heater life heaters can cause fires resulting in will result. death, personal injury, equipment or property damage if not properly After servicing the cooling system, maintained and operated. Regu- operate the vehicle for a day or two larly inspect the engine block heater before using the heater. Trapped wiring and connector for damaged air inside the engine needs time to or frayed wires. Contact your au- escape. thorized dealer or the manufacturer of the heater if you are in need of repairs or information. Failure to comply may result in death, per- 5 sonal injury, equipment or property damage.
CAUTION Always unplug the block heater be- fore starting your engine. Damage to the cooling system could occur if not turned OFF (unplugged).
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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 drops below 12.3V for 3 minutes and on the central electrical panel cover the vehicles electrical system or the key switch is in the ACC or OFF label. power distribution box. All electrical position. During the last 2 minutes the 5 repairs should be performed by an LVD will emit a slow audible beep. 30 authorized dealer. Improper repair seconds before disconnecting loads or modifications will void your war- the alarm will change to a fast beep. ranty and/or cause serious damage The battery voltage must come back to your vehicle. up above a certain voltage before the LVD will reset.
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Light Bulbs Headlight Replacement WARNING! Do not use the Spare Battery A and WARNING! B circuits or other circuits that are Optional HID headlights have high controlled by the LVD to power elec- voltage circuits and should only be tronic engine controls, ABS circuits, serviced by a trained technician. At- or safety/work-related lighting. Be- tempting to service the HID ballast fore adding any device to the vehi- without proper training may result in cle's electrical system, consult your severe electrical shock which could nearest authorized dealer or read lead to death or personal injury. Turn the bulb lock ring the contents of TMC RP-136. Fail- counterclockwise and remove ure to do so may cause equipment the bulb. Do not allow the glass of damage or lead to personal injury. the new headlamp bulb to come into contact with anything. The glass could NOTE become contaminated and cause bulb failure. Reassemble in reverse order. 5 The determination of what cir- cuits/loads that were connected to the LVD was based upon the rec- ommendation from Technology and Maintenance Council (TMC) of the American Trucking Association. To review the recommended practice, see TMC RP-136.
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Headlight Aiming Bulb Specifications Fuses, Circuit Breakers and Relays The headlights were properly Bulb Location Type of Bulb aimed at the factory to meet safety Low Beam H11-LL (SAE), Fuses, circuit breakers, and relays are specifications. If the headlights need to Halogen H7 (ECE) (long life version not located in the Power Distribution Box be adjusted, please have an authorized required) to the left of the steering column behind dealership aim the headlights. Low Beam HID D1-S the clutch pedal. Additional fuses are located in the engine compartment High Beam HB3A – LL (long Halogen life version not (driver's side bulkhead) and also required) in the sleeper under bunk storage Daytime Running 4157K (SAE), compartment. Lamp/ Position 3157K (ECE) Lamp/Turn Signal/ Side Marker Rear tail light/ Turn Not applicable – Signal LED lighting Interior map/dome/ Not applicable – indirect light LED lighting 5
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5
In-Cab Fuse Label
5-90 Y53-6077-1B1 (03/17) ELECTRICAL
Sleeper Fuse Label 5
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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 fuse or relay blows in the Driving and higher than 30 amps. Follow the Operating Instructions manual. circuit protection size/type recom- mended by the component manu- facturer. Installing a fuse or circuit breaker greater than designated may damage the electrical system which could lead to equipment dam- age and/or personal injury.
CAUTION Follow all manufacturers' circuit pro- 5 tection recommendations for the Fuse Puller components and wires being added. Failure to comply may result in equipment damage.
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Batteries NOTE WARNING! If you are unfamiliar with proper Never install a circuit breaker in a Battery Access electrical repair practices and pro- circuit that is designated as “fuse- cedures, see your authorized dealer only” circuit(s). Fuse-only circuits The vehicle is originally equipped with for assistance. are marked with an * on the reverse three or four batteries. Replacement side of the Power Distribution Box batteries must meet the following specifications: maintenance-free, NOTE cover. Using a circuit breaker in those fuse-only circuits may cause group 31 size, threaded stud, 12V/ 650 Easy addition of circuits is provided the circuit to overheat when a short cold cranking ampere (CCA), and 160 by plug-in connectors that have a exists which could lead to equipment minutes of reserve capacity. ground and a power wire. damage and/or personal 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 plates. 2. Remove battery cover for access.
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In-Cab Battery Box WARNING! WARNING! Your vehicle may be equipped Replace only with AGM (Group 31) Electrical damage or battery ex- with Absorbed Glass Mat (AGM) batteries. Use of other batteries plosion can occur when improperly batteries located in the cab under the could result in acid leaks causing charging batteries. Refer to the passenger’s seat. The glass mat in personal injury in the event of a ve- Battery Charging on page 5-97 for AGM batteries are designed to absorb hicle accident. Failure to comply appropriate charging instructions. the battery acid inside the battery that may result in death, personal injury, Failure to comply may result in can leak or spill out in conventional equipment or property damage. death, personal injury, equipment or batteries. This design feature allows property damage. 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 passenger side seat base to the floor pan without first checking the 5 battery box assembly. location of the cables, harnesses or any other component that might be 2. Remove the seat and seat base damaged. Damaging any compo- as one unit to gain access to the nent could result in electrical shock batteries. which could cause personal injury and/or loss of a critical truck sys- tem. Failure to comply may result in death, personal injury, equipment or property damage.
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Removing and Installing Batteries: WARNING! CAUTION 1. Be sure all switches on the vehicle Batteries release gases that are Properly secure battery tie downs are turned OFF. flammable. Batteries are equipped and battery box cover when rein- with vent tubes and flash arrestors stalling batteries after service. Do 2. Wait 2 minutes after turning which vent battery gases out of the not over tighten. Over tightening ignition off then disconnect cab. Ensure all vent tubes, flash ar- can crack the battery case which can negative ground cable first. restors and grommets are properly lead to equipment 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 freezing. If your vehicle is equipped Always dispose of automotive bat- equipment damage. Failure to com- with battery disconnect switches, teries in a safe and responsible man- ply may result in death, personal do NOT disconnect battery power ner. Contact your authorized dealer injury, equipment or property dam- within two minutes of switching the for disposal standards. Call your lo- 5 age. ignition key off. Failure to comply cal authorized recycling center for may result in vehicle or property information on recycling automotive damage. CAUTION batteries. Do not store other items in this bat- tery box. Failure to comply could re- NOTE sult in damage to the truck and/or Make sure to reconnect the ground batteries. (negative) cable last.
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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 1. Place batteries in vehicle and come loose and cause other mo- tighten bolt of holding plate. 2. Install 2 bolts in step strut. Torque torists to have an injury accident. It to 24-32 lb-ft (33-43 Nm). is important that fairings be installed 2. Reconnect positive cable. 3. Install fairing and install 4 bolts. properly. Failure to comply may re- 3. Reconnect ground (negative) Torque to 6-7 lb-ft (8-9 Nm). sult in death, personal injury, equip- ground cable. ment or property damage. 4. Install steps by installing 2 bolts in WARNING! each step. Torque to 24-32 lb-ft (33-43 Nm). WARNING! Battery replacement may alter or Before attempting any work on the disturb battery cable routing. Check WARNING! batteries or electrical system, re- to insure battery cables are free move all jewelry. If metal jewelry or from any point of chaffing. Failure Always reinstall the steps before en- tering the cab. Without the steps you other metal comes in contact with to comply may result in death, per- electrical circuits, a short circuit may 5 sonal injury, equipment or property could slip and fall, resulting in possi- ble injury to yourself. occur causing you to be injured, as damage. well as electrical system failure and damage.
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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 poi- of the battery, warped plates, and sonous and explosive gases, and evaporation of electrolyte. supply levels of electric current high Undercharge: the voltage regulator enough to cause burns. A spark is malfunctioning, the drive belt is or flame near a battery on charge slipping, or your vehicle has undergone may cause it to explode with great long periods of standing idle or short force. Never remove or tamper with distance driving. These conditions the battery caps. Failure to comply 5 result in battery plates becoming may result in death, personal injury, covered with a hard coating. equipment or property 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
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Slow Battery Charging Electrical and Alternator WARNING! Precautions NOTE Always make sure the battery Follow the instructions that come charger is OFF before connecting Take the following precautions to with your battery charger. or disconnecting the cable clamps. avoid burning out alternator diodes: To reduce the danger of explosions • Do not start the engine • It is not necessary to remove the and resulting death or personal in- with alternator disconnected battery from the compartment. jury, do not connect or disconnect (connections removed) from the charger cables while the charger is circuit. WARNING! operating. Charger cables must be connected • Before welding, disconnect all 1. Disconnect the battery cables. positive to positive (+ to +) and neg- electronic connections to the ative to negative (- to -). If con- 2. Connect charger cables. vehicle batteries. nected improperly, batteries could 3. Start charging the battery at a rate • Remove battery power cable and explode. Failure to comply may re- not over 6 amperes. Normally, a insulate it from the vehicle. sult in death, personal injury, equip- battery should be charged at no ment or property damage. • Do not run the engine with the 5 more than 10 percent of its rated batteries disconnected. capacity. 4. After charging, turn OFF charger • Do not disconnect the battery and disconnect charger cables. 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 the battery cables. may become inoperative 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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5-100 Y53-6077-1B1 (03/17) ENGINE ENGINE WARNING! NOTE Engine Maintenance Never idle your vehicle for prolonged Keep the engine exhaust system periods of time if you sense that ex- and the vehicles cab ventilation WARNING! haust fumes are entering the cab. system properly maintained. It is Investigate the cause of the fumes recommended that the vehicles ex- Exhaust fumes from the engine con- and correct it as soon as possible. haust system and cab be inspected: tain carbon monoxide, a colorless If the vehicle must be driven under and odor less gas. Do not breathe • By a competent technician every these conditions, drive only with the the engine exhaust gas. A poorly 15,000 miles, windows open. Failure to repair the maintained, damaged or corroded source of the exhaust fumes may re- • Whenever a change is noticed in exhaust system can allow carbon sult in death, personal injury, equip- the sound of the exhaust system, monoxide to enter the cab. Entry of ment or property damage. carbon monoxide into the cab is also • Whenever the exhaust system, possible from other vehicles nearby. underbody or cab is damaged. Failure to properly maintain your ve- hicle could cause carbon monoxide to enter the cab and cause death or 5 personal injury.
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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 Manual supplied with your vehicle for for all the oil to run into the sump 2. Make sure that the vehicle is information about draining and refilling when the engine is ‘warm.’ If the horizontal, both lengthwise and engine oil, engine crank case capacity, level is checked immediately after crosswise. Check this carefully engine oil type, and changing oil filters, switching off the engine, the dipstick on a vehicle with air suspension. etc. will show a low oil 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. 3. Twist the dipstick handle to unlock You could be burned. Let the en- it, then pull the dipstick out of the gine oil cool down before changing holder. it. Failure to comply may result in death, personal injury, equipment or 4. Wipe the dipstick clean with a 5 property 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.
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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
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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 Miniature 3600L 1.1-1.7 10-15 (for hoses less than 9/16 diameter) Exhaust Clamps Breeze V-Band 54 480
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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 oper- 1. Route the new belt around the ator's manual for further information 5 pulleys, and then rotate the on 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
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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 en- coming from the fan hub. Bearings Do not work on the fan with the en- gine running. The engine fan can that have lost lubricant, and are gine running. The engine fan can engage at any time without warn- dry, will typically emit a squeal engage at any time without warning. ing. Before turning on the ignition, or a growl when the engine is at Before turning on the ignition be sure be sure that no one is near the fan. operating temperature and the that no one is near the fan. Failure Failure to comply may result in death fan clutch is engaged. If noise is to comply may result in death or per- or personal injury. detected, have the fan bearings sonal injury. inspected by an authorized Your truck may be equipped with an dealership. Fan Blade Clearance: Around the fan On/Off or Viscous Fan Drive. Follow 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). 5 • Check the fan bearings for fan 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.
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Air Intake System Turbocharger CAUTION Engine heat, vibration, and age When servicing the air intake and Do not use air intake pipes and con- combine to loosen air intake exhaust systems on a turbocharged nections as a step or to pull your- connections and cause cracks in engine, check the items listed below. self up. This could loosen the con- the tubing and elbows. Leaks in the nections and open the system to un- intake system allow abrasive dust to WARNING! filtered air which could damage the enter the engine and quickly cause engine. Do not operate engine with tur- expensive damage. During your daily bocharger intake piping discon- walk-around inspection, carefully nected. A suction is created when check all tubing, elbows, clamps, the engine is running. This suction supports and fasteners for condition could draw your hand or anything and tightness. else near it into the impeller fan. You • Check the Charge-Air-Cooler for could be injured. Always keep the air leaks annually. The air leaks intake piping connected when you can be caused by cracked tubes will be running the engine. or header. For service see your 5 authorized dealer. Lubricating System: Check the oil lines, housing, and connections. Look for leaks, damage, or deterioration. Leaks could mean you have damaged oil lines or oil seals.
Manifold: With the engine operating, check for leaking manifold or flange gaskets.
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Air Cleaners must be pivoted to provide access for High Frequency Vibration: Vibration servicing the filter element. may indicate turbo rotor imbalance. The following service information is Have your dealer investigate this basic to all air cleaner makes and immediately. If you detect any models. deficiencies, take the vehicle toan authorized dealer for servicing. Delay CAUTION could lead to severe and expensive Failure to replace air filter at proper damage to your vehicle. intervals may result in passage of dirt/debris into the engine or the “dusting” of an engine resulting in significant engine damage. Replacing the Engine Air Intake Service the air cleaner filter elements Filter as specified in the Preventive Maintenance Schedule on page 5-12. 1. Loosen (do not remove) upper 5 This vehicle is equipped with an air inlet 5/16 in. mounting hardware. restriction indicator. Service the filter 2. Remove acorn nut and flat washer, elements when the air inlet restriction then pivot upper stabilizer rod indicator locks in the extreme Up away from cab. position. Paper elements require care and proper handling because they are 3. Loosen the two rearmost M6 hex critical to engine service life. If your socket head screws on the lower vehicle has an external air cleaner clamp. and cab-mounted mirrors, the mirror
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remove and replace the air cleaner ServiSignal™ Mini Indicator NOTE filter element. The two forward screws secure the The ServiSignal™ Mini Indicator is cover to the base. The two rearmost CAUTION installed on the air cleaner or air induction piping so it has access to screws provide the clamping force on To prevent possible engine damage, clean filtered air. As the filter plugs the main support tube. torque the four hex nuts attaching and restriction increases, a red flag the air cleaner cover assembly to the appears in the window. When it body assembly to 8 Lb. ft. (10 N.m) reaches the red zone, the air filter after installing the new air cleaner fil- should be replaced. The indicator can ter element. be reset by pressing the button at the 5. After installation of the new filter end of the indicator. element, rotate the main support tube forward and reinstall the upper stabilizer rod to its mounting bracket. 6. In any sequence, tighten the upper 5 fasteners to a torque of 13 - 17 Lb. ft. (17 - 23 N.m).
1. Steps 1 and 6 7. Tighten the two rearmost screws 2. Steps 2, 5, and 6 in the lower clamp to a torque of 4 3. Steps 3 – 7 - 4.5 Lb. ft. (5 - 6 N.m). 4. Rotate the main support tube rearward to provide clearance to
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Exhaust System Engine Mounting CAUTION The exhaust system is part of the Periodic Inspection: Inspect engine Do not re-torque or reuse existing noise and emission control system. mounts every 60,000 miles (96,560 flange head bolts. These bolts are Periodically check the exhaust for km). Check for the following: factory set to the specified torque. wear, exhaust leaks, and loose or • Inspect both mount and leg If bolts are loose or damaged, they missing parts. For details see Noise must be replaced with the new bolts. Emission Control on page 5-123. fasteners. Check for loose or broken bolts. Replace as Failure to comply may result in equipment or property damage. Please refer to the Engine Operator's necessary. Manual for more details on how to • Check mount and leg for fractures, maintain the emission's components in breaks or deformation. Replace the exhaust system. as necessary. Please refer to the aftertreatment • Check for complete insertion manual for emissions related of motor mount. Replace as components such as the DEF system necessary. 5 and DPF. • New leg to mount flange head bolts should be torqued to 210-230 Lb-Ft (284-311 Nm).
5-110 Y53-6077-1B1 (03/17) 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 ig- line connection. They are optional on nition source (such as a cigarette) the primary fuel tank. could cause an explosion resulting in death or personal injury. Use only the recommended diesel fuel.
CAUTION If anyone ever pours gasoline into your fuel tank, drain the entire sys- tem. Otherwise, the pump and en- 5 gine will be damaged. Don’t try to dilute the gasoline by adding diesel fuel (See Warning above).
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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 recom- part of your truck or any component WARNING! mended. The high heat of welding attached to your truck, observe the nullifies the special heat treatment Do not cut, splice or weld frame following precautions before welding: rails or drill through the top or bot- of the rails, greatly reducing the ten- tom flanges of the rails. These sile strength of the frame rail. If a • Disconnect all electronic devices. operations could affect frame rail frame member becomes cracked It is not possible to list all of the strength leading to a failure resulting from overloading, fatigue, surface electronics that could be affected, in an accident. Rail failures re- damage or a collision, the only but a few examples include the sulting from such modifications are permanent repair is to replace the following: alternator, engine not warrantable. Failure to comply damaged frame member with a new Electronic Control Unit (ECU), may result in death, personal injury, part. transmission ECU, ABS ECU, equipment or property damage. navigation devices, diagnostic In an emergency, a temporary repair devices, and monitoring devices. 5 may be performed. Observe the following precautions to protect • Disconnect battery cables and electronic systems during welding insulate them from the vehicle. operations. Emergency welding • Do not use the ECU or engine procedures are further explained in the ground stud for the ground of the maintenance manuals. Please refer to welding probe. the ordering information on the back 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 Tighten all frame fasteners with a FAS- TORQUE * literature for any special TENER torque wrench. Torque specifications Nm instructions. SIZE Lb-Ft apply to the following fasteners with 5/16 22-30 16-22 • Remove fifth wheel from vehicle. lightly lubricated threads. 3/8 41-54 30-40 Refer to the Shop Manual, “Fifth Wheel Removal.” NOTE 7/16 75-88 55-65 Whenever possible, torque all frame 1/2 109-122 80-90 • Steam clean the fifth wheel and fasteners on the nut end, not the bolt 9/16 156-190 115-140 mounting brackets. head. 5/8 224-265 165-195 • Check all moving parts for 3/4 394-462 290-340 excessive wear or damage. 7/8 517-626 380-460 Replace all worn or broken parts. 1 952-1,129 700-830 • Complete two-month service 1-1/8 1,346- 990-1,170 5 procedure. 1,591 1-1/4 1,877- 1,380- • Install fifth wheel. Refer to 2,217 1,630 the Shop Manual, “Fifth Wheel METRIC WITH NYLON INSERT NUTS Installation.” M5 8-12 6-9 M6 9-15 7-11 M8 23-31 17-23 M10 33-43 24-32
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FAS- TORQUE * Sliding Fifth Wheels TENER Nm Lb-Ft SIZE Lubricate bearing surface of support M12 75-101 55-75 bracket through the grease fittings on M16 163-217 120-160 the side of the fifth wheel plate. Use a M20 352-460 260-340 water resistant lithium-base grease. * ESNA Style Lock Nut, with nylon insert. Lubricate nylon insert nut lightly with SAE NOTE 20/30 oil. The plate must be lifted up slightly to relieve the weight of the bracket while applying grease.
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(03/17) Y53-6077-1B1 5-115 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.
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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 Do not replace U-bolts and nuts with need to have their U-bolts checked and to not be properly secured to the common U-bolts or standard nuts. tightened regularly. Be sure someone suspension, which could cause loss These parts are critical to vehicle with the proper training and the right of vehicle control and an accident. safety. If the wrong U-bolts or nuts tools checks and tightens the U-bolts Loose U-bolts can also cause un- are used, the axle could loosen or on your vehicle. even tire wear and poor alignment. separate from the vehicle and cause Failure to comply may result in New springs can settle in after service, a serious accident. Use only U-bolts death, personal injury, equipment or relieving the tension on the U-bolts. and nuts of SAE Grade 8 specifi- property damage. Loose U-bolts can cause leaf spring cation or better. Failure to comply breakage, axle misalignment, hard may result in death, personal injury, steering and abnormal tire wear. U-bolts are difficult to tighten unless equipment or property damage. you have the right equipment. If you 5 All vehicles should have suspension cannot tighten them correctly yourself, Front Spring Suspension U-Bolts, Grade 8 U-bolts tightened after the first 500 be sure to have them checked and tightened regularly by an authorized U-BOLT TORQUE miles (800 km) of operation. Re-torque SIZE Nm Lb-Ft the front spring pinch bolts and shackle mechanic. DIAME- pinch bolts. TER Tighten U-bolt nuts to the specified (Inch Di- torque value with the vehicle loaded to mensions) its normal gross weight. The following 3/4 333-408 245-300 torque values apply to U-bolts and 7/8 598-734 440-540 nuts with clean threads lubricated with
5-118 Y53-6077-1B1 (03/17) FRONT AXLE AND SUSPENSION
U-BOLT TORQUE SIZE Nm Lb-Ft DIAME- TER (Inch Di- mensions) 1 925-1,060 680-780 1-1/8 1,470- 1,080- 1,660 1,220 1-1/4 1,890- 1,390- 2,120 1,560 1-1/2 3,130- 2,300- 3,860 2,840
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(03/17) Y53-6077-1B1 5-119 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 weld, solder, steam clean, or use a provides comfort for those in the cab • Keep the inlet grille at the base of blow torch near any part of the air through accurate control of the cab the windshield clear of snow, ice, conditioning system. Failure to com- environment in all weather conditions. leaves and other obstructions at ply may result in death, personal in- Regular attention to the items below all times. will help you keep the heater-air jury, 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 joints properly maintained. It is • Check the drain tube of the fresh hazardous to your health. Do not 5 recommended that the vehicle's air inlet for trapped water before expose yourself to leaking refriger- exhaust system and cab be serviced assuming that there is a leak in the ant for prolonged periods near ex- as follows: heating system. cessive heat, open flames, or with- out proper ventilation. Failure to do • Inspected by a competent so may result in death or personal in- technician every 15,000 miles jury. • Whenever a change is noticed in the sound of the exhaust system If a refrigerant leak develops in the presence of excessive heat or an open flame, hazardous gases may be
5-120 Y53-6077-1B1 (03/17) HEATER AND AIR CONDITIONER generated. If you become aware of a Heater Air Conditioner refrigerant leak on your vehicle have your system serviced immediately and • Check all heater controls for WARNING! full-range operation. observe the following precautions: The air conditioning system is under • Check hoses, connections, and pressure. If not handled properly Stay away from the hot engine until the heater core for condition and during servicing, it could explode. exhaust manifold has cooled. leaks. Any servicing that requires depres- Do not permit any open flame in the surizing and recharging the air con- area. Even a match or a cigarette CAUTION ditioning system must be conducted lighter may generate a hazardous During extreme cold weather, do not by a qualified technician with the quantity of poisonous gas. blow hot defroster air onto cold wind- right facilities to do the job. Failure shields. This could crack the glass. to comply may result in death, per- Do not smoke in the area. Inhaling Turn the air direction lever to Defrost sonal injury, equipment or property gaseous refrigerant through a cigarette and adjust the fan speed accordingly damage. may cause violent illness. while the engine warms. If the en- gine is already warm, move the tem- • Listen to the compressor and drive perature selector to Cool, then grad- clutch for noise and vibration. 5 ually increase the temperature when If you find problems, have the you see that the windshield is start- system checked thoroughly. A ing to warm-up. malfunctioning clutch usually indicates trouble elsewhere in the system. • Check the evaporator core, filter, and condenser core for debris restricting air flow. Clean if
(03/17) Y53-6077-1B1 5-121 HEATER AND AIR CONDITIONER
necessary. Small particles may to worsen. Have a qualified be removed with compressed technician correct the problem. air blown through the core in the opposite direction of normal air NOTE flow. A leaking evaporator or condenser core cannot be repaired; it must be WARNING! replaced. Wear eye protection any time you blow compressed air. Small parti- Have the air conditioning system fully cles blown by compressed air could serviced annually by your authorized injure your eyes. dealer. Qualified service technicians will have to evacuate and recharge the • Check the engine belt for condition system. and proper tension. • Check all hoses for kinks, deterioration, chafing, and leaks. 5 Adjust kinked or chafing hoses to eliminate restrictions and prevent further wear. • Check all components and connections for refrigerant leaks. If you discover a leak, do not try to tighten a connection. Tightening a connection may cause a leak
5-122 Y53-6077-1B1 (03/17) NOISE EMISSION CONTROL
NOISE 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 This section describes responsibilities (1) The removal or rendering for the vehicle noise emissions. For inoperative by any person other than • Removing or rendering inoperative information about exhaust emissions, for purposes of maintenance, repair, or the fan clutch. please refer to the aftertreatement replacement, of any device or element system operators manual. of design incorporated into any new • Removing the fan shroud. vehicle for the purpose of noise control Engine There are specific components on prior to its sale or delivery to the the vehicle that are designed to meet ultimate purchaser or while it is in use, • Removing or rendering engine certain Environmental Protection or (2) the use of the vehicle after such speed governor inoperative so as Agency (EPA) emissions and noise device or element of design has been to allow engine speed to exceed regulations. To maintain conformance removed or rendered inoperative by manufacturer's specifications. with the regulations, these components any person. 5 need to be functional and properly • Modifying ECU parameters. maintained. 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 5-129. 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.
5-124 Y53-6077-1B1 (03/17) NOISE 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 5-60. 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.
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5-126 Y53-6077-1B1 (03/17) NOISE EMISSION CONTROL
Diesel Particulate Filters (DPF) Engine Fan and Shroud Hood Insulation Blanket
• Check diesel particulate filter WARNING! • Check all fasteners for condition (DPF), clamps, and mounting and security. Repair or replace brackets. Tighten if necessary. Do not work on the fan with the en- any broken or defective fasteners. Inspect diesel particulate filter gine running. The engine fan can (DPF) for signs of rust or corrosion. engage at any time without warning. • Check for chafing or tears. Patch Anyone near the fan when it turns on it if necessary. Find the cause of • Check internal baffling. You can could be injured. Before turning on the damage. If any component do this by listening for rattling the ignition, be sure that no one is or accessory is causing wear or sounds while tapping on the diesel near the fan. damage and cannot be relocated, particulate filter (DPF) with a put reinforcing pads on the blanket rubber mallet or revving the engine • Check all fasteners for tightness. at the site of wear. up and down through its normal Check for stress cracks in the operating range. shroud. Make sure the shroud is adjusted so that it does not touch the fan blades. • Check to verify that the fan is 5 disengaged (not turning) with 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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Inner Fender Shields and Cab Skirts Noise Control System - Maintenance Log • Check all fasteners that hold the fender shields in place. To ensure your vehicles noise control • Check fender shields for tire requirements are maintained, record marks, worn spots, or damage maintenance checks. Use the from objects thrown from tire following log sheet and retain copies treads. of documents regarding maintenance services performed and parts replaced • Check cab skirts, sills, and on the vehicle. brackets for overall condition and repair them as necessary. Damaged rubber fender shields or cab skirting cannot be repaired. You will need to replace it.
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5-128 Y53-6077-1B1 (03/17) NOISE EMISSION CONTROL
Noise Control System - Maintenance Log
Recom- Repair Repair mended Date & R.O. Work Date & R.O. Work Component Facility & Facility & Interval No. No. Location Performed Location Performed (Miles) Exhaust 25,000 System Routing Integrity Shutters 25,000 Shrouds Hood 10,000 Insulation Blanket Engine 10,000 Mounted Hose Insulators 5 Fasteners Inner Fender 50,000 Shields Cab Skirts 50,000 Fasteners Air Intake 5,000 System Integrity Element
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Recom- Repair Repair mended Date & R.O. Work Date & R.O. Work Component Facility & Facility & Interval No. No. Location Performed Location Performed (Miles) Clutch Type 10,000 Fan Drive
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5-130 Y53-6077-1B1 (03/17) REAR AXLE AND SUSPENSION REAR AXLE AND SUSPENSION WARNING! WARNING! Failure to maintain the specified Do not operate the vehicle if the General Maintenance torque values or to replace worn U-bolts are not properly tightened. parts can cause component system Loose U-bolts will cause the axle WARNING! failure, possibly resulting in an ac- to not be properly secured to the cident. Improperly tightened (loose) suspension, which could cause loss Do not work on the vehicle without suspension U-bolts can lead to un- of vehicle control and an accident. the parking brake set and wheels safe vehicle conditions, including: Loose U-bolts can also cause un- blocked securely. If the vehicle is hard steering, axle misalignment, even tire wear and poor alignment. not secured to prevent uncontrolled spring breakage or abnormal tire Failure to comply may result in vehicle movement, it could roll and wear. See Front Spring Suspension death, personal injury, equipment or may result in death, personal injury, U-bolts on page 5-118 for proper property damage. equipment or property damage. torque specifications. Failure to comply may result in death, per- CAUTION Your vehicle's suspension, by sonal injury, equipment or property design, requires a minimal amount of damage. Do not spray the suspension with 5 maintenance. However, suspensions chemical products or mineral oil; it in over-the-road operations require can cause damage to the bushings. periodic inspection to ensure trouble- free performance. NOTE Failure to follow these recommenda- tions could void warranty.
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Visual Inspection • Visually check for loose or missing Rear Suspension Fasteners fasteners, cracks in hanger, or For all vehicles, mandatory To maintain the performance of the axle connection brackets. maintenance procedures include air suspension, check fastener torque retightening of U-bolts and complete • Check that springs are centered in values after the first 2,000 miles (3,218 inspection. However, even with proper hangers and in good condition. km) of service and every 60,000 miles maintenance, many factors affect the (96,000 km) thereafter. service life of springs and suspension • Check for cracks, wear marks, components, such as: fatigue, vehicle splits, or other defects on the Torque recommendations apply to gross weight, type of load, road surface of the spring. fasteners supplied and installed by conditions, and vehicle speed. vehicle manufacture. The values listed • Replace defective parts. Because in the tables below, are for cadmium It is important that U-bolts remain tight. repaired springs cannot be plated or phosphate and oil fasteners Severe use of your vehicle can cause fully restored to their original only. 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 U-bolts are difficult to tighten unless tightened regularly. Be sure someone are detected. you have the right equipment. If you cannot tighten them correctly yourself, 5 with the proper training and the right • After replacement of any part or be sure to have them checked and tools checks and tightens the U-bolts discovery of loose components, tightened regularly by an authorized on your vehicle. check the torque of all fasteners. mechanic. • 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.
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U-Bolt Torque NOTE Rear Suspension U-Bolts, Grade 8 (lubricated*) NOTE Whenever possible, torque all fas- To ensure an accurate torque read- teners on the nut end, not the bolt U-BOLT TORQUE** ing, use properly maintained and head. SIZE DIAME- calibrated torque wrenches. Clean TER Nm Lb-Ft the nut and bolt. No dirt, grit, or rust Rear Suspension Fasteners (Metric and THREAD should be present. Standard) 3/4 333-408 245-300 SIZE/ TORQUE * 7/8 598-734 440-540 WARNING! TYPE Nm Lb-Ft 1 925-1,060 680-780 Do not operate the vehicle if the M16 nylon- 163-217 120-160 1-1/8 1,470- 1,080- U-bolts are not properly tightened. insert nuts 1,660 1,220 Loose U-bolts will cause the axle M20 nylon- 352-460 260-340 1-1/4 1,890- 1,390- to not be properly secured to the insert nuts 2,120 1,560 suspension, which could cause loss M20 all- 427-475 315-350 1-1/2 3,130- 2,300- of vehicle control and an accident. metal lock 3,860 2,840 nuts 5 Loose U-bolts can also cause un- *Chevron Zinc Lubricant or SAE 20/30 oil even tire wear and poor alignment. 1/2 in. nut 109-122 80-90 should be used on U-Bolt threads Failure to comply may result in 3/4 in. nut 394-462 290-340 **Torque requirements apply to manufacturer proprietary suspensions. All death, personal injury, equipment or 1-1/4 in. 1,877- 1,380- other suspensions must refer and adhere property damage. nut 2,217 1,630 to original manufacturer's shop manual. * Torque requirements apply to manufacturer proprietary suspensions. All • Load the vehicle to its normal other suspensions must refer and adhere to original manufacturer's shop manual. gross weight before tightening U-bolts. Loading the vehicle
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ensures proper adjustment of the Rear Axle Lubrication U-bolt and spring assembly. NOTE Check oil level with the vehicle parked In all cases, lubricant supplier as- WARNING! on level ground and the fluid warm. sumes full responsibility for the per- The level should be even with the Do not replace U-bolts and nuts with formance of their product, and for bottom of the filler hole. common U-bolts or standard nuts. product and patent liability. These parts are critical to vehicle safety. If the wrong U-bolts or nuts For recommended types and brands of are used, the axle could loosen or lubricants, contact your dealer. separate from the vehicle and cause a serious accident. Use only U-bolts and nuts of SAE Grade 8 specifi- cation or better. Failure to comply may result in death, personal injury, equipment or property damage. CAUTION 5 Do not mix lubricants of different grades; although, mixing different brands of the same grade lubricant (meeting MIL L2105C), is accept- able. Lubricants of different grades are not compatible and could dam- age the axle.
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Dana Spicer and Fabco Rear Axle Alignment All Vehicles with Dana Spicer No initial drain is required on Dana and Fabco Axles: See Preventive Continual road shock and load Spicer axles that are factory filled with Maintenance Schedule on page 5-12. stresses may force the rear axles an Dana Spicer-approved synthetic Contact your dealer for approved out of alignment. If you detect rapid lubricant. synthetic lubricant brands. tire wear on the rear axles, you may have misaligned axles. If you suspect • Petroleum-based lubricants must • Dana Spicer Axles with synthetic rapid tire wear, have your rear axle be drained within the first 5,000 lubrication and Out Runner Seals: alignment checked and adjusted by an miles (8,000 km) if converting to drain, flush, and refill at 500,000 authorized dealer. an approved synthetic lubricant. miles (804,000 km). In addition to pre-delivery inspections, Initial Change: See Preventive Axle Housing Breather Vent: suspension alignment should be Maintenance Schedule on page 5-12 • Check and clean the axle housing checked when any one of the following for standard rear axle service intervals. conditions exist: Change mineral-based lubricant in breather vent at each oil level other Dana Spicer and Fabco axle check. • Discovery of loose suspension assemblies (new or rebuilt) within the fasteners. (Loose, defined as any Meritor: 5 first 3,000 to 5,000 miles (4,800 to torque below the recommended 8,000 km). • See Meritor Lubrication torque value.) Maintenance Manual (MM1). • For petroleum-based axles, use • Discovery of elongated holes in a lubricants meeting MIL L2105C/D suspension component. grade specifications or approved synthetic lubrication. Do not use • Bushing replacement. oil additives. • Excessive or abnormal tire wear.
(03/17) Y53-6077-1B1 5-135 STEERING SYSTEM STEERING SYSTEM WARNING! • wheels out of alignment Power Steering Do not operate the vehicle if the • wheel bearings improperly steering system is not working prop- adjusted Oil (under low pressure) provides the erly. You could lose control of your power to operate the steering gear. It vehicle if the steering system is not If you cannot correct the problem, also serves to lubricate moving parts in good working condition, which check with an authorized dealer. and remove heat. A loss of steering could result in a serious accident. efficiency will occur if too much heat For driving safety, visually check Your vehicle is equipped with integral builds up in the system. the steering gear and components. power steering. The system includes Frequent checks are important for an engine-driven fluid pump, a fluid driving safety, especially after trav- reservoir, the steering gear, and eling over rough roads. Failure to connecting hoses. Because of the comply may result in death, per- hydraulic power assist, little effort is sonal injury, equipment or property required to turn the steering wheel. damage. When no input is applied through the steering wheel, the steering gear will 5 return to the neutral position. If, for If the steering feels unbalanced from any reason, the power assist system side-to-side while turning, check for goes out, steering the vehicle is still the following possible causes: possible, yet it will require much • unequal tire pressures greater effort. • vehicle overloaded or unevenly Visually check the following parts: distributed load • Crosstube: Is it straight?
5-136 Y53-6077-1B1 (03/17) STEERING SYSTEM
Fluid Level and Refill • Draglink tube clamp: Check for • Maximum/Minimum level is looseness or interference. Have the power steering fluid and indicated on the reservoir. These same levels are also indicated by • Ball joints and steering U-joints: filters changed at an authorized dealer. two lines on the dipstick in the Check for looseness. CAUTION reservoir. • Steering wheel for excessive When adding fluid, be sure to use • There are two ways to check free-play. Check the simplest fluid of the same type. While many whether the power steering fluid probable causes first: fluids have the same description and is at its proper level. Both checks a. unequal tire pressures intended purpose, they should not are with the engine NOT running. be mixed due to incompatible ad- b. loose cap nuts 1. If you check the fluid with the ditives. Mixing incompatible fluids engine and steering system c. bent crosstube may lead to equipment damage. COLD, the fluid level should be d. lack of lubrication. at/or above the Minimum indicator Check and completely change the • level and should generally not fluid level according to Preventive • If these checks do not reveal the exceed the middle point between Maintenance Schedule on page problem, or if you correct them Maximum and Minimum level 5 5-12. Use the following procedure: and still have a steering problem, indicators. take your truck to an authorized dealer for evaluation. NOTE 2. If you check the fluid with the engine and steering system Before removing reservoir cover, WARM, the fluid should NOT wipe outside of cover so that no dirt exceed the Maximum level can fall into the reservoir. indicator and should generally not drop below the middle point
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between the Maximum and Steering Shaft Minimum level indicators. WARNING! The following are common torque If this chassis is equipped with an Fluid Filter Replacement specifications for most steering shafts. electronic stability system (ESP) and • Torque on U-joint pinch bolt and any part of the steering system (e.g., nut (7/16 in) 74–81 Nm (55 to 60 linkage, steering driveline, column, lb-ft), lubricated. front-end alignment, etc) is repaired, removed, or disassembled in any • Torque on Pitman arm clamp bolt way, or if the steering angle sensor is and nut (3/4 in): 406–433 Nm (300 replaced, the steering angle sensor to 320 lb-ft), lubricated. must be recalibrated. Any repairs or adjustments to any part of the steer- • For off-highway vehicles, tighten ing system must be performed by an the U-bolts after the first day or two authorized dealer. Failure to comply of operation. Then check weekly. may result in death, personal injury, equipment or property damage. 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. 2. Bleed the system if necessary.
5-138 Y53-6077-1B1 (03/17) 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 The slip joints and universal joints of cause them to fail prematurely. The should be inspected every time the drive shaft should be lubricated driveshaft could separate from the a vehicle comes in for scheduled according to Preventive Maintenance vehicle and result in an accident. maintenance (Refer to Spicer Schedule on page 5-12. Make sure lubricant is purged at all Driveshaft service manual DSSM-0100 four ends of each U-joint and loosen 5 (3264-SPL) for detailed instructions.) Use a good quality lithium-soap-base caps if necessary. Also, regularly or equivalent extreme pressure (E.P.) inspect U-joints for excessive wear Use only Spicer Driveshaft approved grease: NLGI Grade 2. or movement, and repair or replace lubricants when greasing Spicer SPL as necessary. Failure to comply U-joints. Use only Spicer Driveshaft approved may result in death, personal injury, lubricants when greasing Spicer SPL equipment or property damage. U-joints.
(03/17) Y53-6077-1B1 5-139 TIRES AND WHEEL
TIRES AND WHEEL Regular, frequent inspection and the Checking Inflation Pressure right care will give you the assurance Tires of safe and reliable tire operation. Give your tires a visual test every day, Here are some tips on maintaining and check inflation with a gauge every WARNING! your tires. week: Do not repair damaged tires unless • When checking tire pressure, you are fully qualified and equipped inspect each tire for damage to to do so. Wheel and tire assem- sidewalls, cuts, cracks, uneven blies cannot be worked on without wear, rocks between duals, etc. If proper tools and equipment, such a tire appears underinflated, check as: safety cages or restraining de- for damage to the wheel assembly. vices. Have all tire repairs per- Don’t forget to check between dual formed by an expert. Stand away wheels. If you find wheel damage, from the tire assembly while the ex- have an expert tire service repair pert is working. Failure to do this it. may result in death or injury. 5 • Maximum tire pressure will be indicated on the sidewall of a tire. Your tires are a very important part of your vehicle’s whole braking system. • Check pressure only when the How fast you can stop depends in tires are cool. Warm or hot tires large measure on how much friction cause pressure buildup and will you get between the road and your give you an inaccurate reading. tires. In addition, keeping your tires in So never deflate a warm tire to the good condition is essential to the safe, specified pressure. efficient operation of your vehicle.
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Underinflated Tires WARNING! WARNING! Low pressure is a tire’s worst enemy. Do not operate a vehicle with under- Do not attempt to raise the vehicle to Underinflation allows tires to flex inflated tires. The extra heat caused remove or install a damaged tire and improperly, causing high temperatures by underinflation can cause sudden wheel assembly if you are not fully to build up. Heat causes early tire tire failure such as a tire fire or blow qualified and not equipped with the damage such as flex break, radial out, which can cause an accident re- proper tools and equipment. Do not cracks, and ply separation. Low sulting in death or personal injury. attempt to re-inflate a tire that has pressure may affect control of your Low pressure may affect control at been run flat. Obtain expert help. vehicle, especially at the front wheels. the front wheels, which could result A person can be seriously injured Most tire wear problems are caused in an accident involving death or per- or killed if using the wrong service by underinflation as the result of slow sonal injury. Keep your tires inflated methods. Truck tires and wheels leaks, so you’ll want to check tire to the manufacturer's recommended should be serviced only by trained pressure regularly. Lower tire pressure air pressure. personnel using proper equipment. does not provide better traction on ice Follow OSHA regulations per sec- or snow. tion 1910.177. 5 NOTE Follow all warnings and cautions contained within the tire and wheel manufacturer's literature.
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Overloaded Tires 1 3 Overloading your truck is as damaging Proper-Inflation: Over-Inflation: to your tires as underinflation. The the correct profile reduces the tread for full contact with contact area with following chart shows how neglect or the road. the road surface, deliberate abuse can affect the life of TREAD CONTACT concentrating all of your tires. WITH ROAD the vehicle weight TREAD on the center of the CONTACT WITH tread. This causes ROAD premature wear of the tire. 2
Under-Inflation: causes abnormal tire deflection, which builds up excessive heat, running the 5 TREAD risk of failure. It CONTACT WITH also causes irregular ROAD wear.
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 Normal 70% 50% 40% 30% 25% Tire Mileage
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Overinflated Tires Matching Tires WARNING! Too much air pressure reduces the tire Be sure to buy matched tires for Do not install regrooved or rein- tread contact area and results in rapid your vehicle, especially on the rear forcement-repaired tires on steering wear in the center of the tread. axles. Mismatched tires can cause axles. They could fail unexpectedly stress between axles and cause the and cause you to lose control of WARNING! temperature of your axle lubricant to your vehicle resulting in an accident get too hot. Matched tires will help Overinflated tires can cause acci- causing death or personal injury. dents. They wear more quickly than your driveline last longer and will give properly inflated tires and are more you better tire mileage. subject to punctures, cracks, and other damage. They could fail and WARNING! cause you to lose control of your ve- Do not mismatch tires, it can be dan- hicle resulting in an accident causing gerous. Never mix tires of different death or personal injury. Be sure all design such as steel belted radials tires are inflated correctly according and bias ply tires, etc. Mixing tire to the manufacturer's recommenda- types and sizes will adversely affect 5 tions. the road-holding ability of both types of tires and can lead to loss of vehi- cle control and causing death or per- sonal injury.
(03/17) Y53-6077-1B1 5-143 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 Drive Axles or Trailers: Replace tires in loss of vehicle control and an ac- at the factory as original equipment on drive axles or trailers when less than cident. Failure to comply may result are certified for Greenhouse Gas 2/32 in. of tread depth remains in any in death, personal injury, equipment and Fuel Efficiency regulations. Re- major groove. Check at three places or property damage. placement tires must be of equal or equally spaced around the tire. See lower rolling resistance level (TRRL the next illustration for recommended or C ). Consult with your tire sup- measuring points for tread depth. NOTE rr plier(s) for appropriate replacement To prolong your tires’ life and make tires. them safer, have their radial and lat- eral run-out checked at your dealer. 5 And of course, you should have your tires balanced anytime you change a tire.
Steer Tire Points (left), Drive Tire Points (right)
5-144 Y53-6077-1B1 (03/17) 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 Chains on the tires of only one tan- by the tire manufacture must be speed. The vehicle should not be dem axle can damage the driveline followed. operated at sustained speed in U-joints and the interaxle differen- excess of maximum rated speed. For warranty information, See Original tial. Your repairs could be costly and Failure to comply with these speed Equipment Tires on page 6-10. time-consuming. restrictions could cause sudden tire failure which can result in death, personal injury or property damage.
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(03/17) Y53-6077-1B1 5-145 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 Cap Nut Torque chart below. After Check hub/wheel mountings after this a wheel failure resulting in an acci- that, check wheel cap nuts at least initial period and retighten. dent. Failure to comply may result once a week. Contact an authorized in death, personal injury, equipment dealer for information on the proper or property 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 5 CONFIGURATION NUTS Nm Lb-Ft 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 15/16-12 1,020-1,220 750-900 Wheel; 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
5-146 Y53-6077-1B1 (03/17) TIRES AND WHEEL
WHEEL and NUT STUD SIZE TORQUE FOR INNER and OUTER CAP NUTS and RIM CLAMP CONFIGURATION NUTS Nm Lb-Ft 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 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 procedure will ensure that the wheel is not lubricate wheel nuts or studs. drawn evenly against the hub. Torque 5 Proper wheel torque can best be each nut to the torque value listed in obtained on level ground. Install lug Wheel Cap Nut Torque on page 5-146. nuts and finger-tighten in the numerical sequence as shown below. See Nut Tightening Sequence for Hub Piloted Disc Wheels on page 5-148 or Nut Tightening Sequence for Stud Piloted Disc Wheels on page 5-148. This
(03/17) Y53-6077-1B1 5-147 TIRES AND WHEEL
Wheel Replacement with WARNING! Disc Brake Option Tighten wheel cap nuts properly. If they are not tightened properly, WARNING! wheel nuts could eventually cause Use only the wheel brand, size and the wheel to become loose, to fail, Nut Tightening Sequence for Stud part number originally installed. Use and/or to come off while the vehicle Piloted Disc Wheels of a different wheel brand or size is moving, possibly causing loss of could cause valve stem to interfere control and may result in death, per- with a brake component which could sonal injury, equipment or property lead to loss of vehicle control. Fail- damage. ure to comply may result in death, personal injury, equipment or prop- erty damage.
Vehicles equipped with front disc brakes are fitted with wheels designed 5 Nut Tightening Sequence for Hub specifically for disc brake applications. Piloted Disc Wheels 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
5-148 Y53-6077-1B1 (03/17) TIRES AND WHEEL with the disc brake assembly. When installing any replacement wheel, WARNING! WARNING! always inspect the tires/wheels to If the hood falls, anyone under it Improperly mounting and demount- ensure there is adequate clearance could be injured. Always make sure ing tire and rim assemblies is dan- between other vehicle components. that the hood hold open device en- gerous. Failure to observe proper gages when the hood is in its open precautions could cause the tire-rim With the hood open, check for position any time anyone gets under assembly to burst explosively, caus- clearance between the wheel and disc the hood for any reason. ing death or personal injury. See brake assembly. Use a hydraulic jack the wheel manufacturer's literature to raise the front of the vehicle off • The hood could hurt someone for the proper way to mount and de- the ground to allow the wheel to spin that is in the way of its descent. mount your tires and rims. Follow freely. While rotating the wheel, check Before lowering the hood, be their precautions exactly. to ensure there is adequate clearance sure no objects or people are in between the wheel and disc brake the way. assembly. WARNING! Always support the vehicle with ap- 5 propriate safety stands if it is neces- sary to work underneath the vehicle. A jack is not adequate for this pur- pose.
(03/17) Y53-6077-1B1 5-149 TIRES AND WHEEL
Disc Wheels
WARNING! Use the correct components and tools when working on wheels. Grooves in the wheel disc or other damage to the disc can weaken the wheel and cause it to eventually come off. This could cause you to lose control of your vehicle, and may result in an accident. Failure to comply may result in death, per- sonal injury, equipment or property damage.
The end of the wheel wrench must 5 be smooth. Burrs on the end of the wrench can tear grooves in the disc. These grooves may lead to cracks in the disc, and can cause it to fail.
5-150 Y53-6077-1B1 (03/17) 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.
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(03/17) Y53-6077-1B1 5-151 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 be- Select from the appropriate lubricant for varying ambient (outside air) To check the transmission fluid level, cause of possible incompatibility, temperatures. park the vehicle on level ground. For which could decrease the effec- an automatic transmission the oil level tiveness of the lubrication or cause should be checked with the engine component failure. idling and the transmission fluid at operating temperature. Checking the Initial Change: drain and replace fluid of a manual transmission maybe according to Preventive Maintenance 5 done with the engine off. Schedule on page 5-12; for some transmissions this may not be required. 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.
5-152 Y53-6077-1B1 (03/17) 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
(03/17) Y53-6077-1B1 5-153 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.
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5-154 Y53-6077-1B1 (03/17) CLUTCH
CLUTCH When the clutch wears, the release Clutch Adjustment - Normal bearing gradually moves toward the Wear Introduction engine, decreasing free pedal and free travel. When all free pedal and free Clutch pedal free travel is usually 1 3/4 Free pedal is the distance the clutch travel are gone, the clutch requires in. to 2 in. (34 to 51 mm). This should pedal moves by applying only slight adjustment. be your guide for determining whether pressure. During free pedal the your truck needs clutch adjustment. release yoke in the transmission The clutch is adjusted by turning an Also, if it becomes increasingly difficult moves until its bearing pads contact adjustment ring that is built into the to shift into gears, or the truck creeps the release bearing. This movement of clutch. When the ring is turned, the with the clutch pedal depressed, your the release yoke is called free travel. release bearing moves back toward clutch needs adjustment. See the Thus, free pedal and free travel are the transmission, restoring free pedal Maintenance Manual for the proper directly related to each other. and clutch free travel. Under normal adjustment procedures. clutch wear this is the only adjustment As the clutch pedal is depressed needed. Do not attempt to change any Some vehicles have automatic clutch further, with harder pressure, the other component. adjustment. If yours doesn't have this release yoke moves the release feature, adjustment will have to be bearing away from the engine. This done by a trained certified mechanic. 5 causes the clutch plate to release from Have the adjustment done before the driven disks in the clutch. This is clutch pedal free travel is reduced to called release travel. And finally, on the minimum allowable 1/2 in. (13 9-, 10-, and 11-speed transmissions, mm). as the pedal is pushed to the last 1/2 to 1 inch of travel, the release bearing contacts and engages the clutch brake. This is called clutch brake squeeze.
(03/17) Y53-6077-1B1 5-155 CLUTCH
Clutch Linkage
This vehicle is equipped with a rod and lever mechanical clutch linkage. Lubricate each pivot point on the clutch linkage.
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5-156 Y53-6077-1B1 (03/17) INFORMATION
CONSUMER INFORMATION AND VEHICLE IDENTIFICATION Vehicle Identification ...... 6-3 General VIN Information ...... 6-3 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 VEHICLE EMISSIONS LIMITED EXPRESS WARRANTY Original Equipment Tires...... 6-10 Greenhouse Gas (GHG) Components Other Than Tires ...... 6-11 Your Warranty Rights and Obligations ...... 6-11 6 Manufacturer's Warranty Coverage ...... 6-12 Owner's Warranty Responsibilities ...... 6-12 Replacement Parts ...... 6-13
(03/17) Y53-6077-1B1 6-1 INFORMATION
PACCAR Responsibilities ...... 6-14 Warranty Limitations...... 6-14
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6-2 Y53-6077-1B1 (03/17) CONSUMER INFORMATION AND VEHICLE IDENTIFICATION
CONSUMER Example VIN: General VIN Information INFORMATION VIN Locations AND VEHICLE The full, 17-digit VIN is located on the IDENTIFICATION Weight Rating Data Label. The label is located on the driver's side door edge 1 Manufacturer Identifier or on the driver's side door frame. Vehicle Identification 2 Vehicle Attributes Each vehicle completed by Peterbilt 3 Reserved Space Motors Company uses a Vehicle 4 Model Year Identification Number (VIN) that 5 Assembly Plant contains the model year designation 6 Serial Number (Chassis Number) of your Peterbilt. The practice is in compliance with 49 CFR 565, Code of Model Year Federal Regulations. J = 2018 The Vehicle Identification Number is K = 2019 on the Peterbilt labels on the left hand L = 2020 door post. The VIN contains 17 digits. M = 2021 The 10th digit is the code for the model Glider Kit Identification year of your vehicle. The example VIN 6 below shows how this code works: 0 (zero) = Glider Kit Plant Code
D = Denton Factory
(03/17) Y53-6077-1B1 6-3 CONSUMER INFORMATION AND VEHICLE IDENTIFICATION
Chassis Number Certification Labels Components and Weights Label
The Chassis Number refers to the last Your vehicle information and The Components and Chassis Weight six characters of the VIN. This number specifications are documented on Label is located on either the driver’s will allow your dealer to identify your labels. As noted below, each label side door edge or on the driver’s vehicle. You will be asked for this contains specific information pertaining side door frame. It includes chassis number when you bring it in for service. to vehicle capacities and specifications number, chassis weight and gross that you should be aware of. weight, plus model information for the Chassis Number Locations vehicle, engine, transmission, and axles. • 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 Y53-6077-1B1 (03/17) CONSUMER INFORMATION AND VEHICLE IDENTIFICATION
Tire, Rim and Weight Rating Data Noise Emission Label Label WARNING! Do not exceed the specified load rat- The Noise Emission Label is located The Tire, Rim and Weight Rating ing. Overloading can result in loss in the driver's side door frame. It Data Label is located on the driver’s of vehicle control and personal in- contains information regarding U.S. side door edge or on the driver’s side jury, either by causing component noise emission regulations, chassis door frame. It contains the following failures or by affecting vehicle han- number, and date of manufacture. information: dling. Exceeding load ratings can Paint Identification Label • GVWR - Gross Vehicle Weight also shorten the service life of the Rating vehicle. The Paint Identification Label contains the paint colors used by the factory • GAWR FRONT, INTERMEDIATE The components of your vehicle to paint your vehicle. It lists frame, and REAR - Gross Axle Weight are designed to provide satisfactory wheels, cab interior and exterior Ratings for Front, Intermediate service, if the vehicle is not loaded colors. This label is located inside the and Rear Axle in excess of either the gross vehicle glove box. 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 6 the vehicle is designed to carry. This includes the weight of the empty ve- hicle, loading platform, occupants, fuel, and any load.
(03/17) Y53-6077-1B1 6-5 CONSUMER INFORMATION AND VEHICLE IDENTIFICATION
Federal Safety Standard Greenhouse Gas Certification Certification Label Emission Emissions Related Control Components This vehicle may be equipped with Identifier The NHTSA regulations require a label components that are identified as VSL, VSLS, Engine Software certifying compliance with Federal Greenhouse Gas Certified components VSLE, or parameters that affect Safety Standards, for United States (GHG). A label on the door is printed VSLD the Vehicle Speed and U.S. Territories, be affixed to with codes that identify the components Limiter each motor vehicle and prescribe manufactured on the vehicle that are IRT5, IRTE Engine software where such label may be located. part of the GHG certification. The parameters that affect the automatic engine This certification label, which indicates codes are translated in the following shutdown timer the date of manufacture and other table: ATS Aerodynamic side skirts pertinent information, is located on and/or fuel tank fairings the driver’s side door edge or on the ARF Aerodynamic roof fairing driver’s side door frame. ARFR Adjustable height aerodynamic roof fairing TGR Gap reducing fairing (tractor to trailer) LRRA, Greenhouse Gas (GHG) LRRD, or Tires LRRS 6
6-6 Y53-6077-1B1 (03/17) 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 ona 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:
(03/17) Y53-6077-1B1 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 Y53-6077-1B1 (03/17) CONSUMER INFORMATION
Canadian Consumer Toll Free 888-327-4236 (800-4249153 TTY) Information 8:00 am to 10:00 pm ET Monday-Friday Canadian customers who wish to report Office of Defects a safety-related defect to Transport Investigations/CRD Canada, Defect Investigations and NVS-216 Recalls, may telephone the toll free 1200 New Jersey Ave SE. Washington, D.C. 20590 hotline 1-800-333-0510, or contact Transport Canada by mail at: www www.safercar.gov @ [email protected] Transport Canada, ASFAD Place de Ville Tower C 330 Sparks Street Ottawa ON K1A 0N5
For additional road safety information, please visit the Road Safety website at:
www.tc.gc.ca 6
(03/17) Y53-6077-1B1 6-9 VEHICLE EMISSIONS LIMITED EXPRESS WARRANTY
VEHICLE EMISSIONS LIMITATIONS LISTED ABOVE. This OR LOST PROFITS; VEHICLE LIMITED EXPRESS Vehicle Emissions Limited Express DOWNTIME; COMMUNICATION Warranty relating to original equipment EXPENSES; LODGING AND/OR WARRANTY tires begins on the date of delivery of MEAL EXPENSES; FINES; the vehicle to the first purchaser or APPLICABLE TAXES OR BUSINESS Original Equipment Tires lessee and accrued time and mileage is COSTS OR LOSSES; ATTORNEY’S calculated when the vehicle is brought FEES; AND ANY LIABILITY YOU MAY PACCAR Inc warrants the tires in for correction of the Warrantable HAVE IN RESPECT TO ANY OTHER installed as original equipment on Emissions Failures relating to the PERSON OR ENTITY RELATING this vehicle only against defects in original equipment tires. TO WARRANTABLE EMISSIONS materials and workmanship which FAILURES. cause the vehicle to fail to comply PACCAR MAKES NO OTHER with applicable U.S. and Canadian VEHICLE EMISSIONS WARRANTIES This Vehicle Emissions Limited greenhouse gas emission limits RELATING TO THE ORIGINAL Express Warranty relating to (“Warrantable Emissions Failures”). EQUIPMENT TIRES, EXPRESS original equipment tires is limited This vehicle emissions limited express OR IMPLIED. WHERE PERMITTED to emissions compliance only. warranty relating to original equipment BY LAW, PACCAR EXPRESSLY The tires are separately warranted tires is valid for two (2) years or 24,000 DISCLAIMS ANY WARRANTY OF by their manufacturer for defects in miles, whichever occurs first. MERCHANTABILITY OR FITNESS materials and workmanship other than FOR A PARTICULAR PURPOSE those which cause non-compliance YOUR SOLE AND EXCLUSIVE RELATING TO VEHICLE EMISSIONS. with U.S. and Canadian GHG 6 REMEDY AGAINST PACCAR Inc PACCAR AND THE SELLING regulations, subject to limitations and IS LIMITED TO THE REPAIR OR DEALER SHALL NOT BE LIABLE FOR conditions contained within the tire REPLACEMENT OF ORIGINAL INCIDENTAL OR CONSEQUENTIAL manufacturer’s warranty agreement. EQUIPMENT TIRES, SUBJECT TO DAMAGES INCLUDING, BUT NOT You are responsible for the safe PACCAR’S TIME AND MILEAGE LIMITED TO: LOSS OF INCOME operation and maintenance of the
6-10 Y53-6077-1B1 (03/17) VEHICLE EMISSIONS LIMITED EXPRESS WARRANTY vehicle and its tires. PACCAR does Greenhouse Gas (GHG) Your Warranty Rights and not warrant wear and tear of the tires. Components Other Than Obligations Tires This vehicle is warranted for This GHG vehicle Warranty applies to components that directly impact the the vehicle (hereafter, vehicle) certified manufacturers greenhouse gas (GHG) with the US Environmental Protection certification with the US Environmental Agency. Protection Agency. PACCAR must warrant these components for the periods of time listed below provided there has been no abuse, neglect or improper maintenance of the vehicle.
If a GHG-related part on your vehicle is found to have a defect in material or assembly, the part will be repaired or replaced by PACCAR.
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(03/17) Y53-6077-1B1 6-11 VEHICLE EMISSIONS LIMITED EXPRESS WARRANTY
Manufacturer's Warranty Owner's Warranty programming) or using non-Original Coverage Responsibilities Equipment replacement parts.
This warranty coverage is provided for The vehicle owner is responsible for If there are any questions five years or 100,000 miles (160,000) performing required maintenance that regarding these warranty rights km, whichever first occurs, from the is listed in your engine and vehicle and responsibilities, please contact date of delivery of the vehicle to Operator’s Manuals. The owner is the vehicle OEM manufacturer at the the first purchaser or first lessee. responsible for presenting the vehicle customer center telephone number Where a Warrantable Condition exists, to a service location as soon as a provided with the vehicle operating PACCAR will diagnose and repair problem exists. Any warranty repairs instructions. the vehicle, parts and labor included, should be completed in a reasonable at no cost to the first purchaser or amount of time. Prior to the expiration of the applicable first lessee and each subsequent warranty, Owner must give notice of purchaser or lessee. This warranty Retain all receipts covering any warranted failure to an authorized does not override any extended maintenance on this equipment. PACCAR dealer and deliver the vehicle warranty purchased to cover specific PACCAR cannot deny warranty solely to such facility for repair. vehicle components. for the lack of receipts or for the failure to ensure the performance of all Owner is responsible for incidental scheduled maintenance. costs such as: communication expenses, meals, lodging incurred by PACCAR may deny warranty coverage Owner or employees of Owner as a 6 if a vehicle component has failed due to result of a Warrantable Condition. abuse, neglect, improper maintenance, unapproved modifications (both Owner is responsible for downtime physical components and computer expenses, cargo damage, fines, all applicable taxes, all business costs,
6-12 Y53-6077-1B1 (03/17) VEHICLE EMISSIONS LIMITED EXPRESS WARRANTY and other losses resulting from a Replacement Parts the emission control parts performed Warrantable Condition. by a facility other than an authorized PACCAR recommends that any PACCAR dealer and may elect to Owner is responsible for maintaining service parts used for maintenance, use parts other than new or genuine all emissions related engine and repair or replacement of GHG approved rebuilt parts and assemblies vehicle computer program settings components be new or genuine for such maintenance, replacement in accordance with manufacturer approved rebuilt parts and assemblies. or repair; however, the cost of such specifications. This responsibility The use of non-genuine engine or service or parts and subsequent includes GHG specific settings vehicle replacement parts that are not failures resulting from such service that may not be altered before the equivalent to the PACCAR engine or or parts may not be fully warranted GHG-related expiration mileage has OEM vehicle manufacturer’s original if the manufacturer determines that been reached for each system. part specification as built from the the replacement part is not of similar factory may impair the engine and material and function as the OEM part Owner is responsible for maintaining vehicle emissions control system from assembled to the vehicle at the factory. all physical parts related to working or functioning effectively, and GHG-regulations in the as-built may jeopardize your GHG warranty configuration and in proper working coverage. order for the full regulatory useful life of 435,000 miles for Class 8 vehicles, In addition, genuine vehicle or engine 185,000 miles for Class 6-7, and parts must be replaced with the same 110,000 for Class 5. material and function as the part assembled on the vehicle from the 6 factory.
The owner may elect to have maintenance, replacement or repair of
(03/17) Y53-6077-1B1 6-13 VEHICLE EMISSIONS LIMITED EXPRESS WARRANTY
PACCAR Responsibilities Warranty Limitations adequate coolants or lubricants; overfueling; overspeeding; lack of The warranty coverage begins when Sole and exclusive remedy against maintenance of cooling, lubricating the vehicle is delivered to the first PACCAR and the Selling Dealer or intake systems; improper storage, purchaser or first lessee. Repairs arising from the purchase and use starting, warm-up, run-in or shutdown and service will be performed by any of this vehicle is limited to the repair practices; unauthorized modifications authorized PACCAR dealer using or replacement of “warrantable to the vehicle and its components. new or genuine approved rebuilt parts failures”, for replacement parts that PACCAR is also not responsible for and assemblies PACCAR will utilize are similar in material and function failures caused by incorrect oil, fuel replacement parts that are selected to OEM specifications and subject to or diesel exhaust fluid or by water, and installed to support the GHG PACCAR’s time, mileage, and hour dirt or other contaminants in the fuel, compliance certification. PACCAR limitations of the greenhouse gas oil or diesel exhaust fluid. Failure will repair parts found by PACCAR to warranty. The maximum time, mileage of replacement parts used in repairs be defective without charge for parts and hour limitations of the warranty due to the above non-warrantable or labor (including diagnosis which begin with the Date of Delivery to the conditions is not warrantable. results in determination that there has first purchaser or first lessee. The been a failure of a warranted part). accrued time, mileage, or hours is This warranty is void if the vehicle is calculated when the vehicle is brought altered with parts that do not meet the in for correction of warrantable failures. material and functional specifications as manufactured from the factory. PACCAR is not responsible for Any alterations to vehicle or engine 6 failures or damage resulting from what computer settings will void GHG PACCAR determines to be abuse, warranty and potentially cause the neglect or uncontrollable acts of nature, vehicle to become non-compliant including, but not limited to: damage with the GHG regulation of the EPA due to accident; operation without Clean Air Act. Any alterations to
6-14 Y53-6077-1B1 (03/17) VEHICLE EMISSIONS LIMITED EXPRESS WARRANTY
GHG specific settings prior to the WARRANTIES MADE BY PACCAR IN VEHICLES OR PROPERTY, GHG related expiration mileage for REGARD TO THIS VEHICLE. ATTACHMENTS, TRAILERS AND each system will void GHG warranty CARGO; LOSS OR DAMAGE and potentially cause the vehicle THIS LIMITED GHG WARRANTY TO PERSONAL CONTENTS; to become non-compliant with the IS THE SOLE WARRANTY MADE COMMUNICATION EXPENSES; GHG regulation of the EPA Clean Air BY PACCAR AND THE SELLING LODGING AND/OR MEAL Act. This warranty is void if certain DEALER. EXCEPT FOR THE ABOVE EXPENSES; FINES; APPLICABLE GHG components are not properly LIMITED WARRANTY, PACCAR AND TAXES OR BUSINESS COSTS OR maintained and thus cannot perform to THE SELLING DEALER MAKE NO LOSSES; ATTORNEYS’ FEES; AND their designed capability. OTHER WARRANTIES, EXPRESS ANY LIABILITY YOU MAY HAVE IN OR IMPLIED. PACCAR AND THE RESPECT TO ANY OTHER PERSON PACCAR is not responsible for failures SELLING DEALER EXPRESSLY OR ENTITY. resulting from improper repair or the DISCLAIM ANY WARRANTY OF use of parts which are not genuine MERCHANTABILITY OR WARRANTY approved parts. OF FITNESS FOR A PARTICULAR PURPOSE. PACCAR is not responsible for the material and labor costs of emission PACCAR AND THE SELLING control parts and assemblies replaced DEALER SHALL NOT BE LIABLE FOR during Scheduled Maintenance of INCIDENTAL OR CONSEQUENTIAL the engine as specified in PACCAR DAMAGES INCLUDING, BUT NOT Operator’s Manuals. LIMITED TO: LOSS OF INCOME 6 OR LOST PROFITS; ENGINE OR THIS WARRANTY, TOGETHER VEHICLE DOWNTIME; THIRD PARTY WITH THE EXPRESS COMMERCIAL DAMAGE, INCLUDING DAMAGE WARRANTIES ARE THE SOLE OR LOSS TO OTHER ENGINES,
(03/17) Y53-6077-1B1 6-15
Index Index
5th wheel primary air pressure gauge..... 5-63 Battery chargning ...... 5-97 maintenance ...... 5-113 secondary air pressure gauge . 5-63 Bendix® AD-IS series air dryer ... 5-61 turbocharger ...... 5-107 Brake adjustment ...... 5-66 A Air system maintenance...... 5-57 Brake system Air tanks ...... 5-62 adjustment ...... 5-66 Accessory drive belts ...... 5-105 Allison transmission lubrication... 5-50 Bulb replacement Adding electrical options ...... 5-92 Automatic Slack Adjusters ...... 5-69 headlight ...... 5-88 Air cleaners...... 5-108 Automatic transmissions Bulb specifications ...... 5-89 Air compressor ...... 5-64 oil level ...... 5-154 Air disc brakes service intervals ...... 5-154 C maintenance ...... 5-67 Axle lubrication...... 5-116 Air dryer...... 5-60 Canadian consumer information....6-9 Air dryer (Bendix® AD-IS series) . 5-61 Certification labels Air dryer overhaul ...... 5-61 B components and weights label...6-4 Air intake system...... 5-107 Batteries federal safety standard certification Air system battery access ...... 5-93 label ...... 6-6 air cleaners ...... 5-108 battery care ...... 5-97 noise emission label ...... 6-5 air compressor...... 5-64 battery charging ...... 5-97 paint identification label...... 6-5 air dryer ...... 5-60 removing and installing tire, rim and weight rating data air gauges and air leaks ...... 5-63 batteries...... 5-95 label ...... 6-5 air intake system ...... 5-107 Battery access ...... 5-93 Checking tire inflation pressure..5-140 7 draining air tanks ...... 5-62 Battery care ...... 5-97 Chrome and aluminum surfaces.. 5-71
(03/17) Y53-6077-1B1 Index-1 Index
Cleaning vinyl and upholstery .... 5-75 Drum brakes engine mounting...... 5-110 Cleaning, protecting and weather maintenance ...... 5-69 exhaust system...... 5-110 stripping ...... 5-72 identification ...... 6-7 Clutch lubrication ...... 5-102 clutch linkage adjustment...... 5-155 E pipe and hose clamp torque identification ...... 6-7 Eaton/Dana axle lubrication...... 5-53 values ...... 5-43, 5-103 Clutch maintenance ...... 5-155 ELC concentration ...... 5-82 Engine (block) heater...... 5-86 Component identification reference 6-7 Electrical and alternator Engine fan ...... 5-106 Components and weights label.....6-4 precautions...... 5-99 Engine lubrication...... 5-102 Consumer information Electrical system Engine maintenance...... 5-101 Federal safety standards ...... 6-8 adding electrical options ...... 5-92 Engine Mounting ...... 5-110 how to order parts ...... 6-8 batteries ...... 5-93 Exhaust system ...... 5-110 Coolant Level...... 5-84 battery care ...... 5-97 Extended life coolant (ELC) Cooling system battery charging ...... 5-97 What to Check in an ELC-filled adding coolant ...... 5-84 electrical and alternator Cooling System ...... 5-82 fan ...... 5-106 precautions ...... 5-99 Exterior maintenance ...... 5-71 fan clutch...... 5-106 fuses, circuit breakers and Exterior washing ...... 5-74 maintenance ...... 5-82 relays...... 5-89 Cooling system maintenance ..... 5-82 removing and installing F batteries...... 5-95 D Electrical system maintenance ... 5-87 Federal safety standard certification Emergency welding...... 5-112 label...... 6-6 Disc wheels...... 5-150 Engine Fifth wheel Drive axles air cleaners ...... 5-108 maintenance ...... 5-113 7 identification ...... 6-7 air intake system ...... 5-107 Frame fastener torque Driveshaft Maintenance ...... 5-139 drive belts ...... 5-105 requirements ...... 5-114
Index-2 Y53-6077-1B1 (03/17) Index
Front axle and suspension Headlight replacement ...... 5-88 air cleaners ...... 5-108 maintenance ...... 5-116 Heater and air conditioner ...... 5-120 air conditioner...... 5-121 Fuel filters ...... 5-111 air conditioner...... 5-121 air intake system ...... 5-107 Fuel shut-off valves ...... 5-111 heater ...... 5-121 air system ...... 5-57 Fuel system Heater and air conditioner Allison transmission lubrication 5-50 fuel filters...... 5-111 maintenance ...... 5-120 brake adjustment ...... 5-66 shut-off valves ...... 5-111 How to order parts ...... 6-8 brake inspection ...... 5-67 Fuller transmission lubrication .... 5-48 chrome and aluminum surfaces 5-71 Fuses, circuit breakers and relays 5-89 I cleaning vinyl and upholstery .. 5-75 clutch ...... 5-155 G In-cab battery box...... 5-94 cooling system...... 5-82 Inspection of the engine oil level 5-102 Eaton/Dana axle lubrication .... 5-53 Gauges electrical system...... 5-87 primary air pressure...... 5-63 K emergency welding ...... 5-112 secondary air pressure ...... 5-63 engine ...... 5-101 GAWR - Gross Axle Weight Rating 6-5 Kingpin lubrication ...... 5-116 exterior ...... 5-71 General VIN information...... 6-3 frame fastener torque Greenhouse Gas (GHG) Components L requirements ...... 5-114 Other Than Tires...... 6-11 frame fastener torque table.... 5-114 Low voltage disconnect (LVD) .... 5-87 Greenhouse Gas Certification ...... 6-6 front axle and suspension Lubricant specifications ...... 5-41 Greenhouse gas certified tires...5-144 lubrication...... 5-116 Lubrication...... 5-44 GVWR - Gross Vehicle Weight fuel system...... 5-111 Rating...... 6-5 Fuller transmission lubrication . 5-48 M heater ...... 5-121 H inspection ...... 5-117 Maintenance 7 Headlight aiming ...... 5-89 5th wheel...... 5-113 lubricant specifications...... 5-41
(03/17) Y53-6077-1B1 Index-3 Index
maintenance schedule...... 5-12 stainless steel...... 5-72 N Meritor axle lubrication...... 5-52 steering and driveline ...... 5-136 New Vehicle Maintenance new vehicle maintenance steering gear lubrication ...... 5-55 Schedule ...... 5-12 schedule ...... 5-12 tail pipe surface cleaning ...... 5-72 NHTSA consumer information ...... 6-8 noise emission control tires ...... 5-140 Noise control inspections ...... 5-124 standards ...... 5-123 transmission ...... 5-152 air intake system ...... 5-125 oil changes...... 5-51 U-bolt torque...... 5-118 diesel particulate filters ...... 5-127 painted surfaces...... 5-71 U-bolt torque table ...... 5-118 engine fan and shroud ...... 5-127 passenger door lower view universal joint lubrication ...... 5-55 engine mounted noise window ...... 5-76 vehicle cleaning ...... 5-73 insulators...... 5-125 preventive maintenance ...... 5-9 washing chassis ...... 5-75 exhaust system...... 5-125 preventive maintenance (pm) washing exterior ...... 5-74 hood insulation blanket ...... 5-127 intervals ...... 5-13 wheel alignment ...... 5-117 inner fender shields and cab rear axle alignment...... 5-135 wheel bearing lubrication ...... 5-54 skirt ...... 5-128 rear axle and suspension...... 5-131 windshield wiper/washer...... 5-81 joints and clamps...... 5-126 rear axle lubrication ...... 5-134 Maintenance Procedures maintenance log...... 5-128 rear suspension fasteners torque inspection of the engine oil piping ...... 5-126 table ...... 5-133 level ...... 5-102 Noise emission control rear suspension U-bolt torque topping up the engine oil ...... 5-103 maintenance ...... 5-123 table ...... 5-133 Maintenance schedule ...... 5-9 Noise emission label...... 6-5 safety restraint system - Manufacturer's Warranty inspection ...... 5-78 Coverage ...... 6-12 safety restraint system - inspection Master lubrication index ...... 5-44 O guidelines ...... 5-79 Matching tires ...... 5-143 Oil changes...... 5-51 7 sliding fifth wheel ...... 5-115 Meritor axle lubrication ...... 5-52 Original Equipment Tires ...... 6-10 Spicer transmission lubrication. 5-50 Overinflated tires...... 5-143
Index-4 Y53-6077-1B1 (03/17) Index
Overloaded tires ...... 5-142 Rear suspension U-bolt torque fluid level and refill ...... 5-137 Owner's Warranty Coverage...... 6-12 table...... 5-133 Steering gear lubrication ...... 5-55 Refilling your radiator ...... 5-85 Steering system maintenance P Remote Keyless Entry (RKE) ....5-100 steering shaft ...... 5-138 removing and installing batteries . 5-95 Suspension lubrication ...... 5-116 PACCAR Responsibilities ...... 6-14 Replacement Parts ...... 6-13 Paint identification label ...... 6-5 Replacing tires ...... 5-144 Painted surfaces ...... 5-71 T Painting ...... 5-113 Passenger door lower view S Tail pipe surface cleaning ...... 5-72 window...... 5-76 Tire and rim data label Pipe and hose clamp torque Safety restraint belts GAWR ...... 6-5 values...... 5-43, 5-103 inspection ...... 5-78 Tire chains...... 5-145 Preventive Maintenance (PM) Safety restraint system Tire, rim and weight rating data Intervals ...... 5-13 inspection ...... 5-78 label...... 6-5 ServiSignal Mini Indicator ...... 5-109 Tires...... 5-140 Sliding 5th wheel greenhouse gas certified tires.5-144 R maintenance ...... 5-115 inflation check ...... 5-140 Rear axle alignment ...... 5-135 Sliding Fifth wheel replacement...... 5-144 Rear axle and suspension maintenance ...... 5-115 tire chains ...... 5-145 maintenance ...... 5-131 Speed restricted tires ...... 5-145 Tires and wheels rear suspension fasteners .....5-132 Spicer transmission lubrication ... 5-50 wheel cap nut torque visual inspection...... 5-132 Stainless steel...... 5-72 sequence ...... 5-147 Rear axle lubrication...... 5-134 Steer axle wheel cap nut torque table ....5-146 Rear suspension fasteners ...... 5-132 identification ...... 6-7 wheel mounting and fastening 5-146 Rear suspension fasteners torque Steering and driveline Topping up the engine oil ...... 5-103 7 table...... 5-133 maintenance ...... 5-136 Transmission
(03/17) Y53-6077-1B1 Index-5 Index
identification ...... 6-7 W lubricants...... 5-153 Warranty maintenance ...... 5-152 Greenhouse Gas (GHG) oil change ...... 5-152 Components Other Than Transmission maintenance ...... 5-152 Tires ...... 6-11 Turbocharger ...... 5-107 Limitations ...... 6-14 Manufacturer's warranty U coverage ...... 6-12 Original equipment tires ...... 6-10 U-bolt torque ...... 5-118 Owner's warranty coverage .... 6-12 U-Joints ...... 5-139 PACCAR responsibilities ...... 6-14 Underinflated tires ...... 5-141 Replacement parts ...... 6-13 Universal joint lubrication...... 5-55 Rights and obligations ...... 6-11 Warranty Limitations...... 6-14 V Warranty Rights and Obligations . 6-11 Washing chassis ...... 5-75 Vehicle cleaning...... 5-73 Welding (emergency)...... 5-112 Vehicle identification Wheel alignment ...... 5-117 chassis number...... 6-4 Wheel bearing adjustment ...... 5-151 chassis number locations...... 6-4 Wheel bearing lubrication ...... 5-54 VIN number ...... 6-3 Wheel cap nut torque...... 5-146 VIN number locations ...... 6-3 Wheel mounting and fastening ..5-146 Vinyl and upholstery Wheel replacement with disc brake cleaning ...... 5-75 option ...... 5-148 7 Windshield wiper/washer...... 5-81 maintenance ...... 5-81
Index-6 Y53-6077-1B1 (03/17)