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OPERATOR’S MANUAL © 2017 Inc. - All Rights Reserved This manual illustrates and describes the operation of features or equipment which may be either standard or optional on this . 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 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. 520

Contents

Safety...... 1

Emergency...... 2

Controls...... 3

Driving...... 4

Maintenance...... 5

Information...... 6 Contents

1 Chapter 1 | SAFETY

In this Chapter:

Applies To...... 7 Using this Manual...... 7 Safety Alerts...... 8 Illustrations...... 9 General Safety Instructions...... 9 Data Recorder...... 12 Environmental Protection Agency...... 12 A Special Word About Repairs...... 13 Additional Sources of Information...... 14 Cab Access...... 14 Cab Tilting...... 15 Standard Seat...... 18 What to do before starting the vehicle...... 23 Vehicle Loading...... 24

SAFETY -

1 Visual inspection while approaching the vehicle...... 25 Weekly Checks...... 25 Daily Checks...... 26

6 Y53-6096-1A1 (01/17) SAFETY - Applies To

Applies To 1

Please take the time to get acquainted with end before you operate this equipment. your vehicle by reading this Operator’s This manual contains useful information for Using this Manual Manual. We recommend that you read and the safe and efficient operation of this understand this manual from beginning to equipment. It also provides service

Y53-6096-1A1 (01/17) 7 SAFETY - Safety Alerts

information, with an outline for performing There are several tools built into this 1 safety checks and basic preventive manual to help you find what you need maintenance inspections. We have tried to quickly and easily. First is the Quick Table Safety Alerts present the information you’ll need to learn of Contents. Located at the front of the about functions, controls, and operation— manual, this lists the main subjects and to present it as clearly as possible. We covered and gives section numbers where Please read and follow all of the safety hope you’ll find this manual easy to use. you can find these subjects. Use the Quick alerts contained in this manual. They are There will be times when you need to take Table of Contents to find information on a there for your protection and information. this manual out of the glovebox. When you large subject like “Maintenance.” Cross- These alerts can help you avoid injury to do, please be sure to return it when you referenced citations also help you get the yourself, your passengers and help prevent are finished using it. That way it will be information you need. If some other part of costly damage to the vehicle. Safety alerts there when you need it the next time or the manual contains further information on are highlighted by safety alert symbols and when you pass the vehicle on to the next the subject you are reading about, we’ll signal words such as “WARNING”, user. indicate that in a cross-reference like this: “CAUTION”, or “NOTE”. Please DO NOT (See What to do before starting the vehicle ignore any of these alerts. on page 23). You won’t have to go Warnings NOTE searching for more information. Finally you’ll find a helpful Subject Index. It’s in the After you’ve read this manual, it should be back of the manual and alphabetically lists stored in the cab for convenient reference and remain with this when sold. the subjects covered. So if you want information on , for example, just Your vehicle may not have all the features look under in the Subject Index. The safety message following this symbol or options mentioned in this manual. You’ll find all the pages listed where brakes and signal word provides a warning against Therefore, you should pay careful attention or braking are discussed. operating procedures which could cause death or injury. They could also cause to the instructions that pertain to just your All information contained in this manual is vehicle. In addition, if your vehicle is equipment or property damage. The alert based on the latest production information will identify the hazard, how to avoid it and equipped with special equipment or options available at the time of publication. not discussed in this manual, consult your the probable consequence of not avoiding Motors Company reserves the the hazard. dealer or the manufacturer of the right to make changes at any time without equipment. notice.

8 Y53-6096-1A1 (01/17) SAFETY - Illustrations

Notes The illustrations are intended to show repair or replacement procedures. The 1 WARNING! procedure will be the same for all applications, although the illustration may Hot engine oil can be dangerous. You could differ. be burned. Let the engine oil cool down be- fore changing it. Failure to comply may re- sult in death, personal injury, equipment or The message following this symbol and property damage. signal word provides important information General Safety that is not safety related but should be Cautions followed. The alert will highlight things that Instructions may not be obvious and is useful to your efficient operation of the vehicle. Important safety notices about operating and servicing your engine. NOTE The safety message following this symbol WARNING! and signal word provides a caution against Pumping the accelerator will not assist in starting the engine. operating procedures which could cause Improper practices, carelessness, or ignor- equipment or property damage. The alert ing any warnings may cause death, person- will identify the hazard, how to avoid it, and al injury, equipment or property damage. the probable consequence of not avoiding Illustrations the hazard. Before performing any repair, read and understand all of the safety precautions Some of the illustrations throughout this and warnings. The following is a list of CAUTION manual are generic and will NOT look general safety precautions that must be exactly like the engine or parts used in followed to provide personal safety. Failure Continuing to operate your vehicle with in- your application. The illustrations can to follow these instructions may cause sufficient oil pressure will cause serious en- contain symbols to indicate an action death or injury. Special safety precautions gine damage. Failure to comply may result required and\or an acceptable or NOT are included in the procedures when they in equipment or property damage. acceptable condition. apply.

Y53-6096-1A1 (01/17) 9 SAFETY - General Safety Instructions

Keep in mind that even a well maintained • Work areas should be dry, well lit, vehicle must be operated within the range well ventilated, free from clutter, id and steam by covering the cap with a 1 large, thick rag. DO NOT try to remove it un- of its mechanical capabilities and the limits loose tools, parts, ignition sources til the surge tank cools down or if you see of its load ratings. See the Weight Ratings and hazardous substances. any steam or coolant escaping. In any situa- label on the driver's door edge. • Wear protective glasses and tion, remove the cap very slowly and care- protective shoes when working. fully. Be ready to back off if any steam or Every new vehicle is designed to conform coolant begins to escape. to all Federal Motor Vehicle Safety • DO NOT wear loose-fitting or torn clothing. Tie back and/or tuck in Standards applicable at the time of • Always use chocks or proper long hair. Remove all jewelry when manufacture. Even with these safety jack stands to support the vehicle or working. features, continued safe and reliable vehicle components before operation depends greatly upon regular • Before beginning any repair, performing any service work. DO vehicle maintenance. Follow the disconnect the battery (negative [-] NOT work on anything that is maintenance recommendations found in cable) and discharge any supported only by lifting jacks or a Preventive Maintenance section. This will capacitors. hoist. Before resting a vehicle on help preserve your investment. • Put a “DO NOT OPERATE” tag in jack stands, be sure the stands are the operator's compartment or on rated for the load you will be placing Make sure your vehicle is in top working the controls. on them. condition before heading out on the road, it • Allow the engine to cool before is the responsible driver's duty to do so. • Before removing or disconnecting slowly loosening the coolant filler Inspect the vehicle according to the any lines, fittings, or related items, cap to relieve the pressure from the Driver's Check List. relieve all pressure in the air, oil, cooling system. , and cooling systems. Remain • Use the proper tool for manually alert for possible pressure when rotating the engine. DO NOT WARNING! disconnecting any device from a attempt to rotate the crankshaft by system that contains pressure. High pulling or prying on the fan. This pressure oil or fuel can cause death Removing the fill cap on a hot engine can practice can cause death, personal cause scalding coolant to spray out and or personal injury. injury, equipment damage, or burn you badly. If the engine has been in • Always wear protective clothing damage to the fan blades, causing operation within the previous 30 minutes, be when working on any refrigerant premature fan failure. very careful in removing the fill cap. Protect lines and make sure that the face, hands, and arms against escaping flu- workplace is well ventilated.

10 Y53-6096-1A1 (01/17) SAFETY - General Safety Instructions

Inhalation of fumes can cause death • Naptha and Methyl Ethyl Ketone specifications. Overtightening or or personal injury. To protect the (MEK) are flammable materials and under-tightening can allow leakage. 1 environment, liquid refrigerant must be used with caution. Follow • Close the manual fuel valves prior systems must be properly emptied the manufacturer's instructions to to performing maintenance and and filled using equipment that ensure safety when using these repairs, and when storing the prevents the release of refrigerant materials. Always keep any vehicle inside. gas. Federal law requires capturing chemicals OUT OF REACH OF • DO NOT perform any repair when and recycling refrigerant. CHILDREN. impaired, tired, fatigued or after • When moving or lifting any heavy • When working on the vehicle, be consuming alcohol or drugs that can equipment or parts, make sure to alert for hot parts on systems that impair your functioning. use proper techniques and have just been turned off, exhaust • Some state and federal agencies in assistance. Ensure all lifting devices gas flow, and hot fluids in lines, the United States of America have such as chains, hooks, or slings are tubes, and compartments. Contact determined that used engine oil can in good condition and are of the with any hot surface may cause be carcinogenic and can cause correct load capacity. Make sure all burns. reproductive toxicity. Avoid lifting devices are positioned • Always use tools that are in good inhalation of vapors, ingestion, and correctly. condition. Make sure you have the prolonged contact with used engine • Corrosion inhibitors and lubricating proper understanding of how to use oil. oils may contain alkali. DO NOT get the tools before performing any • DO NOT connect the jump starting the substance in eyes and avoid service work. Use only genuine or battery charging cables to any prolonged or repeated contact with replacement parts from PACCAR. ignition or governor control wiring. skin. DO NOT swallow. If ingested, • Always use the same fastener part This can cause electrical damage to seek immediate medical attention. number (or equivalent) when the ignition or governor. DO NOT induce vomiting. In case of replacing items. DO NOT use a • Coolant is toxic. If not reused, contact, immediately wash skin with fastener of lesser quality if dispose of coolant in accordance soap and water. In case of harmful replacements are necessary. (e.g., with local environmental regulations. contact, immediately contact a Do not replace a 10.9 grade with 8.8 physician. Always keep any grade fastener.) chemicals OUT OF REACH OF • Always torque fasteners and fuel CHILDREN. connections to the required

Y53-6096-1A1 (01/17) 11 SAFETY - Data Recorder

contact, immediately contact a • The California Department of Motor 1 physician. Vehicles - Licensing Operations CAUTION • Other chemicals in this vehicle are Division also known to the State of California • http://www.dmv.ca.gov/ Corrosive chemicals can damage the en- to cause cancer, birth defects or gine. DO NOT use corrosive chemicals on the engine. Failure to comply may result in other reproductive harm. equipment, or property damage. • Battery posts, terminals, and related Environmental Protection accessories contain lead and lead California Proposition 65 Warning compounds, chemicals known to the Agency State of California to cause cancer • exhaust and some of and reproductive harm. Wash hands Information on use and disposal of its constituents are known to the after handling. hazardous materials. State of California to cause cancer, birth defects, and other reproductive Some of the ingredients in engine oil, harm. hydraulic oil, and oil, • The catalyst substrate located in the Data Recorder engine coolant, , Diesel Particulate Filter (DPF) refrigerant (R12, R134a, and PAG oil), contains vanadium pentoxide, which California Vehicle Code - Section 9951- batteries, etc., may contaminate the has been determined by the State of Disclosure of Recording Device environment if spilled or not disposed of California to cause cancer. Always properly. Your vehicle may be equipped with one or wear protective clothing and eye more recording devices commonly referred protection when handling the to as "event data recorders" (EDR) or catalyst assembly. Dispose of the "sensing and diagnostic modules" (SDM). catalyst in accordance with local If you are involved in an accident, the regulations. If catalyst material gets device(s) may have the ability to record into the eyes, immediately flood vehicle data that occurred just prior to eyes with water for a minimum of 15 and/or during the accident. For additional minutes. Avoid prolonged contact information on your rights associated with with skin. In case of contact, the use of this data, contact: immediately wash skin with soap and water. In case of harmful

12 Y53-6096-1A1 (01/17) SAFETY - A Special Word About Repairs

good mechanical training and the proper tools. If you are sure you have these 1 WARNING! WARNING! requirements, then you can probably perform some repairs yourself. However, Diesel engine exhaust and some of its con- Modifying your vehicle can make it unsafe. all warranty repairs must be performed by stituents are known to the State of California Some modifications can affect your vehicle's to cause cancer, birth defects, and other re- electrical system, stability, or other important an authorized service facility. If you aren’t productive harm. Other chemicals in this ve- functions. Before modifying your vehicle, an experienced mechanic, or don’t have hicle are also known to the State of Califor- check with your dealer to make sure it can the right equipment, please leave all nia to cause cancer, birth defects or other be done safely. Improper modifications can repairs to an authorized service facility. reproductive harm. This warning require- cause death or personal injury. They are the ones equipped to do the job ment is mandated by California law (Propo- safely and correctly. sition 65) and does not result from any change in the manner in which vehicles are Maintenance Manuals manufactured. CAUTION If you do decide to do any complex repair Contact your local government agency for The installation of electronic devices to the work, you’ll need the maintenance On Board Diagnostics (OBD) connector, the information concerning proper disposal. vehicle Controller Area Network (CAN), or manuals. Order them from your authorized their associated wiring is not permitted. Do- dealer. Please provide your Serial ing so can adversely affect vehicle perform- Number when you order, to be sure you A Special Word About ance and/or cause fault codes to be record- get the correct manuals for your vehicle. ed. The OBD connector is provided for tem- Allow about four weeks for delivery. There Repairs porary connection of service tools and for di- will be a charge for these manuals. agnostic purposes only. Final Chassis Bill of Material Your dealer’s service center is the best A complete, non-illustrated computer WARNING! place to have your vehicle repaired. You can find dealers all over the country with printout listing of the parts used to custom- build your vehicle is available through the Do not attempt repair work without sufficient the equipment and trained personnel to get dealer from whom you purchased your training, service manuals, and the proper you back on the road quickly—and keep tools. You could be killed or injured, or you you there. vehicle. could make your vehicle unsafe. Do only those tasks you are fully qualified to do. Your vehicle is a complex machine. Anyone attempting repairs on it needs

Y53-6096-1A1 (01/17) 13 SAFETY - Additional Sources of Information

1 Additional Sources of Cab Access Information Guidelines for getting into the cab

Major component suppliers also supply WARNING! operation manuals specific to their products. Additional manuals and other Always reinstall steps before entering the pieces of literature are included in the cab or accessing the deck plate. Without glove box literature package. Look for steps you could slip and fall. Failure to com- information on products such as the ply may result in personal injury or death. engine, driver's seat, transmission, , , , ABS/ESC, radio, 5th wheel, lane departure and adaptive . WARNING! If you are missing these pieces of literature, ask your dealer for copies. Keep steps clean. Clean any fuel, oil, or grease off the steps before entering the cab Another place to learn more about trucking or accessing the deck plate. Stepping on a is from local truck driving schools. Contact slippery surface can cause a fall which may one near you to learn about courses they result in death or personal injury. offer. Federal and state agencies such as the department of licensing also have Be careful whenever you get into or out of information. The Interstate Commerce your vehicle’s cab. Always maintain at Commission can give you information least three points of contact with your about regulations governing transportation hands on the grab handles and your feet across state lines. on the steps.

14 Y53-6096-1A1 (01/17) SAFETY - Cab Tilting

How to lock and unlock the cab doors Cab Tilting 1 Information on locking your vehicle. Tilting the cab to gain access to the engine The vehicle has one key for cab doors, and equipment requires attention to safety ignition, and the optional sleeper luggage precautions. compartment. Frame-mounted tool box locks and locking fuel tank caps each have Some examples of safety precautions are separate individual keys. use of proper cab tilting equipment, secure loose objects in the cab, remove heavy WARNING! objects from the cab, proper positioning of the vehicle and ensuring that any people or property are at a safe distance from the To help lessen the chance and/or severity of death or personal injury in case of an acci- vehicle. dent, always lock the doors while driving. Along with using the lap shoulder belts prop- erly, locking the doors helps prevent doors WARNING! from inadvertently opening and occupants WARNING! from being ejected from the vehicle. Clear the area in front of the vehicle before tilting the cab. A person in front of the cab Jumping out of the cab or getting into the To lock or unlock the doors from outside could be hit by the cab while it is being tilt- cab without proper care is dangerous. You ed. Failure clear to the area may result in the cab: could slip and fall, which could lead to death death or personal injury. or personal injury. Keep steps clean. Clean 1. Insert the key in the lock. any fuel, oil, or grease off of the steps be- fore entering the cab. Use the steps and 2. Turn the key toward the rear to lock grab handles provided, and always keep at of the vehicle (clockwise); forward least three points of contact between your (counter clockwise) to unlock. hands and feet and the truck. Look where you are going.

Y53-6096-1A1 (01/17) 15 SAFETY - Cab Tilting

device ensures safety and eliminates Check for obstructions overhead 1 danger of mishaps while driving. (branches, power lines, lights, etc.) WARNING! and in front (walls, work benches, other vehicles, etc.). Tilt the cab by using the equipment provided WARNING! on the vehicle or by a hoist with sufficient 4. Place the control valve handle in the capacity. Tilting the cab with an improvised Always ensure the locking safety bar is fully "Raise" position. Handle in "Raise" prop is an unsafe practice. Failure to use engaged before getting under a fully tilted Position. the proper cab tilting equipment may lead to cab. Failure to engage the locking bar may 5. Attach pump handle to the pump death or personal injury. result in the cab falling which may result in and pump to raise the cab (the latch death or personal injury. hooks will release automatically when pump is actuated). WARNING! CAUTION Do not tamper with any component of the cab tilt system. The hydraulic , tilt cyl- Remove heavy items and secure any loose inders and velocity fuses should be serviced items inside the cab before tilting the cab. by an authorized service center. Failure to Heavy items can damage the tilt mechanism comply may result in death or personal in- and loose items can damage equipment in- jury in the event the cab falls due to improp- side the cab. er service of the tilt system. The following cab tilting instructions are labelled and installed on the base of the NOTE companion seat: In case of oil loss in the system or a lockup 1. Park the vehicle on a level surface in the tilt cylinders, refer to the maintenance and turn the tires straight forward. manual for repair instructions. 2. Secure or remove all loose items in the cab. Close all doors. Raising the Cab 3. Check the clearance above and ahead of the cab. Ensure there will 6. Pump until the locking bar can be An independent hydraulic system raises be enough room to clear roof positioned on the anchor mounted and lowers the cab. A positive, dual-locking antennae when you tilt the cab. below the right-hand cab support.

16 Y53-6096-1A1 (01/17) SAFETY - Cab Tilting

The raised cab with lockbar in place should appear like this when complete. 1

Lowering the Cab

1. Place the control valve handle in the "Raise" position and pump until the locking bar can be removed from the anchor and fastened in its stored position.

7. Place the control valve handle in the “Lower” position and allow the cab to settle down slightly on the locking bar.

Y53-6096-1A1 (01/17) 17 SAFETY - Standard Seat

5. Visually inspect the cab latch hooks The driver's seat with can 1 CAUTION to ensure they are closed. be adjusted on the side of the seat for seat 6. Ensure that the control valve handle height and backrest incline. The front of the Do not try to pump the cab down or is in the “Lower” position when seat has controls to move the seat fore and hold it down with hydraulic force. If operating the vehicle. aft. you do, cab damage will occur. 2. Place the control valve handle in the WARNING! "Lower" position. The cab should Standard Seat settle down on the rear mounts. Before driving or riding in vehicle, ensure that there is adequate head clearance at maximum upward travel of seat. Injury may WARNING! occur if head clearance is not adequate. Failure to comply may result in personal in- jury or death. Do not adjust the driver's seat while the ve- hicle is moving. The seat could move sud- denly and unexpectedly and can cause the driver to lose control of the vehicle. Make all Safety Restraint Belts adjustments to the seat while the vehicle is Important safety information on how to use stopped. After adjusting the seat and before driving off, always check to ensure that the seat belts. seat is firmly latched in position. Failure to Safety belts have proven to be the single comply may result in personal injury, death, equipment or property damage. most effective means available for reducing the potential for either death or The standard driver's seat can be adjusted personal injury in motor vehicle accidents. forward and rearward. These movements The combination lap-shoulder belt is 3. Allow at least 20 seconds after the are each controlled by levers located on equipped with a locking mechanism. The cab touches down for the full spring the FRONT of the seat. system adjusts automatically to a person's force to develop in the latch hooks size and movements as long as the pull on the belt is slow. Hard braking or a collision in the rear mounts. Seat with Air Suspension (Optional) 4. Remove the pump handle and store locks the belt. The belt will also lock when in the cab.

18 Y53-6096-1A1 (01/17) SAFETY - Standard Seat

driving up or down a steep hill or in a sharp Correct Use of Restraint Incorrect Use of Restraint curve. Correct Placement of Lap Belt Lap Belt Too High on the Hip 1 Unbelted riders could be thrown into the or other parts of the cab or could be thrown out of the cab. They could strike another person. Injuries can be much worse when riders are unbelted. Always observe user warnings pertaining to safety belts. Your vehicle is equipped with a indicator lamp, located on the face of the .

Correct Placement of Shoulder Belt Should Belt Incorrectly Under the Arm WARNING!

Do not drive vehicle without your seat belt and your passenger's belts fastened. Riding without a safety belt properly fastened can lead to injury or death in an emergency.

WARNING!

Do not use the swivel function while a pas- senger is in the seat and the vehicle is in motion. The seat belt will not provide proper protection if the passenger is not facing for- ward and the vehicle is in an accident. Fail- ure to comply mayresult in death or person- al injury.

Y53-6096-1A1 (01/17) 19 SAFETY - Standard Seat

Safety Restraint Belt Twisted properly use the seat belts and bunk 1 restraint in the vehicle. • Do not strap in more than one person with each belt. • Keep seat belt and bunk restraint buckles free of any obstruction that may prevent secure locking. • Damaged or worn belts in the cab or sleeper, subjected to excessive stretch forces from normal wear, During Pregnancy must be replaced. They may not protect you if you have an accident. Pregnant women should always wear Safety Restraint Tips • Any belts or restraints that have combination lap/shoulder belts. The lap been subjected to an accident belt portion must be worn snugly and as • Do not wear a belt over rigid or should be inspected for any loose low as possible across the pelvis. To avoid breakable objects in or on your (attaching) hardware or damaged pressure on the abdomen, the belt must clothing, such as eye glasses, pens, buckles. never pass over the waist. A properly worn keys, etc., as these may cause seat belt may significantly reduce the risks injury in an accident. • If belts show damage to any part of assembly, such as webbing, to woman and baby in the event of a crash. • Any authorized person sleeping in bindings, buckles or retractors, they your vehicle while it is moving must be replaced. should use the bunk restraint. • Do not allow safety belts (seat or • Any authorized person sitting in the bunk) to become damaged by sleeper area on the sofa bed (if getting caught in door, bunk or seat equipped) while it is moving should hardware, or rubbing against sharp wear a seat belt. objects. • A responsible operator sees to it • All belts must be kept clean or that everyone in the vehicle rides or theretractors may not work properly. sleeps safely. The operator is responsible to inform any • Never bleach or dye seat or bunk passengers or co-drivers how to restraint belts: chemicals can

20 Y53-6096-1A1 (01/17) SAFETY - Standard Seat

weaken them. Do, however, keep d. Make sure any slack is wound them clean by following the care up on the retractor and that the 1 label on the belts. Let them dry WARNING! belt is not twisted. completely before allowing them to Proper seat belt adjustment and use is im- retract or be stowed away. If the belt is locked, lean the body back to portant to maximize occupant safety. Failure remove any tension in the belt. After • Make sure the seat belts and bunk to wear or adjust the safety belt properly releasing the belt, allow the belt to retract restraint of the unoccupied may result in death or personal injury. completely by guiding the belt tongue until passenger seat or bunk is fully the belt comes to a stop. wound up on its retractor or is To fasten the belt: stowed, so that the belt or restraint To unfasten the belt, push the release 1. Grasp the belt tongue. tongue is in its properly stowed button on the buckle and the belt should position. This reduces the possibility 2. Pull belt in a continuous slow motion spring out of the buckle. of the tongue becoming a striking across your chest and lap. object in case of a sudden stop. 3. Insert belt tongue into buckle on • Do not modify or disassemble the inboard side of seat. seat belts or bunk restraint in your 4. Push down until the tongue is vehicle. They will not be available to securely locked with an audible keep you and your passengers safe. click. • If any seat belt or bunk restraint is 5. Pull belt to check for proper not working properly, see fastening and adjustment anauthorized dealer for repair or a. Pull shoulder section to make replacement. sure belt fits snugly across the chest and pelvis. How to Use Lap/Shoulder Belt b. There should be less than one Important safety information on using the inch (25 mm) gap between the seat belts. body and the belt. c. The shoulder belt must be Follow these steps to fasten your seat belt positioned over the shoulder, it and be sure anyone riding with you does must never rest against the the same. neck or be worn under the arm.

Y53-6096-1A1 (01/17) 21 SAFETY - Standard Seat

Tether Belts To eliminate cinching, simply activate the is in its most upward and forward position. Komfort-Latch® device located on the seat 1 Failure to comply may result in death or per- This vehicle may have an external tether belt webbing at the appropriate time: belt installed with a seat, instead of the sonal injury. internal tethering device. Tether belts are 1. Adjust the seat to its proper driving Adjust an external tether by either designed to restrain the seat in the event of position. lengthening or shortening the strap. To a sudden stop or an accident. Internal 2. Latch the seat belt. lengthen it: tether belts do not require adjustment. 3. If available, adjust the seat belt 1. Turn the buckle to a right angle to height adjuster to a comfortable Make sure that the tether belt is attached the webbing. driving position. to the cab floor and seat frame. It should be routed through the buckle on each side. 2. Then pull the buckle. 4. While seated appropriately, push the "on" button to engage the Often the attachments are made using a To shorten the tether, pull on the strap. split-type hook. Make sure both halves of Komfort-Latch. 5. Learn forward in the seat until you the hook are around the anchor bracket. ® Komfort-Latch Feature hear a "click." 6. Return to normal driving position, WARNING! This device is designed to eliminate cinching and provide improved safety and and the Komfort-Latch maintains the preset amount of tension relief. Do not remove, modify, or replace the tether comfort. Cinching is the condition where a belt system with a different tether system. A belt becomes continually tighter around More information and video tutorials can be failed or missing tether belt could allow the you during a rough, bouncy ride. The need found at: http://www.clicktugsnug.com/ seat base to fully extend in the event of an for this feature increases with rough road accident. Failure to comply may result in conditions, particularly over long distances. To disengage the mechanism unbuckle the death or personal injury. seat belt and then press the OFF button of the Komfort-Latch® or tug on the shoulder WARNING! strap. WARNING! Do not set the KomfortLatch® with too much Failure to adjust external tether belts proper- slack. Too much slack may reduce the effec- ly can cause excessive movement of the tiveness of the seat belt. Failure to comply seat in an accident. Tether belts should be may result in death or personal injury. adjusted so that they are taut when the seat

22 Y53-6096-1A1 (01/17) SAFETY - What to do before starting the vehicle

driving. In addition to being an unsafe driver is sure that certain parts and practice, it may be against local or federal accessories are in working order. 1 What to do before starting ordinances to use cellular devices while the vehicle operating the vehicle. Do not drink alcohol and drive. Your reflexes, perceptions, and judgment can be Much has gone into the of affected by even a small amount of Checks before you operate your vehicle. your vehicle including advanced alcohol. You could have a serious or even Safe Vehicle Operation engineering techniques, rigid quality fatal accident, if you drive after drinking. control, and demanding inspections. These Please do not drink and drive or ride with a Be sure to perform pre-trip inspections manufacturing processes will be enhanced driver who has been drinking. before starting and operating the vehicle. by you, the safe driver, who observes the For your safety, as well as those around following: WARNING! you, be a responsible driver: • Knows and understands how to • If you drink alcohol, do not drive. operate the vehicle and all its The use of alcohol, drugs, and certain medi- • Do not drive if you are tired, ill, or controls cations can impair perception, reactions, and driving ability. These circumstances can under emotional stress. • Maintains the vehicle properly substantially increase the risk of an acci- • Uses driving skills wisely Safe driving is only possible with the dent. Failure to comply may result in death, personal injury, equipment or property dam- proper concentration on the driving task. This manual is not a training manual. It age. Keep distraction to a minimum to improve cannot tell you everything you need to your concentration. Examples of know about driving your vehicle. For that distractions may include radio controls, you need a good training program or truck WARNING! GPS navigation controls, cellular telephone driving school. If you have not been calls, cellular text messages, reading or trained, get the proper training before you Do not text and drive. Your reaction time, reaching for something on the floor. drive. Only qualified drivers should drive perceptions and judgment can be affected Minimizing your distractions will improve this vehicle. while texting or using any other form of mo- safe driving and will help avoid an accident bile messaging while driving. Failure to com- involving death or personal injury. For more information, refer to Department ply may result in death, personal injury, of Transportation Regulation 392.7, which equipment or property damage. Be aware of local regulations that may states that interstate commercial motor prohibit the use of cellular telephones while vehicles are not to be driven unless the

Y53-6096-1A1 (01/17) 23 SAFETY - Vehicle Loading

Emergency Equipment You are not expected to become a professional mechanic. The purpose of control, either by causing component fail- 1 It is good practice to carry an emergency ures or by affecting vehicle handling. Ex- your inspections is to find anything that equipment kit in your vehicle. One day, if ceeding load ratings can also shorten the might interfere with the safe and efficient you have a roadside emergency, you will service life of the vehicle. Failure to comply transportation of yourself, any passengers, may result in death or personal injury. be glad the following items are with you: and your load. If you do find something • window scraper wrong and cannot fix it yourself, have an • snow brush authorized dealer or qualified mechanic WARNING! repair your vehicle right away. • container or bag of sand or salt An unevenly distributed load or excessive • emergency light The following operations are to be load over one axle can adversely affect the • warning triangles performed by the driver. Performing these braking and handling of your vehicle, which could result in an accident. Even if your load • small shovel checks and following the maintenance procedures in this manual will help keep is under the legal limits, be sure it is distrib- • first aid kit your vehicle running properly. uted evenly. Failure to comply may result in • fire extinguisher death, personal injury, equipment or proper- • vehicle recovery hitches ty damage. Drivers Checklist Vehicle Loading The Gross Vehicle Weight Rating (GVWR) or the maximum front and rear Gross Axle To keep your vehicle in top shape and Weight Ratings are determined by the maintain a high level of safety for you, your Compare your vehicle's load capacity with the total load you are carrying. If components installed from the factory on to passengers, and your load, make a the vehicle and their designed thorough inspection every day before you adjustments need to be made, make them, do not drive an overloaded vehicle. If you specifications. (Axle weight ratings are drive. You will save maintenance time later, listed on the driver's door edge.) and the safety checks could help prevent a are overloaded or your load has shifted, your vehicle may be unsafe to drive. serious accident. Please remember, too, GVWR is the Gross Vehicle that Federal Motor Carrier Safety Weight Rating. This is the Regulation 392.7 requires a pre-trip WARNING! MAXIMUM WEIGHT your inspection and so do commercial trucking vehicle is allowed to carry, companies. Do not exceed the specified load rating. including the weight of the Overloading can result in loss of vehicle empty vehicle, loading

24 Y53-6096-1A1 (01/17) SAFETY - Visual inspection while approaching the vehicle

platform, occupants, fuel, showing signs of excessive wear or and any load. Never Visual inspection while lack of lubrication? Have a qualified 1 exceed the GVWR of your mechanic examine any vehicle. approaching the vehicle questionable items and repair them without delay. GCW is the actual combined Guidelines for visually inspecting your 4. Check your load. Is it secured weight, or Gross vehicle. properly? Combination Weight (GCW), of your vehicle While approaching the vehicle, inspect the See Also and its load: vehicle, plus general appearance of the vehicle and its Maintenance Schedule on page 131 trailer(s), plus . surroundings for any signs of needed Weekly Checks on page 25 attention. GAWR is the Gross Axle Weight Daily Checks on page 26 Rating. This is the total weight that one axle is NOTE designed to transmit to Weekly Checks the ground. You will find If equipped with a three-piece roof fairing, this number listed on the DO NOT DRIVE WITH ROOF FAIRING driver's door edge. FOLDED DOWN, since the marker lamps A driver should perform these checks of will not be effective in that position. the vehicle weekly. Load be sure any load you Distribution carry is distributed so that Perform these basic inspection steps no axle has to support before operating the vehicle. NOTE more than its GAWR. 1. Check the overall appearance and These checks are in addition to, not in place Be sure that the load on the vehicle is condition. Are windows, mirrors, and of, Federal Motor Carrier Safety Regula- distributed evenly across each axle so that lights clean and unobstructed? tions. These regulations may be purchased by writing to: Superintendent of Documents no axle has to support more than its rated 2. Check beneath the vehicle. Are U.S. Government Printing Office Bookstore GAWR. In total, the vehicle and its load there signs of fuel, oil, or water 710 North Capitol Street N.W. Washington, should not exceed the GAWR for each axle leaks? DC 20402 or [email protected]. and must not exceed the GCW 3. Check for damaged, loose, or missing parts. Are there parts

Y53-6096-1A1 (01/17) 25 SAFETY - Daily Checks

Engine • Controls and Wiring - check for Engine condition and adjustment 1 • Belts • Engine Oil • Components - check • Hoses • Engine Coolant pitman arm, draglink, and power • Clamps steering hoses, etc., for loose, • Fluid • Radiator broken, or missing parts. • Engine Belt • Air Cleaner • Cab Air Conditioner Fresh Air Filter • Fuel Filter (Water Separator) Fuel • Aftertreatments System - check for condition and System on page 192 Components cleanliness. • Windshield Washer Fluid • Exhaust Pipes • Battery Cables - check the condition See Also • Engine Air Pre-cleaner (Optional) - of the battery and alternator cables Visual inspection while approaching the For vocational vehicles with optional for signs of chafing or rubbing. vehicle on page 25 engine air pre-cleaner, check the Make sure that all clamps (straps) purge valve at the bottom of the holding the cables are present and mounted engine air precleaner in good working order. for any obstructions. Make sure the Daily Checks • Hood Latch purge valve will open and close as • Brake Lines and Hoses needed to purge dirt and water from A driver should perform these checks of • Steering Components - (pitman the engine intake air. the vehicle daily, as a minimum. arm, draglink, power steering hoses, • Fluid etc.). (where applicable) - Check level, • Hydraulic Fluid after the engine has warmed up to NOTE operating temperature. Chassis and Cab Extrior These checks are in addition to, not in place Chassis and Cab Exterior of, Federal Motor Carrier Safety Regula- • Lights - are any exterior lights tions. These regulations may be purchased cracked or damaged? • Battery - check battery and by writing to: Superintendent of Documents • Window and Mirrors - clean and terminals. U.S. Government Printing Office Bookstore adjusted? • Wheel Cap Nuts - are they all in 710 North Capitol Street N.W. Washington, • Tires, Wheels and hubs Tires on place and torqued properly - tighten DC 20402 or [email protected]. page 207 Wheels on page 210 if necessary. Wheels on page 210

26 Y53-6096-1A1 (01/17) SAFETY - Daily Checks

• Suspension Components - check for Cab Interior from this area and excessive dirt or loose or missing fasteners. Check pet hair may shorten the service life • Seat - adjust the seat for easy reach 1 damage to springs or other of the sleeper air conditioning air of controls and visibility. suspension parts such as cracks, filter. gouges, distortions, bulges or • Seat Belts - fasten and adjust safety chafing. restraint belts (which may include See Also restraints in the sleeper). • Brake Lines and Hoses - check Visual inspection while approaching the lines, linkages, chambers, parking • Steering Column - adjust for easy vehicle on page 25 and service brake operation. reach and visibility. • Air System - What is the Air • Mirrors - check and readjust mirrors System? on page 155 if necessary. • Steps and Grab Handles • Lights - turn ignition key to the ON position and check for warning lights • Frame Mounted Tanks (Fuel, Diesel and . Check operation of turn Exhaust Fluid, etc) - check signals and emergency lights. underneath the vehicle for signs of fluid leaks. If any are found, correct • Instruments - check all instruments. before operating the vehicle. Is the • Windshield - check operation of tank fill cap secure? Are the tank windshield wipers and washers. straps tight? Is the strap webbing in • Horn - check operation of horn. place? • Fuel - check fuel. Is there enough • Trailer Connections - are they fuel? secure and the lines clear? If they • Diesel Exhaust Fluid - check level. are not being used, are they stored Is there enough fluid? properly? Is the trailer spare wheel • Air conditioning filters in the cab secure and inflated? Is the landing and/or Sleeper - check the condition gear up and the handle secured? of the sleeper air conditioning air • Fifth Wheel - Is the kingpin or the filter. Keep the sleeper floor area sliding fifth wheel locked? behind the passenger front seat clear of debris and pet hair. The sleeper air conditioner draws air

Y53-6096-1A1 (01/17) 27 SAFETY - Daily Checks

1

28 Y53-6096-1A1 (01/17)

Chapter 2 | EMERGENCY 2 In this Chapter:

Roadside Assistance...... 30 How to Recover a Vehicle...... 37

EMERGENCY - Roadside Assistance

question, they will direct you to a 3. Place the transmission in neutral representative who can. (park with automatic transmissions, Roadside Assistance if equipped) and set the parking Low Air Alarm brake. 2 Call toll-free to talk to someone at the 4. Turn OFF the engine. PACCAR Customer Center. These are actions that the operator should 5. Turn ON the emergency flasher and perform if the low air alarm on the use other warning devices to alert instrument cluster turns on. other motorists. If the light and alarm do not turn off at startup, do not try to drive the vehicle until the problem is found and fixed. See Also Vehicle Air Pressure on page 68 1-800-4Peterbilt (800-473-8372) If this alarm turns on while parked or System on page 106 The Customer Call Center is open driving, be sure to perform these tasks: 24-7-365 days a year and staffed with Stop Engine Lamp trained personnel (English and other WARNING! languages if necessary), free of charge, to provide total roadside assistance. Their If the air pressure falls below 60 psi (414 custom mapping system can locate the kPa) the spring brakes may stop the vehicle nearest Authorized dealers and abruptly, which could cause an accident re- Independent Service Providers (ISPs) sulting in personal injury or death. Observe based on the vehicle's location. In addition, the red warning lamps on the gauges. If one the customer center can dispatch services comes on, do not continue to drive the vehi- This warning lamp illuminates when the cle until it has been properly repaired or for jump and pull starts, tires, trailers, fines engine has a serious problem. This is an serviced. and permits, chains, , hazardous emergency and the vehicle should be safely stopped at the soonest opportunity. clean-up, out of fuel (roadside), mechanical 1. Slow down carefully. repairs and preventive maintenance 2. Move a safe distance off the road services. If they can’t answer a specific and stop.

30 Y53-6096-1A1 (01/17) EMERGENCY - Roadside Assistance

drops below the minimum psi (kPa) a Red sudden loss of coolant. Follow these steps Warning Lamp on the oil pressure gauge if the engine is overheating. WARNING! will illuminate and the Stop Engine Lamp will come ON. This should be considered an emergency. 2 You should stop the vehicle as safely as 1. Slow down carefully. possible and turn OFF the ignition. The ve- hicle must be serviced and the problem cor- 2. Move a safe distance off the road rected before driving again. Failure to do so and stop. may cause severe engine or Diesel Particu- 3. Place the transmission in neutral CAUTION late Filter damage, orcause an accident (park with automatic transmissions, which may result in death or personal injury. if equipped) and set the parking The cooling system may overheat if the en- brake. gine coolant is at the minimum level. A sud- 4. Turn OFF the engine. den loss of coolant, caused by a split Low Oil Pressure Lamp or broken hose clamp could also lead to an 5. Turn ON the emergency flasher and overheat condition. Always inspect to en- The low oil pressure warning lamp will use other warning devices to alert sure hoses and clamps are not cracked, illuminate when the engine oil pressure other motorists. worn, or loose. Failure to comply may result drops which can cause damage to the 6. Wait a few minutes to allow oil to in equipment or property damage. engine. drain into the engine oil pan, and then check the oil level. 7. Add oil if necessary. If the problem NOTE persists, contact an authorized The system may also temporarily overheat dealer as soon as possible. CAUTION during severe operating conditions such as: See Also • Climbing a hill on a hot day. Continuing to operate your vehicle with in- Engine, Oil Temperature on page 62 sufficient oil pressure will cause serious en- • Stopping after high-speed/ high- gine damage. Failure to comply may result Engine, Oil Pressure on page 62 load driving. in equipment or property damage. • Debris blocking air flow through Engine is Overheating the cooling module (radiator). It is important to maintain oil pressure within acceptable limits. If oil pressure The cooling system may overheat if the coolant level is below normal or if there is

Y53-6096-1A1 (01/17) 31 EMERGENCY - Roadside Assistance

If the engine coolant temperature warning heat, as indicated by the engine lamp comes on and the audible alarm coolant temperature light, immediate NOTE sounds showing an overheat condition, or action is required to correct the con- dition. Continued unattended opera- if you have any other reason to suspect the Keep the engine running at idle tion of the engine, even for a short speed unless a warning icon turns 2 engine may be overheating, DO NOT time, may result in serious engine on and requires an engine to be TURN OFF THE ENGINE unless a low damage or a fire. Failure to comply shut off. water warning device indicates a loss of may result in death, personal injury, coolant. Follow these steps: equipment or property damage. Follow these steps if the engine coolant CAUTION temperature is rising, or the temperature is WARNING! already above normal, and there are no Prolonged periods of idling after the other warning alarms displayed in the Removing the fill cap on a hot en- engine has reached operating tem- instrument cluster. gine can cause scalding coolant to peratures can decrease engine tem- spray out and burn you badly. If the perature and could cause engine 1. Reduce engine speed, or stop. engine has been in operation within damage from inadequate lubrication. When stopped, place the the previous 30 minutes, be very The normal torsional vibrations gen- transmission in neutral (N) and set careful in removing the fill cap. Pro- erated can also cause transmission tect face, hands, and arms against wear. An idle shutdown feature, the . Keep the engine available on PACCAR engines, can running. See the vehicle operator's escaping fluid and steam by cover- ing the cap with a large, thick rag. be programmed to shut the engine manual for instructions on DO NOT try to remove it until the down after a period of low idle oper- transmission shifting and parking surge tank cools down or if you see ation with no driver activity. A flash- brake information. any steam or coolant escaping. In ing warning lamp will inform the driv- any situation, remove the cap very er of an impending shutdown. Fail- slowly and carefully. Be ready to ure to comply may result in equip- WARNING! back off if any steam or coolant be- ment or property damage. gins to escape. To reduce the chance of personal in- jury, vehicle damage and/or death from overheated engines, which can result in a fire, never leave the en- gine idling without an alert driver present. If the engine should over-

32 Y53-6096-1A1 (01/17) EMERGENCY - Roadside Assistance

this time. If it has not, stop the CAUTION engine and let it cool before checking to see if the coolant is low. WARNING! If the truck is equipped with power 7. Be sure the vehicle is parked on Do not replace a fuse with a fuse of a higher take off (PTO) equipment, the en- level ground or the readings may be rating. Doing so may damage the electrical 2 gine shutdown system can be deac- incorrect. Check the coolant level at system and cause a fire. Failure to comply tivated when the PTO is operational; the cooling module surge tank. may result in death, personal injury, equip- however, engine idle periods should ment or property damage. not exceed five minutes whenever Check the coolant level after each trip possible. Failure to comply may re- when the engine has cooled. The coolant sult in equipment or property dam- age. level should be visible within the surge tank CAUTION —add coolant if necessary. 2. Check to ensure the Oil Pressure See Also Never patch fuses with tin foil or wire. This Gauge reads normal. may cause serious damage elsewhere in 3. Make sure the engine fan is turning Engine - Coolant Temperature on page the electrical circuit, and it may cause a fire. by switching the Engine Fan Switch 66 from AUTO to MAN (Manual). Engine, Low Coolant Level on page 62 4. Increase the engine speed to about Engine, Coolant Temperature on page 62 CAUTION one-half of full operating speed, or Inspect Coolant Level on page 172 1,100 to 1,200 rpm, maximum for 2 If a circuit keeps blowing fuses, have the or 3 minutes. electrical system inspected for a short circuit or overload by an authorized dealer as soon 5. Return the engine speed to normal How to inspect and replace a fuse as possible. Failure to do so could cause idle. Monitor the engine All the electrical circuits have fuses to serious damage to the electrical system temperature. After the temperature protect them from a short circuit or and/or vehicle. returns to normal, allow the engine overload. If something electrical on your to idle 3 to 5 minutes before shutting chassis stops working, the first thing you it off. This allows the engine to cool should check for is a blown fuse. gradually and uniformly. 6. If overheating came from severe Turn the ignition off and turn all lights off. operating conditions, the Locate the fuses in either the cab, sleeper temperature should have cooled by or main power fuse box.

Y53-6096-1A1 (01/17) 33 EMERGENCY - Roadside Assistance

If it is blown, replace it with a fuse of the compartment, mounted to the front wall of same rating. If a fuse of the same rating is the cab. CAUTION not available, a fuse of a lower rating may be temporarily substituted. You can also Fuses for the optional sleeper are located 2 Before replacing a fuse, turn OFF all lights use a fuse from a circuit you can do on a separate fuse box accessible through and accessories and remove the ignition temporarily without (for example an the luggage compartment door. key to avoid damaging the electrical system. accessory circuit or radio). See Also 1. Turn OFF all lights and accessories How to inspect and replace a fuse on page and remove the ignition key to avoid CAUTION 33 damaging the electrical system. Fuses, Circuit Breakers and Relays 2. Determine from the chart on the When replacing a failed circuit breaker, al- fuse panel which fuse controls that ways use an approved circuit breaker with a How to Jump Start a Battery component. current rating equal to or less than the cir- 3. Remove that fuse and see if it is cuit breaker being replaced. Only use the Jump starting a vehicle is not a approved Type II modified reset circuit recommended practice due to the various blown. breakers. NEVER use a Type I (automatic Fuse Puller reset) or Type III (manual reset) circuit battery installations and electrical options. breaker. A fuse with a current rating equal to However, if the vehicle battery is or less than the circuit breaker being re- discharged (dead), the vehicle may start by placed can also be used. using energy from a good battery in another vehicle. This is termed jump starting. Where are the Fuses Located?

When determining if a fuse is blown, it is WARNING! important to know where to find the related fuses. Batteries contain acid that can burn and Fuses for the cab are located in the fuse gasses that can explode. Ignoring safety procedures may result in death, personal in- panel behind the drivers side kick panel. jury, equipment or property damage. Main power relays are located on the power distribution center, in the engine

34 Y53-6096-1A1 (01/17) EMERGENCY - Roadside Assistance

1. Remove any personal jewelry that may come in contact with the WARNING! CAUTION battery terminals. 2. Select a jumper cable that is long Never remove or tamper with battery caps. Applying a higher voltage booster battery enough to attach to both vehicles in Ignoring this could allow battery acid to con- will cause expensive damage to sensitive 2 tact eyes, skin, fabrics, or painted surfaces. electronic components, such as relays, and a way that ensures neither vehicle Failure to comply may result in death, per- the radio. Failure to comply may result in touches each other. sonal injury, equipment or property damage. equipment damage. 3. Position the two vehicles together, but do not allow them to touch. 4. Turn OFF all lights, heater, radio, WARNING! CAUTION and any other accessory on both vehicles. Never jump start a battery near fire, flames, Improper hook-up of jumper cables or not 5. Set the parking brakes: pull out the or electrical sparks. Batteries generate ex- following these procedures can damage the plosive gases that could explode. Keep alternator or cause seri ous damage to both Yellow button located on the dash. sparks, flame, and lighted cigarettes away vehicles. See Air Brake System on page from batteries. Failure to comply may result 106. in death, personal injury, equipment or prop- erty damage. 6. Shift the transmission into park WARNING! position or neutral for manual transmissions. See Operating WARNING! Heed all warnings and instructions of the Manual Transmissions on page 103 jumper cable manufacturer. Failure to com- and see Automatic and Automated ply may result in death, personal injury, Transmissions on page 105. When jump starting using a battery booster, equipment or property damage. it is best to jump start with an equivalently 7. If either vehicle is equipped with powered vehicle. Verify that the booster bat- battery disconnects ensure they are tery has the same volt and cold cranking Be careful that metal tools (or any metal in contact with the positive terminal) do not in the OFF position prior to amperage specifications as the dead battery connecting the two vehicles. before attempting to jump start. Failure to contact the positive battery terminal and comply may cause an explosion resulting in any other metal on the vehicle at the same 8. Attach one end of a jumper cable to death, personal injury, equipment or proper- time. Remove metal jewelry and avoid the positive (+) terminal of the ty damage. leaning over the battery. discharged (dead) battery. This will

Y53-6096-1A1 (01/17) 35 EMERGENCY - Roadside Assistance

have a large red + or P on the 13. Start the vehicle that has the good Cab fuses are located in the center panel. battery case, post, or clamp. battery first. Let it run for 5 minutes. 14. Start the vehicle that has the discharged (dead) battery. 2 NOTE The engine should start. If the engine fails Always connect positive (+) to posi- to start, do not continue to crank the tive (+) and negative (-) to negative . Instead, contact the nearest (-). authorized dealer. 9. Attach the other end of the same cable to the positive (+) terminal of the good (booster) battery. WARNING!

10. Attach the remaining jumper cable When disconnecting jumper cables, make FIRST to the negative (-) terminal sure they do not get caught in any moving (black or N) of the good battery. parts in the engine compartment. Failure to Main power relays are located on the comply may result in death, personal injury, power distribution center in the engine equipment or property damage. compartment. NOTE Reverse the above procedure exactly A small amount of oil in the system when removing the jumper cables. With may be normal and should not, in it- engine running, disconnect jumper cables self, be considered a reason to re- from both vehicles in the exact reverse place the desiccant cartridge. Oil stained desiccant can function ade- order, making sure to first remove the quately. negative cable from the vehicle with the discharged battery. 11. Attach the other end of the negative cable (dead battery truck) to a bare metal part not bolted to the engine Where are the fuses located? block. When determining if a fuse is blown, it is 12. If either vehicle is equipped with important to know where to find the related battery disconnects, ensure that fuses. they are in the ON position.

36 Y53-6096-1A1 (01/17) EMERGENCY - How to Recover a Vehicle

is stopped. You could seriously damage your vehicle by towing it with the driveline How to Recover a Vehicle CAUTION connected and the drive wheels on the ground. Worse, when vehicles are towed, Follow these steps to properly recover a Connect recovery rigging only to hitches in- either by wrecker or piggyback, the 2 vehicle from a situation where the vehicle tended for that purpose. Do not attach to lubricant in the top front of the drive axle bumpers or brackets. Use only equipment is unable to move on its own. designed for this purpose. Failure to comply will drain to the rear. This will leave the top may result in equipment damage. components dry. The resulting friction may damage them. Always remove the main CAUTION drive axle shafts before towing your WARNING! vehicle. Remove the drive axle shafts or lift the driv- ing wheels off the ground before towing the 1. Review and understand all the Before towing a vehicle, test your air brakes vehicle. Towing the vehicle with either the to ensure that you have properly connected cautions and warnings of this wheels on the ground or the axle shafts in and inspected the recovery vehicle’s brake section. the axles will cause damage to the axle system. Failure to do so could lead to a loss gears. 2. Install the recovery hitch. See What of vehicle control which may result in an ac- is a Recovery Hitch? on page 40 cident involving death or personal injury. and How to use a Recovery Hitch on page 41. CAUTION Your vehicle is equipped with removable 3. Disconnect the drive axle shafts and Recovery Hitches, designed for short cover the open hubs. This is If your vehicle has a Meritor axle with a driv- distance recovery purposes only. Use only er-controlled main differential lock, install necessary because if the the provided hitches, according the the caging bolt before removing the axles transmission is driven by the following instructions. When using this for towing, see Driver Controlled Main Differ- driveshaft (rear wheels on the connection, do not transport your vehicle ential Lock. Installing the caging bolt pre- ground), no lubricant will reach the damage by locking internal axle com- over long distances. (If your vehicle does gears and bearings, causing ponents in position. not have the proper hitches, contact your damage to the transmission. See dealer.) How to Prepare the Axles for All lubricating and clutch application oil Towing on page 41. pressure is provided by an engine-driven 4. Install the recovery rigging using a pump, which will not work when the engine safety chain system, See What are

Y53-6096-1A1 (01/17) 37 EMERGENCY - How to Recover a Vehicle

the Best Practices for Recovery • Recommended Practice #602–A — Rigging? on page 45. “Front Towing Devices For WARNING! 5. Make sure the recovered vehicle's and Tractors.” parking brakes are released. See • Recommended Practice #602–B — Do not drive vehicle with malfunctioning 2 Manually Release the Parking “Recovery Attachment Points For brakes. If one of the brake circuits should Brake on page 38. Trucks, Tractors, and Combination become inoperative, braking distances will 6. If you desire to use the recovered Vehicles increase substantially and handling charac- vehicle’s brakes, ensure that the • Recommended Practice #626 — teristics while braking will be affected. You vehicle’s air system is connected to “Heavy Duty Truck Towing could lose control of your vehicle or cause an accident. Have it towed to the nearest that of the recovery vehicle. Ensure Procedures.” dealer or qualified repair facility for repair. that any air line that has been Copies of these can be obtained from the Failure to comply may result in death, per- removed from a driver-controlled sonal injury, equipment or property damage. main differential lock is firmly following address: Technology & capped to prevent loss of air Maintenance Council 950 N. Glebe Road pressure from the recovery vehicle if (703) 838-1763 Arlington, VA 22203 Email: WARNING! it is supplying air pressure. If you [email protected] Website: http:// don’t desire to use the recovered tmc.truckline.com Do not operate a vehicle when the spring vehicle’s brakes, ensure that you brakes have been manually released. Driv- cage the spring brakes before Manually Release the Parking ing a vehicle after its spring brakes are man- attempting to move the vehicle, see ually released is extremely dangerous. The Brake brakes may not function. Failure to comply How to Manually Lock a Differential Recovering a vehicle may require the may result in death, personal injury, equip- on page 42. ment or property damage. 7. Follow state/provincial and local parking brakes to be released. There may laws that apply to vehicles in tow. be times when there is not enough air pressure, or the engine's air is 8. Do not tow vehicles at speeds in not able to produce enough pressure, to excess of 55 mph (90 km/h). release the parking brakes. In such cases, For additional information concerning the parking brakes (or Spring Brakes) can heavy duty truck recovery, refer to the be manually released. following Technology & Maintenance Council (TMC) literature.

38 Y53-6096-1A1 (01/17) EMERGENCY - How to Recover a Vehicle

WARNING!

Do not disassemble a spring brake cham- ber. These chambers contain a powerful 2 spring that is compressed. Sudden release of this spring may result in death or personal injury. 4. Insert the release stud through the opening in the spring chamber where the cap was removed. Insert WARNING! it into the pressure plate. Turn the release stud 1/4 turn clockwise in Releasing the spring brakes on an unse- the pressure plate. This secures the cured vehicle could lead to an accident. The cross pin into the cross pin area of vehicle could roll, which may result in death, 2. Remove the release stud assembly personal injury, equipment or property dam- the pressure plate and locks it into age. Always secure the vehicle with wheel from the side pocket, and remove the manual release position. chocks, chains, or other safe means to pre- the release nut and washer from the vent rolling before manually releasing the release stud. spring brakes.

To move a vehicle immobilized by the spring brakes due to loss of air pressure in the brake system, perform the following procedure: 5. Assemble the release stud washer 1. Remove the cap from the spring and nut on the release stud. chamber 3. Slide out the release stud.

Y53-6096-1A1 (01/17) 39 EMERGENCY - How to Recover a Vehicle

made up of the following parts, are recommended for the proper recovery of your vehicle: 2

6. With a wrench, turn the release stud assembly nut until the compression spring is 90-95 percent caged. While doing this, check to make What is a Recovery Hitch? If your vehicle is not equipped with the sure the push rod (adapter push rod A removable recovery hitch is a device that proper recovery hitch assembly, contact an or service push rod) is retracting. Do attaches to the sockets in the front authorized dealer to obtain the proper not over-torque the release stud in the event the vehicle needs to be equipment. assembly. (S-Cam type maximum: recovered. These hitches are designed for 50 lb-ft, Wedge type maximum: 30 short distance and intermittant duty to help lb-ft). The spring brake is now pull a vehicle. These hitches are not mechanically released. designed to be used as towing devices for long distance. Specially designed hitches are required to recover your vehicle. The recovery hitches attach to the frame. Two hitch assemblies,

40 Y53-6096-1A1 (01/17) EMERGENCY - How to Recover a Vehicle

6. Ensure that the tow pin and lock clip to the vehicle may occur if rigging is not are installed before using the hitch. WARNING! connected properly. 7. Remove the hitches and store all Do not use parts from other trucks or materi- parts after recovering the vehicle. als from other sources to repair a hitch or to CAUTION 2 replace a missing hitch. The parts provided How to Prepare the Axles for for recovery are made of high strength ma- When recovering ditched or bogged vehi- Towing terials and are specifically designed for vehi- cles, stay well below Maximum Capacities. cle recovery. Failure to use the correct facto- Even at loads below maximum, the physical If the vehicle is going to be towed from the ry equipment may result in an accident in- strain of recovering a vehicle could damage volving death or personal injury. front axle and using the rear axle for axles, suspensions, fifth wheels, etc. support, then the axle shafts should be prepared [removed] so that minimal Use the following procedure to install the CAUTION damage is made to the differential during Vehicle Recovery Hitches. See Recovery the towing process. Hitch Assembly illustration for part Connect recovery rigging only to hitches in- identification. Ensure that the recovered vehicle does not tended for that purpose. Do not attach to have an open air line. An open air line on bumpers or brackets. Use only equipment 1. Check square sockets behind lower the recovered vehicle will cause a leak in designed for this purpose. Failure to comply bumper for obstructions, clear if may result in equipment damage. the air system of the recovery vehicle if necessary. both vehicles’ brake systems are 2. With lock pins removed, insert connected. This could cause a loss of How to use a Recovery Hitch hitches through bumper and into the system air, which can cause the service square hitch socket. brakes not to function, resulting in the 3. Align the hole in the with sudden application of the spring brakes CAUTION the square hitch socket hole. causing wheel lock-up, loss of control, or 4. Insert the lock pin into the square overtake by following vehicles. Recovery pull maximums assume the tow hitch socket hole and through the rigging evenly distributes the load between both recovery hitches. See examples in Re- hole in the tow hitch until the lock covery Rigging for details. Serious damage tab is within the square hitch socket. 5. Rotate the lock pin 90 degrees to secure the pin in place.

Y53-6096-1A1 (01/17) 41 EMERGENCY - How to Recover a Vehicle

not work when the engine is stop- Follow these procedures if the vehicle has ped. When vehicles are towed either a driver controlled differential lock. WARNING! by wrecker or piggyback, lubricant in the top front of the drive axle will This procedure should be done before the An open air line on the recovered vehicle drain to the rear. This will leave the axle shafts are removed. 2 will cause a leak in the air system of the re- top components dry, resulting in fric- covery vehicle if both vehicles’ brake sys- tion that will seriously damage these tems are connected. This could cause a components. CAUTION loss of system air, which can cause the service brakes not to function, resulting in 2. If the vehicle has driver controlled Failure to install the caging bolt when towing the sudden application of the spring brakes differential lock, then manually lock vehicles with driver-control main differential causing wheel lock-up, loss of control, or the differential. lock can result in damage by failing to lock overtake by following vehicles. You could be 3. Remove drive axle shafts. internal components in position. in an accident involving death or personal 4. Cover the open ends of the hubs to injury. Ensure that any air line that has been removed from a driver-controlled main differ- prevent dirt and debris from entering ential lock is firmly capped to prevent loss of the axle. WARNING! air pressure from the recovery vehicle if it is supplying air pressure. An open air line on the recovered vehicle CAUTION will cause a leak in the air system of the re- covery vehicle if both vehicles’ brake sys- 1. Lift driving wheels off the ground or Water, dirt and other material can tems are connected. This could cause a remove the driveline and axle shafts enter an open hub or axle. This can loss of system air, which can cause the before towing the vehicle. contaminate the axle fluid and cause service brakes not to function, resulting in possible damage to components. the sudden application of the spring brakes Ensure that the hubs are covered causing wheel lock-up, loss of control, or CAUTION with plastic whenever a drive axle overtake by following vehicles. You could be shaft is removed. in an accident involving death or personal injury. Ensure that any air line that has been Failure to lift the driving wheels off removed from a driver-controlled main differ- the ground or remove the driveline ential lock is firmly capped to prevent loss of and axle shafts before towing the How to Manually Lock a Differential air pressure from the recovery vehicle if it is vehicle could seriously damage your Always lock the differential when the axles supplying air pressure. vehicle. All lubricating and clutch ap- plication oil pressure is provided by are being removed to aid in re-installation. an engine-driven pump, which does

42 Y53-6096-1A1 (01/17) EMERGENCY - How to Recover a Vehicle

• If you don’t desire to use the recovered vehicle’s brakes, ensure CAUTION that you cage the spring brakes before attempting to move the A recovered vehicle will have no operational vehicle. brake system. Additionally, the rear axle 2 spring brakes will probably be applied. 1. Remove the air line and firmly cap the air line from the vehicle. (2) 2. Remove the caging bolt from its storage hole. (1) 3. Screw the caging bolt into the air line hole. (2) When fully engaged, a 0.25 - 0.5 in. (6.35-12.7 mm) space will remain between the air cylinder and the bolt head. This action will lock the differential by pushing a piston into a “lock” position. 1. Caging bolt storage location 2. Location of air line to differential lock actuator • If you desire to use the recovered vehicle’s brakes, ensure that the vehicles air system is connected to that of the recovery vehicle. Also ensure that any air line that has been removed from a driver- controlled main differential lock is firmly capped to prevent loss of air pressure from the recovery vehicle.

Y53-6096-1A1 (01/17) 43 EMERGENCY - How to Recover a Vehicle

Recovery Hitch Capacities The maximum rated loads for vehicle recovery varies depending on the direction 2 or angle of pull. These capacities are listed in the table below and are for the two hitches working together, simultaneously.

Direction of Pull Maximum Capacity (lb)

Directly Forward 80,000 lb

Directly Vertical or 14,600 lb Horizontally to the Side

45 degrees in any Direction 20,000 lb

44 Y53-6096-1A1 (01/17) EMERGENCY - How to Recover a Vehicle

What are the Best Practices for 1. Into the pinion cage, add 1 pint (.47 Recovery Rigging? liter) of lubricant or into the interaxle differential, add 2 pints (.94 liter) of Use these guidelines when recovering a approved lubricant. vehicle with rigging and hitches. 2. After adding the specified type and 2 amount of lubricant, drive the CAUTION vehicle. It should be unloaded. Drive 1 to 2 (1.5 to 3 km) at a speed lower than 25 mph (40 km/h). This Recovery pull maximums assume the tow rigging evenly distributes the load between will thoroughly circulate the lubricant both recovery hitches. See examples in Re- through the assembly. covery Rigging for details. Serious damage 3. If the parking brakes were manually to the vehicle may occur if rigging is not Use a double chain or cable setup that released, they will need to be connected properly. distributes the load equally to both hitches. modified back to their normal See 1 or 2 in Recovery Rigging illustration. operating condition. 4. If the differential lock was manually CAUTION Never loop a single chain or cable through locked, then the caging bolt needs both hitches (3). to be put back in its storage location When recovering ditched or bogged vehi- cles, stay well below Maximum Capacities. Use a spreader or equalizer bar to and the differential lock air line Even at loads below maximum, the physical distribute the load on both hitches (1). needs to be re-installed in its normal strain of recovering a vehicle could damage position. axles, suspensions, fifth wheels, etc. If no spreader bar is available, connect the main tow chain or cable no closer than 6 ft. Add lubricant back to the axles after from the vehicle (2). recovering the vehicle and before putting it back in to service. Returning to Service After Recovering Once the vehicle is recovered, the axles need to have oil added to prevent gear damage during operation.

Y53-6096-1A1 (01/17) 45 EMERGENCY - How to Recover a Vehicle

What to do if the Vehicle is Stuck in Follow these practices to avoid Towing the Vehicle Sand, Mud, Snow or Ice transmission damage: Towing the vehicle should be done by • Always start vehicle in motion with either an authorized dealer or a 2 WARNING! the shift lever in first gear. commercial vehicle towing service. The • Be sure that transmission is fully dealer or commercial towing service will Do not spin the wheels faster than 35 mph engaged in gear before releasing have the necessary equipment to safely (55 km/h). Spinning a at the clutch pedal (manual only). tow the vehicle and should be able to make readings faster than 35 mph (55 km/h) can • Do not shift into reverse while the arrangements to limit any damage to the be dangerous. Tires can explode from spin- vehicle. The towing service and the dealer ning too fast. Under some conditions, a tire vehicle is moving. should be aware of towing regulations and may be spinning at a speed twice that • If the vehicle needs to be recovered shown on the speedometer. Any resulting from being stuck, do not permit the safety precautions. tire explosion could cause injury or death to vehicle to be towed for long The towing service will ensure that the a bystander or passenger, as well as exten- distances without removing the following precautions are taken: sive vehicle damage: including tire, trans- driveshaft. mission and/or rear axle malfunction. • Use of a safety chain system. If tire chains are needed, make sure they • Abide by all local towing regulations. These suggestions are provided to improve are installed on both sides of the driving the ability to free a vehicle if the vehicle axle. Installing chains on only one side of • Ensure that the towing device does gets stuck in sand, mud, snow, or ice: the axle can cause equipment damage. not contact any surfaces that could be damaged while in transit. • Move the gearshift lever or selector • If towing from the front, ensure that from First to Reverse. CAUTION the rear axles are prepared for • Apply light pressure on the towing. accelerator pedal while the Chains on the tires of only one tandem axle • If towing from the rear, ensure that transmission is in gear. can damage the driveline U-joints and the all body components such as roof, interaxle differential. Repairs could be costly • Remove your foot from the side and chassis fairings are accelerator while shifting. and time-consuming. Failure to comply may result in equipment damage. secured properly to avoid damage • Do not race the engine. while in transit. • For best traction and safety, avoid spinning the wheels.

46 Y53-6096-1A1 (01/17) EMERGENCY - How to Recover a Vehicle

WARNING!

Secure the roof, side and chassis fairings while towing from the rear. An unsecured 2 fairing may come off of the vehicle during transit. Failure to secure the fairings while towing may cause an injury accident result- ing in death or personal injury.

Y53-6096-1A1 (01/17) 47 EMERGENCY - How to Recover a Vehicle

2

48 Y53-6096-1A1 (01/17)

Chapter 3 | CONTROLS

In this Chapter: 3 Getting to Know the Dash...... 52 Gauges in the Center Cluster...... 54 Left Hand Accessories Overhead...... 55 Right Hand Accessories Overhead for Dual Sit Steer Applications...... 55 Guide to the Warning Symbols...... 55 Introduction...... 65 Speedometer...... 65 Tachometer...... 66 Engine - Coolant Temperature...... 66 Fuel Level...... 66 Engine, Oil Pressure...... 67 Diesel Exhaust Fluid (DEF)...... 68 Vehicle Air Pressure...... 68 Driver Information Display...... 68

CONTROLS -

Information Display...... 69 Virtual Gauges...... 69 Engine Speed RPM Detail...... 70 Ignition Timer...... 70 3 Trip Information...... 70 Truck Information...... 71 Diagnostic Display...... 71 Transmission Display...... 71 Active Warnings...... 72 Clock...... 72 Settings...... 72 Menu Control Switch...... 73 Switches in the Center Console...... 73 Dual Station Switch...... 74 Steering Column Controls...... 74 How to Use the Turn Signal...... 74 How to Turn on High Beams...... 75 How to Momentarily Flash High Beams...... 75 How to Flash Marker and Clearance Lights...... 76

50 Y53-6096-1A1 (01/17) CONTROLS -

Operate the Windshield Wipers...... 76 How to Spray Windshield Washer Fluid...... 77 Trailer Brake Hand Valve...... 77 Heating and Air Conditioning...... 77 Air Conditioner Control Panel...... 78 3 How to Manually Control the Air Conditioner for the Cab...... 80 Dash Switches...... 80

Y53-6096-1A1 (01/17) 51 CONTROLS - Getting to Know the Dash

steer, dual sit and dual steer and right hand Getting to Know the Dash stand up configuration.

Cab interior dashboard overview for Low Cab Forward applications with left hand 3

1. Information Display 2. 3. Automatic Transmission Gear Selector 4. Air Switches and Parking Brake 5. Electronic Switches for Controls from Either Driving Position

52 Y53-6096-1A1 (01/17) CONTROLS - Getting to Know the Dash

6. Left Hand Side Electronic Switches 7. Arm Rest, Storage (Optional) Right Hand Stand Up 12. Accelerator Pedal Right Hand Dual Drive Dual Sit Cab Station Station Left Hand Drive Station Right Hand (Curb) Side Instrument Cluster 1 2 3 for Dual Sit and Steer Applications 4 3 5 6 7 8 9 10

1. Gauges 11 12 1. Gauges 2. Information Display 2. Information Display 1. Parking Brake 3. Ignition Switch 3. Engine Start/Stop Switch 2. Flipper Brake Valve 4. Menu Control Switch 4. Menu Control Switch 3. Menu Control Switch 4. City Horn 5. Information Display 6. Headlight Switch 7. Tranmission Controls 8. Engine Stop/Start 9. Turn signal / Windshield Wipers 10. Gauges 11. Brake Foot Pedal

Y53-6096-1A1 (01/17) 53 CONTROLS - Gauges in the Center Cluster

Right Hand Standup Drive Station sequence. The total sequence should only take no more than 10 seconds to complete. Right Hand (Curb) Side Instrument Cluster Completing this sequence will indicate a Gauges in the Center for Stand Up Applications successful Self Test. Have your Cluster instrumentation system checked by a 1 qualified service technician if does not 3 2 successfully complete. Standard Gauges Audible Alarm 3 The audible alarm will sound during the 4 Instrumentation System Self Test. The audible alarm will also sound in conjunction with most warning lights. These events include but are not limited to headlight on, fifth wheel, stop engine, primary/secondary air, and driver door open warnings. Optional Icons 1. Tachometer Additional icons may be operational 1. Information Display 2. Information Display depending on individual vehicle 3. Secondary Air Pressure 2. Speedometer specifications. These will be included in the 3. Air Pressure Instrument System Self Test. 4. Fuel Level 4. DEF Gauge 5. Diesel Exhaust Fluid 6. Primary Air Pressure Instrument System Self Test NOTE 7. Speedometer When the ignition switch is turned on the Some optional lights may illuminate even instrumentation system will undergo a Self though your vehicle is not equipped with Test. This test will verify the operation of that particular feature. the gauges and warnings. During the Instrumentation System Self Test, multiple warning icons will be displayed in a

54 Y53-6096-1A1 (01/17) CONTROLS - Left Hand Accessories Overhead

Right Hand Overhead Acessories indicated on the right side of the view next Left Hand Accessories to an icon that represents the severity.

Overhead WARNING! 1. Map Light These accessories are located in the left 2. Radio extender controls Do not ignore a warning light or audible hand side overhead compartment of the 3. Air Conditioner alarm. These signals tell you something is low cab forward application. wrong with your vehicle. It could be a failure 3 in an important system, such as the brakes, Left Hand Overhead Acessories which could lead to an accident causing Guide to the Warning death or injury. Have the appropriate system Symbols checked immediately. Some messages can be managed by the 1. Radio The warning lights and audible alarm may operator while others may require an 2. Air Conditioner indicate a system malfunction. Check the authorized dealer repair. The following is a 3. Map Light lights frequently, and respond properly as list of Warning Light/Indicator Symbols that soon as you see one go on. These lights appear in the instrument cluster. could save you from a serious accident. Right Hand Accessories • The Symbol Name A single warning will result in the symbol • the appearance of the Symbol Overhead for Dual Sit and text to alert the operator. Multiple • the Symbol Color when it is Steer Applications warnings will appear a smaller icons with a illuminated maxiumum of six icons appear in the view. • whether the symbol is standard If more than six are active, the MCS can be (Std) or optional (Opt) These accessories are located in the right used to view the others active warnings. hand side overhead compartment of the The total number of active warnings are low cab forward application and dual sit and steer configuration.

Y53-6096-1A1 (01/17) 55 CONTROLS - Guide to the Warning Symbols

Symbol Name Color Standard or Optional

Axle, Stability Control Yellow OPT

Axles, Traction Control Yellow OPT 3 Axle, Temperature Yellow OPT Brakes, Anit-Lock Brake System Yellow STD

Brake, Park Brake Red STD

Brakes, Trailer Anti-Lock Brake System Yellow STD

Differential, Inter Axle Lock Yellow OPT

Emissions, Diesel Particulate Filter (DPF) Yellow STD

Emissions, Diesel Exhaust Fluid Quality Yellow STD

Emissions, Engine Derate Yellow STD

Emissions, High Exhaust System Temperature Yellow STD

Emissions, Malfunction Indicator Lamp Yellow STD

Engine, Air Filter Restriction Yellow STD

Engine, Check Engine Yellow STD

Engine, Low Coolant Level Yellow STD

Engine, Coolant Temperature Red STD

Engine, Oil Pressure Red STD

Engine, Oil Temperature Red OPT

Engine, Overspeed Air Shutdown Red OPT

56 Y53-6096-1A1 (01/17) CONTROLS - Guide to the Warning Symbols

Symbol Name Color Standard or Optional

Engine, (Brake) Yellow OPT

Engine, Stop Engine Red STD

Engine, Wait To Start Yellow OPT

Fifth wheel, Slide Unlocked Red STD 3

Front Axle Engaged/Disengaged Yellow OPT

Fuel Water In Fuel (WIF) Yellow OPT

Lights, High Beam Blue STD

Seat Belt Fasten Red STD

Suspension Dump Yellow STD

Tire Inflation (TPMS) Yellow OPT

Transmission, Check Red OPT

Transmission, Oil Temperature High Yellow OPT

Transmission, Neutral Yellow OPT

Turn Signal, Left Green STD

Turn Signal, Right Green STD

Voltmeter Red STD

Monitors wheel speed for poor traction. If a wheel begins to slip due to poor traction, it Axle, Traction Control may reduce engine power or apply brakes in an effort to regain traction.

Y53-6096-1A1 (01/17) 57 CONTROLS - Guide to the Warning Symbols

• Illuminates during the power-on self- problem is detected, the ESC test when the ignition is turned ON. Warning lamp will turn on and stay It turns off after a few seconds if no NOTE on. system problems are detected. If an • Illuminates when the ESC system is ATC problem is detected, the ATC For more information about the stability con- trol system installed on your vehicle, please regulating individual wheel brakes to warning lamp will turn on and stay refer to additional material supplied with this correct the vehicle’s direction of on. operator manual, included in your glove box travel. (Refer to Advanced ABS with 3 • Illuminates when the ATC is informational packet. Stability Control for more regulating wheel spin and turns off information.) after the traction control event has ended. Axle, Stability Control WARNING! • Flashes continuously when the ATC/ Deep Snow & Mud switch is If this chassis is equipped with an electronic turned on, indicating that this stability control (ESC) and is modified (e.g. feature is active. adding or removing an axle, converting from a truck to a tractor, converting from a tractor to a truck, changing the body, lengthening of WARNING! the and/or frame, relocating Calculates the driver’s intended path of frame components, or modifying pneumatic If this chassis is equipped with an electronic or electrical ABS/ESC harnesses) the ESC travel from wheel speed and steering angle stability control (ESC) and is modified (e.g. must be disabled by a qualified technician. If adding or removing an axle, converting from sensors, then compares calculations to the you have any questions, contact your au- a truck to a tractor, converting from a tractor actual direction of travel. The system uses thorized dealer. Failure to comply may result to a truck, changing the body, lengthening of individual wheel brakes to re-adjust the in death, personal injury, equipment or prop- the wheelbase and/or frame, relocating path of the vehicle. erty damage. frame components, or modifying pneumatic or electrical ABS/ESC harnesses) the ESC • The Stability Control Icon (ESC or must be disabled by a qualified technician. If Electronic Stability Control) you have any questions, contact your au- illuminates during the power-on self thorized dealer. Failure to comply may result test when the ignition is turned ON. in death, personal injury, equipment or prop- It turns off after a few seconds if no erty damage. system problems are detected. If a

58 Y53-6096-1A1 (01/17) CONTROLS - Guide to the Warning Symbols

axle and type of lubricant. Very high • Illuminates during normal operating temperatures signal a need to have your conditions to indicate a problem with NOTE axle(s) lubrication checked. the ABS System. • Illuminates when a problem exists For more information about the stability con- with Automatic Traction Control trol system installed on your vehicle, please CAUTION refer to additional material supplied with this (ATC). operator manual, included in your glove box Driving with very hot temperatures in your informational packet. See Also 3 rear drive axles can cause serious damage Automatic Traction Control on page 107 to axle bearings and seals. Have your axle Axle, Front Driven lubrication checked if you notice a sign of overheating. Brake, Park Brake This icon will appear when the front driven axle is engaged. Depending on the vehicle configuration, there may be a single gauge for more than just the forward and rear driver. The icon will have a label FWD or REAR to represent which axle the temperature is causing the warning light. Axle, Oil Temperature (Forward or Illuminates in the status indicator when Rear) Brakes, Anti-Lock Brake System parking brakes are applied.

This warning icon is to alert the operator of Brakes, Trailer Anti-Lock Brake elevated axle lubricant temperature. System

Illuminates during the Instrumentation System Self Test. Have the ABS system These temperatures will vary with the kind checked by an authorized dealer if the ABS of load you are carrying and the driving Illuminates during the Instrumentation Warning Lamp stays on for more than 3 conditions you encounter. Maximum axle System Self Test and the tractor/truck is seconds. temperature may vary, depending upon the connected with a ABS equipped trailer.

Y53-6096-1A1 (01/17) 59 CONTROLS - Guide to the Warning Symbols

Illuminates during normal operating conditions to indicate a problem with the skin. Allow adequate cooling time before ap- WARNING! proaching, working on or near any part of Trailer ABS System. This should be the exhaust system or surrounding compo- checked by an authorized dealer as soon If this light is on, do not park in an area of nents. as possible. combustible vapors or materials. You must keep combustibles at least five (5) feet away Illuminates when the temperature and exhaust components NOTE from the exhaust (outlet) stream (as it exits 3 the tail pipe) while the HEST lamp isillumi- become extremely hot. nated. Always park your vehicle outside. Tractors/Trucks and trailers built after Failure to do so could ignite an explosion or 03/01/2001 must be able to turn on an In- harm bystanders which could result in seri- Emissions, Malfunction Indicator Cab Trailer ABS Warning Lamp (per U.S. ous injury. Lamp FMVSS121). The industry chose Power Line Communication (PLC) as the standard method to turn it on. On trailers built prior to 03/01/2001 verify trailer ABS system status WARNING! via the required external warning lamp mounted on the trailer. The indicator lamp If this light is on, do not park in an area on the trailer should be yellow and identified where people are close by. You must keep Illuminates when an engine emissions with the letters ABS. combustibles at least five (5) feet away failure has occurred. The vehicle can be fromthe exhaust outlet while the HEST lamp safely driven but should be serviced to See Also is illuminated. Failure to do so could result inserious injury. correct the problem. The situation should Automatic Traction Control on page 107 not be considered an emergency. In some cases, the Malfunction Indicator Lamp will Emissions, High Exhaust System WARNING! activate in conjunction with the High Exhaust Temperature, Diesel Particulate Temperature If this light is on, temperature of the tailpipe, Filter (DPF) and Diesel Exhaust Fluid exhaust pipes, the diesel particular filter (DEF) Warning Lights. (DPF) / selective catalytic reduction (SCR) device and surrounding components includ- ing enclosures and steps becomes elevated during engine operation or any regeneration event and can cause serious burns to the

60 Y53-6096-1A1 (01/17) CONTROLS - Guide to the Warning Symbols

Emissions, Engine Derate Diesel Exhaust Fluid (DEF) Gauge The aftertreatment system requires attention and as a result is derating the output of the engine. Engine aftertreatment system includes a diesel particulate filter and DPF warning lamp. 3 Diesel Exhaust Fluid (DEF) Lamp Engine aftertreatment system includes a diesel exhaust fluid (DEF) warning lamp on The operator should perform a stationary the DEF gauge and additional warning 1 2 regeneration of the DPF and check the lamps in the instrument cluster. DEF fluid level. Seek service at the next DEF Warning Lamp in Instrument Cluster 1. DEF Symbol available opportunity if the warning icon 2. DEF Gauge Warning Lamp stays on. The DEF lamp(s) will illuminate when the fluid in the DEF tank reaches a low level. If Diesel Particulate Filter (DPF) the lamp illuminates but the level is full, Warning Lamp seek service immediately for DEF fluid quality or DEF equipment repair. This warning symbol will appear when the DPF needs to be regenerated and then also during the regeneration cycle. This Fifth Wheel Slide, Unlocked icon may also appear if the system is attempting to automatically regenerate while the vehicle is in Power Take Off operation mode.

Y53-6096-1A1 (01/17) 61 CONTROLS - Guide to the Warning Symbols

This icon will appear when the switch is in Engine, Coolant Temperature Engine, Oil Pressure the UNLOCKED position. This warning will appear when the engine If oil pressure drops below the minimum coolant temperature has reached a value psi a red warning light in the gauge will turn Engine, Check Engine that needs attention. on, the Stop Engine light will come on and an audible alarm tone will sound.

3 CAUTION Illuminates when a non emissions related problem exists, but the vehicle can still be See Also Continuing to operate your vehicle with in- safely driven. Vehicle should be serviced to sufficient oil pressure will cause serious en- Engine is Overheating on page 31 correct the problem but the situation should gine damage. Failure to comply may result not be considered an emergency. in equipment or property damage. Engine, Oil Temperature It is important to maintain oil pressure Engine, Low Coolant Level This warning icon will turn on if the oil within acceptable limits. For further temperature exceeds the maximum limits, information on engine oil and normal operating pressures, see the Engine Operation and Maintenance Manual. If the oil pressure fails to rise within 10 seconds after the engine starts, stop the engine and lluminates with an audible alarm indicating determine the cause. Check the engine critically low coolant level. The vehicle (See the Engine Operation and manufacturer's manual for the correct oil must be serviced to correct the problem Maintenance Manual for details.) pressure ranges for your vehicle's engine. but the situation should not be considered If the oil pressure suddenly drops, or the See Also an emergency. audible alarm and engine oil pressure Low Oil Pressure Lamp on page 31 warning light come on while driving. For See Also Check Engine Oil Level on page 187 further information on engine gauges and Engine is Overheating on page 31 operating your engine properly, refer to Engine Maintenance material. See Also

62 Y53-6096-1A1 (01/17) CONTROLS - Guide to the Warning Symbols

Low Oil Pressure Lamp on page 31 switch is turned on. (Engine retarders are Engine, Wait To Start Check Engine Oil Level on page 187 an option.) This warning icon will appear when the system needs some time before attempting Voltmeter Engine, Stop Engine to start the engine. This icon will appear when the engine is ON and the charging system voltage is either below 10 volts or above 15 volts. 3

Illuminates and an audible alarm tone will You may see this appear if the system has sound when a major engine system detected a situation where the starter is too problem exists. hot and needs to cool down. Alternatively, you may see it when the engine grid heater Engine, Overspeed Air Shutdown is on and needs some time to warm up. WARNING! (PACCAR PX and ISL engines)

If the Stop Engine warning lamp illuminates, it means you have a serious engine system Engine, Air Filter Restriction problem. This should be considered an emergency. You should stop the vehicle as This icon indicates that the engine air filter Illuminates when the Engine overspeed air safely as possible and turn OFF the ignition. needs to be maintained. shutdown system is activated. The vehicle must be serviced and the prob- lem corrected before driving again. Failure to comply may result in death, personal in- Engine, Retarder (Brake) jury, equipment or property damage.

See Also Stop Engine Lamp on page 30

Illuminates when the engine retarder (compression brake or )

Y53-6096-1A1 (01/17) 63 CONTROLS - Guide to the Warning Symbols

Suspension Dump engine. Consult the engine manufactures CAUTION manual or engine dealer for fuel restriction specifications. Continued operation with the Air Filter Re- striction Gauge reading 25 in. H2O may Fuel Water In Fuel (WIF) cause damage to the engine. Inspect the fil- ter and replace if necessary. Holes in the 3 paper element render an air cleaner useless Illuminates when suspension air bags are and may cause the Air Filter Restriction deflated. Gauge to give a false reading, even if the el- ement is clogged. Replace the element if it is damaged. Seat Belt Fasten Illuminates when water has been detected in the fuel. Fuel Filter Restriction Lights, High Beam This warning will appear when there is a restriction from the fuel filter to the fuel pump. Replace the filter with an approved filter only. Do not substitute the wrong Illuminates when the ignition key is turned micron element. on as a reminder to fasten your seat belt. Illuminates when the high beams are on. This icon will flash with audible alarm if the are left ON when the door is Tire Inflation (TPMS) opened and the key switch is OFF. In addition, this icon will flash, but without an audible alarm, if there is a problem with NOTE the low beam headlights or the low beam headlight wiring. In such event, the high The maximum allowable restriction could beam headlights will turn on at 50% normal vary according to the type or make of the brightness.

64 Y53-6096-1A1 (01/17) CONTROLS - Introduction

Illuminates when tire pressures need to be Transmission, Oil Temperature checked. (Tire Pressure Monitoring System High is an optIion.) Introduction

Transmission, Check On the pages that follow you will find descriptions of some of the gauges on your instrument panel. 3 Some gauges will display a red LED Illuminates when the oil in the main warning light, with some accompanied by transmission becomes too hot. an audible alarm, whenever the limits of the function being displayed are exceeded. Illuminates when transmission has Turn Signal, Left recorded a fault code. This icon may also appear in the Transmission Display menu WARNING! of the Driver Performance Center. If the user is in this display menu, the icon does Do not ignore a warning light or audible not indicate a fault code. alarm. These signals tell you something is wrong with your vehicle. It could be a failure Blinks when the left turn signal or the in an important system, such as the brakes, Transmission, Neutral hazard light function is operating. which could lead to an accident causing death or injury. Have the appropriate system This symbol will appear when the checked immediately. transmission is in Neutral. Turn Signal, Right

Speedometer

The Speedometer indicates the vehicle speed in miles per hour (mph) and in Blinks when the right turn signal or the kilometers per hour (km/h). hazard light function is operating.

Y53-6096-1A1 (01/17) 65 CONTROLS - Tachometer

Tachometer

Engine speed information. The Tachometer measures the engine In addition to indicating empty and full, the speed in revolutions per minute (rpm). gauge(s) also indicate the fuel level in 3 Under normal operating conditions the graduated increments. When the fuel level The rpm detail is also available as a water temperature gauge should register for the tank is below 1/4 full, a red warning viewable screen in the instrumentation between 165° and 205°F (74° and 90°C). light in the gauge will come on. cluster as a virtual gauge. The tachometer Under certain conditions, somewhat higher is a useful gauge when attempting to drive temperatures may be acceptable. But the efficiently. It will let you match driving maximum allowable temperature is 210°F WARNING! speed and gear selection to the operating (99°C), except for certain special engines. Do not carry additional fuel containers in range of your engine. If the engine speed Check your engine manual to be sure. your vehicle. Fuel containers, either full or gets too high, you can select a higher gear See Also empty, may leak, explode, and cause or to lower the rpm's. If the engine speed feed a fire. Do not carry extra fuel contain- drops too low, you can select a lower gear Engine is Overheating on page 31 ers. Even empty ones are dangerous. Fail- to raise the rpm's. To avoid engine Engine is Overheating on page 31 ure to comply may result in death or person- damage, do not let the pointer exceed al injury. maximum governed speed. (See your Engine Operation and Maintenance Manual for rpm recommendations.) Fuel Level

The indicates the total Engine - Coolant (approximate) amount of fuel in the fuel Temperature tank.

The water temperature gauge shows the temperature of the engine coolant.

66 Y53-6096-1A1 (01/17) CONTROLS - Engine, Oil Pressure

WARNING! NOTE CAUTION

Diesel fuel in the presence of an ignition This vehicle may be manufactured with dif- Continuing to operate your vehicle with in- source could cause an explosion. A mixture ferent fuel systems and different draw tube sufficient oil pressure will cause serious en- of or alcohol with diesel fuel in- locations. Because of this and the amount of gine damage. Failure to comply may result creases this risk of explosion. Do not re- road crown, it is recommended that you do in equipment or property damage. move a fuel tank cap near an open flame. not operate your vehicle with less than one- 3 Use only the fuel and/or additives recom- quarter of your truck’s fuel capacity. Allowing It is important to maintain oil pressure mended for your engine. Failure to comply the fuel level to go below one-quarter of ca- within acceptable limits. For further may result in death, personal injury, equip- pacity could result in the lack of fuel to keep ment or property damage. the engine running. In addition, you will want information on engine oil and normal to keep the fuel tanks at least half-full to re- operating pressures, see the Engine duce condensation of moisture in the tanks. Operation and Maintenance Manual. If the CAUTION This moisture can damage the engine. oil pressure fails to rise within 10 seconds after the engine starts, stop the engine and Use only Ultra Low Sulfur Diesel (ULSD) See Also determine the cause. Check the engine Fuel, as recommended by engine manufac- Final Stopping Procedures on page 127 manufacturer's manual for the correct oil turers. If you need further information on pressure ranges for your vehicle's engine. fuel specifications, consult the Engine Oper- If the oil pressure suddenly drops, or the ation and Maintenance Manual. audible alarm and engine oil pressure Engine, Oil Pressure warning light come on while driving. For further information on engine gauges and NOTE If oil pressure drops below the minimum operating your engine properly, refer to psi a red warning light in the gauge will turn Engine Maintenance material. For Export vehicles, the fuel gauges will not on, the Stop Engine light will come on and state: ULTRA LOW SULFUR DIESEL FUEL See Also an audible alarm tone will sound. ONLY. Low Oil Pressure Lamp on page 31 Check Engine Oil Level on page 187

Y53-6096-1A1 (01/17) 67 CONTROLS - Diesel Exhaust Fluid (DEF)

Each gauge indicates the amount of air pressure in each system in pounds per cle until it has been properly repaired or serviced. Diesel Exhaust Fluid (DEF) square inch (psi). On vehicles equipped with metric air pressure gauges, the gauge The diesel exhaust fluid gauge shows the face plate includes a kPa (major) scale and WARNING! approximate amount of DEF fluid in the psi (minor) scale. DEF tank. The air pressure warning light and the audi- 3 ble alarm tone indicate a dangerous situa- NOTE tion: there is not enough air pressure in the CAUTION air tanks for repeated braking and the brake Be sure the air pressure registers more than system has failed. Without the use of your Use Diesel Exhaust Fluid only. Failure to do 100 psi (690 kPa) in both service systems service brakes your spring brakes could so may damage components of the Diesel before you move the vehicle. suddenly apply causing a wheel lockup, loss Particulate Filter (DPF). of control, or overtake by following vehicles. This may cause an accident resulting in Besides empty and full, the gauge also NOTE death or personal injury. Bring the vehicle to indicates 1/4, 1/2, and 3/4 of total capacity. a safe stop right away, while you still have control of the vehicle. DEF fluid is required to meet certain If the pressure in either or both circuits falls emission requirements. Do not allow your below 65 psi (448 kPa), a red warning light See Also DEF tank to remain empty. Please refer to in the gauge will turn on and an audible alarm tone will sound when the engine is Low Air Alarm on page 30 your emission supplemental manual for running. more details about DEF fluid.

WARNING! Driver Information Display Vehicle Air Pressure If the air pressure falls below 60 psi (414 kPa) the spring brakes may stop the vehicle The display can show multiple warning The Primary Air Pressure gauge indicates abruptly, which could cause an accident re- lights. Warning information will appear pressure in the rear braking system. The sulting in personal injury or death. Observe momentarily and then will minimize in the Secondary gauge indicates pressure in the the red warning lamps on the gauges. If one screen. Reviewing the warnings can be front braking system. comes on, do not continue to drive the vehi-

68 Y53-6096-1A1 (01/17) CONTROLS - Information Display

done by navigating the menu via the Menu 4. Clock alarm sounds Control Switch. function is identified in the following descrip- 5. Driver or passenger door is opened tions. 6. Hazard warning lamp switch is on The various functions may be accessed by Information Display navigating through Menu Screens using Virtual Gauges the MCS. The bullets in the Menu Bar allow access to each item by pushing the The Driver Information Display is located at The virtual gauges function is selected 3 MCS when the desired bullet is highlighted. the top of the instrument cluster. through the rotary MCS knob and is available in both parked and driving WARNING! modes. Rotating the MCS to this menu will allow Do not look at the Instrument Cluster Dis- you to view the most recent virtual gauge. play for prolonged periods while the vehicle is moving. Only glance at the monitor briefly while driving. Failure to do so can result in the driver not being attentive to the vehicle’s road position or situation, which could lead to an accident and possible death, personal injury or equipment damage. In addition to a blank screen, the following It displays important vehicle information are menu items and the information through a constant monitoring of systems available within each menu selections. While in this menu, press the MCS to scroll when any of the following conditions are through all of the available virtual gauges met: on the truck. NOTE 1. Ignition key in ON or ACC positions 2. Ignition timer is active Some Driver Information Display functions 3. Menu Control Switch (MCS) button are only accessible when the vehicle is is pushed (independent of ignition parked. Other functions are accessible while the vehicle is moving or when parked. Each key switch position)

Y53-6096-1A1 (01/17) 69 CONTROLS - Engine Speed RPM Detail

3 This function allows the driver to set a Trip Information functions area accessible Engine Speed RPM Detail timer to shut off the truck. After the timer is when when parked: set, the ignition key may be turned to the 1. Instant Information RPM reading of actual engine RPM off position and removed. The engine will (Accessible while parked or driving). continue to run for the programmed time. • Trip Economy The ignition timer may be set for up to 30 • Average Speed minutes. 2. Trip Result • Trip Distance Trip Information • Trip Eng. Hours 3. Idle Information.

When accessing the trip information menu, • Trip Idle Hours Engine RPM between the chevron markers push the MCS on this menu (bullet). To • Trip Idle % indicates efficient engine operating , push the MCS again. To reset the trip 4. PTO Information. conditions. values, press the Trip Reset Button on the main gauge instrument • PTO Hours cluster. • PTO Trip Hours Ignition Timer • PTO Trip % To reset the Trip Values, press the Trip Ignition timer is set from this menu and Odometer Reset Button on the main gauge accessible while parked only. instrument cluster.

70 Y53-6096-1A1 (01/17) CONTROLS - Truck Information

While moving, this menu will only display Engine Make instantaneous fuel economy. Model Engine Controller Software Version Governed Speed Limit Engine Power 3 Transmission Make Model Transmission The diagnostic display menu (bullet) will Controller Software indicate a fault that is generated by the Version vehicle's Engine, ABS and/or Transmission systems. While on this menu item the Truck Information Antilock-Brake Make display will either indicate "No Faults System Model Found" or "Faults Found". If "Faults Found" This menu provides information about the is active, pushing the MCS will display new vehicle such as serial numbers. ABS Controller menus for more information. Software Version

Transmission Display Diagnostic Display This menu will show gear number that Diagnostic fault information can be coincides with the current transmission expanded in this menu. This information is gear selected. The menu also displays the available when the vehicle is parked. transmission icon to let the user know what Chassis Chassis Number Fleet ID Cab Controller Software Version

Y53-6096-1A1 (01/17) 71 CONTROLS - Active Warnings

screen they are in. (Does not indicate a To turn alarm ON/OFF: fault code.) Clock 1. When in the Settings Menu, scroll through the list of menu items to This information is accessible when the “Alarm”. Press the MCS. vehicle is parked or driving. 2. Press the MCS to turn the alarm ON 3 or OFF. How to Set Time in the Information Settings Display

This information is accessible only when The information display has a clock for 2 the vehicle is parked. time zones and an alarm. This information is available for Automated To set the time for local, home or alarm: Transmissions and is accessible when the The Settings menu screen allows the driver vehicle is parked or driving. Refer to the to view and/or change the following menu 1. When in the Settings Menu, scroll Automated Transmission Operator’s items: through the list of menu items. Manual for additional information. • Alarm ON/OFF • Home/Local Time • Display Format 12 Hour (AM/PM) or Active Warnings 24 Hour (military) • Units of measure This information is accessible when the • Set Alarm Time vehicle is parked or driving. This menu • Set Clock (Home) Time selection will display all active warning 2. Press the MCS to select the item to icons. The display will read “No Warnings” • Set Local Time change. when there are no active warnings. • Set Language (English, Spanish or 3. Rotate the MCS knob to change the French) hour. AM/PM changes when scrolling to “12”. Press the MCS. How to Turn Alarm On/Off

72 Y53-6096-1A1 (01/17) CONTROLS - Menu Control Switch

1. When in the Settings Menu, scroll • Setting values through the list of menu items to • Selecting menu screens "Language". 2. Push 2. Press the MCS. 3. Rotate the MCS to display either • Confirm desired selection English, Spanish or French. 4. Rotate the MCS knob to change the 4. Press the MCS knob to select the Switches in the Center 3 minutes. Scrolling above “59” or desired language. below “ 00” will increment or Console decrement the hour, respectively. 5. Press the button above the MCS to Menu Control Switch These switches are available in the center return to the settings menu. console for either left hand or right hand The MCS is used to navigate the Driver driving position. How to Set Units of Measure Information Display unit. The Menu Control Switch is located on the dash to the right of the . To set the units of measure, such as miles versus kilometers: 1. When in the Settings Menu, scroll through the list of menu items to "Units". 2. Press the MCS. 3. Press the MCS to display either Standard or Metric units.

How to Set Language

The MCS has the following functions: To change the language from English to 1. Marker Ligtht either French or Spanish: 1. Spin 2. Headlights

Y53-6096-1A1 (01/17) 73 CONTROLS - Dual Station Switch

3. Station Selector (for Dual Steer side of the cab cannot be used when right Applications) hand operation is in effect. Vehicle How to Use the Turn 4. Fog Lights operation will revert back to the left hand 5. Mirror Control drive position when the ignition is turned to Signal the OFF position. 6. Cab Lighting Dimmer Control 7. Differential Lock The lever-action turn signal/high beam 8. Differential Lock switch is located on the left side of the 3 Steering Column Controls steering column. Each time a turn indicator 9. Lift Axle is activated the buzzer emits a short beep. 10. Lift Axle The turn signal lever is mounted on the left The ignition key must be turned to ON for 11. Lift Axle side of the steering column. The lever the signal/switch to operate. controls several functions: turn signal, high beam, and windshield wiper control. Dual Station Switch NOTE

If the vehicle turn signals and turn signal in- The dual station switch allows the controls dicators in the dash gauge cluster ever be- for the vehicle from left hand to right hand gin flashing at an accelerated rate (115 cy- operation. cles per minute) when the turn signal lever is in the OFF (center) position, or when a Right/Left turn has been selected, the prob- lem may be related to a failed turn signal switch or turn signal module. In either case, the problem is not a failed bulb. Contact your nearest authorized dealer to have the problem corrected as soon as possible.

1. Push the lever up to engage the 1. Mulitfunction turn signal/wiper/ RIGHT turn signal and down to Pushing this switch will engage electronic washer engage the LEFT turn signal. switchs on the right hand side of the 2. City Horn vehicle. Certain controls on the left hand

74 Y53-6096-1A1 (01/17) CONTROLS - How to Turn on High Beams

How to Turn on High How to Momentarily Flash Beams High Beams

The high beam function is operated by the The "flash to pass" high beam function is same steering column lever for the turn operated by the same steering column 3 2. Release the signal stalk signals. High beams will not turn on if the lever for the turn signals. The high beam headlights are turned off. flash to pass will work if the headlights are 3. The turn signal will cancel when the not on. turn is complete. 1. Gently pull the turn signal lever, Each time the turn indicator is activated the toward the steering wheel, until you 1. Gently push the turn signal lever, audible warning emits a short beep. hear the switch click and the beam away from the steering wheel. changes. WARNING!

After you complete a turn, shut the system off by returning the lever to the "OFF" (cen- ter) position. Failure to shut off a turn signal could confuse other drivers and result in an injury accident. An indicator light in the in- 2. The lever will automatically return strument panel will flash until the turn signal 2. To return to previous beam: pull the when the lever is released. is turned off. lever towards the steering wheel again. The blue indicator light in the instrument panel will momentarily turn ON and the The blue indicator light in the instrument high beams will flash. The high beams will panel will turn ON and the high beams will not remain on if the lever is still pressed. turn on.

Y53-6096-1A1 (01/17) 75 CONTROLS - How to Flash Marker and Clearance Lights

overriding this functionality is attainable via the Settings Menu in the instrument cluster NOTE Operate the Windshield display. Go to Settings - > Wiper Interlock and turn this value to OFF. The “flash to pass” functionality of the head- Wipers light switch is not available for vehicles man- Avoid running the wiper blades over a dry ufactured with High Intensity Discharge This vehicle is equipped with a two speed, windshield to prevent scratching the glass. (HID) headlamps. Please check with local intermittent windshield wiper system. The Spray on washer fluid first. A scratched 3 regulations regarding restrictions on using windshield wiper system is integrated with high beam flashing. windshield will reduce visibility. the exterior lights so that the low beam headlights will turn on when the windshield A seven-position rotary wiper switch wipers turn on. (located on the turn signal lever) operates NOTE the windshield wipers and washer. If you need to use the windshield wipers: Continued pressing of the high beam flash WARNING! will not keep the high beams on. 1. Rotate the end of the turn signal Clean blades regularly with a damp cloth to lever to change the wiper mode remove road film and wax buildup. Do not from off to on. How to Flash Marker and drive with worn or dirty wiper blades. They 2. Continue to rotate the outer knob of can reduce visibility, making driving hazard- the turn stalk lever to adjust the Clearance Lights ous which may lead to an injury accident re- sulting in death or personal injury. wiper speed.

A button on the turn stalk will momentarily flash the marker and clearance lights when CAUTION pushed. 1. Push the small button on the end of Do not use or engine coolant in the windshield washer reservoir, damage to the turn stalk seals and other components will result. • 4 levels of intermittent speeds • Low wiper speed To override this function, turn the headlights on and then off again and the • High wiper speed low beams will turn off. Permanently

76 Y53-6096-1A1 (01/17) CONTROLS - How to Spray Windshield Washer Fluid

How to Spray Windshield Trailer Brake Hand Valve Washer Fluid This hand valve, mounted on the steering wheel column, provides air pressure to This vehicle is equipped with a functrion to apply the trailer brakes only. It operates wash the windshield and simulatenously independently of the foot treadle valve. engage the wipers. 3 1. Fan Control See Also 2. Air Distribution CAUTION Air Brake System on page 106 3. Air Temperature Control If the electric pump is operated for a long 4. Air Conditioner Button for Cold Air period (more than 15 seconds) with a dry 5. Recirculation Button reservoir, the pump motor may be damaged. Heating and Air If you need to use the windshield wipers Conditioning WARNING! washer: This vehicle's heating and air conditioning Do not drive with visibility reduced by fog, 1. Push the outer knob in. system controls are located in the header. condensation, or frost on the windshield. If this vehicle is a Dual Sit and Steer Your view may be obscured, which may re- sult indeath, personal injury, equipment or configuration, there will be a control property damage. For clear visibility and installed above both driver's positions. safe driving it is extremely important for you Vehicles with dual steer configuration will to follow the instructions pertaining to the have two air conditioner controls that can function and use of the ventilation/heating modify the air temperature settings for the and defogging/defrosting system. If in doubt, • Press and hold will activate the cab. consult your dealer. Maximum heating out- washer fluid and wipers. put and fast defrosting can be obtained only after the engine has reached operating tem- • Instant press and release will perature. activate the washer fluid only.

Y53-6096-1A1 (01/17) 77 CONTROLS - Air Conditioner Control Panel

the exhaust fumes may result in death, per- WARNING! sonal injury, equipment or property damage. NOTE

Exhaust fumes from the engine contain - If you are required to idle your vehicle for bon monoxide, a colorless and odorless CAUTION long periods of time, install an auxiliary gas. Do not breathe the engine exhaust gas. heater or automatic idle control. These aux- A poorly maintained, damaged or corroded Do not stay in the vehicle with the engine iliary devices can reduce fuel consumption 3 exhaust system can allow carbon monoxide running or idling for more than 10 minutes and save you money. to enter the cab. Entry of carbon monoxide with the vehicle's Heater and A/C ventilation into the cab is also possible from other vehi- system in RECIRC or at LOW FAN SPEED. cles nearby. Failure to properly maintain Even with the ventilation system on, running NOTE your vehicle could cause carbon monoxide the engine while parked or stopped for pro- to enter the cab, resulting in death or per- longed periods of time is not recommended. sonal injury. If you are parked next to idling vehicles, move your vehicle or do not stay in your ve- hicle for prolonged periods of time. NOTE WARNING! Keep the engine exhaust system and the Never idle your vehicle for prolonged peri- vehicles cab ventilation system properly Air Conditioner Control ods of time if you sense that exhaust fumes maintained. It is recommended that the ve- are entering the cab. Investigate the cause hicles exhaust system and cab be inspected Panel of the fumes and correct it as soon as possi- (1) By a competent technician every 15,000 ble. If the vehicle must be driven under miles (24,140 km) (2) Whenever a change is these conditions, drive only with the win- These symbols for the air conditioner noticed in the sound of the exhaust system operate various system functions. dows open. Failure to repair the source of (3) Whenever the exhaust system, under- body, or cab is damaged.

78 Y53-6096-1A1 (01/17) CONTROLS - Air Conditioner Control Panel

Symbols for the air conditioning control panel

Image Function

The source of air entering the cab can be set to either outside air or recirculation air using the button inside the fan speed control dial. Recirculated air is automatically selected in defrost modes. 3

The fan speed is adjusted by rotating the dial clockwise to increase speed or counterclockwise to decrease speed. Setting the fan dial to "O" turns the HVAC system off.

The button inside the temperature control dial engages the A/C compressor. When activated the indicator on the button will illuminate. During AUTO mode, the A/C button indicator will remain illuminated at all times even though the compressor may be cycling.

Floor Vents

Defrost Vents (and Fresh air intake)

Panel and Floor Vents

Panel Vents

Floor and Defrost Vents (and Fresh air intake)

Y53-6096-1A1 (01/17) 79 CONTROLS - How to Manually Control the Air Conditioner for the Cab

5. Select the recirculation button for FRESH or RECIRC air. How to Manually Control NOTE the Air Conditioner for the The temperature of the air from the vents Fan Control Dial must also be in the ON po- will fluctuate as the vehicle works to Cab sition for A/C to be on. A/C engages auto- achieve the chosen cab temperature. matically in AUTO, defrost and floor/defrost. When idling for short periods of time, keep 3 Information on controls to set cab heating The air conditioner defaults to Manual the fan ON and set the air mode to FRESH and air conditioning. mode when turned on. The fan speed, air air. For vehicles with a sleeper, the cab temperature, and air outlets are selected control can be used to activate/deactivate Temperature The cab temperature is using the dials on the controller. the sleeper HVAC using the button inside Control Set set using the the mode dial. Point temperature control dial. 1. To adjust the fan speed, turn the fan The operating range is control dial clockwise to increase 60°F (16°C) and 84°F speed or counterclockwise to (28°C). Adjustments of decrease speed. Setting the fan dial Dash Switches 2° increments. to "O" turns the HVAC system off. 2. To adjust the temperature setting, This custom vehicle will have a wide Air The button inside the turn the temperature control dial to variety of switch controlled equipment. Conditioner temperature control dial the desired temperature. The However, this particular vehicle may not Button engages the A/C system automatically adjusts the have every switch identified in this section compressor. When outlet air temperature to achieve the of the operator manual. Some air device activated the indicator desired cab temperature. switches on the dash may require that the on the button will vehicle either be at a specific speed, park illuminate. During AUTO 3. Push the snowflake button if the air temperature needs to be colder, this brakes set or another device to be on or off mode, the A/C button for the air device to operate. The indicator will remain button will manually turn on the compressor. instrument display will display information illuminated at all times regarding what needs to change in order 4. To adjust the air distribution, turn the even though the for the air device to operate as expected. air distribution dial to the desired compressor may be The following table provides a complete list position as indicated by the cycling. of icons that may be found on the switch. graphics.

80 Y53-6096-1A1 (01/17) CONTROLS - Dash Switches

Title Color Standard or Optional

Axle, Differential Lock - Tridrive Amber OPT

Axle, Diff-Lock - Dual Amber OPT

Axle, Diff-Lock - Forward Rear Amber OPT

Axle, Diff-Lock - Rear Rear Amber OPT 3

Axle, Diff-Lock - Single Rear Amber OPT

Axle, Diff-Lock - Steer Amber OPT

Axle, Inter-Axle Differential Locked (Tandem) Amber OPT

Axle, Two Speed Green OPT

Back Up Alarm Mute Amber OPT

Batteries, Low Voltage Disconnect (LVD) None STD

Brakes, ABS Off-Road Amber OPT

Brakes, Parking Brake Valve Red STD

Cab Dimmer Switch None STD

Dump Truck Gate Red OPT

Engine, Brake Level None OPT

Engine, Brake On/Off Green OPT

Engine, Cruise Control On/Off Green STD

Engine, Cruise Control Set/Resume None STD

Engine, Fan Override Green OPT

Engine, Heater Green OPT

Y53-6096-1A1 (01/17) 81 CONTROLS - Dash Switches

Title Color Standard or Optional

Engine, Overspeed Air Shutdown (Test) Amber OPT

Engine, Overspeed Air Shutdown (Manual) None OPT

Engine, Remote Amber OPT 3 Engine, Under Hood Air Intake Amber OPT Exhaust, Diesel Particulate Filter (DPF) Regeneration None STD

Fifth Wheel Slide Red OPT

Fuel Heater Amber OPT

Generic Air, Accessory Green OPT

Generic, Spare SPARE Green OPT

Ignition Key Switch None STD

Lights, Auxiliary Green OPT

Lights, Beacon Green OPT

Lights, Daytime Running (Override) Green OPT

Lights, Dome None STD

Lights, Exterior Lights Self Test None STD

Lights, Flood Amber OPT

Lights, Flood ISO 3732 Spare Amber OPT

Lights, Fog Green OPT

Lights, Hazard Red STD

Lights, Headlight and Parking Lights None STD

Lights, Marker / Clearance / Cab None STD

82 Y53-6096-1A1 (01/17) CONTROLS - Dash Switches

Title Color Standard or Optional

Lights, Marker / Clearance / Trailer None OPT

Lights, Park Light None STD

Lights, Spot Green OPT Mud and Snow Traction Control None STD 3 Pintle Hook Green OPT

Power Take-off (PTO) Amber OPT

Power Take-off (PTO), Forward Amber OPT

Power Take-off (PTO), Rear Amber OPT

Roofdenser Green OPT

Suspension, Air Retention Amber OPT

Suspension, Axle, Pusher Green OPT

Suspension, Axle, Tag Amber OPT

Suspension, Dump Amber OPT

Suspension, Third Axle Lift Green OPT

Trailer Air Supply Red STD

Trailer, Axle (3rd Axle) Lift Green OPT

Trailer, Axle Lift Forward Green OPT

Trailer, Axle Lift Rear Green OPT

Trailer, Belly Dump Red OPT

Trailer, Belly Dump Gate Center Red OPT

Trailer, Belly Dump Gate Front Red OPT

Y53-6096-1A1 (01/17) 83 CONTROLS - Dash Switches

Title Color Standard or Optional

Trailer, Belly Dump Gate Rear Red OPT

Trailer, Dump Gate Red OPT

Trailer, Hotline Green OPT 3 Trailer, Suspension Air Dump Amber OPT Transmission, Transfer Case Amber OPT

Transmission, Transfer Case 2 Speed Amber OPT

Winch Clutch Green OPT

Axle, Diff-Lock - Dual Turn switch on to engage Forward Rear Axle Diff Lock.

Axle, Diff-Lock - Steer

Turn switch on to engage Rear Rear Axle Turn switch on to engage Front and Rear Diff Lock. Axle Diff Lock. Axle, Diff-Lock - Single Rear Axle, Diff-Lock - Forward Rear Turn switch on to engage Front Axle Diff Lock.

Axle, Diff-Lock - Rear Rear

Turn switch on to engage Single Rear Axle Diff Lock.

84 Y53-6096-1A1 (01/17) CONTROLS - Dash Switches

Axle, Inter-Axle Differential Locked differential. In addition, a vehicle with If your vehicle is equipped with a Low (Tandem) Tridrive will have an interaxle differential Voltage Disconnect (LVD) feature, the LVD lock switch. is integrated into the main load center. See Also Brakes, ABS Off-Road Axle, Inter-Axle Differential Locked (Tandem) on page 85 3 Axle, Two Speed Turn switch on to engage Inter-Axle Differential Lock.

Axle, Differential Lock - Tridrive Turn switch on to engage ABS Off-Road mode.

If equipped, the two speed axle switch See Also allows you to select axle high and low Anti-Lock Brake Systems (ABS) on page ranges. The low range (Off) provides 107 maximum torque for operating off-highway. The high range (On) is a faster ratio for Brakes, Parking Brake Valve highway speeds.

Batteries, Low Voltage Disconnect (LVD) Pull yellow knob to activate parking brakes.

Tridrives will have these axle differential See Also lock controls and are 2 separate switches. Air Brake System on page 106 FRONT will control the forward rear and REAR will control the center/rear-rear axle

Y53-6096-1A1 (01/17) 85 CONTROLS - Dash Switches

Cab Dimmer Switch Engine, Brake On/Off Engine, Cruise Control Set/Resume

3 Turn switch on to activate Engine Brake This switch is used to alter the brightness system. For more information on when and The Cruise Control Set/Resume switch of the instrument panel lights. how to use the engine brake in your allows you to SET the desired speed or vehicle, see the engine brake owner’s RESUME the desired speed after the manual for additional engine brake cruise control function has been NOTE information. interrupted.

The Switch is an ON or OFF See Also Engine, Cruise Control On/Off switch. The panel lights are on full intensity Engine, Cruise Control On/Off on page 86 during the day and go to Dimmer mode when headlamps are on. Engine, Fan Override Gate

Turn switch on to activate CruiseControl System. If the vehicle has the optional The optional engine fan switch allows you Turn switch on to open Dump Truck Gate. Predictive cruise control, this switch will to control the engine fan manually or have a different icon and will be located on automatically. the steering wheel. See Also See Also Engine Fan Control on page 100 Engine, Cruise Control Set/Resume on page 86

86 Y53-6096-1A1 (01/17) CONTROLS - Dash Switches

Engine, Heater Engine, Overspeed Air Shutdown (Test) CAUTION

Only operate the under hood intake air Turn switch on to activate the Engine switch when outside temperatures are be- Heater. low 32° F (0° C). Engaging the under hood air intake while temperatures are above freezing may result in engine damage. 3 Engine, Remote Throttle Hold down switch and increase engine rpm to test that Engine Overspeed Air Exhaust, Diesel Particulate Filter Shutdown system functions correctly. A (DPF) Regeneration system reset will be required before restarting engine. See EOAS system Turn switch on to activate Remote Throttle manufacturer's instruction manual for Control. details.

Engine, Overspeed Air Shutdown Engine, Under Hood Air Intake (Manual) This switch opens a door in the engine air filter housing so that the air is taken from Manually controls the diesel particulate under the hood instead of outside air. This filter regeneration process. Refer to Engine switch can be useful when starting the Aftertreatment Controls Operator's Manual vehicle in cold weather conditions. for additional information.

Turn switch on to engage the Engine Fifth Wheel Slide Overspeed Air Shutdown system. A system reset will be required before re- starting engine. See EOAS system manufacturer's instruction manual for details.

Y53-6096-1A1 (01/17) 87 CONTROLS - Dash Switches

Turn switch on to “Unlock” Fifth Wheel Fuel Heater Ignition Key Switch Slide mechanism. The switch is guarded to protect you from accidentally activating or The ignition key switch (located to the left releasing the lock. of the steering column) has four positions: ACC (Accessories), OFF, ON, and START. WARNING! Turn switch on to activate Fuel Heater. Lights, Auxiliary 3 Do not move the fifth wheel while the trac- tor-trailer is in motion. Your load could shift suddenly, causing you to lose control of the Generic Air, Accessory vehicle. Never operate the vehicle with the switch in the UNLOCK position. Always in- spect the fifth wheel after you lock the switch to be sure the fifth wheel slide lock is engaged. Failure to comply may result in Provides accessory air to the end of frame death, personal injury, equipment or proper- connection when switch is turned on. Turn switch on for Auxiliary Lights. ty damage.

NOTE Lights, Beacon NOTE The generic air accessory switch is de- Vehicles having an air slide fifth wheel have signed by the original equipment manufac- a fifth wheel slider lock controlled by a turer to reset when the ignition power is switch on the instrument panel. By placing turned off. When ignition is turned off, this the switch in the unlock position you can circuit will exhaust air pressure. slide the fifth wheel to various positions to Turn switch on for Beacon Light(s). adjust . Generic, Spare SPARE

Turn switch on to power customer installed accessory.

88 Y53-6096-1A1 (01/17) CONTROLS - Dash Switches

Lights, Daytime Running (Override) headlights operate normally. Also, during Turn switch on for trailer mounted Flood engine cranking the DRL is temporarily Lights. turned off. Lights, Fog Lights, Dome

This switch overrides the normal operation 3 of the Day Time Running Light (DRL) system. During normal operation the DRL will turn on lights when the headlights are turned off, engine is on and the park Turn switch on for Fog Lights. brakes are dissengaged. The override Turn switch on for Cab Dome Lights. switch will turn the DRL off in these instances. The DRL is also turned off when NOTE the headlights are turned ON. Lights, Flood Across the U.S.A. and Canada, State/ Provincial requirements vary as to when WARNING! high beams and fog lights can and cannot be used together. Some states allow only Do not use daytime running lights (DRL) four lights to be used together, while some during periods of darkness or reduced visi- allow more. How your lights are arranged bility. Do not use DRL as a substitute for will affect whether you can operate head- headlights or other lights during operations Turn switch on for cab mounted Flood lights and fog lights concurrently always comply with the state or provincial require- that require lighting of your vehicle. Failure Lights. to comply may result in death, personal in- ments where you are driving. jury, equipment or property damage. Lights, Flood (Spare) If the headlight switch is turned OFF, the DRL system engages automatically after the engine starts and you release the parking brake. If the headlight switch is ON, the DRL system is overridden, and

Y53-6096-1A1 (01/17) 89 CONTROLS - Dash Switches

Lights, Hazard

Turn switch for park/marker lights and headlights. When the Headlights are ON, Turn switch on to control Cab and Vehicle the dash lights, side, and tail lights are also Marker/Clearance lights. 3 on. Headlights will turn on if the windshield This switch operates the emergency wipers are turned on. Manually turning the flashers. With the switch in the ON headlights on and then off will override this NOTE position, the emergency flasher makes all function until the next time the vehicle is four turn signals (front and rear) flash turned on. An interrupt switch for the trailer marker simultaneously. The flasher works lights is mounted on the end of the turn sig- independently of the ignition switch. You nal lever. should always use the flasher if the vehicle CAUTION is disabled or parked under emergency Lights, Marker/Clearance/Trailer conditions. If you have confirmed there is a problem in the low beam wiring circuit, proceed with caution to the next available exit/turnoff and WARNING! safely pull your vehicle completely off the road and call for assistance. Driving your Use your Hazard Warning Light System any vehicle with the headlamps on high beam time you have to stop off the road or on the (at reduced intensity) for a prolonged period side of the road, day or night. A hard-to-see could lead to an injury accident. Contact vehicle can result in an injury accident. An- your nearest dealer to have the problem Turn switch on to control Trailer Marker/ other vehicle could run into you if you do not corrected as soon as possible. Clearance lights separately from the set your flashers and follow the placement of emergency signals per FMCSR 392.22. vehicle marker/clearance lights. Lights, Marker/Clearance Lights, Headlight

90 Y53-6096-1A1 (01/17) CONTROLS - Dash Switches

Lights, Park Light Momentarily push switch in to engage switch) will go out immediately even Traction Control (TC). though PTO disengagement may not have occurred. Pintle Hook NOTE Actual PTO engagement/disengagement 3 Turn switch on for Park Lights. When the may be delayed momentarily since it is con- trolled by the air system and mechanical Park Lights are on the dash lights, side and movement. tail lights are also on. Turn switch on to remove the slack from Lights, Spot the Tow Hook. CAUTION

Power Take-off (PTO) Increasing engine rpm before the PTO is ac- tually engaged could prevent the PTO from engaging and/or cause PTO damage.

Power Take-off (PTO), Forward Turn switch on for Spot Light. This vehicle may be equipped with a dash Mud and Snow Traction Control mounted switch that controls PTO engagement/disengagement. When the operator activates the switch for the PTO, Your vehicle may be equipped with a dash the status indicator lamp (located on the mounted switch that controls forward PTO switch) will immediately illuminate even engagement/disengagement. though PTO engagement may not have occurred. If the PTO is engaged and the operator turns the switch OFF, the PTO status indicator lamp (located on the

Y53-6096-1A1 (01/17) 91 CONTROLS - Dash Switches

Power Take-off (PTO), Rear Suspension, Dump Suspension, Air Retention

Your vehicle may be equipped with a dash 3 mounted switch that controls the rear PTO engagement/disengagement. Turn switch on to deflate suspension air Suspension, Third Axle Lift bags. The switch is guarded to protect you Suspension, Axle, Pusher from accidentally deflating the suspension.

WARNING!

Do not operate the Air Suspension Deflate Turn switch on to raise Third Axle. Switch (Dump Valve) while driving. Sudden deflation while your vehicle is moving can Turn switch on to lower Single or Forward affect handling and control and could lead to Trailer Air Supply Pusher Axle. an accident. Use this switch only when your vehicle is not moving. The red octagon knob controls the air supply to the trailer. Suspension, Axle, Tag CAUTION Trailer, Axle (3rd Axle) Lift

Operating a vehicle with air suspension bags either overinflated or underinflated may cause damage to driveline compo- nents. If a vehicle must be operated under such conditions, do not exceed 5 mph (8 Turn switch on to lower tag axle. km/h). Failure to comply may result in equip- ment damage. Turn switch on to lift 3rd Trailer Axle.

92 Y53-6096-1A1 (01/17) CONTROLS - Dash Switches

Trailer, Axle Lift Forward

Turn switch on to open Trailer Dump Gate. Turn switch on to open Trailer Rear Belly Dump Gate. 3 Turn switch on to lift Forward Trailer Axle. Trailer, Belly Dump Gate Center Trailer, Hotline Trailer, Axle Lift Rear

Turn switch on to supply electrical power to Turn switch on to open Trailer Center Belly trailer accessories. Turn switch on to lift Rear Trailer Axle. Dump Gate. Trailer, Suspension Air Dump Trailer, Belly Dump Trailer, Belly Dump Gate Front

Turn switch on to deflate Trailer Air Turn switch on to open Trailer Front Belly Turn switch on to open Trailer Belly Dump. Suspension. Dump Gate. Trailer, Dump Gate Trailer, Belly Dump Gate Rear

Y53-6096-1A1 (01/17) 93 CONTROLS - Dash Switches

Transmission, Transfer Case

3 Turn switch on to shift the transfer case.

Transmission, Transfer Case 2 Speed

Turn switch on to shift the 2 speed transfer case.

Winch Clutch

Turn switch on to engage Winch Clutch.

94 Y53-6096-1A1 (01/17)

Chapter 4 | DRIVING

In this Chapter:

Starting and Operating...... 96 How to Use Engine Start Switch on Right Hand Drive...... 96 4 Starting and Warming Up...... 96 Engine Operations...... 100 Transmission...... 103 Brakes...... 106 Axle and Suspension...... 114 Aftertreatment System...... 123 Dual Steer Operation...... 124 Driving Tips and Techniques...... 124 Stopping the Vehicle...... 126

DRIVING - Starting and Operating

Starting and Operating NOTE

Some starters are equipped with overcrank Since each vehicle is custom-equipped, all 1. Press and hold ENGINE START protection. Check the Engine Operation and engine operation instructions in this when using the right hand drive Maintenance Manual for details. manual are general. You will want to position to start the engine. When the outside temperature is above consult the manual for your engine to find 2. Press ENGINE STOP when using out details about your specific engine’s 50°F (10°C), you can use the following the right hand drive position to stop procedure: 4 needs. You may need to use a slightly the engine. different procedure from the one outlined 1. Set the parking brake. here. 2. Put your main transmission in Starting and Warming Up Neutral. How to Use Engine Start 3. Disengage (depress) the clutch How to Start Vehicle in Normal (with ). Switch on Right Hand Weather 4. Turn the key switch to ON. Drive a. If the center display prompts for a Anti-Theft passcode, use CAUTION Right hand drive station has an Engine the Menu Control Switch to enter the four digit code. Start/Stop switch to enable engine Never operate the starter motor while the operation from the curb side position. engine is running. The starter and flywheel 5. Turn the ignition key to the START gears could clash or jam, severely damag- position. If the engine does not start The Engine Start/Stop switch will only work ing them. within 30 seconds, release the when the ignition switch on the left hand ignition switch. To avoid overtaxing side cockpit is in the ON position and the the starter motor or the batteries, RH Steer switch is in the engaged position. don’t use the starter for more than 30 seconds. Let the starter motor cool and the batteries recover for two minutes before trying again. If

96 Y53-6096-1A1 (01/17) DRIVING - Starting and Warming Up

the engine still won’t start after a started within the 6 minute timeframe, the properly grounded AC electrical source. Do couple of tries, check the fuel lines operator will have to re-enter the passcode not start the engine with the heater for possible fuel starvation or air to start the engine. plugged in. leaks. Starting failure may mean fuel isn’t reaching the injectors. Tips to Remember When Starting WARNING! 6. As soon as the engine starts, begin Vehicle in Cold Weather to watch the oil pressure gauge. Engine block heaters can cause fires which Check your engine manufacturer’s In cold weather, fast engine starting helps may result in death, injury and/or property manual for the right pressure for relieve the loads on the electrical system damage if not properly maintained and oper- your engine. If the oil pressure and cranking motor. Using the special cold ated. Regularly inspect the engine block doesn’t rise within a few seconds, starting equipment will help starting. heater wiring and connector for damaged or 4 stop the engine. Find out what is frayed wires. Do not use the heater if there wrong before restarting the engine. If you follow a few simple guidelines, you are any signs of problems. Contact your au- will extend the service life of your engine: thorized dealer or the manufacturer of the 7. Slowly engage (release) the clutch heater if you are in need of repairs or infor- after the engine has started. • Keep the electrical system in top mation. 8. Wait for the oil pressure gauge to condition. reach normal operating pressure • Use the best quality fuel of the before operating the vehicle or idling recommended grade. CAUTION faster than 1,000 rpm. • Use recommended engine lubricating oil. Always unplug heater before starting the en- gine. Damage to the cooling system could Anti-Theft (Optional) • For manual transmissions and occur if the heater is not turned OFF (un- auxiliary transmissions, leave the plugged). Certain vehicles have functionality to transmission in neutral and allow require an operator to enter a 4 digit code the transmission lubricating oil to Depending on engine make, when the to start the vehicle. warm up (approximately 3-5 temperature falls below -10°F (-24°C), the If the wrong code is entered, the display minutes) before operating vehicle. block heater is required. will show a lock icon. The unlock icon will Engine Block Heater (Optional) appear once the correct code is entered and the operator will have up to 6 minutes To preheat the engine before starting, plug to turn the ignition on. If the engine is not the optional engine block heater into a

Y53-6096-1A1 (01/17) 97 DRIVING - Starting and Warming Up

Engine Warm Up ternal oil lines leading to the turbo- monoxide to enter the cab. Entry of charger will slow the oil flow until the carbon monoxide into the cab is also oil warms, reducing oil available for possible from other vehicles nearby. The purpose of engine warm-up is to allow the bearings. Watch the engine oil Failure to properly maintain your ve- oil film to be established between pistons temperature or pressure gauge for a hicle could cause carbon monoxide and liners, shafts and bearings while your warming trend before increasing en- to enter the cab, resulting in death engine gradually reaches operating gine idle speed (rpm). or personal injury. temperature. 3. Continue the engine warm-up until 1. After you’ve started your engine, the coolant temperature reaches at WARNING! idle it at approximately 600 rpm least 130°F (54°C). At this temperature, you can use partial 4 while you check: Never idle your vehicle for pro- throttle. Wait until the coolant longed periods of time if you sense a. oil pressure temperature is at least 160°F (71°C) that exhaust fumes are entering the b. air pressure before operating at full throttle. cab. Investigate the cause of the c. alternator output fumes and correct it as soon as pos- a. Under most circumstances, sible. If the vehicle must be driven 2. After a few minutes of idling at 600 idling your engine for long under these conditions, drive only rpm, increase your idle speed to periods merely wastes fuel. In with the windows open. Failure to 900 or 1,000 rpm. Continue your severe arctic weather repair the source of the exhaust warm-up. This procedure allows oil conditions, however, you may fumes may result in death, personal to warm and flow freely while injury, equipment or property dam- need longer idling to be sure all age. pistons, liners, shafts, and bearings parts of your engine are fully expand slowly and evenly. In lubricated. extremely cold temperatures, you may have to increase idle speed. WARNING!

NOTE Exhaust fumes from the engine con- tain carbon monoxide, a colorless In colder climates where the temper- and odorless gas. Do not breathe ature is often below freezing, the the engine exhaust gas. A poorly warm-up for turbocharged engines maintained, damaged or corroded is especially important. Chilled ex- exhaust system can allow carbon

98 Y53-6096-1A1 (01/17) DRIVING - Starting and Warming Up

than five minutes. Long periods of How to Warm Up the Transmission WARNING! idling after the engine has reached operating temperatures can de- In cold weather (below 32°F (0°C), you To reduce the chance of personal in- crease engine temperature and may find shifting sluggish when you first jury, vehicle damage and/or death cause gummed piston rings, clog- start up. Transmission warm-up is from overheated engines, which can ged injectors, and possible engine especially important at this time, but it is result in a fire, never leave the en- damage from lack of lubrication. The normal torsional vibrations generat- always a good idea to warm-up your gine idling without an alert driver transmission before starting out on the present. If the engine should over- ed can also cause transmission road. heat, as indicated by the engine wear. coolant temperature light, immediate To warm-up the transmission lubricating oil action is required to correct the con- during engine warm-up, with a single 4 dition. Continued unattended opera- NOTE tion of the engine, even for a short transmission (manual and automatic): time, may result in serious engine Keep the engine exhaust system 1. Put the transmission in Neutral. damage or a fire. Failure to comply and the vehicles cab ventilation sys- may result in death, personal injury, tem properly maintained. It is recom- 2. Release the clutch pedal (manual equipment or property damage. mended that the vehicles exhaust only) and operate the transmission system and cab be inspected (1) By in neutral for 3 to 5 minutes prior to a competent technician every operating the transmission in either CAUTION 15,000 miles (24,140 km) (2) When- forward or reverse range. ever a change is noticed in the sound of the exhaust system (3) 3. If you have a two-transmission The use of a winterfront can result in Whenever the exhaust system, un- combination: excessive engine coolant, oil, and derbody, or cab is damaged. charge air (intake) temperatures, a. Put the main transmission in which can lead to overheating and gear. possible engine damage. NOTE b. Put the auxiliary transmission in Neutral. This will allow the transmission countershaft to CAUTION If you are parked next to idling vehi- cles, move your vehicle or do not turn, agitating the oil and stay in your vehicle for prolonged warming it. Do not allow your engine to idle, at periods of time. low rpm's (400–600 rpm), longer

Y53-6096-1A1 (01/17) 99 DRIVING - Engine Operations

Cruise Control on page 101 comply may result in death or personal in- Engine Operations Cancelling and Resuming Cruise Control jury. on page 102 How to Change Cruise Set Speed on page Stationary Power Take Off 102 CAUTION Operation Do not operate the engine fan in the MAN- The cruise control buttons for this vehicle Engine Fan Control UAL position for extended periods of time. may be used to control the engine rpm Important guidelines to using the engine The fan hub was designed for intermittent when the vehicle is stationary and the fan control. operation. Sustained operation will shorten 4 operator wants to use the Power Take Off the fan hub’s service life as well as reduce (PTO) on the engine. Use the cruise The engine fan switch on the dash has a fuel economy. control options in the same manner as with manual and an automatic mode. In the the vehicle in motion, but instead of setting manual mode, the engine fan will engage vehicle speed, the engine speed (rpm) is until the switch is back into automatic CAUTION set instead. mode. In automatic mode, the engine fan operation is controlled by the engine The fan or equipment near it could be dam- 1. Ensure parking brakes are applied. computer. aged if the fan turns on suddenly when you 2. Ensure transmission is in Neutral. do not expect it. Keep all tools and equip- 3. Engage PTO per the manufacturer's ment away from the fan. operating instructions. WARNING! 4. Move the ON/OFF switch to the ON Using a Winterfront position. Do not work on or near the fan with the en- gine running. Anyone near the engine fan A winterfront or other air flow restriction 5. Toggle the SET/RESUME switch to when it turns on could be injured. If it is set device may be mounted in front of the obtain the desired engine rpm. at MANUAL, the fan will turn on any time the ignition key switch is turned to the ON posi- Cancel the PTO operation by canceling the tion. In AUTO, it could engage suddenly engine rpm set speed. This can be done by without warning. Before turning on the igni- tapping the brake or clutch pedal or by tion or switching from AUTO to MANUAL, be using the cruise control switches. sure no workers are near the fan. Failure to See Also

100 Y53-6096-1A1 (01/17) DRIVING - Engine Operations

radiator to increase cab heater Engine Control Display (SCR), Regeneration Switch and warning temperature in cold climates. lights. The DPF will trap soot from the Your vehicle may come with an optional engine exhaust gases. The SCR uses Engine and Driver Information Display. Diesel Exhaust Fluid to reduce the levels of CAUTION This instrument records information on NOx in the engine exhaust. The ATS will engine diagnostics, scheduled periodically clean (regenerate) the DPF. The use of a winterfront can result in exces- maintenance, driving conditions, and Please refer to the Exhaust Aftertreatment sive engine coolant, oil, and charge air (in- general trip information. The specific System Supplement provided with the take) temperatures, which can lead to over- features of your display may vary heating and possible engine damage. vehicle for more detailed description of depending on engine make. functionality and warnings. 4 CAUTION What is Exhaust Aftertreatment Cruise Control

A winterfront should only be used at temper- This vehicle has cruise control. Cruise atures below 40°F (4°C). Use of a winter- control functions and features may vary front above 40°F (4°C) can decrease life of depending upon which engine you have. cooling module components. Remove win- For specific explanation of your cruise terfront as soon as the ambient temp reach- control, see the cruise control or engine es 41°F (5°C). The use of a winterfront manual included with your vehicle. above 40°F (4°C) can result in excessive engine coolant, oil, and charge air (intake) This vehicles electronic system will perform temperatures, which can lead to overheating a ‘rationality check’ every time the vehicle and possible engine or coolant module dam- is started. This check is to ensure that the age and emissions non-compliance. service brakes are working before allowing The winterfront is designed to minimize the cruise control to function. This safety temperature differences across the radiator feature is designed to ensure that a driver is able to cancel the cruise set speed by and reduce the possibility of cooling Vehicles manufactured with diesel engines using the service brake pedal. The system module damage. Aftermarket winterfronts have an exhaust Aftertreatment System will not allow cruise control operation if it may not provide the proper airflow (ATS) to control vehicle exhaust emissions. does not pass the ‘rationality check.’ The distribution and could cause cooling The system consists of a Diesel Particulate instrument cluster will prompt you to press module damage. Filter (DPF), Selective Catalyst Reduction the service brake pedal if it has not been

Y53-6096-1A1 (01/17) 101 DRIVING - Engine Operations

pressed since the vehicle has been • Press the + button on the Right started. In vehicles with Eaton Steering wheel pod if available. transmissions, the cruise control switches • Press the SET portion of the may be located on the shift control knob. SET/RESUME button on the How to Use Set Cruise Control dash 2. Accelerate the vehicle via 2. To decrease speed: Speed When Driving accelerator pedal to the desired Information on using the cruise control. cruise speed. • Press the - button on the Right 3. Press the "SET" button to set the Steering wheel pod if available. This vehicle may have cruise control cruise speed. • Press the RESUME portion of 4 switches located on the steering wheel the SET/RESUME button on the instead of the switches on the dash board. dash The instructions are still the same. these NOTE instructions do not apply to Adaptive Cancelling and Resuming Cruise Cruise Control. While the buttons are also Cruise Control may not hold the set Control used to control PTO operations, these speed going down hills. If the speed At times the operator will need to override instructions are specifically for vehicle increases going down a hill, use the cruise control and take over. speed. The vehicle speed must be greater brakes to slow down. This will can- cel Cruise Control. than 19 mph (30 kph) for PACCAR There are three ways to cancel the set powered vehicles or 30 mph (49 kph) for The cruise set speed will appear in speed in cruise control: Cummins powered vehicles and the engine the instrument panel display. speed must be over 1,100 rpm for the 1. Tap the brake pedal cruise set speed to work. How to Change Cruise Set Speed 2. Tap the clutch pedal 3. Turn the cruise control system off To Set the Cruise Speed Once the cruise set speed is set, the (ON/OFF button on steering wheel operator can push certain buttons to or the CANCEL button on the dash) 1. Turn the cruise function on by using increase or decrease speed. the ON/OFF button Using the brake or clutch pedal to cancel The cruise icon will appear in the The vehicle cruise control must be on and set speed allows the operator to use the instrument panel display. the cruise speed engaged. RESUME feature. Pressing the RESUME button will resume the vehicle speed 1. To increase speed: previously set.

102 Y53-6096-1A1 (01/17) DRIVING - Transmission

When turning the system off, the previous will allow your clutch to slip, causing set speed is removed from memory. The brake. A non functioning clutch brake will excessive heat and wear, damage could make shifting very difficult when the vehicle operator will have to manually reset the is stationary. result. cruise speed. When you must idle your engine for any 1. Depress the clutch pedal past the period of time, shift your transmission to first 1/2 inch (13 mm) for neutral and disengage the clutch (take your Transmission approximately 5 1/2 in (139.7 mm) foot OFF of the pedal). This helps prevent of total pedal travel. unnecessary wear to your clutch release How to Use the Hyrdaulic Clutch 2. Depress the clutch pedal another bearing, and it is less tiring for you, too. 1/2 in (13 mm) to engage the clutch Certain vehicles have a hydraulic clutch to brake. • Always use the clutch when making 4 upshifts or downshifts. shift a manual transmission. The clutch brake is used for stopping transmission gears, • Never coast with the transmission in neutral and the clutch disengaged. CAUTION allowing you to easily shift into first gear or reverse without grinding • To provide smooth gear engagements while shifting, use Be careful not to apply the clutch brake gears. The clutch brake is not while the vehicle is moving. The purpose of necessary when shifting into other proper coordination between shift the clutch brake is to stop the transmission gears while in motion. lever and clutch. so that you can shift into a starting gear If the clutch pedal is pressed completely to without grinding gears. Applying the clutch Operating Manual Transmissions brake when the vehicle is moving causes a the floor and the transmission is not braking effect on the and shortens shifting, then it is time to have the clutch Follow these instructions if the vehicle has the service life of the clutch brake. adjusted or serviced. a manual transmission. If the transmission has a butt-tooth The transmission shift pattern for your CAUTION condition and you cannot engage a gear, vehicle may be located on the shift control gradually release the clutch. Then the drive knob. In addition to understanding the shift Do not push the clutch pedal completely to gear can roll enough to allow the teeth to pattern and its location, you should read the floor when shifting while the vehicle is in line up properly and complete the shift. the transmission manufacturer’s manual motion. using the clutch brake while shifting provided with your vehicle before operating a vehicle in motion will damage the clutch The clutch is not a footrest. Do not drive with your foot resting on the clutch pedal. It the vehicle. After making sure the vehicle's

Y53-6096-1A1 (01/17) 103 DRIVING - Transmission

oil and air pressure are correct and all 6. Do not allow your vehicle to roll rpm, which is where maximum torque and other parts and systems are in proper (even a little) in the opposite power are obtained. working condition: direction during clutch engagement. If you need to start up on an incline, Shift carefully in a new vehicle. The 1. For vehicles with a clutch pedal, apply your service brakes before transmission may be a little stiff at first. locate the clutch pedal and engage you release the parking brake. Then Avoid gear clashing, by closely following the clutch brake. release your service brakes as you these procedures. When you are operating 2. Shift into a low gear. engage the clutch and apply throttle. a new vehicle or one that has been exposed to cold weather, you want the For further instructions on operating your transmission lubricant (fluid) to circulate 4 CAUTION transmission, see the transmission and coat the contacting surfaces of the manufacturer's Driver/Operator's gears. Metal contacting metal in moving Always use first gear or a low speed Instruction Manual. parts may seriously damage your range to start the vehicle in motion. transmission, do not drive in one gear for The use of a higher gear or speed If you want to shift directly into any gear long periods of time until the transmission range forces undue strain on the en- other than first or reverse, depress the gine, clutch, other transmission lubricant has a chance to coat all clutch pedal only far enough to release the contacting surfaces. components, and may cause dam- clutch. Fully depressing the pedal applies age. the clutch brake and could cause gear • Always select a starting gear that 3. Evaluate the road surface hang-up. will provide sufficient gear reduction conditions and terrain your vehicle for the load and terrain. If you have a misaligned gear condition in is on. Select a gear low enough to • Never downshift when the vehicle is your vehicle's transmission and cannot let your vehicle start forward with moving too fast. the throttle at idle. start, gradually release the clutch, allowing the drive gear teeth to line up properly. • Never slam or jerk the shift lever to 4. Push the parking brake valve Then the drive gear can roll enough to complete gear engagement. handle (Yellow) against the dash allow the teeth to line up properly and • Never coast with the transmission in panel to release the brakes. complete the shift. The best engine neutral and the clutch disengaged. 5. Release the clutch pedal (manual performance and maximum economy is only), then gradually accelerate to obtained if gears are properly selected. permit smooth starting. This efficiency is achieved by always selecting gears within optimum engine

104 Y53-6096-1A1 (01/17) DRIVING - Transmission

How to Shift using Double Clutch 5. Release the pedal to engage the Method clutch. brake pedal and firmly press on the acceler- ator pedal. Whether you are upshifting or down shifting, it is best to double clutch. Double Automatic and Automated clutching is easier on the transmission and Transmissions WARNING! on the engine, helping your vehicle match engine speed with driveline speed and An automatic or automated transmission Do not leave the cab of your vehicle without achieving clash-free shifts. makes shifting much easier. It remains applying the parking brake. The truck could important to completely understand how to roll and cause an accident resulting in death To double clutch: operate the transmission to optimize its or personal injury. Always apply the parking efficiency. Please read the manual for your brake before you leave the cab. 4 1. Push the clutch pedal down to automatic or automated transmission disengage the clutch. included with your vehicle. Hill Hold 2. Move the gear shift lever to neutral. 3. Release the pedal to engage the For automated transmissions, there is no clutch. This lets you control the rpm "park" position. So you will need to apply of the mainshaft gears, allowing you the parking brake before leaving the cab. to match the rpm of the mainshaft The hill hold feature is available as an gears to those of the output shaft. WARNING! option with certain automated transmissions. This feature holds the a. a. Upshifts: let the engine and vehicle while on a hill to allow the operator gears slow down to the rpm If your vehicle has an automated transmis- sion, be aware that it can roll backwards to release the service brakes and press the required for the next gear. when stopped on a hill or grade, or when accelerator. This feature will hold the b. b. Downshifts: press starting from a stop on a hill or grade. Fail- vehicle if the vehicle is attempting to go up accelerator, increase engine ure to comply may result in death, personal a hill from a stop in either drive or reverse. and gear speed to the rpm injury, equipment or property damage. Ob- required in the lower gear. serve the following guidelines: (1) When stopped on a hill or grade, press the brake 4. Now quickly press the pedal to pedal. (2) When starting from a stop on a hill disengage the clutch and move the or grade, quickly remove your foot from the gear shift lever to the next gear speed position.

Y53-6096-1A1 (01/17) 105 DRIVING - Brakes

Auxiliary Transmission is delivered to the brake Certain conditions may result in your brake system through the valve at the brake surfaces becoming overheated (above Information about using the auxiliary pedal and is controlled with various valves 800°F or 427°C). Overheated brakes will transmission. and braking circuits. The brake system is damage linings and drum surfaces, If you have an auxiliary transmission, see designed with separate front, rear and ultimately decreasing braking performance. your transmission manufacturer’s manual (when applicable) trailer circuits so that if Refer to Retarders and Descending a for its proper operation. one circuit is compromised and loses air, grade to avoid overheating the brakes. the other circuits will not be affected. Safety valves in each circuit will protect the Parking Brake other circuits in the event that a circuit 4 Brakes loses air. The air compressor on the engine will Air Brake System 1 typically provide 100-130 psi (690-896 This vehicle’s brake system functions with kPa) to the air tanks. The vehicle is also the use of compressed air generated from designed with an air dryer, which removes the engine’s air compressor. The moisture from the compressed air in order compressed air is stored in various air to protect all components in the air system. tanks to ensure that air pressure is 2 The brake system may be further available whenever the driver needs it. enhanced by additional devices such as brake proportioning valves, Anti-lock WARNING! braking systems or sensors designed to let you know if your brake pads need to be 3 Do not drive through water deep enough to serviced. Certain conditions may result in wet brake components, as it may cause the the brake surfaces getting wet. Brake brakes to work less efficiently than normal. surfaces that are wet do not perform as The vehicle's stopping distance may be lon- well as when they are dry. There may be ger than expected, and the vehicle may pull 1. Normal Run Position situations where wet brake surfaces cannot to the left or right when brakes are applied, 2. Trailer Park with Vehicle Released which could contribute to an accident involv- be avoided. In such situations, apply the ing death or personal injury. brakes while in motion, to dry the brake 3. System Park or Trailer Charge with surfaces. Vehicle Parked

106 Y53-6096-1A1 (01/17) DRIVING - Brakes

Parking brakes work in reverse action of Low Air Alarm on page 30 Anti-Lock Brake Systems (ABS) the regular brakes. When the parking Information on using the anti-lock brake brakes are engaged, air is exhausted from Automatic Traction Control the spring chambers, which allows the system. spring to engage the brakes. This design General information on ABS and automatic also provides a safety function if a brake traction control. This vehicle may be equipped with an anti- circuit has a leak and loses air. In such a lock braking system (ABS). This ABS scenario, the parking brakes will apply. reduces the possibility of wheel lock-up. If a wheel is about to lock during braking, the The vehicle’s parking brake controls are ABS will automatically adjust air pressure the yellow diamond shaped knob on your to the brake chambers on the appropriate 4 dash board. If the vehicle is equipped to wheel(s) to prevent wheel lock-up. The tow a trailer, then there will be an additional Your truck/tractor ABS is equipped with an ABS is automatically turned on when the red octagon shaped knob for the trailer automatic traction control (ATC) feature. ignition switch is turned on. parking brakes. Parking brakes will be This feature is controlled by a switch on the engaged when either of these knobs are dash. Do not allow the traction control lamp pulled OUT. (If one knob is pulled out, the WARNING! to remain on continuously for an extended other knob will automatically pop out.) length of time. Extended continuous use of The Anti-Lock Brake System is a critical ve- Pushing IN a knob will disengage the the ATC can cause overheating of the drive hicle safety system. For the safety of you respective parking brakes. If you push in wheel brakes. Engine torque or vehicle and others around you, have the vehicle the yellow knob only, you will disengage speed should be reduced to eliminate submitted for periodic preventive mainte- the vehicle’s parking brakes but will not wheel spin and prevent excessive nance checks as well as having any sus- disengage the trailer parking brakes (if application of the ATC system. Except for pected problems immediately checked by an authorized dealer. Failure to properly applicable). Either knob will pop back out if checking for proper illumination of the ABS maintain your brake system can lead to seri- and traction control warning lamps when the system pressure is not above 60 psi ous accidents. Failure to comply may result (414 kPa). The instrument panel display first starting the vehicle, and for monitoring in death, personal injury, equipment or prop- will provide a message any time the these lamps while driving, no special erty damage. parking brakes (vehicle or the trailer) are operating procedures are required. For set and the vehicle is put into motion. detailed system description, see literature for your specific ABS that was provided See Also with your vehicle.

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on towed vehicle(s). In most cases, the ABS power will be supplied through the on the trailer should be yellow and identified with the letters ABS. WARNING! Auxiliary circuit on the primary 7-way trailer light line connector. If the vehicle was Do not rely on an anti-lock brake system For doubles or triples, the lamp does not manufactured with a switchable Auxiliary that is functioning improperly. You could lose distinguish between trailers. An ABS control of the vehicle resulting in a severe circuit for trailer accessories, an additional problem in any of the trailers will activate accident, causing death or personal injury. If 7-way connector would have been the Trailer ABS Warning Lamp. your ABS lamp goes on while you are driv- provided for trailer ABS power. In either ing or stays on after the self-check, your an- case, the ABS power line on the vehicle If you change the intended service in any ti-lock system might not be working. The will be PLC equipped. way (e.g., number of axles, multiple 4 ABS may not function in an emergency. You trailers, add switchable trailer accessories, will still have conventional brakes, but not etc.) from the date the vehicle was anti-lock brakes. If the lamp indicates a CAUTION problem, have the ABS checked. manufactured, you should contact your trailer manufacturer and/or trailer anti-lock Do not splice into the non-switchable Auxili- Vehicles without anti-lock brake systems brake manufacturer to determine if the ary circuit on the primary 7-way trailer light power available at the 7-way trailer light (ABS) are typically equipped with a bobtail line. Doing so may cause the trailer ABS to brake proportioning system. When a trailer malfunction. This circuit is dedicated for line is adequate. Failure to do so might is not connected, the drive axle brake trailer ABS power. To add a switchable aux- result in insufficient power to the trailer application pressure will automatically be iliary circuit, contact a dealership. ABS system, which may affect its limited by the proportioning system. When operation. driven in a bobtail mode, these tractors will require greater brake pedal application to NOTE CAUTION provide the equivalent braking to a bobtail tractor not equipped with a proportioning Tractors/Trucks and trailers built after The center pin of the 7-way trailer light line system. 03/01/2001 must be able to turn on an In- Cab Trailer ABS Warning Lamp (per U.S. may be constantly powered for ABS. Make Trailer ABS Pwer Line FMVSS121). The industry chose Power sure it will not accidently turn on trailer Communication (PLC) Line Communication (PLC) as the standard equipment. method to turn it on. On trailers built prior to North American on-highway vehicles are 03/01/2001 verify trailer ABS system status equipped with a separate electrical circuit via the required external warning lamp to power the anti-lock brake system (ABS) mounted on the trailer. The indicator lamp

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Special Trailer ABS (Without PLC) Electronic Stability Control is a feature that which might trigger the stability Option reduces the risk of rollovers, jackknifing, system. and other loss of control situations. ESC If a trailer does not have PLC, but it does • Always operate the vehicle safely, features include Roll Stability Program have ABS that is powered through an drive defensively, anticipate (RSP) and Yaw Control. optional second trailer connector (ISO obstacles and pay attention to road, weather, and traffic conditions. ABS, 3731) and that trailer ABS is designed to During operation, the ECU of the Bendix® ATC, and ESC stability systems are control the Trailer ABS Warning Lamp in Advanced ABS system constantly no substitute for prudent, careful the cab and the vehicle has been ordered compares performance models to the driving. with the option to turn on this lamp for vehicle’s actual movement, using the these types of trailers, then this lamp will wheel speed sensors of the ABS system, Roll Stability Program 4 turn on when that trailer ABS has a system as well as lateral, yaw, and steering angle ® problem. This should be checked by a sensors. If the vehicle shows a tendency to Bendix Roll Stability Program (RSP), an dealer as soon as possible. The Trailer leave an appropriate travel path, or if element of the overall ESC system, ABS Warning Lamp will not turn on for the critical threshold values are approached, addresses rollover conditions. In the case power-on test when connected to these the system will intervene to assist the of a potential roll event, the ECU will types of trailers. driver. override the throttle and quickly apply brake pressure at all wheel ends to slow the vehicle combination. The level of NOTE braking application during an RSP event will be proportional to roll risk. Very few trailers built before 03/01/2001 have this option. Trailers built after A Real World Example of How the 03/01/2001 are built with PLC technology. RSP System Operates ESC may reduce the vehicle speed Excessive speed for road conditions Advanced ABS with Stability automatically. To minimize unexpected creates forces that exceed the threshold at Control deceleration and reduce the risk of a which a vehicle is likely to rollover on a collision the operator must: higher-friction surface. The system What you need to know about your automatically reduces engine torque and vehicle's braking, traction, and stability • Avoid aggressive driving applies the service brakes (based on the control features. maneuvers, such as sharp turns or projected rollover risk) to reduce the abrupt lane changes at high speeds,

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

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

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modified to allow short periods (0.25 seconds) of locked-wheel cycles. At trol possibly resulting in an accident involv- ing death or personal injury. WARNING! speeds below 10 mph, the ABS control software is turned off to allow locked While the off road mode can improve vehi- Additionally, the ESC stability system’s wheels. When the Off-Road ABS function cle control and shorten stopping distances, effectiveness may be greatly reduced if: some steering ability may be reduced on is enabled, the Retarder Disable output is certain surfaces resulting from the momen- turned off. That is, the engine retarders are • The load shifts due to improper tarily sliding tires. Always operate your vehi- left to function without ABS intervention. retention, accident damage or the cle at safe operating speeds. Failure to do For additional information, see the Off- inherently mobile nature of some so may cause you to lose control of the ve- Road ABS pamphlet in your vehicle’s glove loads (for example, hanging meat, 4 hicle and could result in an accident or per- box. live animals or partially laden sonal injury. tankers). Effectiveness and Limitations • The vehicle has an unusually high CAUTION ESC is designed and optimized for trucks or off-set center of gravity (CG). and for tractors that tow single trailers. If a • One side of the vehicle drops off the Never drive your vehicle on improved roads/ tractor equipped with ESC is used to power pavement at an angle that is too highways with the Off-Road ABS function multiple trailer combinations (known as large to be counteracted by a turned on. When you drive your vehicle onto "doubles" or "triples") the effectiveness of reduction in speed. an improved road surface or highway, im- the ESC system may be greatly reduced. • The vehicle is used to haul double mediately turn off the Off-Road ABS switch. or triple trailer combinations. Failure to do so will cause the ABS system to not function properly in an ABS event un- WARNING! • If very rapidly winding steering der 25 mph and could result in an accident inputs are inputted at high speeds. or personal injury. Exercise extreme care when towing doubles • There are mechanical problems with or triples with a vehicle equipped with Elec- suspension leveling of the tractor or The ABS lamp flashes slowly during off- tronic Stability Program. Excessive speed trailer resulting in uneven loads. road mode engagement. This is done to and aggressive maneuvers, such as sharp • The vehicle is maneuvering on a alert you of a modification to the ABS turns, sudden steering inputs or abrupt lane high banked road creating either control software. At speeds above 25 mph, changes should be avoided because these maneuvers could cause loss of vehicle con- additional side forces due to the the ABS controller operates in the normal weight (mass) of the vehicle or a on-highway mode. At speeds between 10 and 25 mph, the ABS control software is

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deviation between expected and ESC system must be disabled immediately actual yaw rates. by a qualified mechanic. WARNING! • Gusty winds are strong enough to cause significant side forces on the WARNING! If the Steering Angle Sensor is not recali- vehicle and any towed vehicles. brated, the Yaw Control system will not function properly. A uncalibrated sensor To maximize the effectiveness of ESC: Failure to disable ESC "Electronic Stability Control" when modifying a vehicle could re- could result in a loss of control of your vehi- • Loads must be properly secured sult in a loss of vehicle control possibly re- cle which can lead to an accident involving death or personal injury. and evenly distributed at all times. sulting in an accident involving death or per- sonal injury. • Drivers need to exercise extreme 4 caution at all times, and avoid sharp Retarders turns, sudden steering inputs or WARNING! abrupt lane changes at high speeds, Ideally, you should always slow your particularly if: vehicle with your retarder (where permitted For vehicles equipped with ESC" Electronic by law) and use your service brakes only Stability Control" do not replace the vehi- • The vehicle hauls loads that for stopping completely. Operating this way cle’s steering wheel with an aftermarket or could shift, different part number than originally sup- will greatly prolong the life of your brakes. • The vehicle or load has a high or plied. Using a different steering wheel could Various retarders are available, which off-set center of gravity (CG) cause ESC to malfunction causing a loss of function against the engine, driveline, or when loaded, or vehicle control possibly resulting in an acci- dent involving death or personal injury. transmission. These are devices that use • The vehicle tows doubles or your engine’s power to slow down your triples. Whenever maintenance or repair work is vehicle. They save wear and tear on your The ESC system was specifically performed to the steering mechanism, service brakes and can be a safety feature, calibrated and validated only for your linkage, gear, adjustment of the wheel too, because they can keep your brakes vehicle’s original factory-built configuration. track, or if the steering angle sensor is from overheating. If your vehicle’s chassis components are replaced or the steering wheel is changed altered (for example; a wheelbase or re-centered, the Steering Angle Sensor extension or reduction, tag axle addition or must be re-calibrated. removal, tractor to truck conversion or steering system component change) the

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We recommend that you do not use your engine retarder to slow down when you are WARNING! bobtailing or pulling an empty trailer. WARNING!

Do not use any of the vehicle’s retarders in Do not rely on your automatic transmission any situation that requires an immediate hydraulic retarder to stop your vehicle. If stop and/or in situations of poor traction your engine shuts down, the vehicle’s re- (such as wet, icy or snow covered roads). tarder will cease to operate which may lead Trying to use the retarder instead of the to an accident involving death or personal service brakes may cause a loss of vehicle This vehicle may have a transmission injury. Always be ready to suddenly apply control, which may result in an accident in- retarder. Take your foot off the throttle and the service brakes. 4 volving death or personal injury. operate the retarder switch. When you do not need full retarder effect, you can apply See Also it intermittently (off and on) to cause Engine Brake Operation for a Vehicle with WARNING! gradual or partial slowing. Continuous Automated Transmission application of your retarder will cause your Engine Brake Operation The service brakes must be used in an hydraulic fluid to get hotter. Intermittent emergency. The retarder alone might not application will help prevent overheating. stop you fast enough to prevent an accident. Failure to comply may result in death, per- Axle and Suspension sonal injury, equipment or property damage. WARNING! The retarder is NOT intended as the Using an engine retarder can cause a wheel Differential Lock primary brake for the vehicle, nor is it an lockup. The trailer is not loading the tires . The retarder only helps enough to give the traction you may need. the service brakes by using pressure to When you are bobtail or unloaded, you can slow the drivetrain. Use the service brakes have a serious accident if your wheels lock for quick stops. Do not use the retarder suddenly during braking. You could be killed when operating on road surfaces with poor or injured. Don’t use your retarder when you are driving bobtail or with an unloaded trail- traction (such as wet, icy, or snow covered er. The vehicle may be equipped with roads or gravel). Retarders can cause the switches to lock the either of the rear axle wheels to skid on a slippery surface. differentials. Depending on how the vehicle is specified, a combination of individual

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switches may be available that can lock the switch has a guard to protect you from interaxle driveline and/or any combination activating it accidentally. Always park your of the forward rear or rear-rear driving WARNING! vehicle with the range selector in LOW. axles. The interaxle differential switch Do not put the differential lock in the LOCK allows each axle to turn independently. In Important tips on operating a Dual Range position while the wheels are spinning freely Axle with Interaxle Differential: certain situations, engaging the interaxle (slipping), you could lose control of the vehi- differential lock relieves stress on the rear cle or cause axle damage. Switch to LOCK • Shift the axle with the inter-axle axles and reduces tire wear. Engaging this only when the wheels are not spinning. Fail- differential in the unlocked position switch will also provide better traction in ure to comply may result in death, personal only. injury, equipment or property damage. slippery or loose gravel conditions. • When you are driving with poor 4 In the LOCK position, continuous operation traction, lock the differential. When on paved, dry surfaces, put stress on the Dual Range (Two-Speed) Rear Axle you have the differential locked, axles, and can possibly damage the drive with the axle in LOW range Your vehicle may be equipped with a two- internal gears. The switch has a guard to only. speed or dual range axle (option). You can prevent accidental operation of the switch. • When you are driving on a surface select two rear axle ratios for operating with good traction, keep the under heavy loads or rough terrain as well Locking the differentials is typically used interaxle differential unlocked. You as for over the road hauling. during ice or snow conditions and without can drive with the axle in the LOW tire chains, unpaved roads that have loose or HIGH range. sand, mud or uneven surfaces. Look • Always UNLOCK the inter-axle ahead and predict when the differential differential before shifting the axle needs to be locked. Stop the vehicle and speed range. lock the differentials before approaching.

While using the differential in the locked The Low Range provides maximum torque position, do not exceed 25 mph (40 km/h). for hauling heavy loads or traveling over When disengaging the differential lock, rough terrain. The High Range is a faster reduce the throttle to prevent drivetrain ratio for highway speeds and general over damage. the road conditions. A switch on the accessory switch panel controls the Dual Range Rear Axle. You will notice that the

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When going downhill the wheels will not 2. Maintain your vehicle speed slow down, but will tend to speed up, which (accelerator depressed) and move WARNING! makes gear synchronization almost the Range Selector lever to HIGH. impossible. As a result, the axle is neither Never shift the axle when moving downhill. 3. Keep driving with the accelerator in HIGH nor LOW range and all engine/ Engine driveline disengagement may occur, depressed until you want the axle to eliminating engine retardation and allowing driveline retardation is lost. Without engine shift. the wheels to spin faster than the current retardation it is more difficult to slow the 4. To make the axle shift, release the speed of the engine. This may require se- vehicle down and greater stress is put on accelerator until the axle shifts. You vere braking to slow the vehicle down and the brake system. are now in the HIGH axle range for can result in an accident. Failure to comply highway speeds. Shift the 4 may result in death, personal injury, equip- ment or property damage. CAUTION transmission normally to reach your desired cruising speed. To avoid damaging your vehicle shift the How to Operate Two Speed Axle - CAUTION axle at slower travel speeds until you are High to Low used to driving with a dual range axle. If you shift the axle range with the inter-axle These steps should be used if operating a differential in LOCK, you could seriously How to Operate Two Speed Axle - 2 speed axle in HIGH range on improved damage the axles. Never shift the axle Low to High roads and preparing to drive on rough range with the differential locked. terrain. These steps should be used if operating a Proper shifting of the axle depends on the 2 speed axle in LOW range on rough When you go from highway driving to synchronization of engine/driveline and terrain and preparing to drive on an rough terrain, shift the axle to the LOW wheel speed. When you shift the axle, the improved surface. range following this procedure: connection between the engine and wheels When you go from rough terrain to highway 1. Maintain your vehicle speed is momentarily disengaged while the driving, shift the axle to the HIGH range (accelerator depressed) and move gearing is synchronized. Normally when following this procedure: the Range Selector lever to LOW. the axle is shifted the speed of the engine, axle, and wheels adjust, allowing for proper 1. Be sure the differential is 2. Keep driving with the accelerator gear engagement. UNLOCKED. depressed until you want the axle to downshift.

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3. To make the axle downshift, release Operation of the auxiliary axles includes Contact an authorized dealership if you are and depress the accelerator quickly the proper maintenance of the system and unable to identify the axle creep rating of to increase the engine rpm. The calibration of its controls. Operating the this vehicle. axle will shift to LOW range. auxiliary axles will also require a firm • Liftable/steerable (axle lift 4. You are now in the LOW axle range understanding of the Gross Axle Weight calibration required) for rough terrain and heavy loads. Rating (GAWR) and the load that is being Shift the transmission normally to carried. • Liftable/non-steerable (axle lift maintain the desired speed. calibration required) The vehicle will have switches on the dash • Non-liftable (some suspensions to control the position of the auxiliary axles. require dump valve calibration) What is an Auxiliary Axle In certain situations, however, the system 4 will override the controls to protect the axle Adjustable auxiliary axles (commonly system. Replace with new text: For Self WARNING! known as Pusher or Tag axles) can add to Steering Lift Axles, the axle will raise when the productivity of the vehicle by increasing the park brakes are applied or if the vehicle Do not operate or park the vehicle with aux- the load capabilities of the vehicle when is placed in reverse. For Non-Steer Lift iliary axles in the down/ loaded position Axles, the axle will only automatically raise when vehicle is unladen, or is being unload- they are in the deployed (down) position. ed. Raise or dump air into driver controlled if the park brakes are applied and there are auxiliary axle(s) prior to unloading vehicle. no park brakes on the lift axle. Non-Steer Failure to do so can result in loss of vehicle Lift Axles do not automatically raise when control or rollaway that may result in death, the vehicle is placed in reverse. personal injury, equipment or property dam- age. Operating the auxiliary liftable axles must be performed in a manner that does not See Also There are different configurations of axles exceed the axle creep rating. Axle creep Vehicle Loading on page 24 with different functionality (liftable versus ratings are weight and speed limits that are steerable). Without the extra axle, the allowed while the vehicle is fully loaded (in excessive weight can reduce the service excess of the vehicle’s standard GAWR) life of vehicle components such as, but not and the axle is in its up position. Axle creep limited to, the frame rail, axles, suspension ratings are assigned by the axle and brakes. manufacturer and are based on axle model and intended service of the vehicle.

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Auxiliary Axle Pressure Regulator obtained. By reducing air pressure at and manuevering the vehicle, at very slow pusher or tag axle, load will be transferred speeds, with auxiliary axles in the up Information on using the auxiliary axle to drive axles. Do not overload drive axles. position. In these situations, the load pressure regulator. exceeds the gross axle wieght rating of the Always deflate air springs of the auxiliary Vehicles with liftable auxiliary axles will axles. axles before attempting to unload vehicle. have knobs available to adjust the This allows maximum traction of the drive Operator's using vehicles equipped with pressure in the auxiliary axle suspension. axles to control the vehicle. liftable auxiliary axles must consider creep These knobs are in addition to the tag and ratings when any liftable axle is unloaded pusher axle switches that control the axle Depending on the suspension, various or in the raised position. Liftable auxiliary position. calibrations may be required. Contact your axles should only be raised (or unloaded) 4 authorized dealer or axle/suspension Adding more pressure to the auxiliary axle to improve maneuverability in an off-road manufacturer for specific calibration will increase the pressure the auxiliary axle use or when vehicle is unloaded. procedures. pushes down. Increasing pressure will decrease load on the drive axles and will Some suspensions require dump valve WARNING! descrease traction. Decreasing pressure calibration. For example, some dead axles will transfer more weight to the drive axles do not lift, but the air can be dumped out of Never operate the vehicle with more pres- and will result in more traction from the them to unload them when empty. Air sure in the lift axles than is necessary to drive axles. pressure is controlled via an adjustable carry the load, as determined by the calibra- regulator. These axles need to be tion procedure described. Failure to do so Deflate the auxiliary axle suspension calibrated for load. can result in loss of traction and stability at before or uncoupling a trailer. the steer and/or drive axles and can result in After the trailer is coupled or de-coupled, Contact your authorized dealer or axle/ increased braking distance, which could then increase pressure to balance traction suspension manufacturer for dump valve cause loss of vehicle control resulting in an and axle load requirements. Inflate air calibration procedures. accident. Failure to comply may result in springs of the auxiliary axles to the desired death, personal injury, equipment or proper- ty damage. pressure after coupling to a loaded trailer What is Axle Creep Rating while still maintaining proper traction of the drive axles. Vehicles outfitted with auxiliary axles, and full truck configuration, will have an axle Adjust the pressure regulator control knob creep rating which defines how much load to a lower pressure until desired traction is is allowed when the vehicle has a full load

118 Y53-6096-1A1 (01/17) DRIVING - Axle and Suspension

Perform this procedure at or near a weight the calibration of the auxiliary axles. If tires scale. Procedure can be performed while NOTE are installed with a different loaded radius, the calibration procedure must be repeated. parked on the weight scale if scale is Failure to do so can cause equipment dam- available. To obtain the desired axle load Axle Creep ratings MUST NOT be exceed- age. distribution, you must correlate the ed. suspension air gauge pressure to the Contact your dealer or axle manufacturer actual axle load by scaling the axle to determine what the creep rating is for weight(s) and adjusting the pressure to CAUTION your particular axle(s) and configuration. obtain the desired load. Once the desired Creep ratings are generally limited to the load or load range is achieved, document Always lower the axles as soon as possible after receiving a load. Never exceed 5 miles following: the pressure-to-load ratio or setting for 4 future use. per hour when driving with a load with the • Tandem rear axles only auxiliary axle(s) raised/unloaded. Failure to lower the axle(s) can overload the frame • Straight trucks only and remaining axles, and could cause • Maximum spring mount centers per NOTE equipment damage. axle manufacturers specifications This procedure must be performed prior to • Maximum tire static loaded radius placing the vehicle into service. (SLR) per axle manufacturers CAUTION specifications Add: Perform this procedure at or near a Do not modify the air system and/or control See Also weight scale. Procedure can be performed while parked on the weight scale if scale is functionality on a factory installed auxiliary Vehicle Loading on page 24 axle(s). Modifying the factory operation of available. the pusher and/or tag axle(s) will void your warranty, and can cause equipment dam- Pusher or Tag Suspension Setting the To obtain the desired axle Calibration age. Pressure- load distribution, you must Calibrating the suspension is important to to-Load correlate the suspension ensure that the correct axle loads meet Ratio air gauge pressure to the CAUTION weight limits and obtain the proper load actual axle load by scaling distribution. the axle weight(s) and A change in tire size on either the auxiliary adjusting the pressure to axles or the drive/steer axles can change

Y53-6096-1A1 (01/17) 119 DRIVING - Axle and Suspension

obtain the desired load. achieving an estimated ground not be altered. Incorrectly adjusted ride Once the desired load or load). height may result in improper interaxle U- load range is achieved, 5. After setting the pressure to obtain joint working angles. This can result in pre- document the pressure-to- the desired axle load, verify proper mature driveline wear and driveline load ratio or setting for ground loading with the weight vibration. scale. future use. If it becomes necessary to reset the , you may temporarily set it by These instructions are general in nature. NOTE following the next procedure. Proper ride For more specific instructions, review the height measurement and values are shown 4 pusher or tag suspension manufacturers Exceeding local, state or federal weight lim- in the illustration and table below. maintenance manual or contact the its may result in citations. Contact your local nearest authorized dealer. commercial weight enforcement office for limits in your area. CAUTION 1. Park loaded vehicle on level surface with wheels blocked. Completing this procedure will enable you to safely reach the nearest authorized dealer 2. Release vehicles spring brakes. (Do NOTE or repair facility to have ride height and pin- not release for Liftable/Non- ion angle reset using the proper equipment Steerable pusher or tag axles). Steerable-pusher and/or tag axle(s) will raise when the transmission is shifted into and technique. Do this as soon as possible 3. Lower the pusher/tag axles with the reverse or when the parking brakes are ap- to avoid potential driveline damage. axle lift control flip valve. (For some plied. non-liftable axles, inflate air suspension). NOTE 4. Adjust the amount of load on each Air Suspension Ride Height axle by turning the pressure Suitable wheel chocks are at a minimum an Information on air suspension and 18-inch (46 cm) long 4x4. regulator clockwise to increase the adjusting the ride height. load or counterclockwise to decrease the load. (The suspension Vehicles equipped with rear or front air 1. Park the vehicle, engage the manufacturer may publish pre- suspensions have their ride height and parking brakes and clock the established Pressure-to-Load Ratio axle (pinion) angle(s) preset at the factory. wheels. Pressure Settings to assist you in These are precision settings and should

120 Y53-6096-1A1 (01/17) DRIVING - Axle and Suspension

2. Locate the air suspension ride 6. Rotate the valve either clockwise or 8. Torque the mounting fasteners to height valve counterclockwise until air pressure 55-75 lb-in (6.2-8.5 Nm.). in the air springs provides the ride 9. Remove the alignment pin or dowel. height specified for that suspension. 10. Repeat Steps 2 through 6 above for Measure the ride height from the the RH valve on vehicles with a bottom of the frame rail to the dual-valve system. approximate centerline of the rearmost drive axle hub: • For tandem axles, make the vertical measurement at the 4 centerline of the suspension • For a single axle, make the measurement in front of the axle, 3. Ensure that the tractor is fully laden in the area forward of the tires during this procedure. Do not use but not past the suspension these procedures on a vehicle that bracket. is not laden (bobtail). 7. When at the correct ride height, 4. Ensure the air supply and delivery ensure that the height control valve plumbing of the height control valve lever is in the neutral position, then is consistent with the following install either the built-in alignment illustrations. pin or a 1/8-inch (3 mm) dowel. 5. Loosen the fasteners mounting a height control valve to its bracket.

Y53-6096-1A1 (01/17) 121 DRIVING - Axle and Suspension

Air Ride Height Data Tandem Axle Laden Ride Height - These are factory settings for ride height of inches (mm)

the rear air suspension. Air Leaf 11.70 (297)

Air Trac 11.00 (279)

Low Air Leaf 8.50 (216)

Low Low Air Leaf 6.50 (165) 4 FLEX Air 8.50 (216) 1. Ride Height Tandem Axle Unladend Ride Height - 2. Centerline of suspension inches (mm)

Air Leaf 12.0 (305) Single Axle Laden Ride Height - inches (mm) Air Trac 11.38 (289) Low Air Leaf 8.75 (222) Air Trac 11.00 (279) Low Low Air Leaf 6.75 (171) Low Air Leaf 6.50 (165) FLEX Air 8.75 (222)

Single Axle UnLaden Ride Height - inches (mm)

Air Trac 11.39 (289)

Low Air Leaf Built Before 8.75 (222) April 2004

Low Air Leaf Built After 6.75 (171) April 2004

122 Y53-6096-1A1 (01/17) DRIVING - Aftertreatment System

What to do if an Air Spring (SCR), Regeneration Switch and warning Ruptures lights. The DPF will trap soot from the CAUTION engine exhaust gases. The SCR uses Diesel Exhaust Fluid to reduce the levels of If an air spring is ruptured, drive the vehicle Operating a vehicle with air suspension NOx in the engine exhaust. The ATS will to a safe stop off the highway to investigate bags either overinflated or underinflated periodically clean (regenerate) the DPF. may cause damage to driveline compo- the problem. Aftertreatment System Detail nents. If a vehicle must be operated under such conditions, do not exceed 5 mph (8 WARNING! km/h). Failure to comply may result in equip- ment damage. Do not continue to drive with ruptured air 4 springs. The air loss can cause the spring You can get to a repair facility by removing brakes to apply allowing your brakes to drag the height control link connected to the and burn up the linings, which could lead to axle and to the suspension air valve control an accident causing death or personal in- arm. This will cause the air valve control jury. Do not continue to operate the vehicle arm to center in the closed position. in this condition. Removing the link will allow the air system of the truck to operate normally so that the WARNING! vehicle can be driven to a service center. 1. Hydrocarbon Doser from Turbo 2. Aftertreatment Unit (DPF, DEF Doser Do not drive the vehicle if the air pressure is and SCR) less than 100 psi (690 kPa). Driving the ve- Aftertreatment System 3. Filtered/Treated Exhaust hicle with less than 100 psi (690 kPa) could 4. Diesel Exhaust Fluid (DEF) Tank make the brakes unsafe to use which could cause an accident involving death or per- General information on the emissions Please refer to the Exhaust Aftertreatment sonal injury. aftertreatment system in your vehicle. System Supplement provided with the This vehicle has an exhaust Aftertreatment vehicle for more detailed description of System (ATS), to control vehicle exhaust functionality and warnings. emissions.The exhaust Aftertreatment system consist of a Diesel Particulate Filter (DPF), Selective Catalyst Reduction

Y53-6096-1A1 (01/17) 123 DRIVING - Dual Steer Operation

transmission is driven by the rear wheels, and the countershaft gear (which lubricates Dual Steer Operation Driving Tips and the transmission components by oil splash) Techniques will only be turning at idle speed. Dual steer vehicles are equipped with dual- control electronic shift controls that may Descending a Grade This section covers additional driving tips have an auto neutral control and a shift and techniques on how to drive your shock eliminator feature. Follow the vehicle more efficiently. WARNING! procedures below to operate these types of vehicles. Do not hold the brake pedal down too long 4 Coasting or too often while going down a steep or long grade. This could cause the brakes to overheat and reduce their effectiveness. As WARNING! a result, the vehicle will not slow down at the usual rate. To reduce the risk of an accident Do not coast with the transmission in neutral which could cause death or personal injury, or with the clutch pedal depressed—it is a before going down a steep or long grade, dangerous practice. Coasting in neutral may reduce speed and shift the transmission into result in damage to your drivetrain when you a lower gear to help control your vehicle try to re-engage the transmission. You could speed. Failure to follow procedures for prop- 1. Bring the vehicle to a complete stop lose control of the vehicle which can lead to er downhill operation could result in loss of an accident involving death or personal in- by using the foot brake pedal vehicle control. jury. 2. Shift the transmission to neutral and Engine Overspeed pull out the parking valve knob. Do not coast with the transmission in 3. Move to the drive station you want neutral or with the clutch pedal depressed. to operate from. Besides being illegal and dangerous, CAUTION 4. Toggle the switch according to the coasting is also expensive. It causes location. If on the right hand side, premature failure or damage to the clutch To avoid engine damage, do not let the en- then toggle the switch to the ON and transmission and overloads the brake gine rpm go beyond the maximum governed rpm—valve damage could result if over- position. Operating from the left system. Coasting with the transmission in speed conditions occur. hand side, then toggle the switch neutral also prevents proper transmission OFF. component lubrication. During coasting the

124 Y53-6096-1A1 (01/17) DRIVING - Driving Tips and Techniques

higher gear to bring engine rpm within the optimum speed range. NOTE WARNING! • When driving downhill: shift to a lower gear, use the engine brake (if Often these recommendations are secon- Do not look at the Instrument Cluster Dis- dary to maintaining an adequate and safe so equipped), and use the service play for prolonged periods while the vehicle speed relative to the surrounding traffic and brake, keeping the engine speed is moving. Only glance at the monitor briefly road conditions. below 2,100 rpm. while driving. Failure to do so can result in the driver not being attentive to the vehicle’s Operate the engine within the optimum When the engine speed reaches its road position or situation, which could lead engine rpm range and do not allow the maximum governed speed, the injection to an accident and possible death, personal injury or equipment damage. rpm's to exceed the maximum governed pump governor cuts off fuel to the engine. 4 However, the governor has no control over speed. See your Engine Operation and Fuel Consumption Maintenance manual for information the engine rpm when it is being driven by regarding engine rpm. When the engine is the vehicle's transmission, for example, on The vehicle's fuel consumption is used as a brake to control vehicle speed steep downgrades. Apply service brakes or connected to five important factors: (e.g., while driving down a grade), do not shift to a higher gear. Fuel economy and maintenance, driving habits, general allow the engine rpm to exceed maximum engine performance are also directly condition of the road, traffic conditions, and governed speed. Under normal load and related to driving habits: vehicle load. road conditions operate the engine in the • The best results in trip time and fuel lower end of the range. Proper maintenance will keep the vehicle economy are obtained while driving running like new even after long periods of The tachometer is an instrument that aids the vehicle at a steady speed. use. The driver must perform daily and in obtaining the best performance of the • Shift into higher or lower gears (or weekly checks of the vehicle. engine and manual transmission, serving apply the service brake) to keep as a guide for shifting gears. Refer to the engine rpm near the lower end of Maintenance factors affecting fuel Engine Operation and Maintenance the optimum operating range. consumption: manual for optimum engine rpm. • Avoid rapid acceleration and • air and/or fuel filters partially braking. • If the engine rpm moves beyond the clogged maximum governed speed, • engine valves out of adjustment indicating an overspeed condition, • injection pump improperly apply the service brake or shift to a synchronized

Y53-6096-1A1 (01/17) 125 DRIVING - Stopping the Vehicle

• injection nozzles defective or • very high load the engine suddenly, the temperature of uncalibrated • inadequate roads the turbocharger could rise as much as • improperly inflated tires • traffic conditions 100°F (55°C) above the temperature • wheel bearings improperly adjusted reached during operation. A sudden rise in temperature like this could cause the • clutch improperly adjusted or worn bearings to seize or the oil seals to loosen. (slipping) Stopping the Vehicle • fuel leaks Refueling

Wrong driving habits must be corrected A hot engine stores a great amount of Air space in your fuel tanks allows water to 4 and the recommendations on economic heat. It doesn’t cool down immediately condense there. To prevent this driving should be followed. Driving factors after you shut it off. Always cool your condensation while you are stopped, fill affecting fuel consumption: engine down before shutting it off. You will your tanks to 95 percent of capacity. When greatly increase its service life. refueling, add approximately the same • excessive speed and unnecessary amount to each fuel tank on vehicles with fast acceleration Idle the engine at 1000 rpm for five more than one tank. • long periods of idling minutes. Then low idle for thirty seconds • driving with foot resting on the before shutdown. This will allow circulating (manual transmission) clutch pedal coolant and lubricating oil to carry away WARNING! heat from the cylinder head, valves, Do not carry additional fuel containers in General Condition Other factors affecting pistons, cylinder liners, turbocharger, and your vehicle. Fuel containers, either full or fuel consumption are related to loads and bearings. This way you can prevent type of roads on which the vehicle empty, may leak, explode, and cause or serious engine damage that may result feed a fire. Do not carry extra fuel contain- operates. It is not always possible to from uneven cooling. ers. Even empty ones are dangerous. Fail- choose the most adequate road, but it ure to comply may result in death or person- must be kept in mind that the ideal road is Turbocharger al injury. the one that allows a steady speed in high This cooling-down practice is especially gear, without requiring frequent braking important on a turbocharged engine. The and acceleration. The following general turbocharger contains bearings and seals conditions can affect fuel consumption: that are subjected to hot exhaust gases. • overload While the engine is operating, heat is • unbalanced load carried away by circulating oil. If you stop

126 Y53-6096-1A1 (01/17) DRIVING - Stopping the Vehicle

Final Stopping Procedures • Engine Compression WARNING! 2. If you are parked on a steep grade, These suggestions will help ensure that block the wheels. your vehicle is ready to go after a long stop Diesel fuel in the presence of an ignition (such as over night). source could cause an explosion. A mixture of gasoline or alcohol with diesel fuel in- Your vehicle will be easier to get going creases this risk of explosion. Do not re- when you are ready, and it will be safer for move a fuel tank cap near an open flame. anyone who might be around it. Please Use only the fuel and/or additives recom- remember, too, that in some states it is mended for your engine. Failure to comply may result in death, personal injury, equip- illegal to leave the engine running and the 4 ment or property damage. vehicle unattended.

WARNING! CAUTION Using the trailer hand brake or air brakes to Use only Ultra Low Sulfur Diesel (ULSD) hold a parked vehicle is dangerous. Be- Fuel, as recommended by engine manufac- cause they work with air pressure, these 3. Drain water from the air reservoirs. turers. If you need further information on brakes could come loose. Your vehicle could fuel specifications, consult the Engine Oper- roll, causing an accident involving death or While the engine and air supply ation and Maintenance Manual. personal injury. Always set the parking system are still warm, drain brakes. Never rely on the trailer hand brake moisture from the air reservoirs. If your vehicle is equipped with fuel shut-off or truck air brakes to hold a parked vehicle. Open the reservoir drains just valves for the take-off and return lines, they enough to drain the moisture. Don’t are located on the fuel lines entering the 1. Set the parking brake before leaving deplete the entire air supply. Be top of the fuel tank. Fuel shut-off valves for the driver’s seat. To hold your sure to close the drains before the fuel crossover line are on the bottom of vehicle while it is parked, don’t rely leaving the vehicle. the fuel tank, at the crossover line on: connection. • Air Brakes • Hand Control Valve for Trailer Brakes

Y53-6096-1A1 (01/17) 127 DRIVING - Stopping the Vehicle

4

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

128 Y53-6096-1A1 (01/17)

Chapter 5 | MAINTENANCE

In this Chapter:

Maintenance Schedule...... 131 New Vehicle Maintenance Schedule...... 152 Lubricants...... 153 Checking Oil Level...... 154 5 Inspect Power Steering Fluid...... 154 What is the Air System?...... 155 What is an Air Dryer?...... 156 Air Tanks...... 158 How to Check for Air System Leaks...... 159 What is an Air Compressor?...... 159 Brake System...... 160 Cab Maintenance...... 165 Cooling System Maintenance...... 168 Safety Restraint System - Inspection...... 173

MAINTENANCE -

Windshield Wiper/Washer...... 175 Electrical System...... 176 Engine Maintenance...... 186 Fuel System...... 192 Frame...... 192 Front Axle and Suspension...... 194 Heater and Air Conditioner Maintenance...... 196 5 Noise and Emission Control...... 199 Rear Axle and Suspension...... 201 Steering System...... 204 Driveline...... 207 Tires...... 207 Wheels...... 210 Transmission Maintenance...... 211 Mechanical Clutch ...... 212 Specification Reference Charts...... 212

130 Y53-6096-1A1 (01/17) MAINTENANCE - Maintenance Schedule

death, personal injury, equipment or proper- may result in death, personal injury, equip- Maintenance Schedule ty damage. ment or property damage.

Preventive maintenance program begins WARNING! WARNING! with the daily checks. Routine vehicle checks can help avoid many large, If work has to be done with the engine run- Always support the vehicle with appropriate ning, always (1) set the parking brake, (2) safety stands if it is necessary to work un- expensive, and time consuming repairs. block the wheels, and (3) ensure that the derneath the vehicle. A jack is not adequate The vehicle will operate better, be safer, shift lever or selector is in Neutral. Failure to for this purpose. Failure to comply may re- and last longer. Neglect of recommended comply may result in death, personal in- sult in death, personal injury, equipment or maintenance can void your vehicle’s jury,equipment or property damage. property damage. warranty. Some maintenance operations demand skills and equipment you may not 5 have. For such situations, please take your WARNING! WARNING! vehicle to an authorized Service Center. Excercise extreme caution to prevent neck- When working underneath the vehicle with- ties, jewerly, long hair or loose clothing from out appropriate safety stands but with the WARNING! getting caught in the fan blades or anyother wheels on the ground (not supported), make moving engine parts. Failure to comply may sure that (1) the vehicle is on hard level Before attempting any procedures in the en- result in death, personal injury, equipment or ground, (2) the parking brake is applied, (3) gine compartment, stop the engine and let it property damage. all wheels are blocked (front and rear) and cool down. Hot components can burn skin (4) remove the ignition key so that the en- on contact. Failure to comply may result in gine cannot be started. Failure to comply death, personal injury, equipment or proper- WARNING! may result in death, personal injury, equip- ty damage. ment or property damage. Disconnect the battery ground strap when- ever you work on the fuel system or the WARNING! electrical system. When you work around fuel, do not smoke or work near heaters or If the engine must be operating to inspect, other fire hazards. Keep an approved fire be alert and cautious around the engine at extinguisher near to you. Failure to comply all times. Failure to comply may result in

Y53-6096-1A1 (01/17) 131 MAINTENANCE - Maintenance Schedule

defined for applications where the vehicle information on maintenance is NOT used off of a paved road during procedures consult your vehicle WARNING! normal operation. City Delivery is defined maintenance manual. for applications where frequent start and Never start or let the engine run in an en- • The initial fill of drive axle lubricant stopping is required during normal closed, unventilated area. Exhaust fumes must be changed before the end of from the engine contain carbon monoxide, a operation and the highway is used the first scheduled maintenance colorless and odorless gas. Carbon monox- infrequently and for short periods of time. interval. See the axle ide can be fatal if inhaled. Failure to comply manufacturer's operator's manual Off highway is defined for applications may result in death, personal injury, equip- for recommended lubrication where the vehicle may be driven off the ment or property damage. specifications and service intervals. pavement on a regular basis, even if it is • The initial fill of lubricant in manual The following pages contain a table of an infrequent basis and/or for a brief time transmissions must be changed maintenance tasks with the related period. Please contact an authorized before the end of the first intervals for each task on the right side of service dealership if there are questions 5 maintenance interval. See the the table. The top of the table displays a regarding which interval to follow. Consult transmission manufacturer's guide to a maintenance interval and its the supplier for specific recommendations operator's manual for recommended schedule. Some tasks are dependent on where discrepancies develop between lubrication specifications and the vehicle application. These tasks will be these recommendations in this table and service intervals. shown as separate tasks and will have the component supplier recommendations. words “ON HIGHWAY”, “CITY DELIVERY” • If your vehicle is equipped with an • Engine lubricating oil change or “OFF-HIGHWAY” after the description. automatic transmission, consult the intervals aren’t listed here. Refer to These tasks are differentiated because owner’s manual for it that came with your engine’s operating manual for they are dependent on the vehicle’s your vehicle to obtain lubricant recommendations. For specific operating environment. On highway is check and change intervals.

132 Y53-6096-1A1 (01/17) MAINTENANCE - Maintenance Schedule

Preventative Maintenance Intervals

I A B C D E

At first 15,000 mi/24,000 15,000 mi/24,000 km/ 30,000 mi/48,000 km 60,000 mi/96,000 km/ 6 120,000 mi/ 192,000 km/ 240,000 mi/ 384,000 km km or at first PM Monthly Months Annually

Maintenance Schedule 5 System Component Task I A B C D E

Frame Fifth Wheel Check the kingpin lock and plate for wear and function: • lubricate (NLGI #2 grease).

Inspect fifth wheel operation; see Frame Fastener • Torque Requirements on page 214

Frame Fasteners Check for tightness: tighten to the specified torque value as required; see Frame Fastener Torque • Requirements on page 214.

Crossmembers and Mounting Brackets Inspect for cracks and loose fasteners. Replace or tighten to the specified torque value as required; see • Frame Fastener Torque Requirements on page 214.

Engine Mounting Inspect engine mounts every 60,000 miles (96,560 km); see Engine Mounting on page 191. Contact an • authorized vehicle OEM dealership if engine mounts need servicing.

Y53-6096-1A1 (01/17) 133 MAINTENANCE - Maintenance Schedule

System Component Task I A B C D E

Front Axle Total Vehicle Alignment Check and adjust as required. • •

Steering Knuckle Spindles, Thrust Bearings, Kingpins, Inspect for wear and damage and endplay. Shim or Drawkeys, Tie Rod Ends, Steering Stops, and replace as required; see Front Axle and Suspension on • Bushings. page 194.

Kingpin Bushings, Thrust Bearings, and Tie Rod Ball Lubricate with approved grease. • Ends

Drawkeys Tighten nuts • •

Front Axle (Dana) Total Vehicle Alignment Check and adjust as required. • •

Kingpin Bushings, Thrust Bearings, and Tie Rod Ball Lubricate with approved grease. • 5 Ends (ON HIGHWAY)

Kingpin Bushings, Thrust Bearings, and Tie Rod Ball Lubricate with approved grease. • Ends (OFF-HIGHWAY)

Steering Knuckle Spindles, Thrust Bearings, Kingpins, Inspect for wear and damage and for endplay. Shim or Drawkeys, Tie Rod Ends, Steering Stops, and replace as required. • Bushings (ON HIGHWAY)

Steering Knuckle Spindles, Thrust Bearings, Kingpins, Inspect for wear and damage and for endplay. Shim or Drawkeys, Tie Rod Ends, Steering Stops, and replace as required. • Bushings (OFF-HIGHWAY)

134 Y53-6096-1A1 (01/17) MAINTENANCE - Maintenance Schedule

System Component Task I A B C D E

Front Suspension Front Spring Inspect for cracked leaves, worn bushings, and • excessive corrosion.

Spring Pins and Shackles Inspect for worn parts and excessive joint clearance. • Shim or replace as required.

Shock Absorbers Inspect for leaking, body damage, and damaged or worn bushings. Replace as required. Check the shock • mounting stud torque.

Spring Pins Lubricate with approved grease. •

Check for proper function. •

U-bolts (ON HIGHWAY) Check the general condition and the tightness of the 5 nuts. Tighten the nuts to the specified torque value as • • required; see Suspension U-Bolts, Grade 8 on page 213.

U-bolts (VOCATIONAL) Check the general condition and the tightness of the nuts. Tighten the U-bolts after the first day or two of operation. Then tighten the nuts to the specified torque • • value as required; see Suspension U-Bolts, Grade 8 on page 213.

U-bolts (OFF HIGHWAY) Check the general condition and the tightness of the nuts. Tighten the U-bolts after the first day or two of operation. Then tighten the nuts to the specified torque • value as required; see Suspension U-Bolts, Grade 8 on page 213.

Y53-6096-1A1 (01/17) 135 MAINTENANCE - Maintenance Schedule

System Component Task I A B C D E

Drive Axle (Dana) Axle Housing Visually inspect for damage or leaks. •

Check oil level. Check "cold." Torque the drain plug. •

Drain the lubricant while warm. Flush each unit with See manufacturer's service requirements. clean flushing oil. Change the lubricant.

Air Shift Unit Check the lubricant level. •

Remove the housing cover and drain the lubricant. • Wash the parts thoroughly and dry in air.

Breather Clean or replace. •

Lube Pump (ON HIGHWAY) Remove the magnetic strainer and inspect for wear 5 • particles. Wash in solvent and dry in air.

Lube Pump (OFF HIGHWAY) Remove the magnetic strainer and inspect for wear • particles. Wash in solvent and dry in air.

Lube Filter (ON HIGHWAY) Change. •

Lube Filter (OFF HIGHWAY) Change. •

Magnetic Drain Plug and Breather (ON HIGHWAY) Clean or replace. •

Magnetic Drain Plug and Breather (OFF HIGHWAY) Clean or replace. •

136 Y53-6096-1A1 (01/17) MAINTENANCE - Maintenance Schedule

System Component Task I A B C D E

Drive Axle (Meritor Axle Housing Check the "cold" fill level at the differential carrier plug Line Haul / ON for a pinion angle of less than 7 degrees, or at the axle • HIGHWAY) bowl plug for a pinion angle of greater than 7 degrees. Tighten the plug to 35-50 lb-ft (47-68 Nm)

Visually inspect for damage or leaks. •

Drain and replace the lubricant See Rear Axle Lubrication on page 203

Lubricant Filter Change the filter •

Breather Check the operation. If the cap doesn’t rotate freely, • replace.

Input Shaft and Pinion Shaft Check and adjust the endplay. • 5

Axle Shaft Tighten the rear axle flange nuts to the specified torque • value.

Interaxle Differential Check the operation. •

Y53-6096-1A1 (01/17) 137 MAINTENANCE - Maintenance Schedule

System Component Task I A B C D E

Drive Axle (Meritor Axle Housing Check the "cold" fill level at the differential carrier plug City Delivery / for a pinion angle of less than 7 degrees, or at the axle • OFF HIGHWAY) bowl plug for a pinion angle of greater than 7 degrees. Tighten the plug to 35-50 lb-ft (47-68 Nm)

Visually inspect for damage or leaks. •

Drain and replace the lubricant. See Rear Axle Lubrication on page 203

Lubricant Filter Change the filter •

Breather Check the operation. If the cap doesn’t rotate freely, • replace.

5 Input Shaft and Pinion Shaft Check and adjust the endplay. •

Axle Shaft Tighten the rear axle flange nuts to the specified torque • value.

Interaxle Differential Check the operation. •

Drive Axle (SISU) Axle Housing Change the oil in the differential carrier and the hubs, • • and clean the magnetic oil drain plugs.

Check the wheel bearing hubs and adjust if necessary. • •

Visually inspect for damage or leaks. • •

Check the oil level in the differential carrier and hubs. •

Breather Check the breather for proper operation. •

Lube Filter Clean the suction filter for the optional pressure • lubrication system.

S-cam Brakes Overhaul the brakes: degrease all moving parts, check • the bushings and seals for wear.

138 Y53-6096-1A1 (01/17) MAINTENANCE - Maintenance Schedule

System Component Task I A B C D E

Rear Suspension U-bolts Check the torque. Tighten to specified torque value as • •

Frame and Crossmembers Bolts Check the torque. Tighten to specified torque value as •

Mounting Brackets and Fasteners Check the condition and the fastener torque. Tighten to the specified torque value as required; see Suspension • • U-Bolts, Grade 8 on page 213.

Drum Brakes (All) Slack Adjusters Check the push rod travel and check the control arm for cracks. Adjust at reline; see Auto Slack Adjuster on • page 162.

Lubricate (NLGI #2 grease). •

Brake Camshaft Bearing Check for excessive camshaft play in the axial and 5 radial 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. Check the pivot and mounting plate for integrity. • Check the plunger boot for cracks. Lubricate roller pin, pivot pin, and plunger (NLGI #2 grease).

Brake Air System Check air lines and fittings for leaks; see How to Check for Air System Leaks on page 159. Adjust routing as • required to prevent chafing. Check tank mounting and condition.

Clean or replace the inline filters. •

Brake Lining Inspect: replace as required. •

Y53-6096-1A1 (01/17) 139 MAINTENANCE - Maintenance Schedule

System Component Task I A B C D E

Disc Brakes Brake Pads Inspect: replace as required. • (Bendix®) Brake Disc/rotor Inspect for visible cracks, heat checking, galling, or scoring of surface. Check for runout (max allowable is • 0.002 in.).

Caliper Sliding Function Ensure caliper slides freely with no obstructions or • excessive play.

Caliper Slide Pins Inspect protective caps of the guide pins for damage or • cracking.

System Operation Check operation: inspect as per manufacturer’s service • 5 literature.

140 Y53-6096-1A1 (01/17) MAINTENANCE - Maintenance Schedule

System Component Task I A B C D E

Hub, Drum, and Hubs (non-LMS) Check the bearing endplay and adjust as required; see • Hubcap Wheels on page 210.

Hubs (non-LMS) with Outrunner Seals Clean the components and check for excessive wear or damage. Change the oil and seal; see Wheels on • page 210.

Hubs (non-LMS) with Standard Seals Clean the components and check for excessive wear or damage. Change the oil and seal; see Wheels on • page 210.

Hub Seals (all) Check for leaks: replace as required. •

LMS Hubs (Dana) Inspect for leaks. Check the bearing endplay and • adjust as required; see Wheels on page 210. 5

LMS Hubs (Dana) with Synthetic Lubricant Service the bearings, seals and oil. This interval may be different depending on the results of the regular 500,000 miles/ 800,000 km inspection. See Wheels on page 210.

LMS Hubs (Dana) with Mineral Lubricant Service the bearings, seals and oil. This interval may be different depending on the results of the regular 350,000 miles/ 560,000 km inspection. See Wheels on page 210.

Brake Drums Inspect for visible cracks, heat checking, galling or scoring of 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 flange, and fill plug for leaks and for proper • installation. Replace broken or damaged parts. Check the lubricant level and add as required.

Y53-6096-1A1 (01/17) 141 MAINTENANCE - Maintenance Schedule

System Component Task I A B C D E

Main and Auxiliary Main and Auxiliary Transmission and Transfer Case Inspect for visible damage, signs of overheating, and • • Transmission leaks.

Check the drain plugs for tightness. •

Mounting Brackets and Fasteners Check the condition of the fasteners and their torque. • Tighten to the specified torque value as required.

Oil Cooler Clean the fins (air-to-oil type) and body. Check the • hose condition and for leaks: replace as required.

Main and Auxiliary Transmission Check the oil level: refill as required. •

Main and Auxiliary Transmission (ON HIGHWAY) Drain lubricant while warm. Flush each unit with clean 500,000 miles/ 800,000 km 5 flushing oil.

Main and Auxiliary Transmission (OFF HIGHWAY) Drain lubricant while warm. Flush each unit with clean • • flushing oil.

Auxiliary Cotta Transfer Case TR2205 Fabco Transfer Case Inspect: Check oil level, inspect for leaks and any • Transmission TC142/TC143/TC170/ TC270 Marmon-Harrington visible damage. Transfer Case MVG2000/MVG2000SD Initial oil change: Drain oil while warm: flush case with gear oil-compatible fluid, clean magnetic drain plug, • • and refill. Do not flush the case with any solvent.

Change oil. •

Air Intake Air Intake Piping, Mounting, and Charge Air Cooler Check the system for broken pipes, leaks, joint integrity, cleanliness, and proper support; see Air • Intake System on page 190.

Air Cleaner Replace the engine intake air cleaner element. When required by air restriction indicator or required by the engine manufacturer's operator manual.

142 Y53-6096-1A1 (01/17) MAINTENANCE - Maintenance Schedule

System Component Task I A B C D E

Clutch Clutch Hydraulic Fluid Replace fluid and bleed system. 240,000 miles/384,000 km or 2 years, whichever occurs first.

Clutch Release Bearing Lubricate. •

Inspect and adjust when necessary (no adjustment • required for SOLO type )

Cooling Hoses Check the radiator and heater hoses for leaks. • •

Extended Life Coolant (ELC) Check the freeze point; see Cooling System • Maintenance on page 168.

Check for contamination using test strips; see Cooling • System Maintenance on page 168. 5

Replace blank water filter if applicable. •

Perform lab analysis. If lab analysis shows coolant is unsuitable for continued use: Flush, drain, and refill. • Add ELC Extender; see Cooling System Maintenance on page 168.

Flush, drain, and refill with new coolant; see Cooling • System Maintenance on page 168.

Fan Clutch Check for air leaks. See Engine Fan on page 189. 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 • • disengagement.

Y53-6096-1A1 (01/17) 143 MAINTENANCE - Maintenance Schedule

System Component Task I A B C D E

Tires and Wheels Tires Check inflation pressure; see Tires on page 207. Weekly "cold" using calibrated gauge.

Inspect for cuts, irregular wear, missing lugs, sidewall • damage, etc.

Disc Wheels Inspect the wheel disc for any cracks or surface irregularities. Inspect the edge and bead seat area • for damage. Replace any damaged wheels - DO NOT ATTEMPT TO REPAIR.

Demountable Rims Inspect the mounting ring, rim gutter, side ring, and • lock ring for damage: replace as required.

Wheel Nuts and Studs Check the tightness of the fasteners and tighten the 5 fasteners to the specified torque as required; see • Wheels on page 210.

Inspect for damaged hex corners, stripped or damaged threads, and excessive corrosion: clean or replace as • required.

144 Y53-6096-1A1 (01/17) MAINTENANCE - Maintenance Schedule

System Component Task I A B C D E

Power Steering Reservoir Check the fluid level; see Power Steering Fluid on • page 205.

Reservoir (ON HIGHWAY) Drain, replace the filter, and refill; see Power Steering • • Fluid Filter on page 205.

Reservoir (OFF HIGHWAY) Drain, replace the filter, and refill. See Power Steering • • Fluid on page 205.

Steering Gear Check the lash of the sector shaft: adjust as required. •

Grease the trunnion bearing (EP NLGI #2 lithium- • based, moly-filled, HD grease).

Grease the input shaft seal (EP NLGI #2 lithium-based, • 5 moly-filled, HD grease).

Power Assist Cylinder Lubricate the ball joints. Inspect for leaking rod seals, damaged ball joint boots, and damage to cylinder rod • or barrel.

Hoses and Tubes Check for leaks and chafing. •

Y53-6096-1A1 (01/17) 145 MAINTENANCE - Maintenance Schedule

System Component Task I A B C D E

Steering Steering Linkage Check all joints for excessive lash: replace as required; • Components see Steering System on page 204.

Draglink Tube Clamp and Ball Socket Check the torque: tighten to specified torque value as • • required.

Pitman Arm Clamp Bolt and Nut Check the torque: tighten to specified torque value as • • required.

Steering Intermediate Shaft Check the torque on the pinch bolt and nut. • •

Steering Intermediate Shaft U-joints (ON HIGHWAY) Lubricate [EP NLGI #2 HD grease, +325°F to -10°F • • (+163°C to -23°C) range].

Steering Intermediate Shaft U-joints (OFF HIGHWAY Lubricate [EP NLGI #2 HD grease, +325°F to -10°F 5 • • or CITY DELIVERY) (+163°C to -23°C) range].

Draglink and Tie Rod Arm Ball Sockets (ON Lubricate (EP NLGI #2 lithium-based, moly-filled, HD • • HIGHWAY) grease).

Draglink and Tie Rod Arm Ball Sockets (OFF Lubricate (EP NLGI #2 lithium-based, moly-filled, HD • • HIGHWAY or CITY DELIVERY) grease).

Fuel and Tanks Fuel Tanks Inspect tanks, brackets, hoses, and fittings for correct location, tightness, abrasion damage, and leaks: repair • or replace as required.

Fuel Tank Breathers Check for proper function: clean the drain hoses. •

Fuel Tank Straps Check the strap tightness: tighten to proper torque value as required; aluminum tank - 30 lb-ft (41 Nm) • • cylindrical steel tank - 8 lb-ft (11 Nm)

Fuel Tank Steps Check for snug fit of side plates against tank and tank straps. Check for damaged or broken steps, missing bolts, and missing grommet between tank and side • plate. Replace missing or damaged parts and adjust for fit as required.

146 Y53-6096-1A1 (01/17) MAINTENANCE - Maintenance Schedule

System Component Task I A B C D E

Driveshafts Models SPL-90, 1710 and 1810 Slip Member and U- Lubricate * • • joints Inspect U-joint inspections should be performed every time a vehicle comes in for scheduled maintenance. **

Model SPL-100 Slip Member and U-joints Lubricate * •

Inspect U-joint inspections should be performed every time a vehicle comes in for scheduled maintenance. **

Models SPL- 140/140HD/170/ 170HD/250/250HD Slip Lubricate * • Members and U-joints (ON HIGHWAY and LINEHAUL) Inspect U-joint inspections should be performed 5 every time a vehicle comes in for scheduled maintenance. **

Models SPL- 140/140HD/170/ 170HD/250/250HD Slip Lubricate * • Members and U-joints (OFF HIGHWAY) Inspect U-joint inspections should be performed every time a vehicle comes in for scheduled maintenance. **

Models SPL-140XL/ 170XL/250XL Slip Members and Lubricate * 350,000 mi (560,000 km) 1st interval and U-joints (ON HIGHWAY and LINE HAUL) then every 100,000 mi (160,00 km) after that.

Inspect U-joint inspections should be performed every time a vehicle comes in for scheduled maintenance. **

Models SPL-140XL/ 170XL/250XL Slip Members and Lubricate * • U-joints (OFF HIGHWAY and CITY) Inspect U-joint inspections should be performed every time a vehicle comes in for scheduled maintenance. **

Y53-6096-1A1 (01/17) 147 MAINTENANCE - Maintenance Schedule

System Component Task I A B C D E

* Use only Spicer Driveshaft approved lubricants when greasing Spicer U-joints. ** Refer to Spicer Driveshaft service manual DSSM-0100 (3264-SPL) for detailed instructions.

Battery Boxes, Battery Cables Check the condition of the cables, cushion clamps, Tool Boxes, and nylon tie straps, and routing. Replace a cushion clamp Steps if the rubber has deteriorated. Repair or tighten • terminals, and secure cables to prevent chafing. Replace damaged cables (cuts, cracks, or excessive wear); see Batteries on page 181.

Batteries (ON HIGHWAY and LINE HAUL) Check for cracks and damage, electrolyte level, condition of terminals, and tightness of holddowns; see • Batteries on page 181.

5 Batteries (OFF- HIGHWAY) Check for cracks and damage, electrolyte level, condition of terminals, and tightness of holddowns; see • Batteries on page 181.

Battery Box and Tray (ON HIGHWAY and LINE HAUL) Check the box integrity. Clean the drain tube and check for acid leaks. Check condition of all equipment • mounted under the box.

Battery Box and Tray (OFF-HIGHWAY) Check the box integrity. Clean the drain tube and check for acid leaks. Check condition of all equipment • mounted under the box.

Battery Cable Fasteners Check battery cable fasteners and tighten as necessary to 10-15 lb-ft (13.6-20.3 Nm) as specified on • the battery label.

148 Y53-6096-1A1 (01/17) MAINTENANCE - Maintenance Schedule

System Component Task I A B C D E

Electrical and Headlamps Check the aim and adjust as required. • Lights Warning Lights in Light Bar Check at the ignition start position to verify bulbs and • driver information display function.

Turn, Stop, Reverse Lights and Signals Visual check. •

Alternator Check operation and output. •

Check tightness of the pulley nut. •

Check the tension of the drive belt; see Install Engine • Belt on page 188.

Check tightness of the terminal hex nuts. • 5

Starter Check torque on hex nuts. •

ECM Connector Check the tightness of the ECM connector. •

Wheel Sensors Check for damaged sensors and connectors, and worn • or frayed wires.

Fuel and Diesel Exhaust Fluid Tank Sending Unit Check the mounting screws and electrical connections • • for worn or damaged wires and connectors.

Power Supply Harnesses (engine, Transmission, etc.) Check for worn or damaged insulation, corroded terminals, frayed wires, and oil or fluid leaks on the • connectors or wiring.

Check for worn or damaged insulation, corroded • terminals, frayed. Wash to remove excess grease.

Y53-6096-1A1 (01/17) 149 MAINTENANCE - Maintenance Schedule

System Component Task I A B C D E

Cab Structure, Hood Lubricate the lower hood pivot (only if lube fittings are • Doors and Hoods present).

Hinges and Latch Lubricate with silicone spray. •

Body and Cab Holddown Bolts Check the condition and tightness. •

Heating and Air Air Conditioner Operate the system. • Conditioning Heater and Air Conditioner Perform the checks per Heater and Air Conditioner • Maintenance on page 196

Full operational and diagnostic check. •

5 Cabin Fresh Air Filter (ON HIGHWAY) Inspect and clean, replace if necessary. •

Cabin Fresh Air Filter (OFF-HIGHWAY) Inspect and clean, replace if necessary. •

Condenser Clear any debris from the front of the condenser. •

Sleeper Air Filter Inspect and clean, replace if necessary. •

Recirc Cab Air Filter (ON HIGHWAY) Please contact an authorized dealer when the service interval is required to inspect the cabin recirculation air • filter.

Recirc Cab Air Filter (OFF-HIGHWAY) Please contact an authorized dealer when the service interval is required to inspect the cabin recirculation air • filter.

150 Y53-6096-1A1 (01/17) MAINTENANCE - Maintenance Schedule

System Component Task I A B C D E

Aftertreatment System Check for leaks and proper support; see Noise and • System Emission Control on page 199.

Diesel Particulate Filter Clean filter. Refer to the Engine Maintenance Manual.

Diesel Exhaust Fluid Tank Inspect the tank, straps, brackets, hoses and fittings for abrasion damage, leaks, tightness and fully engaged • connectors.

Diesel Exhaust Fluid Supply Module Replace filter. Refer to the Engine Maintenance Manual.

Air Air Compressor Governor Replace air strainer. • Air Lines Check condition and routing to prevent chafing. • 5 System Lubricate; see What is the Air System? on page 155. •

Inline Filters Replace elements or clean with solvent. •

Air Dryer Perform the checks listed; see What is an Air Dryer? • on page 156.

Air Dryer (ON HIGHWAY) Overhaul. 360,000 miles/576,000 km

Air Dryer (OFF HIGHWAY) Overhaul. •

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 System Inspect. 20,000 miles/32,000km If the vehicle is exposed to severe environmental or working conditions, more frequent inspections may be necessary.

See Also

Y53-6096-1A1 (01/17) 151 MAINTENANCE - New Vehicle Maintenance Schedule

Visual inspection while approaching the vehicle on page 25 New Vehicle Maintenance Schedule

Maintenance tasks to perform in the first 5,000 miles (4,800 km).

Operation/ First 3,000-5,000 First 50-100 mi/ First 500 mi/800 First 2,000 mi/ Frequency First Day mi/4,800 - 8,000 80-160 km km 3,218 km km

Steering Shaft U-Bolts. • 5 (OFF-HIGHWAY)

Wheel Mounting •

Front Axle U-Bolt Torque •

Charge Air Cooler and Air Intake Pipe Clamps, re- • torque fasteners.

Rear Suspension • Fasteners

Transmission Lubrication See the manufacturer's operator's manual

Axle Lubrication See the manufacturer's operator's manual

152 Y53-6096-1A1 (01/17) MAINTENANCE - Lubricants

into the cab is also possible from other vehi- Lubricants CAUTION cles nearby. Failure to properly maintain your vehicle could cause carbon monoxide to enter the cab, resulting in death or per- Do not mix different types of lubricants. Mix- In this section you will find the basic sonal injury. information you need to do the routine ing lubricants (oil and grease) of different brands or types could damage vehicle com- lubrication your vehicle requires. ponents; therefore, drain (or remove) old lu- WARNING! Of course you will want to schedule service bricants from the unit before refilling it. more frequently if you are operating under Engine Never idle your vehicle for prolonged peri- severe conditions such as extreme heat or ods of time if you sense that exhaust fumes cold, with very heavy loads, off-road, etc. Proper engine lubrication depends on the are entering the cab. Investigate the cause For any special service requirements, outside temperatures where you will be of the fumes and correct it as soon as possi- consult your service manuals and your driving. Use the oil recommended for the ble. If the vehicle must be driven under 5 lubricant supplier. Please remember: one conditions you are most likely to be these conditions, drive only with the win- dows open. Failure to repair the source of key to keeping your truck running at top operating in. You will find a complete the exhaust fumes may result in death, per- economy and in prolonging its life is proper engine lubrication service guide in the sonal injury, equipment or property damage. lubrication servicing. Neglecting this Engine Operation Manual that came with essential aspect of vehicle care can cost your vehicle. The engine operator manual time and money in the long run. contains specific maintenance tasks that NOTE you or a qualified service technician need to perform to maintain the engine. WARNING! Keep the engine exhaust system and the vehicles cab ventilation system properly maintained. It is recommended that the ve- Handle lubricants carefully. Vehicle lubri- WARNING! hicles exhaust system and cab be inspected cants (oil and grease) can be poisonous and (1) By a competent technician every 15,000 cause death, personal injury or sickness. Exhaust fumes from the engine contain car- miles (24,140 km) (2) Whenever a change is They can also damage the paint on the ve- bon monoxide, a colorless and odorless noticed in the sound of the exhaust system hicle. gas. Do not breathe the engine exhaust gas. (3) Whenever the exhaust system, under- A poorly maintained, damaged or corroded body, or cab is damaged. exhaust system can allow carbon monoxide to enter the cab. Entry of carbon monoxide

Y53-6096-1A1 (01/17) 153 MAINTENANCE - Checking Oil Level

with the filler opening. Use care when Access the power steering reservior in the checking the oil level with a finger. Just engine compartment. Take all safety NOTE because you can reach the oil level with a precautions when opening the hood. finger, does not mean the oil level is Use only an exact replacement DPF in ex- correct. haust systems. Using a noncompliant DPF CAUTION as a replacement could violate these stand- Improper Oil Level ards and also void the emission system’s When adding fluid, be sure to use fluid of warranty. the same type. While many fluids have the same description and intended purpose, Transmissions, Axles and Hubs they should not be mixed due to incompati- See the manufacturer's operator's manual ble additives. Mixing incompatible fluids may lead to equipment damage. for recommended lubrication specifications Correct Oil Level 5 and maintenance intervals. 1. Turn engine off and open hood. Driveline Universal Joints 2. Wipe outside of power steering reservior cover so that no dirt can Refer to the Spicer Universal Joints and fall into the reservoir. Driveshafts service manual and lubrication See Also 3. Verify that the fluid level is at the specifications. Lubrication Specification Chart on page correct level. Add more fluid if See Also 216 required. Lubrication Specification Chart on page 4. Check fluid for air bubbles which 216 may indicate contamination, Inspect Power Steering discoloration, or burnt smell; correct source of such problems before Fluid replacing fluid and filter. Checking Oil Level If incompatible (insoluble) fluids are mixed Regularly check the power steering fluid for in a power steering system, air bubbles proper level and fluid condition. For oil reservoir with side filler plugs can be produced at the interface of the two (transmission, axles, steering gear boxes, fluids. This can cause cavitation, which transfer cases, etc.) the oil must be level reduces the lubrication between moving

154 Y53-6096-1A1 (01/17) MAINTENANCE - What is the Air System?

parts in the gear. This could result in worn components. The mixture of two different ply may result in death, personal injury, equipment or property damage. fluids, although harmless to individual WARNING! internal components, may initiate a Prior to the removal of any air system com- chemical reaction that produces a new ponent, always block and hold the vehicle WARNING! compound that will attack seals and other by a secure means other than the vehicle's internal components. Do not mix different own brakes. Depleting air system pressure Never exceed recommended air pressure fluids. may cause the vehicle to roll unexpectedly and always wear safety glasses when work- resulting in an accident causing death or ing with air pressure. Never look into air jets personal injuries. Keep hands away from or direct them at anyone. Failure to comply chamber push rods and slack adjusters, may result in death, personal injury, equip- What is the Air System? they may apply as system pressure drops. ment or property damage. Important safety information about your 5 vehicle's air system. WARNING! WARNING!

The operation of the vehicle’s braking After completing any repairs to the air sys- Never attempt to disassemble a component system and many vehicle accessories tem, always test for air leaks, and check the until you have read and understood recom- depends upon the storage and application brakes for safe operation before putting the mended procedures. Some components of a high-pressure air supply. vehicle in service. Failure to comply may re- contain powerful springs and injury can re- sult in death, personal injury, equipment or sult if not properly disassembled. Use only property damage. proper tools and observe all precautions WARNING! pertaining to use of those tools. Failure to comply may result in death, personal injury, Do not attempt to modify, alter, repair or dis- WARNING! equipment or property damage. connect any component of the air system. Repairs or modifications to the air system, Never connect or disconnect a hose or line other than what is described in this section, containing air pressure. It may whip as air should only be performed by an authorized escapes. Never remove a component or dealer. Failure to comply may result in death pipe plug unless you are certain all system or personal injury. pressure has been depleted. Failure to com-

Y53-6096-1A1 (01/17) 155 MAINTENANCE - What is an Air Dryer?

possible level, follow these maintenance procedures. WARNING! WARNING! Daily Checks Completely bypassing a Bendix® ADIS air If the supply and service air tanks are not dryer will bypass the system’s pressure pro- drained at the recommended frequency, wa- • Drain moisture from the supply and tection valves. This could lead to loss of air ter could enter the air lines and valves. This service air tanks. pressure or damage to the vehicle’s air sys- could cause corrosion or blockage, which • Operate air devices to circulate tem, which could cause an accident involv- could compromise the brake system safety lubricants within the unit. ing death or personal injury. Always adhere and potentially cause an accident. Failure to to the manufacturer’s procedure if it is nec- comply may result in death, personal injury, Periodically essary in an emergency to temporarily by- equipment or property damage. pass an ADIS series air dryer. Failure to • Clean filter screens ahead of the comply may result in death, personal injury, Your vehicle’s compressor takes outside air valves by removing the screens and 5 equipment or property damage. and compresses it, usually to 100-120 psi soaking them in solvent. Blow them (689-827 kPa). The compressed air then dry with pressurized air before goes to the reservoirs to be stored until reinstalling them. WARNING! needed. When you operate your air Twice a Year brakes, the stored compressed air flows If a different air dryer brand or model is in- into the chambers where it is used to apply stalled on the vehicle other than what was • Maintain the air compressor to originally installed, it could cause the air your truck and trailer brakes. That is why, prevent excessive oil by-pass. See system to not perform correctly unless the when you push down on your brake pedal, your maintenance manual for full air system design is reviewed and modi- you don’t feel the same amount of details. fications made to comply with Federal Motor pressure on the pedal that you do when • Replace worn seals in valves and Vehicle Safety Standards (FMVSS) 121 Air- you apply the brakes on your car. All you air motors as they are needed. Brake Systems. Failure to abide by this are doing on your truck is opening an air warning and maintain compliance to FMVSS valve to allow air to flow into the brake 121 could cause loss of vehicle control and may lead to death or serious personal injury. chambers. Contamination of the air supply system is the major cause of problems in What is an Air Dryer? air-operated components such as brake valves, and suspension height control The function of the air dryer is to collect valves. To keep contaminants to the lowest and remove air system contaminants in solid, liquid and vapor form before they

156 Y53-6096-1A1 (01/17) MAINTENANCE - What is an Air Dryer?

enter the brake system. It provides clean, conditions can also cause water Overhaul dry air to the components of the brake accumulation and should be considered Maintenance intervals typical for on- system, which increases the life of the before replacing the desiccant cartridge. highway operation would be 2 - 3 years, system and reduces maintenance costs. • Air usage is exceptionally high and 350,000 miles or 10,800 hours. not normal for a highway vehicle. Maintenance intervals typical for high duty NOTE This may be due to accessory air cycle usage such as transit bus, refuse demands or some unusual air hauler, dump truck, cement mixers and off- Because no two vehicles operate under requirement that does not allow the highway operation would be 1 year, identical conditions, maintenance and main- compressor to load and unload 100,000 miles or 3,600 hours. tenance intervals will vary. Experience is a (compressing and non-compressing valuable guide in determining the best main- cycle) in a normal fashion or it may tenance interval for any one particular oper- NOTE ation. be due to excessive leaks in the air system. Review the warranty policy before perform- 5 • In areas where more than a 30°F ing any maintenance procedures. An ex- NOTE (17°C) range of temperature occurs tended warranty may be voided if unauthor- in one day, small amounts of water ized maintenance is performed during this A small amount of oil in the system may be can accumulate in the air brake period. normal and should not, in itself, be consid- system due to condensation. Under ered a reason to replace the desiccant car- these conditions, the presence of Bendix® AD-IS Series Air Dryer tridge. Oil stained desiccant can function ad- small amounts of moisture is normal equately. and should not be considered as an Your vehicle may be equipped with a indication that the dryer is not ® Every 900 operating hours or 25,000 miles Bendix AD-IS series air dryer. Any air performing properly. (40,200 km) or every three (3) months check for moisture in the air brake system • An outside air source has been by opening air tanks, drain cocks, or valves used to charge the air system. This and checking for presence of water. air did not pass through the drying bed. A tablespoon of water found in the air tank would point to the need for a desiccant cartridge change. However, the following

Y53-6096-1A1 (01/17) 157 MAINTENANCE - Air Tanks

dryer replacement should be made with an Standards (FMVSS 121 - Air Brake identical component. Systems). As the Warning above states, any other type of air dryer installed in the CAUTION place of an AD-IS Series will require WARNING! changes, modifications and/or additions to Do not use penetrating oil, , or your vehicle’s air system to maintain wax-based oils in the air system. These flu- Use of an air dryer brand or model that dif- ids may cause severe damage to air system compliance with FMVSS 121. fers from what was originally installed could components. cause the air system to not perform correct- ly unless the full air system design is re- viewed and modifications are made to com- Air Tanks ply with Federal Motor Vehicle Safety Stand- ard (FMVSS) 121 Air Brake Systems. Fail- ure to abide by this warning and maintain Air tanks on the vehicle act as a reservior 5 compliance with FMVSS 121 could cause for the air system to use without running loss of vehicle control and may lead to the air compressor all of the time. These death or serious personal injury. air tanks require maintenance to keep them operational. The AD-IS Series air dryer has incorporated into its design various components that have typically been WARNING! installed separately on the vehicle (see below for components/areas affected): If the supply and service air tanks are not drained at the recommended frequency, wa- To eject moisture from the air system • Pressure protection valves ter could enter the air lines and valves. This tanks, pull the line that is connected to the • Safety valve could cause corrosion or blockage, which moisture ejection valve. Continue pulling could compromise the brake system safety until the air comes out free of water. • Governor and plumbing and potentially cause an accident. Failure to • Plumbing of the front and rear comply may result in death, personal injury, Daily service air tanks equipment or property damage. The supply and service air tanks, must be • Plumbing to accessory systems drained on a daily basis. Operate air These components are required to meet devices daily to circulate lubricants within the Federal Motor Vehicle Safety the unit.

158 Y53-6096-1A1 (01/17) MAINTENANCE - How to Check for Air System Leaks

Periodically These tests should determine where air is dealer (or any other properly equipped serv- escaping. Clean filter screens ahead of the valves by ice center) if a leak is detected. Failure to removing the screens and soaking them in check the brakes or follow these procedures solvent. Blow them dry with pressurized air could cause a system failure, increasing the risk of an accident and may result in death, What is an Air before reinstalling them. personal injury,equipment or property dam- • Maintain the air compressor to age. Compressor? prevent excessive oil bypass. 1. Build up air pressure in the system • Replace worn seals in valves and Air systems have an air compressor that to the governor cutout point or until provides compressed air to the system. air motors as they are needed. Your 120 psi (827 kPa) is reached. authorized dealer carries rebuild kits 2. Stop the engine and release the All , regardless of make or for most units. service brakes. model, run continuously while the engine is 3. Without applying the brake pedal, running. System pressure is controlled by 5 observe the rate of air pressure the governor. The governor acts in How to Check for Air drop. This rate should not exceed conjunction with the unloading mechanism System Leaks 2.0 psi (14 kPa) per minute. in the compressor cylinder block to start and stop compression of air. The 4. Start the engine and build up the air compressor is unloaded when the system pressure again. Use these steps if the air gauges in the pressure reaches 120 psi (827 kPa) and dash or any warning lights turn on that 5. Stop the engine, and apply the compression is reestablished when system indicate that a air leak exists in the system. brakes fully. Apply the brake pedal pressure falls to 100 psi (690 kPa). Checking for air leaks should also be done and hold it down for five minutes. after any service or repair has been done The pressure drop should not Preventive Maintenance to the air system. exceed 3.0 psi (21 kPa) per minute. The following service checks are provided 6. If you detect excessive leakage (air for your information only and should be pressure loss greater than 3.0 psi WARNING! performed by a certified mechanic. Contact (21 kPa) after five minutes of brake your dealer or the engine manufacturer's application), a leakage test should Do not operate the vehicle if leakage in the Maintenance Manual for further information be made at the air line connections air system is detected. Conduct the follow- on servicing air compressors. After ing procedure and contact an authorized and at all air brake control units. completing any repairs to the air system,

Y53-6096-1A1 (01/17) 159 MAINTENANCE - Brake System

always test for air leaks, and check the brakes for safe operation before putting the vehicle in service. Below is a list of areas CAUTION CAUTION to maintain for the air compressor: When draining the engine cooling system is The air brake system of this vehicle was • Inspect compressor air filter required, to prevent damage from freezing, configured for ONE of the following opera- element, if so equipped, and replace the compressor must also be drained at the tions: tractor or truck, and complies with the element if clogged. Check cylinder head and block. Engine damage respective portions of FMVSS 121. A tractor compressor mounting and drive for could occur if the cooling system is not peri- shall not be operated or configured as a odically drained and maintained. See Cool- truck, nor shall a truck be operated or con- alignment and belt tension. Adjust if ing System for further information. figured as a tractor, without significant modi- necessary. fications to the air brake system in order to • Remove compressor discharge retain compliance with FMVSS 121. Contact valve cap nuts and check for your dealer for instructions. 5 presence of excessive carbon. If Brake System excessive carbon is found, clean or replace the compressor cylinder General information about your vehicle's WARNING! head. Also, check compressor brake system and its components. discharge line for carbon, and clean Do not use brake linings with a thickness below the specified minimum. Such linings or replace the discharge line if To operate your vehicle safely and profitably, you need some understanding of will have lining rivets exposed that can dam- necessary. age the brake drum and reduce brake effi- its brake systems. For more on brakes, see • Disassemble compressor and ciency, which could cause death, personal the Index, under Brakes. thoroughly clean and inspect all injury or system failure. parts. Repair or replace all worn or damaged parts, or replace WARNING! compressor with a factory exchange unit. Do not work on the brake system without the parking brake set and wheels chocked securely. If the vehicle is not secured to pre- vent uncontrolled vehicle movement, it could roll and cause death, serious personal injury or damage to the vehicle.

160 Y53-6096-1A1 (01/17) MAINTENANCE - Brake System

interrelated and must conform to original specifications: WARNING! • Tire Size Do not use any replacement part in the • Drum brakes brake system unless it conforms exactly to original specifications. A nonconforming part • Cam Radius in your vehicle's brake system could cause • Wedge Angle a malfunction resulting in an accident caus- • Drum Radius ing death or personal injury. Sizes and types are so related to one another that a seem- • Brake Linings ingly unimportant change in one may result • Brake Chambers in a change in how well the brakes work for • Slack Adjusters 1. Brake Caliper you on the road. If parts do not work togeth- • Disc Brakes er properly, you could lose control of your 2. Caliper Mounting Flange vehicle, which could cause a serious acci- • Disc Rotors 3. Brake Rotor 5 dent. All vehicle operators should check their 4. Inspection Notches Brake adjustment and brake balance must brakes regularly. How to inspect brake pads on disc be set carefully to (1) make the most brakes efficient use of the forces available for Air Disc Brakes Have brake pads inspected by a qualified braking and (2) allow equal stopping forces mechanic for wear at regular intervals at all wheels. Once a brake system is set This vehicle may have disc brakes instead of drum brakes. according to the Preventive Maintenance to specifications, changing any one of its Schedule. In severe service or off-highway components or any combination of applications inspect the linings more components may cause the system to not frequently. work as well. All parts have to work together to perform as they should. Any To inspect the brake pads: replacement components in your brake system should be exactly equal to the 1. Park on level ground and chock the original components. Any changes from wheels. the original specifications can affect the 2. Temporarily release the parking whole system. All of the following areas are brakes.

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3. Looking from the ground up at the 3. Temporarily release the parking bottom of the caliper and rotor, brakes. compare the relative position of two 4. Grab the caliper and move it. This notches; one located on the caliper movement is Running Clearance. and the other on the carrier. 5. Proper Running Clearance is 0.08 4. Take a measurement from between inch (2 mm) of movement of the these two notches and compare brake caliper (approximately the them to the specifications to thickness of a nickel) in the inboard/ determine if the pads need to be outboard direction. replaced. Have a qualified mechanic provide further Have a qualified mechanic perform a inspection if the caliper does not move or detailed inspection if the notches are not appears to move more than the specified 5 found. The pads and rotors should be clearance measured and compared against the 1. Retracted Position, no brake pedal applied manufacturers specifications located in the Auto Slack Adjuster brake manufacturer’s service manual. 2. Applied Position, brake pedal engaged Inspect Caliper for The autoslack adjuster is a mechanism to Running Clearance maintain the correct amount of space between the braking surface and the Inspection Running clearance describes the amount friction material. of movement between the caliper and the Important information about checking the mounting flange. brakes. Regularly inspect caliper for Running Have brake drum linings inspected by a Clearance: qualified mechanic for wear at regular intervals according to the maintenance 1. Stop the vehicle on level ground schedule. In severe service or off-highway and let the brakes cool down. Hot applications inspect the linings more brake calipers can burn skin on frequently. In addition, periodically check contact. the brake chamber stroke. Replace the 2. Chock the wheels.

162 Y53-6096-1A1 (01/17) MAINTENANCE - Brake System

slack adjuster if proper stroke cannot be maintained. Operational checks of automatic slack adjusters 1. Start the vehicle and get the air system up to normal operating pressure. Do not apply the parking brake. 2. Apply pressure to the brake pedal and measure the distance the air chamber pushrod traveled. 3. Compare the results to the 5 specification to determine if the automatic slack adjusters need replacing.

WARNING!

Manual adjustment of automatic slack ad- justers is a dangerous practice that could have serious consequences. It gives the op- erator a false sense of security about the ef- fectiveness of the brakes. Contact the Serv- ice Department at your dealership if the stroke exceeds specifications. A stroke ex- ceeding specifications may indicate a prob- lem with the slack adjuster or the brake foundation.

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Automatic Slack Adjuster Stroke Specification Replace the slack adjuster if proper stroke cannot be maintained.

Chamber Type Stroke

36 (rear brakes) 1 1/2" - 2 1/2" (38-57mm)

30 (rear brakes) 1 1/2" - 2" (38-51 mm)

16,20 and 24 (front 1" - 1 3/4" (25.4-44.4 mm) brakes) 5

164 Y53-6096-1A1 (01/17) MAINTENANCE - Cab Maintenance

• Most chemical cleaners are fluids. They may be toxic, flammable or haz- concentrates that require dilution. Cab Maintenance ardous in other ways. Failure to comply may result in death, personal injury, equipment or • Only use spot removing fluids in property damage. well ventilated areas. General recommendations for cleaning the • Any vehicle is subjected to exterior and interior of the cab. deterioration from industrial fumes, WARNING! Cab exterior and interior components need ice, snow, corrosive road salt, etc., maintenance to ensure longevity and safe to name just a few causes. Do not clean the underside of chassis, fend- operations. ers wheel covers, etc. without protecting Exterior your hands and arms. You may cut yourself on sharp edged metal parts. Failure to com- Wash painted surfaces frequently to WARNING! ply may result in death, personal injury, remove and caustic deposits which equipment or property damage. may stain the finish. Always allow hot surfaces to cool down be- 5 fore attempting to work near them. Failure to To prevent rust, keep chromed parts clean comply may result in death or personal in- WARNING! and protected with wax at all times, jury. especially in winter conditions where the Moisture, ice, and road salt on brakes may roads are salted. affect braking efficiency. Test the brakes WARNING! carefully after each vehicle wash. Failure to • If necessary, use a commercial comply may result in death, personal injury, chrome cleaner to remove light rust. Handle cleaning agents carefully. Cleaning equipment or property damage. • Chrome surfaces are best cleaned agents may be poisonous. Keep them out of with fresh water. Wipe dry to the reach of children. Failure to comply may Vehicle Cleaning result in death, personal injury, equipment or preserve their luster. A commercial property damage. • Observe all caution labels. chrome cleaner will remove light rust. After cleaning, wax flat • Always read directions on the surfaces and apply a thin coat of container before using any product. WARNING! rust preventive lubricant around • Do not use any solution that can bolts or other fasteners. damage the body paint. Do not use gasoline, , naphtha, • Clean aluminum wheels and nail polish remover or other volatile cleaning bumpers with warm water. Tar

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remover will get rid of heavy polishing compound to clean off the Cleaning Interior Vinyl and deposits of road grime. To prevent rust, followed by a coating of wax. Upholstery spotting, wipe aluminum surfaces • Never use steel wool when cleaning dry after washing. stainless steel because minute NOTE • Under corrosive conditions, such as particles of the steel wool can driving on salted roads, clean embed in the surface of the Strong cleaning agents such as hand sani- aluminum parts with steam or high stainless steel and cause rust tizer, solvents, paint thinners, window clean- pressure water from a hose. A mild staining. er and gasoline/ diesel fuel must never be soap solution will help. Rinse used on your vehicle's interior.Repeated ex- thoroughly. Weather Stripping posure to chemicals such as sunscreen, in- sect repellents containing DEET, or brake Frequent washings of the vehicle are To maintain the tailpipe quality finish, wash fluid may cause accelerated wear, tackiness required to remove grime and the tailpipe with a soft cloth, mild soap and or discoloration of interior surfaces. contaminants that can stain and oxidize water or glass cleaner. A non-abrasive 5 paint and accelerate corrosion of plated chrome polish can be used sparingly on Wipe vinyl upholstery and lining with a and polished metal surfaces. Waxing offers hard to clean areas. Do Not clean your good commercial upholstery cleaner. Do added protection against staining and high heat chrome using scouring pads, not use acetone or lacquer thinner. Clean oxidation. But to allow enough time for your abrasive chrome polish, highly acidic fabric upholstery with upholstery shampoo truck's finish to cure, wait about 30 days chemical cleaners or any other abrasive specially formulated for this purpose. after the date of manufacture before cleaners. waxing. Do not apply wax in the hot sun • First remove loose dirt, dust or Even high quality stainless steel parts can and do not friction burn the paint with a debris with a vacuum cleaner. rust under prolonged exposure to salt buffing machine. Occasionally spray • Use a soft brush to loosen caked on water, especially when the salt-laden weather-stripping on doors and windows dirt before vacuuming it away. moisture is held against the metal surface with silicone compound to help preserve • Wipe the fabric surface with a by road grime. It is, therefore, important to resiliency. This is especially useful in slightly damp cloth and dry the seat frequently clean salty moisture and grime freezing weather to prevent doors and fabric thoroughly. If the fabric is still from stainless steel surfaces. windows from sticking shut with ice. dirty, wipe using a mixture of mild soap and lukewarm water, then dry • If surface rust is encountered, wash thoroughly. the surface and use a commercial • If the stain does not come out use an upholstery shampoo specially

166 Y53-6096-1A1 (01/17) MAINTENANCE - Cab Maintenance

formulated for this purpose. Test the and the value of your vehicle. Your dealer cleaner on a hidden place to make has a number of vehicle-care products and ply may result in death, personal injury, equipment or property damage. sure it does not affect the fabric can advise you on which ones to use for adversely. Follow the instructions on cleaning the exterior and interior of your the container. vehicle. WARNING! Other interior surfaces may be cleaned using a mixture of mild soap and lukewarm WARNING! Moisture, ice, and road salt on brakes may affect braking efficiency. Test the brakes water or an automotive interior cleaner, carefully after each vehicle wash. Failure to Handle cleaning agents carefully. Cleaning used on its intended surface (i.e. use comply may result in death, personal injury, agents may be poisonous. Keep them out of leather conditioner on leather surfaces, equipment or property damage. etc.). the reach of children. Failure to comply may result in death, personal injury, equipment or Avoid frequent or repeated use of the property damage. following products on interior surfaces: CAUTION 5 • Alcohol-based cleaners (including WARNING! Do not aim the water jet directly at door hand sanitizer) locks or latch. Tape the key holes to prevent Do not use gasoline, kerosene, naphtha, water from seeping into the lock cylinders. • -based cleaners Water in lock cylinders should be removed • Bleach nail polish remover or other volatile cleaning fluids. They may be toxic, flammable or haz- with compressed air. To prevent locks from • Acetone ardous in other ways. Failure to comply may freezing in the winter, squirt glycerin or lock deicer into the lock cylinders. • Any other strong solvent result in death, personal injury, equipment or • Abrasive cleaners property damage. • Sunscreen NOTE WARNING! How to Wash the Exterior of the To allow enough time for your truck's finish Vehicle Do not clean the underside of chassis, fend- to cure, wait at least thirty days after the ers wheel covers, etc. without protecting date of manufacture before waxing. A well-cared-for vehicle can look like new your hands and arms. You may cut yourself many years later. Regular and correct care on sharp edged metal parts. Failure to com- 1. Begin by spraying water over the will contribute to maintaining the beauty dry surface to remove all loose dirt

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before applying the car wash and Corrosive materials used for ice and snow To clean the screen, dampen a clean, soft, wax solution. removal and dust control can collect on the lint-free cloth with water only. A mild glass underbody. If these materials are not cleaner that does not contain alcohol or • Do not wash the vehicle in direct removed, accelerated corrosion (rust) can ammonia may also be used. Cleaners that sunshine. occur on underbody parts such as fuel contain alcohol and/or ammonia will • Do not spray water directly into lines, frames, floor pan, and exhaust eventually dry-out, crack and "yellow" the the cab vents. system, even though they have been screen. Wipe the screen gently back and 2. Using soapy water, wash the vehicle provided with corrosion protection. forth. You can also use a commercial with a clean soft cloth or a soft cleaner especially designed for LCD brush made for automotive At least every spring, flush these materials screens. cleaning. from the under body with plain water. Be sure to clean any area where mud and • Use cool or warm water and a other debris can collect. Sediment packed Cooling System 5 mild, household type soap. in closed areas of the frame should be Strong industrial detergents and loosened before being flushed. If desired, Maintenance cleaning agents are not your dealer can do this service for you. recommended. 5. Wipe everything dry with a chamois Information about concentration and • Do not use stiff brushes, paper to avoid water spots. To prevent condition of coolant, including filter. towels, steel wool, or abrasive water spotting, dry off the cosmetic cleaning compounds because surfaces with a clean cloth or Your engine’s cooling system is standard they will scratch painted, plated, chamois. with Nitrited forumulated Extended Life and polished metal surfaces. 6. Remove road tar with an automotive Coolant (ELC) that meets or exceeds 3. Rinse surfaces frequently while type tar remover or mineral spirits. ASTM D 6210 requirements. Nitrite-Free washing to flush away dirt that might 7. After cleaning and drying, apply a Extended Life Antifreeze/Coolant can be scratch the finishes during the quality automotive wax. used if it meets ASTM D6210 and washing operation. Cummins CES 14439. ELC consists of a mixture of , water, and 4. Hose dirt and grime from the entire Care of Display Screens on the chassis. nitrited organic acid technology (NOAT) Dashboard corrosion inhibitors. ELC prevents If an oil leak develops, you will be able to corrosion and scale formation as well as From time to time it may be necessary to detect it easier. clean the display screen.

168 Y53-6096-1A1 (01/17) MAINTENANCE - Cooling System Maintenance

provides freezing and boiling point protection. low all requirements listed in the engine manufacturers owner’s manual. NOTE

WARNING! Maximum recommended ELC concentration NOTE is 60% ELC and 40% water by volume (a Coolant is toxic. DO NOT get the fluid in 60/40 coolant mixture). The minimum rec- eyes. If contact occurs, flood eyes with large Coolant is harmful to the environment. Un- ommended concentration is 40%. amounts of water for 15 minutes. Avoid pro- used coolant must be stored as a toxic haz- longed or repeated contact with skin. In ardous material in leakproof containers. Condition case of contact, immediately wash skin with Used coolant must be processed as indus- soap and water. DO NOT take internally. If trial chemical waste. Please follow HAZMAT Perform a visual inspection of the ELC. It swallowed, seek immediate medical atten- guidelines with both used and unused cool- should have no cloudiness or floating tion. DO NOT induce vomiting. Failure to ants. debris. Determine the chemical inhibitor comply may result in death, personal injury, concentration level by using an ELC- 5 equipment or property damage. Concentration specific test kit or test strips. Inhibitor Check the level of freeze/boilover concentration level determines corrosion protection. If you are concerned about CAUTION protection, which is determined by the ELC concentration. Use a glycol refractometer possible coolant quality, contamination, or mechanical problems, submit a coolant The engine cooling system has very specific to determine glycol level. Add ELC to obtain the ELC/water ratio required to sample for analysis. Improper maintenance maintenance and inspection requirements. may cause coolant degradation and could Failure to follow requirements can damage provide the protection you need. A 50/50 the engine. Engine damage can include but mix of ELC and water is adequate for most result in damage to the cooling system and is not limited to freezing, boiling, corrosion, applications. For extremely cold operating engine components. Consult your dealer or pitted cylinder liners. This information is conditions, the ratio can be adjusted to a the ELC manufacturer’s representative for found in the engine manufacturers owner’s higher concentration of ELC. recommended ELC test kits, test strips, manual. It is the owner’s responsibility to fol- and laboratory sample procedures. In an ELC-filled cooling system, the freeze point should be maintained between -30° F and -45° F (-34° C and -43° C).

Y53-6096-1A1 (01/17) 169 MAINTENANCE - Cooling System Maintenance

ELC Condition

Below Minimum Recommended Levels Above Maximum

Desired 0% 10% 15% 20% 25% 30% 35% 40% 45% 50% 55% 60% 65% 70% 75% 80% 85% 90% 100% ELC/ Water Ratio

Freeze +32 +25 +20 +15 +10 +5 -5 -12 -23 -34 -50 -65 -75 -84 -70 -55 -43 -30 -5 Point °F (0) (-4) (-7) (-9) (-12) (-15) (-21) (-24) (-31) (-37) (-46) (-54) (-59) (-64) (-57) (-48) (-42) (-34) (-21) (°C)

Coolant Extender blank filter at the interval specified in the 5 Coolant Mix Ratio Preventive Maintenance Schedule. Never Add ELC extender if necessary according use filters that contain SCAs in an ELC- to the concentration level required. DO filled system. NOT add coolant extender to nitrite-free Freeze Protection coolant. -30 F -45 F -34 C -43 C CAUTION

Use of non-genuine coolant filters can cause severe engine damage.

40% 50% 60% Min Factory Max

Coolant Filter If your vehicle came with a non-chemical filter ("blank filter"), replace it only with a

170 Y53-6096-1A1 (01/17) MAINTENANCE - Cooling System Maintenance

Cooling System Sealing Additives Cooling System Soluble Oils

OK OK

1 1

1. Do not use sealing additives. 1. Do not use soluble oils.

CAUTION CAUTION 5 The use of sealing additives in the cooling The use of soluble oils in the cooling system system can cause damage to the engine. can cause damage to the engine. Soluble Sealing additives can plug various areas of oils in the cooling system can: Coolant may be added via the fill cap on the radiator, EGR system and oil cooler. The the tank. plugging of the cooling system can hamper • Damage heat transfer surfaces. heat transfer, causing internal engine dam- • Damage seals and hoses. age. Do not use sealing additives in the • Corrode brass and copper. cooling system. The use of sealing additives can: Failure to comply may result in equipment or property damage. • Build up in coolant low-flow areas. • Plug the radiator and oil cooler. Where to add Coolant? • Damage the water pump seal. The coolant surge tank is located on a Failure to comply may result in equipment or structure behind the cab. property damage.

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1. Fill Cap How to Add Coolant to the Cooling WARNING! 2. Sight Glass System Add coolant through the surge tank fill cap. Removing the fill cap on a hot engine can Inspect Coolant Level Do not remove the pressure cap to fill the cause scalding coolant to spray out and cooling system. burn you badly. If the engine has been in Top off coolant when the level in the surge operation within the previous 30 minutes, be tank is below the sight glass on the side of very careful in removing the fill cap. Protect the tank. Coolant is added through the WARNING! face, hands, and arms against escaping flu- pressure cap fill neck. id and steam by covering the cap with a large, thick rag. DO NOT try to remove it un- Do not remove the radiator fill cap while the til the surge tank cools down or if you see engine is hot. Scalding steam and fluid un- any steam or coolant escaping. In any situa- der pressure may escape. You could be tion, remove the cap very slowly and care- badly burned. Failure to comply may result 5 fully. Be ready to back off if any steam or in death or personal injury. coolant begins to escape.

NOTE

If frequent topping off is necessary and there are no visible signs of coolant leaks when the engine is cold, check for leaks with the engine operating at normal temper- ature.

NOTE 1. Fill Cap Do not use the pressure cap to fill the surge 2. Sight Glass tank with fluid. See Also Engine is Overheating on page 31

172 Y53-6096-1A1 (01/17) MAINTENANCE - Safety Restraint System - Inspection

tank. Continue to fill the surge tank percent concentration of antifreeze, as a until the coolant level remains shortened heater life will result. NOTE approximately ½ in. above the "MIN" line. This may take up to 2 After servicing the cooling system, operate Do not overfill a cooling system. Excess minutes, depending on the outside the vehicle for a day or two before using coolant may result in overflow, loss of anti- temperature. the heater. Trapped air inside the engine freeze, and reduced corrosion protection. needs time to escape. 8. Operate the engine throttle until the 1. If your cooling system is built with operating temperature stabilizes drain valves in the upper engine (when the thermostat opens). coolant pipe, open them before 9. Fill the surge tank as necessary to Safety Restraint System - filling the surge tank. raise the coolant level to ½ in. Inspection 2. Close any open coolant drains in above the "MIN" level. the system. 10. Operate the engine at high idle for The seat belt system, including webbing, 5 3. Remove the surge tank fill cap (do another 10 minutes and then fill the buckles, latches, and mounting hardware, not remove the surge tank pressure surge tank again to ½" above the endures heavy use in heavy-duty vehicles, cap). "MIN" level. much more than seat belt systems in 4. Fill the system with premixed 11. Replace the surge tank fill cap. passenger . All users should be aware coolant through the surge tank fill of the factors contributing to this heavy use Check the coolant level after each trip. Add cap. Pour coolant at a steady flow and reduced belt life. coolant as necessary. You may find your rate until the surge tank is full (to the coolant level is not up to the correct level base of the fill neck). It may be soon after you have filled the radiator. This necessary to pause for 1 minute WARNING! may be because all the trapped air in the and then re-fill if the fluid level system has not yet been purged. It takes a Failure to properly inspect and maintain re- dropped. little time for all of the air to leave the straint systems can lead to injury or loss of 5. Close any drain valves that were system after you fill your radiator. life. Without periodic inspection and mainte- opened in Step 1. nance to detect unsafe conditions, seat re- 6. Start the engine and idle at low rpm. Use a solution of half ethylene glycol straint components can wear out or not pro- tect you in an accident. 7. During low rpm idle, air will purge antifreeze and half water for best heater from the cooling system which will performance. Do not use more than 65 lower the coolant level in the surge

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2. Web cut or frayed at D-loop web • Environmental conditions, such as guide. dirt and ultraviolet rays from the WARNING! 3. Comfort Clip cracked or damaged. sun, will reduce the life of the seat belt system. It is important to remember that any time a 4. Buckle casting broken. vehicle is involved in an accident, the entire 5. Retractor Web Storage for damage. Due to these factors, the three-point safety seat belt system must be replaced. Unex- (located behind trim panel) belt system installed in your vehicle posed damage caused by the stress of an 6. Tethers for web wear and proper requires thorough inspection every 20,000 accident could prevent the system from functioning properly the next time it is need- tightness of mounting hardware. miles (32,000 km). If the vehicle is exposed ed. Failure to comply may result in death or 7. Mounting hardware for corrosion, to severe environmental or working personal injury. proper tightness of bolts and nuts. conditions, more frequent inspections may 8. Web for deterioration, due to be necessary. Any seat belt system that Seat Belt Inspection Points exposure to the sun. shows cuts, fraying, extreme or unusual 5 wear, significant discoloration due to UV Factors contributing to reduced seat belt (ultraviolet) exposure, abrasion to the seat life: belt webbing, or damage to the buckle, latch plate, retractor hardware or any other • Heavy trucks typically accumulate obvious problem should be replaced twice as many miles as the average immediately, regardless of mileage. passenger car in a given time period. Inspection Guidelines • Seat and cab movement in trucks Follow these guidelines when inspecting causes almost constant movement for cuts, fraying, extreme or unusual wear of the belt due to ride characteristics of the webbing, and damage to the buckle, and seat design. The constant retractor, hardware, or other factors. movement of the belt inside the Damage to these areas indicates that belt restraint hardware and the potential system replacement is necessary. for the belt to come in contact with the cab and other vehicle parts, contributes to the wear of the entire 1. Web cut or frayed or extremely worn system. at latch area.

174 Y53-6096-1A1 (01/17) MAINTENANCE - Windshield Wiper/Washer

4. Check buckle and latch for proper sun's ultraviolet rays. Replace the operation and to determine if latch system. WARNING! plate is worn, deformed, or damaged. Once the need for replacement of the seat Replace the entire belt system (retractor belt has been determined, be certain it is 5. Inspect the retractor web storage and buckle side) if replacement of any one only replaced with an authorized PACCAR device, which is mounted on the part is necessary. Unexposed damage to Parts replacement seat belt. If the one or more components could prevent the floor of the vehicle, for damage. The inspection indicates that any part of the system from functioning properly the next retractor is the heart of the occupant seat belt system requires replacement, the time it is needed. Failure to comply may re- restraint system and can often be entire system must be replaced. An sult in death or personal injury. damaged if abused, even installation guide is attached to every unintentionally. Check operation to 1. Check the web wear in the system. replacement belt. Utilize the proper guide ensure that it is not locked up and The webbing must be closely for your type of seat, and follow the that it spools out and retracts examined to determine if it is instructions very closely. It is vitally webbing properly. 5 coming into contact with any sharp important that all components be 6. If tethers are used, be sure they are or rough surfaces on the seat or reinstalled in the same position as the properly attached to the seat and, if other parts of the cab interior. These original components that were removed adjustable, that they are adjusted in areas are typical places where the and that the fasteners be torqued to accordance with installation web will experience cutting or specification. This will maintain the design instructions. Tethers must also be abrasion. Cuts, fraying, or excessive integrity of the mounting points for the seat inspected for web wear and proper wear would indicate the need for belt assembly. Contact your dealer if you tightness of mounting hardware. replacement of the seat belt system. have any questions concerning seat belt 7. Mounting hardware should be 2. The web guide (D-loop) is the replacement. evaluated for corrosion, and for area where almost constant tightness of bolts and nuts. movement of the seat belt webbing occurs because of relative 8. Check web in areas exposed to Windshield Wiper/Washer movement between the seat and ultraviolet rays from the sun. If the cab. color of the web in these areas is gray to light brown, the physical The windshield wiper system is 3. Check the Komfort-Latch for cracks strength of the web may have maintenance free. Check wiper blades or possible damage and check for deteriorated due to exposure to the proper operation.

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annually or every 60,000 miles (96,000 service or maintenance of the vehicle), km). please wait 10 minutes before WARNING! disconnecting battery power. CAUTION Before attempting any work on the batteries or electrical system, remove all jewelry. If CAUTION metal jewelry or other metal comes in con- Do not use antifreeze or engine coolant in tact with electrical circuits, a short circuit the windshield washer reservoir, damage to may occur causing you to be injured, as well Wait at least 10 minutes after the key switch seals and other components will result. as electrical system failure and damage. is turned OFF before disconnecting battery power. The system uses battery power to Washer Reservoir circulate DEF and prevent overheating of the DEF system. Failure to comply may re- Daily: Check reservoir water level, located CAUTION sult in equipment or property damage. in the engine compartment. If necessary, 5 refill to the proper level. Do not modify or improperly repair the vehi- cles electrical system or power distribution What is Low Voltage Disconnect? box. All electrical repairs should be per- formed by an authorized dealer. Improper General information on low voltage Electrical System repair or modifications will void your warran- disconnect. ty and/or cause serious damage to your ve- hicle. The LVD may increase battery life and prevent unnecessary jump start conditions WARNING! by ensuring that an unattended load does Aftertreatment System Power not deplete the battery charge to a level Battery posts, terminals and related acces- Requirements that will prevent you from starting your sories contain lead and lead compounds, vehicle. chemicals known to the State of California The aftertreatment system uses battery to cause cancer and reproductive harm. Wash hands after handling. power for up to 10 minutes after the ignition is turned off. After the ignition turns off, the aftertreatment system circulates DEF to help cool down the fluid and prevent overheating. For situations where the battery will be disconnected (ie for

176 Y53-6096-1A1 (01/17) MAINTENANCE - Electrical System

audible beep. After 2 minutes of flashing the warning on the DPC, the LVD will shut- WARNING! off any circuit connected through the LVD system. Even if the ignition switch is cycled Do not use the Spare Battery A and B cir- OFF and ON again, the LVD will continue cuits or other circuits that are controlled by the LVD to power electronic engine controls, to fault until it sees battery voltage at, or ABS circuits, or safety/work related lighting. above, 12.2V. Before adding any device to the vehicle's electrical system, consult your nearest au- Circuits Disconnected By LVD thorized dealer or read the contents of TMC • Cab Dome Lamps RP136. Failure to do so may cause equip- ment damage or lead to personal injury. • Cab Accessories • Spare LVD wiring for customer added accessories 5 NOTE

The determination of what circuits/loads that NOTE were connected to the LVD was based upon the recommendation from Technology and All LVD circuits are color-coded blue on the Maintenance Council (TMC) of the Ameri- central electrical panel cover label. can Trucking Association. To review the rec- ommended practice, see TMC RP-136.

The LVD will disconnect non-vital battery loads when battery voltage drops below 12.2V for 2 minutes and the key switch is in the ACC or OFF position. During the next 30 seconds, the LVD will flash the Battery Disconnect Telltale in the Driver Information Display. As the telltale flashes an audio warning will also sound. During the last 2 minutes the LVD will emit a slow

Y53-6096-1A1 (01/17) 177 MAINTENANCE - Electrical System

Vehicle Light Bulb Specifications

Bulb Type of Notes Location Bulb

Headlight Halogen (long life H5054-LL version not required)

Headlight N/A LED Light (Optional)

Rear tail light/ Turn N/A LED lighting Signal

5 Interior map/dome/ N/A LED lighting indirect light

NOTE

Do not replace factory installed halogen headlamps with LED headlamps.

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Aiming Headlights Fuses, Circuit Breakers and Relays Location of Fuses Please have an authorized dealership aim Fuses, circuit breakers, and relays are the headlights. located in the Power Distribution Box which is located under the panel between the The headlights were properly aimed at the seats and closest to the rear window. factory to meet safety specifications. If the headlights need to be adjusted, please have an authorized dealership aim the headlights.

5

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5

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Altering the Electrical System wires being added. Failure to comply may tact eyes, skin, fabrics, or painted surfaces. Refer to a wiring diagram for your chassis result in equipment damage. Failure to comply may result in death, per- before adding electrical options to ensure sonal injury, equipment or property damage. proper electrical system performance. NOTE WARNING! WARNING! If you are unfamiliar with proper electrical repair practices and procedures, see your Replace only with AGM (Group 31) batter- Do not replace a fuse with a fuse of a higher authorized dealer for assistance. ies. Use of other batteries could result in rating. Doing so may damage the electrical acid leaks causing personal injury in the system and cause a fire. Failure to comply event of a vehicle accident. Failure to com- may result in death, personal injury, equip- Batteries ply may result in death, personal injury, ment or property damage. equipment or property damage. Information on maintaining your vehicle's batteries. 5 WARNING! WARNING! Regular attention to the charging system will help prolong the service life of the Battery cables and air/electrical harnesses Never install a circuit breaker in a circuit that batteries. is designated as "fuse only" circuit(s). Fuse are mounted to the bottom of the floor. Do only circuits are marked with an * on the re- not drill or screw into floor pan without first checking the location of the cables, har- verse side of the Power Distribution Box WARNING! cover. Using a circuit breaker in those fuse nesses or any other component that might only circuits may cause the circuit to over- be damaged. Damaging any component heat when a short exists which could lead to Batteries contain acid that can burn and could result in electrical shock which could equipment damage and/or personal injury. gasses that can explode. Ignoring safety cause personal injury and/or loss of a critical procedures may result in death, personal in- truck system. Failure to comply may result jury, equipment or property damage. in death, personal injury, equipment or prop- erty damage. CAUTION WARNING! Follow all manufacturers' circuit protection recommendations for the components and Never remove or tamper with battery caps. Ignoring this could allow battery acid to con-

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standing idle or short distance driving. These conditions result in battery plates WARNING! CAUTION becoming covered with a hard coating.

Electrical damage or battery explosion can Properly secure battery tie downs and bat- Vibration: loose battery hold-downs may occur when improperly charging batteries. tery box cover when reinstalling batteries af- cause battery plate failure. Failure to comply may result in death, per- ter service. Do not over tighten. Over tight- sonal injury, equipment or property damage. ening can crack the battery case which can Short Circuits: these discharge the battery lead to equipment damage. by draining electricity. WARNING! Dirty or Loose Connections: improper CAUTION connections may stop the flow of electrical Batteries release gases that are flammable. power to and from the battery. Batteries are equipped with vent tubes and The Diesel Exhaust Fluid (DEF) system Battery Charging 5 flash arrestors which vent battery gases out purges to prevent damage from freezing. If of the cab. Ensure all vent tubes, flash ar- your vehicle is equipped with battery discon- restors and grommets are properly installed nect switches, do NOT disconnect battery WARNING! and ensure they are clear and functioning power within two minutes of switching the properly. Failure to reinstall or keep the vent ignition key off. Failure to comply may result Batteries can injure you severely. They con- tubes and grommets clear or ensure the in vehicle or property damage. flash arrestor(s) are functioning properly tain acid, produce poisonous and explosive could result in death, personal injury, equip- gases, and supply levels of electric current ment or property damage. Here are some common causes of battery high enough to cause burns. A spark or failure: flame near a battery on charge may cause it to explode with great force. Never remove Overcharge: this condition results from or tamper with the battery caps. Failure to CAUTION improper voltage regulator adjustment. It comply may result in death, personal injury, results in overheating of the battery, equipment or property damage. Do not store other items in the battery box. warped plates, and evaporation of Failure to comply could result in damage to electrolyte. Except for using small trickle charges to the truck and/or batteries. maintain battery condition, you should Undercharge: the voltage regulator is have your vehicle's batteries charged by a malfunctioning, the drive belt is slipping, or qualified service facility. To help reduce the your vehicle has undergone long periods of risk of personal injuries, follow these

182 Y53-6096-1A1 (01/17) MAINTENANCE - Electrical System

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

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Cranking Battery Specification Replacement batteries must meet the following specifications.

Category Specification

General Maintenance free

Group 31

Stud Type Thread

Cold Crank Amp 650 5 Voltage 12V Reserve Capacity 160 minutes

184 Y53-6096-1A1 (01/17) MAINTENANCE - Electrical System

Removing Batteries Installing Batteries 2. Reconnect positive cable. 3. Reconnect ground (negative) Information on removing batteries. Follow the procedure below to reinstall ground cable. main batteries on the vehicle: After accessing the battery, these steps can be used to remove them from the Slow Battery Charging vehicle. NOTE A slow trickle charge is recommended for 1. Be sure all switches on the vehicle Always dispose of automotive batteries in a optimum performance from the batteries. are turned OFF. safe and responsible manner. Contact your 2. Wait 2 minutes after turning ignition authorized dealer for disposal standards. off then disconnect negative ground Call your local authorized recycling center WARNING! cable first. for information on recycling automotive bat- teries. Charger cables must be connected positive 3. Disconnect positive cable. to positive (+ to +) and negative to negative 5 4. Unscrew the holding plate bolts with ( - to - ). If connected improperly, batteries open end wrench. NOTE could explode. Failure to comply may result in death, personal injury, equipment or prop- erty damage. Make sure to reconnect the ground (nega- NOTE tive) cable last.

Always dispose of automotive bat- WARNING! teries in a safe and responsible WARNING! manner. Contact your authorized Always make sure the battery charger is dealer for disposal standards. Call OFF before connecting or disconnecting the your local authorized recycling cen- Battery replacement may alter or disturb cable clamps. To reduce the danger of ex- ter for information on recycling auto- battery cable routing. Check to insure bat- plosions and resulting death or personal in- motive batteries. tery cables are free from any point of chaff- jury, do not connect or disconnect charger ing. Failure to comply may result in death, cables while the charger is operating. Follow the procedures below to reinstall personal injury, equipment or property dam- age. batteries on the vehicle and replace parts removed for access. 1. Place batteries in vehicle and tighten bolt of holding plate.

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6. After charging, turn OFF charger • Do not polarize the alternator. The and disconnect charger cables. alternator should not be polarized NOTE like a generator. To ensure correct Alternator polarity, use a test lamp or a Some vehicles may have an ultra capacitor voltmeter. mounted in the battery box. These devices have a similar shape to a battery but have Take the following precautions to avoid two positive posts and one negative posts. burning out alternator diodes: Do not attach battery chargers to these de- Engine Maintenance vices to recharge the vehicles batteries. • Do not start the engine with Connect directly to the conventional two alternator disconnected post charging batteries to charge them. Important precautions before perfoming (connections removed) from the engine maintenance on your vehicle. circuit. NOTE • Before welding, disconnect all These topics relate to the operator 5 electronic connections to the vehicle maintenance tasks for the engine. Follow the instructions that come with your batteries. Information provided here is in addition to battery charger. • Remove battery power cable and information contained in the Engine insulate it from the vehicle. Operator Manual supplied with the vehicle. 1. Access the battery terminals, the • Do not run the engine with the batteries do not have to be removed batteries disconnected. WARNING! from the vehicle. • Do not disconnect the battery 2. Make sure the battery charger is cables or alternator connection Exhaust fumes from the engine contain car- turned off. cables with the engine running. bon monoxide, a colorless and odorless 3. Disconnect the battery cables. gas. Do not breathe the engine exhaust gas. • Never turn the ignition switch from A poorly maintained, damaged or corroded 4. Connect charger cables. the ON position to the START exhaust system can allow carbon monoxide 5. Start charging the battery at a rate position with the engine running. to enter the cab. Entry of carbon monoxide not over 6 amperes. Normally, a • When charging the battery (installed into the cab is also possible from other vehi- battery should be charged at no in the vehicle) disconnect the cles nearby. Failure to properly maintain more than 10 percent of its rated battery cables. your vehicle could cause carbon monoxide capacity. to enter the cab, resulting in death or per- • Do not reverse the cables of the sonal injury. alternator, starter motor, or battery.

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1. Make sure that the rail noticed in the sound of the exhaust system is standing on a flat and level WARNING! (3) Whenever the exhaust system, under- body, or cab is damaged. surface. Never start or let the engine run in an en- 2. Make sure that the vehicle is closed, unventilated area. Exhaust fumes horizontal, both lengthwise and from the engine contain carbon monoxide, a Check Engine Oil Level crosswise. Check this carefully on a colorless and odorless gas. Carbon monox- vehicle with air suspension. Note Refer to the engine manufacturer's Engine ide can be fatal if inhaled. Failure to comply that the engine may be inclined up Operation and Maintenance Manual may result in death, personal injury, equip- to 4° depending on the vehicle supplied with your vehicle for information ment or property damage. model and wheelbase. about draining and refilling engine oil, engine crank case capacity, engine oil 3. Twist the dipstick handle to unlock WARNING! type, and changing oil filters, etc. it, then pull the dipstick out of the holder. 5 Never idle your vehicle for prolonged peri- ods of time if you sense that exhaust fumes WARNING! are entering the cab. Investigate the cause of the fumes and correct it as soon as possi- Hot engine oil can be dangerous. You could ble. If the vehicle must be driven under be burned. Let the engine oil cool down be- these conditions, drive only with the win- fore changing it. Failure to comply may re- dows open. Failure to repair the source of sult in death, personal injury, equipment or the exhaust fumes may result in death, per- property damage. sonal injury, equipment or property damage.

NOTE NOTE It takes approximately 15 minutes for all the Keep the engine exhaust system and the oil to run into the sump when the engine is vehicles cab ventilation system properly ‘warm.’ If the level is checked immediately maintained. It is recommended that the ve- after switching off the engine, the dipstick hicles exhaust system and cab be inspected will show a low oil level. 4. Wipe the dipstick clean with a lint- (1) By a competent technician every 15,000 free cloth. miles (24,140 km) (2) Whenever a change is

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5. Place the dipstick back into the Engine, Oil Temperature on page 62 replacement, please see engine holder. Engine, Oil Pressure on page 62 Operator’s Manual included with this 6. Pull the dipstick out again and chassis. check the oil level. The oil level Topping Up the Engine Oil 2. After topping up, wait 1 minute and should always be between the 2 check the oil level again. marks on the dipstick. 3. Reinstall the oil fill cap and twist to Engine Oil Dip Stick Markings lock it in place.

Install Engine Belt You can extend the reliability and service life of your vehicle's drive belts with proper 1 attention to installation, and maintenance. 5 Neglect could cause belt failure. The result could be the loss of the electrical or air system as well as possible engine damage from overheating. So it's a very good idea 2 to check your belts frequently and replace them as soon as you detect trouble.

NOTE

See the engine manufacturer's operator's manual for further information on replacing engine drive belts. 1. High oil level (1) 2. Low oil level (2) Follow this procedure to install an 7. Reinstall the dipstick and twist to 1. Top up with oil, if necessary, via the accessory drive belt: lock it in place. filler opening. Use the correct grade 1. Route the new belt around the in the correct quantity. For oil See Also pulleys, and then rotate the

188 Y53-6096-1A1 (01/17) MAINTENANCE - Engine Maintenance

automatic tensioner so that the idler pulley swings toward the belt routing. The following figure shows WARNING! an example of the rotation direction Do not work on or near the fan with the en- to release the tensioner. gine running. Anyone near the engine fan when it turns on could be injured. If it is set at MANUAL, the fan will turn on any time the ignition key switch is turned to the ON posi- tion. In AUTO, it could engage suddenly without warning. Before turning on the igni- tion or switching from AUTO to MANUAL, be sure no workers are near the fan. Failure to comply may result in death or personal in- jury. 5 Your truck may be equipped with an On/Off 2. Slip the belt around the idler pulley or Viscous Fan Drive. Follow these attached to the automatic tensioner. guidelines to check your engine fan: 3. Release the automatic tensioner. • Check the fan bearings for fan hub 4. Check the belt alignment on each bearing looseness, loss of lubricant pulley. The belt must fall between and any abnormal conditions. (For the flanges of each pulley. example, fan belt misaligned or excessive wear/damage.) Before Engine Fan starting the engine and with the engine off, look and feel for General maintenance information and looseness in the fan hub. precautions about the engine fan. • With the engine idling and the hood open, stand at the front of the vehicle. Listen for any noises coming from the fan hub. Bearings that have lost lubricant, and are dry,

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will typically emit a squeal or a growl the intake system allow abrasive dust to when the engine is at operating enter the engine and quickly cause temperature and the fan clutch is expensive damage. During your daily walk- WARNING! engaged. If noise is detected, have around inspection, carefully check all Do not operate engine with turbocharger in- the fan bearings inspected by an tubing, elbows, clamps, supports and take piping disconnected. A suction is creat- authorized dealership. fasteners for condition and tightness. ed when the engine is running. This suction could draw your hand or anything else near Check the Charge-Air-Cooler for air leaks Engine Fan Blade it into the impeller fan. You could be injured. annually. The air leaks can be caused by Verify that there is enough fan blade Always keep the intake piping connected cracked tubes or header. For service see clearance with the fan shroud. Around the when you will be running the engine. your authorized dealer. fan shroud, the recommended distance is 1 When servicing the air intake and exhaust in. (25 mm) from front edge of any fan systems on a turbocharged engine, check blade-to-radiator side member. Minimum CAUTION the items listed below: 5 clearance is 3/4 in. (19 mm). Do not use air intake pipes and connections Lubricating System • Rear edge of any blade must be no as a step or to pull yourself up. This could closer than 3/8 in. (9 mm) to the loosen the connections and open the sys- Check the oil lines, housing, and nearest engine component. If this tem to unfiltered air which could damage the connections. Look for leaks, damage, or cannot be obtained, the fan spacer engine. deterioration. Leaks could mean you have or fan is not correct. damaged oil lines or oil seals. • The leading edge of any fan blade See Also must be 1 in. (25 mm) from the Pipe and Hose Clamp Torque Values on Manifold inside edge of the shroud. page 221 With the engine operating, check for leaking manifold or flange gaskets. Air Intake System Turbocharger High Frequency Vibration General information and precautions on General information about maintaining the Vibration may indicate turbo rotor how to maintain the air intake system. turbocharger. imbalance. Have your dealer investigate Engine heat, vibration, and age combine to this immediately. If you detect any loosen air intake connections and cause deficiencies, take the vehicle to an cracks in the tubing and elbows. Leaks in authorized dealer for servicing. Delay could

190 Y53-6096-1A1 (01/17) MAINTENANCE - Engine Maintenance

lead to severe and expensive damage to mirrors, the mirror must be pivoted to For details on how to maintain the your vehicle. provide access for servicing the filter emisssions components in the exhaust element. system, see "Noise and Emission Control" Air Cleaners in your vehicle operator's manual. Please refer to the Engine Operator's Manual for The following service information is basic more details on how to maintain the to all air cleaner makes and models. emission's components in the exhaust system. WARNING! Engine Mounting Do not use air cleaner components as grab Periodic Inspection: Inspect engine mounts handles. These components may break if you are using them to support your weight. every 60,000 miles (96,560 km). Failure to comply may result in personal in- 5 jury or damage to vehicle components. CAUTION

CAUTION Do not re-torque or reuse existing flange head bolts. These bolts are factory set to the specified torque. If bolts are loose or Failure to replace air filter at proper intervals damaged, they must be replaced with the may result in passage of dirt/debris into the Replace the filter by releasing the (6) tabs around the perimeter of the lid. new bolts. Failure to comply may result in engine or the “dusting” of an engine result- equipment or property damage. ing in significant equipment damage. Exhaust System Check for the following: Your vehicle is equipped with an air inlet restriction indicator. Service the filter General information on maintaining the • Inspect both mount and leg elements when the air inlet restriction exhaust system. fasteners. Check for loose or broken indicator locks in the extreme Up position. bolts. Replace as necessary. The exhaust system is part of the noise Paper elements require care and proper • Check mount and leg for fractures, and emission control system. Periodically handling because they are critical to breaks or deformation. Replace as check the exhaust system for wear, engine service life. If your vehicle has an necessary. external air cleaner and cab-mounted exhaust leaks, and loose or missing parts.

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• Check for complete insertion of motor mount. Replace as Use only the fuel and/or additives recom- comply may result in death, personal injury, mended for your engine. Failure to comply equipment or property damage. necessary. may result in death, personal injury, equip- • New leg to mount flange head bolts ment or property damage. should be torqued to 210-230 lb-ft WARNING! (284-311 Nm). CAUTION Frame welding is NOT recommended. The high heat of welding nullifies the special Fuel System If anyone ever pours gasoline into your fuel heat treatment of the rails, greatly reducing tank, drain the entire system. Otherwise, the the tensile strength of the frame rail. If a pump and engine will be damaged. Don’t try frame member becomes cracked from over- Important information on your vehicle's fuel to dilute the gasoline by adding diesel fuel loading, fatigue, surface damage or a colli- system. (See Warning above). sion, the only permanent repair is to replace 5 the damaged frame member with a new Location of Fuel Shut-off Valves Fuel Filters part. Fuel shut-off valves for the fuel crossover See Engine Manufacturer’s Operator Emergency Welding line are on the bottom of the secondary Manual provided with this chassis. fuel tank, at the crossover line connection. In an emergency, a temporary repair may They are optional on the primary fuel tank. be performed. Observe the following precautions to protect electronic systems Specification Frame during welding operations. Emergency Use only diesel fuel as recommended by welding procedures are further explained in engine manufacturers. the maintenance manuals. Please refer to the ordering information on the back cover WARNING! to obtain a maintenance manual. WARNING! Do not cut, splice or weld frame rails or drill In the event of emergency welding of a through the top or bottom flanges of the Diesel fuel in the presence of an ignition frame rail and when welding any other part rails. These operations could affect frame source could cause an explosion. A mixture of your truck or any component attached to rail strength leading to a failure resulting in of gasoline or alcohol with diesel fuel in- your truck, observe the following an accident. Rail failures resulting from such creases this risk of explosion. Do not re- modifications are not warrantable. Failure to precautions before welding: move a fuel tank cap near an open flame.

192 Y53-6096-1A1 (01/17) MAINTENANCE - Frame

• Disconnect all electronic devices. It transmission ECU, ABS ECU, navigation is not possible to list all of the devices, diagnostic devices, and electronics that could be affected, monitoring devices. NOTE but a few examples include the following: alternator, engine Whenever possible, torque all frame fasten- Fifth Wheel Monthly Maintenance ers on the nut end, not the bolt head. Electronic Control Unit (ECU), transmission ECU, ABS ECU, Proper preventive maintenance is essential • Refer to specific manufacturer's navigation devices, diagnostic to trouble-free service and safe operation literature for any special devices, and monitoring devices. of the fifth wheel. instructions. • Disconnect battery cables and • Refer to specific manufacturer's • Remove fifth wheel from vehicle. insulate them from the vehicle. literature for any special Refer to the Shop Manual, "Fifth • Do not use the ECU or engine instructions. Wheel Removal." ground stud for the ground of the • Steam clean the fifth wheel. • Steam clean the fifth wheel and welding probe. 5 • Check lock guard operation using a mounting brackets. • Ensure that the ground connection commercial lock tester. • Check all moving parts for for the welder is as close to the weld • Clean and oil all moving parts. excessive wear or damage. Replace point as possible. This ensures all worn or broken parts. maximum weld current and • Lubricate the lock mechanism with a • Complete two-month service minimum risk to damage of lithium-base grease. procedure. electrical components on the • All grease fittings (especially those vehicle. which grease the top surface of the • Install fifth wheel. Refer to the Shop fifth wheel). Manual, "Fifth Wheel Installation." Painting Tighten all frame fasteners with a torque Do not electrostatically paint your truck or Fifth Wheel Bi-Annual Maintenance wrench. See Frame Fastener Torque any component on your truck without first Requirements on page 214. removing all of the electronic components Proper preventive maintenance is essential from the truck. It is not possible to list all of to trouble-free service and safe operation Sliding Fifth Wheels the electronics that could be affected, but a of the fifth wheel. few examples include the alternator, Lubricate bearing surface of support engine Electronic Control Unit (ECU), bracket through the grease fittings on the

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side of the fifth wheel plate. Use a water Kingpin Lubrication Suspension Lubrication resistant lithium-base grease.

NOTE

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

Front Axle and Each standard spring anchor pin has a grease fitting. Pressure lubricate spring Suspension pins as specified. At regular intervals, the 5 spring leaves may be lubricated with a Lubrication and inspection of front axle rust-inhibiting oil applied with a spray gun assemblies. or brush. Depending on your suspension, lubricate all spring pins until grease flows Axle Lubrication out of both ends of the bushing. Look for signs of rust or water in the flushed grease. Refer to the axle manufacturer's operator's Lubricate with approved lubricant. If a pin will not accept grease, it should be manual for lubrication specifications and Lubricate knuckle thrust bearings, knuckle removed, cleaned, and inspected. service intervals. pins, and tie rod ends. Lack of lubrication causes premature wear and hard steering. Lubrication schedule may be shortened if CAUTION necessary. Do not spray the suspension with chemical products or mineral oil; it can cause damage to the bushings.

194 Y53-6096-1A1 (01/17) MAINTENANCE - Front Axle and Suspension

Inspection Suspension U-Bolts U-bolts are difficult to tighten unless you have the right equipment. If you cannot For all vehicles, mandatory maintenance It is important that U-bolts remain tight. tighten them correctly yourself, be sure to procedures include retightening all U-bolts Severe use of your vehicle will cause them have them checked and tightened regularly and inspecting the suspension for loose to loosen faster. But all vehicles need to by an authorized mechanic. Tighten U-bolt fasteners, abnormal wear, or damage. have their U-bolts checked and tightened nuts to the specified torque value with the However, even with proper maintenance, regularly. Be sure someone with the proper vehicle loaded to its normal gross weight. the service life of leaf springs is affected by training and the right tools checks and See Suspension U-Bolts, Grade 8 on page many factors, such as: fatigue, vehicle tightens the U-bolts on your vehicle. New 213 specifications for torque values gross weight, type of load, road conditions, springs can settle in after service, relieving applying to U-bolts and nuts, with clean and vehicle speed. Check for cracks, wear the tension on the U-bolts. Loose U-bolts threads lubricated with Chevron zinc marks, splits, or other defects on the can cause breakage, axle lubricant (SAE 20 or 30 oils acceptable but surface of the spring. Defective parts must misalignment, hard steering and abnormal not preferred). be replaced. Because repaired springs tire wear. All vehicles should have 5 cannot be fully restored to their original suspension U-bolts tightened after the first service life, replace the complete assembly 500 miles (800 km) of operation. Re-torque WARNING! if cracks or other defects are detected. the front spring pinch bolts and shackle Visually inspect shock absorbers and pinch bolts. Do not replace U bolts and nuts with com- rubber bushings. mon U bolts or standard nuts. These parts are critical to vehicle safety. If the wrong U WARNING! bolts or nuts are used, the axle could loosen or separate from the vehicle and cause a For driving safety and comfort, and to Do not operate the vehicle if the suspension serious accident. Use only U bolts and nuts prolong the life of your vehicle, it is U bolts are not properly tightened. Loose U of SAE Grade 8 specification or better. Fail- important to have wheels correctly aligned. bolts will cause the axle to not be properly ure to comply may result in death, personal Check tire wear frequently. Uneven tire secured to the suspension, which could injury, equipment or property damage. wear is a sign that the wheels may be cause loss of vehicle control and an acci- misaligned. If you see uneven wear, take dent. Loose U bolts can also cause uneven See Also your vehicle to an authorized dealer tire wear and poor alignment. Failure to Suspension U-Bolts, Grade 8 on page 213 comply may result in death, personal injury, familiar with aligning wheels on your equipment or property damage. Wheel Cap Nut Torque Specifications on vehicle. page 215

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Frame Fastener Torque Requirements on To allow for proper operation of the vehicle page 214 ventilation system, proceed as follows: to leaking refrigerant for prolonged periods near excessive heat, open flames, or with- Suspension U-Bolts, Grade 8 on page 213 • Keep the inlet at the base of out proper ventilation. Failure to do so may the windshield clear of snow, ice, result in death or personal injury. leaves and other obstructions at all If a refrigerant leak develops in the times. Heater and Air Conditioner presence of excessive heat or an open Maintenance • Keep the exhaust pipe area clear to flame, hazardous gases may be help reduce the buildup of exhaust generated. If you become aware of a gas under the vehicle. refrigerant leak on your vehicle have your Important information to know about • Check the drain tube of the fresh air system serviced immediately and observe maintaining the air conditioner for a Low inlet for trapped water before the following precautions: Stay away from Cab Forward vehicle. assuming that there is a leak in the the hot engine until the exhaust manifold heating system. 5 The combination heater-air conditioner has cooled. Do not permit any open flame provides comfort for those in the cab Special Precautions in the area. Even a match or a cigarette through accurate control of the cab lighter may generate a hazardous quantity environment in all weather conditions. of poisonous gas. Do not smoke in the Regular attention to the items below will WARNING! area. Inhaling gaseous refrigerant through help you keep the heater-air conditioner a cigarette may cause violent illness. unit running well. Keep the vehicle's Excessive heat may cause the pressurized components of the air conditioning system ventilation system, engine exhaust system to explode. Never weld, solder, steam clean, and cab joints properly maintained. It is or use a blow torch near any part of the air recommended that the vehicle's exhaust conditioning system. Failure to comply may system and cab be serviced as follows: result in death, personal injury, equipment or property damage. • Inspected by a competent technician every 15,000 miles • Whenever a change is noticed in WARNING! the sound of the exhaust system • Whenever the exhaust system, Air conditioning refrigerant can be hazard- underbody or cab is damaged ous to your health. Do not expose yourself

196 Y53-6096-1A1 (01/17) MAINTENANCE - Heater and Air Conditioner Maintenance

Heater • Check all components and death, personal injury, equipment or proper- connections for refrigerant leaks. If ty damage. you discover a leak, do not try to CAUTION tighten a connection. Tightening a WARNING! connection may cause a leak to During extreme cold weather, do not blow worsen. Have a qualified technician hot defroster air onto cold . This could crack the glass. Turn the Air Flow Wear eye protection any time you blow correct the problem. Control Dial to Defrost and adjust the fan compressed air. Small particles blown by speed accordingly while the engine warms. compressed air could injure your eyes. If the engine is already warm, move the NOTE Temperature Control Dial to cool, then grad- • Listen to the compressor and drive ually increase the temperature when you clutch for noise and vibration. If you A leaking evaporator or condenser core cannot be repaired; it must be replaced. see that the windshield is starting to warm find problems, have the system up. Failure to comply may result in equip- checked thoroughly. A ment damage. Have the air conditioning system fully 5 malfunctioning clutch usually serviced annually by your authorized indicates trouble elsewhere in the • Check all heater controls for full- dealer. Qualified service technicians will system. range operation. have to evacuate and recharge the system. • Check hoses, connections, and • Check the evaporator core, filter, heater core for condition and leaks. and condenser core for debris restricting air flow. Clean if How to Replace Air Conditioner Air Conditioner necessary. Small particles may be Filter removed with compressed air blown How to replace air conditioner filter for left through the core in the opposite WARNING! hand steer, dual seat dual steer, and right direction of normal air flow. hand steer cab configurations. The air conditioning system is under pres- • Check the engine belt for condition sure. If not handled properly during servic- and proper tension. This procedure is for left hand steer, dual ing, it could explode. Any servicing that re- • Check all hoses for kinks, seat dual steer, and right hand steer cab quires depressurizing and recharging the air deterioration, chafing, and leaks. configurations. The fresh air filter for the conditioning system must be conducted by a Adjust kinked or chafing hoses to cab HVAC is located in front of the qualified technician with the right facilities to passenger footwell. The filter is accessible do the job. Failure to comply may result in eliminate restrictions and prevent further wear. from inside the cabin via two Phillips head

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fasteners. Inspect and clean cab air filter element every 3 - 6 months of service. The filter is reusable and should be gently rinsed with water. If the filter element is worn or broken, you should replace the cab air filter. 1. Remove the access door.

3. Repeat these steps for the other side of the cab. 5 How to Replace Air Conditioner Filter for Right Hand Stand Up Inspect and clean cab air filter element How to replace air conditioner filter for right every 3 - 6 months of service. The filter is hand stand up configurations of the low reusable and should be gently rinsed with cab forward vehicle. water. If the filter element is worn or This procedure is for right hand stand up broken, you should replace the cab air cab configurations. The fresh air filter for filter. the cab HVAC is located behind the 1. Remove the 4 screws that hold the 2. Pull out the air filter. passenger seat and at the top of the air (2) filter brackets to the box. The handling unit. filter will come off once the brackets are removed.

198 Y53-6096-1A1 (01/17) MAINTENANCE - Noise and Emission Control

Environmental Protection Agency (EPA) Tampering with Noise Control emissions and noise regulations. To System 1 maintain conformance with the regulations, Federal law prohibits the following acts or these components need to be functional the causing thereof: and properly maintained. Noise Emission Warranty 1. The removal or rendering inoperative by any person other Peterbilt warrants to the first person who than for purposes of maintenance, purchases this vehicle for purposes other repair, or replacement, of any than resale and to each subsequent device or element of design purchaser that this vehicle as incorporated into any new vehicle manufactured by Peterbilt, was designed, for the purpose of noise control prior built and equipped to conform at the time it to its sale or delivery to the ultimate left Peterbilt's control with all applicable purchaser or while it is in use, or 5 U.S. EPA Noise Control Regulations. 2. The use of the vehicle after such device or element of design has This warranty covers this vehicle as Be sure to inspect and replace the filter been removed or rendered designed, built and equipped by Peterbilt, located in the left side footwell. How to inoperative by any person. Among and is not limited to any particular part, Replace Air Conditioner Filter on page 197 those acts presumed to constitute component or system of the vehicle. tampering are the acts listed below: Defects in design, assembly or in any part, Noise and Emission component or system of the vehicle as • Air Intake System manufactured by Peterbilt, which, at the Control time it left Peterbilt's control, caused noise • Removing or rendering emissions to exceed Federal standards, inoperative the air cleaner/ silencers or intake piping. Information about the federal law are covered by this warranty for the life of prohibitaing tampering with the noise and the vehicle. • Engine Cooling System emissions systems. • Removing or rendering the fan There are specific components on the clutch inoperative. vehicle that are designed to meet certain • Removing the fan shroud. • Engine

Y53-6096-1A1 (01/17) 199 MAINTENANCE - Noise and Emission Control

• Removing or rendering engine • Removing noise insulators • Check the induction tubing, elbow speed governor inoperative so from engine block or from connections, clamps, brackets, and as to allow engine speed to around the oil pan. fasteners for deterioration, cracks, exceed manufacturer's • Cutting holes in, or cutting and security. specifications. away part of noise insulators. • If you find an air leak anywhere • Modifying ECU parameters. • Removing hood-mounted noise between the air cleaner and the • Exhaust System insulation. engine, repair that leak immediately. • Removing or rendering inoperative exhaust system Inspecting Noise and Emission CAUTION components. Components • Fuel System Air leaks cause excessive noise and may If, during periodic inspection and result in serious damage to the engine. If 5 • Removing or rendering engine maintenance of other systems and you do not repair them the engine damage speed governor inoperative, components, it is found that parts of the will not be covered by your warranty. Repair allowing engine speed to noise control system require attention, we all air leaks as soon as you find them. exceed manufacturer's recommend that those parts be inspected Engine Mounted Noise Insulators specifications. at more frequent intervals to assure adequate maintenance and performance. • Removing of air signal • Check condition. Is the insulator attenuator on engines The following instructions are based on secure? How you do this will equipped with this device. inspection of the noise control system at depend on the method of attaching • Removing of diesel exhaust regular intervals as indicated in the Noise the noise insulators on the engine fluid tank and system. Control System - Maintenance Log on and around the oil pan (bolts, snap • Inner Shields and Cab page 219. fasteners, or straps). Tighten loose Skirts fasteners and repair or replace any Air Intake System worn or damaged fasteners. • Removing shield or skirts. • Do all checks and maintenance • Check insulators around fasteners • Cutting away parts of shields, procedures listed in this manual and stress points, especially where skirts or damaged or loose under Engine Air Intake System and they may be affected by engine portions of shields or skirts. Air Cleaner. vibration. Repair any cracked or • Noise Insulating Blankets damaged mounting points. Use

200 Y53-6096-1A1 (01/17) MAINTENANCE - Rear Axle and Suspension

suitable reinforcing plates to ensure • Check exhaust piping for rust, Hood Insulation Blanket that the insulators will remain in corrosion, or damage. Replace position. deteriorated piping before holes Inner Fenders Shields and Cab Skirts appear. If piping is perforated at any Exhaust System point, temporary patching or lagging • Check for exhaust leaks, which is acceptable until you can have Rear Axle and Suspension would indicate a leaking manifold permanent repairs made. On gasket; replace gasket if necessary. turbocharged engines, check joints Maintenance requirements for rear axle • Check cap screws for tightness, at flanges and mounting brackets suspension. including those at the flanges. Refer for tightness. Your vehicle's suspension, by design, to the engine manufacturer's service Diesel Particulate Filter (DPF) requires a minimal amount of maintenance. manual for proper tightening However, suspensions in over-the-road sequence and torque values. • Check diesel particulate filter (DPF), clamps, and mounting brackets. operations require periodic inspection to 5 Joints and Clamps Tighten if necessary. Inspect diesel ensure trouble-free performance. • Check for leaks, and tighten as particulate filter (DPF) for signs of necessary. Check for deterioration rust or corrosion. WARNING! or dents in pipes and clamps which • Check internal baffling. You can do could allow exhaust to escape. this by listening for rattling sounds Do not work on the vehicle without the park- while tapping on the diesel ing brake set and wheels blocked securely. • Replace any serviceable joints, If the vehicle is not secured to prevent un- flexible pipes and gaskets at the particulate filter (DPF) with a rubber mallet or revving the engine up and controlled vehicle movement, it could roll service intervals. and may result in death, personal injury, down through its normal operating equipment or property damage. Selective Catalysts Reduction (SCR) range. • Check SCR canister filter, clamps Diesel Exhaust Fluid Tank (See and mounting brackets. Tighten if Aftertreatment System manual.) necessary. Inspect SCR canister for signs of rust or corrosion. Exhaust Tail Pipe Exhaust Piping Engine Fan and Shroud

Y53-6096-1A1 (01/17) 201 MAINTENANCE - Rear Axle and Suspension

inspect the suspension periodically, as noted below: WARNING! CAUTION • Visually check for loose or missing Do not operate the vehicle if the suspension Do not spray the suspension with chemical fasteners, cracks in hanger, or axle U bolts are not properly tightened. Loose U products or mineral oil; it can cause damage connection brackets. bolts will cause the axle to not be properly to the bushings. secured to the suspension, which could • Check that springs are centered in cause loss of vehicle control and an acci- hangers and in good condition. dent. Loose U bolts can also cause uneven NOTE • Check for cracks, wear marks, tire wear and poor alignment. Failure to splits, or other defects on the comply may result in death, personal injury, surface of the spring. equipment or property damage. Failure to follow these recommendations could void warranty. • Replace defective parts. Because repaired springs cannot be fully 5 WARNING! Visual Inspection restored to their original service life, replace the complete assembly if For all vehicles, mandatory maintenance cracks or other defects are Failure to maintain the specified torque val- procedures include retightening of U-bolts ues or to replace worn parts can cause detected. and complete inspection. However, even component system failure, possibly resulting • After replacement of any part or with proper maintenance, many factors in an accident. Improperly tightened (loose) discovery of loose components, affect the service life of springs and suspension U bolts can lead to unsafe vehi- check the torque of all fasteners. cle conditions, including: hard steering, axle suspension components, such as: fatigue, misalignment, spring breakage or abnormal vehicle gross weight, type of load, road • New springs settle-in after the tire wear. Failure to comply may result in conditions, and vehicle speed. It is vehicle's initial service, causing the death, personal injury, equipment or proper- important that U-bolts remain tight. Severe U-bolts to become loose. ty damage. use of your vehicle can cause them to Rear Suspension Fasteners loosen faster. But all vehicles need to have their U-bolts checked and tightened To maintain the performance of the air regularly. Be sure someone with the proper suspension, check fastener torque values training and the right tools checks and after the first 2,000 miles (3,218 km) of tightens the U-bolts on your vehicle. After service and every 60,000 miles (96,000 the first 500 miles (800 km) of operation, km) thereafter. Torque recommendations apply to fasteners supplied and installed by

202 Y53-6096-1A1 (01/17) MAINTENANCE - Rear Axle and Suspension

vehicle manufacture. The values listed in Rear Axle Lubrication the at the back of this chapter (Specification Reference Charts), are for NOTE Lubrication requirements for rear axles. cadmium plated or phosphate and oil See the axle manufacturer's operator's fasteners only. U-bolts are difficult to Whenever possible, torque all frame fasten- ers on the nut end, not the bolt head. manual for lubrication specifications and tighten unless you have the right service intervals. equipment. If you cannot tighten them Load the vehicle to its normal gross weight correctly yourself, be sure to have them before tightening U-bolts. Loading the Check oil level with the vehicle parked on checked and tightened regularly by an vehicle ensures proper adjustment of the level ground and the fluid warm. The level authorized mechanic. U-bolt and spring assembly. should be even with the bottom of the filler hole. Rear Suspension U-Bolts WARNING! Rear Axle Alignment NOTE 5 Do not replace U bolts and nuts with com- Continual road shock and load stresses To ensure an accurate torque reading, use mon U bolts or standard nuts. These parts may force the rear axles out of alignment. properly maintained and calibrated torque are critical to vehicle safety. If the wrong U If you detect rapid tire wear on the rear wrenches. Clean the nut and bolt. No dirt, bolts or nuts are used, the axle could loosen axles, you may have misaligned axles. If grit, or rust should be present. or separate from the vehicle and cause a serious accident. Use only U bolts and nuts you suspect rapid tire wear, have your rear of SAE Grade 8 specification or better. Fail- axle alignment checked and adjusted by an ure to comply may result in death, personal authorized dealer. WARNING! injury, equipment or property damage. Suspension alignment should be checked Do not operate the vehicle if the suspension See Also when any one of the following conditions U bolts are not properly tightened. Loose U exist: bolts will cause the axle to not be properly Suspension U-Bolts, Grade 8 on page 213 secured to the suspension, which could Wheel Cap Nut Torque Specifications on • Discovery of loose suspension cause loss of vehicle control and an acci- page 215 fasteners. (Loose, defined as any dent. Loose U bolts can also cause uneven Frame Fastener Torque Requirements on torque below the recommended tire wear and poor alignment. Failure to torque value.) comply may result in death, personal injury, page 214 equipment or property damage. Suspension U-Bolts, Grade 8 on page 213 • Discovery of elongated holes in a suspension component.

Y53-6096-1A1 (01/17) 203 MAINTENANCE - Steering System

• Bushing replacement. Because of the hydraulic power assist, little any way, or if the steering angle sensor is effort is required to turn the steering wheel. • Excessive or abnormal tire wear. replaced, the steering angle sensor must be recalibrated. Any repairs or adjustments to When no input is applied through the any part of the steering system must be per- steering wheel, the steering gear will return Steering System formed by an authorized dealer. Failure to to the neutral position. If, for any reason, comply may result in death, personal injury, the power assist system goes out, steering equipment or property damage. the vehicle is still possible, yet it will require The steering system consists of a power much greater effort. steering pump, gearbox and reservior. Oil (under low pressure) provides the power to operate the steering gear. It also Visually check the following parts: serves to lubricate moving parts and • Crosstube: Is it straight? WARNING! remove heat. A loss of steering efficiency will occur if too much heat builds up in the • Draglink tube clamp: Check for 5 Do not operate the vehicle if the steering system. looseness or interference. system is not working properly. You could • Ball joints and steering U-joints: lose control of your vehicle if the steering If the steering feels unbalanced from side- Check for looseness. system is not in good working condition, to-side while turning, check for the which could result in a serious accident. For • Steering wheel for excessive free- driving safety, visually check the steering following possible causes: play. Check the simplest probable gear and components. Frequent checks are • unequal tire pressures causes first: a. unequal tire important for driving safety, especially after pressures b. loose cap nuts c. bent • vehicle overloaded or unevenly traveling over rough roads. Failure to com- crosstube d. lack of lubrication. ply may result in death, personal injury, distributed load equipment or property damage. • wheels out of alignment If these checks do not reveal the problem, • wheel bearings improperly adjusted. or if you correct them and still have a steering problem, take your truck to an WARNING! If you cannot correct the problem, check authorized dealer for evaluation. with an authorized dealer. If this chassis is equipped with an electronic stability system (ESC) and any part of the Your vehicle is equipped with integral steering system (e.g., linkage, steering power steering. The system includes an driveline, column, front end alignment, etc) engine-driven fluid pump, a fluid reservoir, is repaired, removed, or disassembled in the steering gear, and connecting hoses.

204 Y53-6096-1A1 (01/17) MAINTENANCE - Steering System

Power Steering Fluid cold. Each of the conditions have a 1. Park the vehicle and turn the engine MAX and a MIN mark. off Have the power steering fluid and filters 2. Open the hood and locate the • If you check the fluid with the changed at an authorized dealer. power steering filter housing engine and steering system COLD, the fluid level should be 3. Open the housing by taking off the CAUTION at/or above the Minimum top of the housing indicator level and should 4. Replace the filter When adding fluid, be sure to use fluid of generally not exceed the middle 5. Replace the fluid the same type. While many fluids have the point between Maximum and 6. When adding new fluid, bleed the same description and intended purpose, Minimum level indicators. they should not be mixed due to incompati- power steering system by turning on ble additives. Mixing incompatible fluids may • If you check the fluid with the the engine and turning the steering lead to equipment damage. engine and steering system wheel full right and then full left. Add WARM, the fluid should NOT fluid when necessary as air bleeds 5 exceed the Maximum level out of the system. NOTE indicator and should generally not drop below the middle point Before removing reservoir cover, wipe out- between the Maximum and side of cover so that no dirt can fall into the Minimum level indicators. reservoir.

Check and completely change the Steering Fluid Filter level. Use the following procedure: The power steering system has a filter that 1. Park the vehicle on level ground needs to be maintained. and turn the engine off. 2. Open hood CAUTION 3. Open the fill cap to the power steering reservior. In addition to the Servicing the power steering system without reservoir itself, the cap has a bleeding it of trapped air may cause dam- dipstick that indicates fluid level age to the power steering pump. when the fluid is hot and when it is

Y53-6096-1A1 (01/17) 205 MAINTENANCE - Steering System

Steering Shaft Bolt Torque Specifications Pitman Arm Clamp Bolt Fastener torque specifications for steering shaft. Fastener Size Tightening Specification ft- For off–highway vehicles, tighten the U– lb (N•m) bolts after the first day or two of operation.

Then check weekly. The following are 3/4 inch 300-320 (406-433) common torque specifications for most steering shafts.

WARNING! 5 Steering U-joint Pinch Bolt If this chassis is equipped with an electronic stability control (ESC) and is modified (e.g. Fastener Size Tightening adding or removing an axle, converting from Specification ft- a truck to a tractor, converting from a tractor lb (N•m) to a truck, changing the body, lengthening of the wheelbase and/or frame, relocating frame components, or modifying pneumatic 7/16 inch 55-60 (74-81) or electrical ABS/ESC harnesses) the ESC must be disabled by a qualified technician. If you have any questions, contact your au- thorized dealer. Failure to comply may result in death, personal injury, equipment or prop- erty damage.

206 Y53-6096-1A1 (01/17) MAINTENANCE - Driveline

you can stop depends in large measure on Checking Inflation Pressure how much friction you get between the Low pressure is a tire’s worst enemy. Driveline road and your tires. In addition, keeping Underinflation allows tires to flex your tires in good condition is essential to improperly, causing high temperatures to General lubrication information for the safe, efficient operation of your vehicle. build up. Heat causes early tire damage drivelines. Regular, frequent inspection and the right such as flex break, radial cracks, and ply care will give you the assurance of safe separation. Low pressure may affect See the driveshaft manufacturer's and reliable tire operation. Here are some control of your vehicle, especially at the operator's manual for lubrication tips on maintaining your tires. specifications and service intervals. front wheels. Most tire wear problems are Proper Over Under caused by underinflation as the result of slow leaks, so you’ll want to check tire WARNING! pressure regularly. Lower tire pressure does not provide better traction on ice or 5 Improper lubrication of U joints can cause snow. Give your tires a visual test every them to fail prematurely. The driveshaft could separate from the vehicle and result in day, and check inflation with a gauge every an accident. Make sure lubricant is purged week: at all four ends of each U joint and loosen TREAD CONTACT WITH ROAD caps if necessary. Also, regularly inspect U • When checking tire pressure, joints for excessive wear or movement, and inspect each tire for damage to repair or replace as necessary. Failure to sidewalls, cuts, cracks, uneven comply may result in death, personal injury, WARNING! wear, rocks between duals, etc. If a equipment or property damage. tire appears underinflated, check for Do not repair damaged tires unless you are damage to the wheel assembly. fully qualified and equipped to do so. Wheel Don’t forget to check between dual and tire assemblies cannot be worked on wheels. If you find wheel damage, Tires without proper tools and equipment, such as: safety cages or restraining devices. have an expert tire service repair it. Have all tire repairs performed by an expert. • Maximum tire pressure will be Information on maintaining your vehicle's Stand away from the tire assembly while the indicated on the sidewall of a tire. tires. expert is working. Failure to do this may re- • Check pressure only when the tires sult in death or injury. Your tires are a very important part of your are cool. Warm or hot tires cause vehicle’s whole braking system. How fast pressure buildup and will give you

Y53-6096-1A1 (01/17) 207 MAINTENANCE - Tires

an inaccurate reading. So never deflate a warm tire to the specified Vehicle Tire Expected pressure. NOTE Load Pressure Total Tire Mileage Follow all warnings and cautions contained WARNING! within the tire and wheel manufacturers liter- 100% Over 55% Low 25% ature. Do not operate a vehicle with underinflated tires. The extra heat caused by underinfla- Overloaded Tires Overinflated Tires tion can cause sudden tire failure such as a Overloading your truck is as damaging to tire fire or blow out, which can cause an ac- Too much air pressure reduces the tire your tires as underinflation. The following cident resulting in death or personal injury. tread contact area and results in rapid chart shows how neglect or deliberate Low pressure may affect control at the front wear in the center of the tread. wheels, which could result in an accident in- abuse can affect the life of your tires. Overinflating the tires reduces the tread 5 volving death or personal injury. Keep your tires inflated to the manufacturer's recom- contact area with the road surface, mended air pressure. concentrating all of the vehicle weight on Effects of Load and Pressure on the center of the tread. This causes Tire Life premature wear of the tire. WARNING!

Do not attempt to raise the vehicle to re- Vehicle Tire Expected WARNING! move or install a damaged tire and wheel Load Pressure Total Tire assembly if you are not fully qualified and Mileage Overinflated tires can cause accidents. They not equipped with the proper tools and wear more quickly than properly inflated tires and are more subject to punctures, equipment. Do not attempt to reinflate a tire Normal Normal Normal that has been run flat. Obtain expert help. A cracks, and other damage. They could fail person can be seriously injured or killed if 20% Over 20% Low 70% and cause you to lose control of your vehi- using the wrong service methods. Truck cle resulting in an accident causing death or tires and wheels should be serviced only by 40% Over 30% Low 50% personal injury. Be sure all tires are inflated trained personnel using proper equipment. correctly according to the manufacturer's 60% Over 35% Low 40% Follow OSHA regulations per section recommendations. 1910.177. 80% Over 45% Low 30%

208 Y53-6096-1A1 (01/17) MAINTENANCE - Tires

Matching Tires places equally spaced around the tire. Drive Axles or Trailers: Replace tires on Be sure to buy matched tires for your drive axles or trailers when less than 2/32 CAUTION vehicle, especially on the rear axles. in. of tread depth remains in any major Mismatched tires can cause stress groove. Check at three places equally Chains on the tires of only one tandem axle between axles and cause the temperature can damage the driveline U-joints and the spaced around the tire. of your axle lubricant to get too hot. interaxle differential. Repairs could be costly Matched tires will help your driveline last and time-consuming. Failure to comply may longer and will give you better tire mileage. WARNING! result in equipment damage.

Do not replace original equipment tires with Speed Restricted Tires WARNING! load ratings less than the original tires. Do- ing so could lead to unintentional overload- WARNING! Do not mismatch tires, it can be dangerous. ing of the tire, which could cause a failure Never mix tires of different design such as resulting in loss of vehicle control and an ac- 5 steel belted radials and bias ply tires, etc. cident. Failure to comply may result in This vehicle may be equipped with speed Mixing tire types and sizes will adversely af- death, personal injury, equipment or proper- restricted tires. Check each tire’s sidewall fect the road holding ability of both types of ty damage. for maximum rated speed. The vehicle tires and can lead to loss of vehicle control should not be operated at sustained speed and causing death or personal injury. in excess of maximum rated speed. Failure to comply with these speed restrictions NOTE could cause sudden tire failure which can result in death, personal injury or property WARNING! To prolong your tires’ life and make them damage. safer, have their radial and lateral run-out Do not install regrooved or reinforcement re- checked at your dealer. And of course you paired tires on steering axles. They could should have your tires balanced anytime Gas Certified Tires fail unexpectedly and cause you to lose con- you change a tire. trol of your vehicle resulting in an accident Verify if your vehicle is equipped with causing death or personal injury. Tire Chains Greenhouse Gas certified tires by checking the Vehicle Emission Control label on the Replacing Tires If you need tire chains, install them on both driver's side door frame. If these tires were sides of each driving axle. Front: Replace front tires when less than installed at the factory, Lower Rolling 4/32 in. of tread remains. Check at three

Y53-6096-1A1 (01/17) 209 MAINTENANCE - Wheels

Resistance codes (LRR) identify which After the vehicle travels about 50 to 100 Vehicles equipped with front disc brakes tires are certified. miles (80 to 160 km), wheel mountings are fitted with wheels designed specifically seat in and will lose some initial torque. for disc brake applications. If it ever Check hub/wheel mountings after this becomes necessary to replace an original NOTE initial period and retighten. Threads should equipment wheel, the replacement wheel be clean and dry. Do not lubricate wheel must be the same brand and size as the The tires installed on this vehicle at the fac- nuts or studs. take-off wheel. On vehicles equipped with tory as original equipment may be certified for Greenhouse Gas and Fuel Efficiency 22.5 in. disc wheels, installing the wrong replacement wheel could result in the regulations. Replacement tires must be of WARNING! equal or lower rolling resistance level (TRRL wheel valve stem making contact with the or Crr). Consult with your tire supplier(s) for disc brake assembly. When installing any Never use oil or grease on studs or nuts; im- appropriate replacement tires. replacement wheel, always inspect the proper torque readings will result, which could cause improper wheel clamping and tires/wheels to ensure there is adequate 5 In order to limit the rolling resistance of the could lead to a wheel failure resulting in an clearance between other vehicle tires and optimize fuel economy, the accident. Failure to comply may result in components. With the hood open, check maintenance procedures specified by the death, personal injury, equipment or proper- for clearance between the wheel and disc tire manufacture must be followed. Please ty damage. brake assembly. Use a hydraulic jack to see Vehicle Emissions Limited Express raise the front of the vehicle off the ground Warranty for warranty on greenhouse gas Wheel Replacement with Disc to allow the wheel to spin freely. While certified tires. Brake Option rotating the wheel, check to ensure there is See Also adequate clearance between the wheel and disc brake assembly. Greenhouse Gas Certification Label on WARNING! page 229 Use only the wheel brand, size and part number originally installed. Use of a differ- ent wheel brand or size could cause valve stem to interfere with a brake component Wheels which could lead to loss of vehicle control. Failure to comply may result in death, per- Information on maintaining your vehicle's sonal injury, equipment or property damage. wheels.

210 Y53-6096-1A1 (01/17) MAINTENANCE - Transmission Maintenance

Disc Wheels Wheel Cap Nut Torque Specifications on page 215 WARNING! WARNING! Frame Fastener Torque Requirements on Improperly mounting and demounting tire page 214 and rim assemblies is dangerous. Failure to Use the correct components and tools when observe proper precautions could cause the working on wheels. Grooves in the wheel tire rim assembly to burst explosively, caus- disc or other damage to the disc can weak- ing death or personal injury. See the wheel en the wheel and cause it to eventually Transmission Maintenance manufacturer's literature for the proper way come off. This could cause you to lose con- to mount and demount your tires and rims. trol of your vehicle, and may result in an ac- General maintenance recommomendations Follow their precautions exactly. cident. Failure to comply may result in death, personal injury, equipment or proper- for maintaining your vehicle's transmission. ty damage. See the transmission manufacturer's WARNING! operator's manual for lubrication The end of the wheel wrench must be 5 specifications and service intervals. Always ensure the hood hold open latch is smooth. Burrs on the end of the wrench engaged to keep the hood fully open any can tear grooves in the disc. These time anyone gets under the hood for any grooves may lead to cracks in the disc, and CAUTION reason. Failure to do so may cause the can cause it to fail. hood to close uncontrollably which may re- sult in death or personal injury. When adding oil, types and brands of oil Wheel Bearings should not be intermixed because of possi- For safe, reliable operation and adequate ble incompatibility, which could decrease the service life, your wheel bearings must be effectiveness of the lubrication or cause WARNING! component failure. adjusted properly at the recommended Always support the vehicle with appropriate intervals. Contact your authorized dealer to See Also safety stands if it is necessary to work un- make sure the wheel bearings are properly derneath the vehicle. A jack is not adequate adjusted. Lubrication Specification Chart on page for this purpose. Failure to comply may re- 216 sult in death, personal injury, equipment or See Also property damage. Suspension U-Bolts, Grade 8 on page 213

Y53-6096-1A1 (01/17) 211 MAINTENANCE - Mechanical Clutch

and free travel are gone, the clutch before clutch pedal free travel is reduced to requires adjustment. The clutch is adjusted the minimum allowable 1/2 in. (13 mm). Mechanical Clutch by turning an adjustment ring that is built into the clutch. When the ring is turned, the Clutch Adjustment release bearing moves back toward the Under normal wear conditions, the clutch The clutch in this vehicle is actuated via a transmission, restoring free pedal and will require periodic adjustment. See the combination of mechanical linkages from clutch free travel. Under normal clutch clutch manufacturer's Service Manual for the cab to the transmission. wear this is the only adjustment needed. the proper adjustment procedures. Free Pedal Travel Do not attempt to change any other component. Free pedal travel is the distance the clutch pedal moves by applying only slight Clutch Linkage Specification Reference pressure. During free pedal the release Have your authorized dealer service the Charts 5 yoke in the transmission moves until its clutch according to the clutch bearing pads contact the release bearing. manufacturer’s service guidelines. This This movement of the release yoke is vehicle is equipped with a rod and lever called free travel. Thus, free pedal and free mechanical clutch linkage. Lubricate each travel are directly related to each other. As pivot point on the clutch linkage. Replace the clutch pedal is depressed further, with with the recommended fluid Component harder pressure, the release yoke moves Lubrication Index. Lubrication Specification the release bearing away from the engine. Chart on page 216 This causes the clutch plate to release from the driven disks in the clutch. This is Clutch Adjustment called release travel. And finally, as the Clutch pedal free travel is usually 1 3/4 in. pedal is pushed to the last 1/2 to 1 inch of to 2 in. (34 to 51 mm). This should be your travel, the release bearing contacts and guide for determining whether your truck engages the clutch brake. This is called needs clutch adjustment. Some vehicles clutch brake squeeze. When the clutch have automatic clutch adjustment. If yours wears, the release bearing gradually doesn’t have this feature, adjustment will moves toward the engine, decreasing free have to be done by a trained certified pedal and free travel. When all free pedal mechanic. Have the adjustment done

212 Y53-6096-1A1 (01/17) MAINTENANCE - Specification Reference Charts

Suspension U-Bolts, Grade 8 U-Bolt Torque Torque Torque specifications for suspension u- Size (N•m) ( lb-ft) bolts. Diameter (inches) Tighten all U-Bolts with a torque wrench. Torque specifications apply to the following 1 1/4 1,890-2,120 1,390-1,560 fasteners with lightly lubricated threads. Chevron Zinc Lubricant or SAE 20/30 oil 1 1/2 3,130-3,860 2,300-2,840 should be used on U-Bolt threads. Torque M20 475 +/- 27 350 +/- 20 requirements apply to manufacturer proprietary suspensions. All other suspensions must refer and adhere to The values shown here are for suspension original manufacturers shop manual. u-bolts and should not be applied to bolts 5 and fasteners for the frame. See Also Standard and Metric Fastener Torque for Grade 8 U-Bolts Front Axle and Suspension on page 194 Rear Axle and Suspension on page 201 Wheels on page 210 U-Bolt Torque Torque Size (N•m) ( lb-ft) Diameter (inches)

3/4 333-408 245-300

7/8 598-734 440-540

1 925-1,060 680-780

1 1/8 1,470-1,660 1,080-1,220

Y53-6096-1A1 (01/17) 213 MAINTENANCE - Specification Reference Charts

Frame Fastener Torque Fastener Size Tightening Requirements Specification lb-ft (N•m) Torque specifications for standard and metric frame fasteners, including the fifth 1 700-830 (952-1,129) wheel. 1-1/8 990-1,170 (1,346- 1,591) Use ESNA Style Lock Nut, with nylon 1-1/4 1,380-1,630 (1,877- 2,217) insert. Lubricate nylon insert nut lightly with SAE 20/30 oil. Tighten all frame fasteners with a torque wrench. Torque specifications Metric Fastener Tightening apply to the following fasteners with lightly Size (with nylon Specification lb-ft lubricated threads. These values are insert nuts) (N•m) 5 applicable to fasteners on the frame and do not apply to u-bolts for the suspension. M5 6-9 (8-12) M6 7-11 (9-15) Fastener Size Tightening M8 17-23 (23-31) Specification lb-ft (N•m) M10 24-32 (33-43)

5/16 16-22 (22-30) M12 55-75 (75-101)

3/8 30-40 (41-54) M16 120-160 (163-217)

7/16 55-65 (75-88) M20 260-340 (352-460)

1/2 80-90 (109-122) M20 (All Metal Lock 315-350 (427-475) Nuts) 9/16 115-140 (156-190)

5/8 165-195 (224-265) See Also

3/4 290-340 (394-462) Front Axle and Suspension on page 194 Rear Axle and Suspension on page 201 7/8 380-460 (517-626) Wheels on page 210

214 Y53-6096-1A1 (01/17) MAINTENANCE - Specification Reference Charts

Wheel Cap Nut Torque At the first scheduled lube interval, have all procedure for the wheels on your truck. Specifications wheel cap nuts torqued to their specified This is a job you may not be able to do value. After that, check wheel cap nuts at yourself. You need the right torquing Torque specifications for wheel cap nuts, least once a week. equipment to do it. including standard and metric fasteners. Contact an authorized dealer for information on the proper installation

Torque for Two Piece Flanged Cap Nuts Wheel and Nut Stud Size Configuration lb-ft N•m

Hub-Piloted Disc-Type Wheel w/Two Piece M22-1.5 450-500 610-680 Flanged Cap Nuts: Steel or Aluminum 5 Wheel PHP-10; Budd Uni-Mount-10; WDH-8

Stud Backnuts (when used) 3/4-16 175-200 240-270

1-14 175-300 240-410

Cast Wheel Assembly Rim Clamp 1/2" Dia. 5/8" Dia. 3/4" Dia. 80-90 110-120 Nut Torque 1/2" Dia. 5/8" Dia. 3/4" Dia. 160-185 220-250

1/2" Dia. 5/8" Dia. 3/4" Dia. 225-245 305-335

See Also Front Axle and Suspension on page 194 Rear Axle and Suspension on page 201 Wheels on page 210

Y53-6096-1A1 (01/17) 215 MAINTENANCE - Specification Reference Charts

Lubrication Specification Chart *Consult manufacturer or lubricant supplier for special details.

NOTE

The responsibility for meeting these specifi- cations, the quality of the product, and its performance in service rests with the lubri- cant supplier.

Lubricant Symbol Key 5 Type Application

ATF MD3 or MERCON®-approved automatic transmission fluid

BB High temperature ball bearing grease. Chevron SRI Mobile Grease HP, Texaco Multifax 2

CB Engine oil for mild to moderaterequirements

CC/CD Engine oil for severe requirements (MIL-L-2104B /MIL-L-45199B w/ 1.85% max. sulfated ash

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

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)

216 Y53-6096-1A1 (01/17) MAINTENANCE - Specification Reference Charts

Type Application

GL Straight mineral gear lubricant

HD Hypoid Gear Oil, A.P.I. - GL-5, SAE 75W-90FE synthetic gear lubricant

HT High Temperature grease (Timken Spec. 0-616)

MP Multipurpose gear lubricant (MIL-L-2105B)

DOT3 or Brake Fluid DOT4

5 Component Lubrication Index

Application Type

Steering Column CL

Alternator Bearing BB (1)

Fan Hub BB (1)

Power Steering Reservoir ATF

Steering Drag Link CL

Steering Knuckles CL

Spring Pins CL

Clutch Release Bearings BB

Brake Shoe Anchor Pins HT

Y53-6096-1A1 (01/17) 217 MAINTENANCE - Specification Reference Charts

Application Type

Brake Cam Bearings HT

Slack Adjusters CL

Starter Bearings CC

Turbocharger Aneroid CC

Water Pump BB (1)

Suspension Fittings (other than threaded pins and bushings) EP

Steering Shaft Grease Fittings EP

5 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)

(1) Consult manufacturer or lubricant supplier for special details.

See Also Lubricants on page 153 Checking Oil Level on page 154 Transmission Maintenance on page 211

218 Y53-6096-1A1 (01/17) MAINTENANCE - Specification Reference Charts

Steering Gear Lubrication The following recommendations are for general purpose steering systems (both TRW and Sheppard).

Application Type

For normal temperatures Automatic Transmission Fluid (ATF) Type E or F or Dexron® III

For cold temperatures of -22ºF (-30ºC) and above ATF Type A

For extremely cold temperatures between -22ºF (-30ºC) and -40ºF (-40ºC) ATF Type B

Noise Control System - maintenance checks. Use the following log 5 Maintenance Log sheet and retain copies of documents regarding maintenance services performed To ensure your vehicles noise control and parts replaced on the vehicle. requirements are maintained, record

Component Recom- Date & Repair Work Date & Repair Work mended R.O. No. Facility & Performed R.O. No. Facility & Performed Interval Location Location (Miles)

Exhaust System Routing 25,000 Integrity

Shutters Shrouds 25,000

Hood Insulation Blanket 10,000

Engine Mounted Hose 10,000 Insulators Fasteners

Y53-6096-1A1 (01/17) 219 MAINTENANCE - Specification Reference Charts

Component Recom- Date & Repair Work Date & Repair Work mended R.O. No. Facility & Performed R.O. No. Facility & Performed Interval Location Location (Miles)

Inner Fender Shields 50,000

Cab Skirts Fasteners 50,000

Air Intake System Integrity 5,000 Element

Clutch Type Fan Drive 10,000 5

220 Y53-6096-1A1 (01/17) MAINTENANCE - Specification Reference Charts

Pipe and Hose Clamp Torque Values Torque specifications for engine parts.

These references are for pipes and hoses in the engine area.

Application Type of Clamp in-lb N•m

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 5 Plastic Air Intake Pipes Constant Torque CT-L 4.5 40 (maximum)

Charge Air Intake Hoses Flex Seal 7.9-11.3 70-100

B9296 6-7 50-60

Fuel, Oil and Water Heat Exchangers (for Miniature 3600L 1.1-1.7 10-15 hoses less than 9/16" diameter).

See Also Air Intake System on page 190

Y53-6096-1A1 (01/17) 221 MAINTENANCE - Specification Reference Charts

5

222 Y53-6096-1A1 (01/17)

Chapter 6 | INFORMATION

In this Chapter:

Consumer Information...... 224 Vehicle Identification Labels...... 224 Clean Idle...... 227 Greenhouse Gas Certification Label...... 229 Vehicle Emissions Limited Express Warranty...... 230 6

INFORMATION - Consumer Information

and if it finds that a safety defect exists in a Transport Canada, ASFAD Place de Ville group of vehicles, it may order a recall and Tower C 330 Sparks Street Ottawa ON Consumer Information remedy campaign. However, NHTSA K1A 0N5 cannot get involved in individual problems between you, your dealer, and vehicle For additional road safety information, How to Order Replacement Parts manufacturer. Contacting NHTSA is please visit the Road Safety website at: Replacement parts may be obtained from possible through telephone, written mail http://www.tc.gc.ca an authorized dealership. When you order, and email. NHTSA also has a website it is IMPORTANT that you have the where you can input your comments See Also following information ready: directly to them on the web. Please use http://www.safercar.gov any of the four ways to contact NHTSA: http://www.tc.gc.ca • Your name and address. • Serial number of the truck. • The name of the part you need. Toll Free 888-327-4236 (800-4249153 TTY) 8:00 am to • The name and number of the 10:00 pm ET Monday-Friday Vehicle Identification component for which the part is Office of Defects Investigations/CRD NVS-216 1200 Labels 6 required. New Jersey Ave SE. Washington, D.C. 20590 www.safercar.gov • The quantity of parts you need. Information explaining the vehicle • How you want your order shipped. email: [email protected] identification number location, component, National Highway Traffic and Safety chassis weight, and tire labels. Administration (NHTSA) Transport Canada Each vehicle completed by Peterbilt Motors If you believe that your vehicle has a Company uses a Vehicle Identification defect, which could cause a crash or could Canadian customers who wish to report a Number (VIN) that contains the model year cause death or personal injury, you should safety-related defect to Transport Canada, designation of your vehicle. The practice is immediately inform the National Highway Defect Investigations and Recalls, may in compliance with 49 CFR 565, Code of Traffic Safety Administration (NHTSA) in telephone the toll free hotline Federal Regulations. addition to notifying the vehicle 1-800-333-0510, or contact Transport Canada by mail at: The full, 17-digit VIN is located on the manufacturer. If NHTSA receives similar Weight Rating Data Label. The label is complaints, it may open an investigation,

224 Y53-6096-1A1 (01/17) INFORMATION - Vehicle Identification Labels

located on the driver's side door edge or • Right frame rail, top flange, about 3 Tire, Rim and Weight Rating Data on the driver's side door frame. ft. from the front end Label

• Cab back, left-hand rear panel, The Tire, Rim and Weight Rating Data lower edge Label is located on the driver’s side door • Tire, Rim, and Weight Rating Data edge or on the driver’s side door frame. It label (truck) contains the following information: • Components and Weights label • GVWR - Gross Vehicle Weight • Noise Emission label Rating • Paint Identification label • GAWR FRONT, INTERMEDIATE Certification Labels and REAR - Gross Axle Weight Ratings for Front, Intermediate and Your vehicle information and specifications Rear Axle are documented on labels. As noted below, • TIRE/RIM SIZES AND INFLATION each label contains specific information PRESSURES - Tire/Rim Sizes and pertaining to vehicle capacities and Cold Pressure Minimums specifications that you should be aware of. 6 • VIN including CHASSIS NUMBER. Components and Chassis Weight Label The components of your vehicle are designed to provide satisfactory service, if The Components and Chassis Weight the vehicle is not loaded in excess of either Label is located on either the driver’s side the gross vehicle weight rating (GVWR), or door edge or on the driver’s side door the maximum front and rear gross axle Chassis Number frame. It includes chassis number, chassis weight ratings (GAWRs). The Chassis Number refers to the last six weight and gross weight, plus model characters of the VIN. This number will information for the vehicle, engine, allow your dealer to identify your vehicle. transmission, and axles. You will be asked for this number when you bring it in for service. Chassis Number Locations

Y53-6096-1A1 (01/17) 225 INFORMATION - Vehicle Identification Labels

Noise Emission Label Standards, for United States and U.S. Territories, be affixed to each motor vehicle The Noise Emission Label is located in the WARNING! and prescribe where such label may be driver's side door frame. It contains located. This certification label, which Do not exceed the specified load rating. information regarding U.S. noise emission indicates the date of manufacture and Overloading can result in loss of vehicle regulations, chassis number, and date of other pertinent information, is located on control, either by causing component fail- manufacture. ures or by affecting vehicle handling. Ex- the driver’s side door edge or on the ceeding load ratings can also shorten the Paint Identification Label driver’s side door frame. service life of the vehicle. Failure to comply may result in death or personal injury. The Paint Identification Label contains the Component Identification paint colors used by the factory to paint Each of the major components on your your vehicle. It lists frame, wheels, cab vehicle has an identification label or tag. interior and exterior colors. This label is NOTE For easy reference, record component located inside the glove box. numbers such as, model, serial, and GVW is the TOTAL SCALE WEIGHT the ve- hicle is designed to carry. This includes the Federal Safety Standard assembly number. weight of the empty vehicle, loading plat- Certification Label 6 form, occupants, fuel, and any load. The NHTSA regulations require a label certifying compliance with Federal Safety

226 Y53-6096-1A1 (01/17) INFORMATION - Clean Idle

Engine: For further information, please refer to the Engine Operation and Maintenance Manual.

Transmission: For both manual and automatic transmissions, the identification number is stamped on a tag affixed to the right rear side of the transmission case.

Clutch: Enclosed in clutch housing. Location depends on manufacturer.

Steer Axle: The front axle serial number is stamped on a plate located on the center of the axle beam.

Axle Specification Number: Usually stamped on the right rear side of the axle housing. This number identifies the complete axle.

Axle Housing Number: Usually located on the left forward side of the housing arm. This tag identifies the axle housing.

Axle Differential Carrier Identification: Usually located on the top side of the differential carrier. The following information is either stamped, or marked with a metal tag: Model No., Production Assembly No., Serial No., Gear Ratio, and Part Number.

chosen to adopt CARB emissions below. requirements). Trucks with this type of Clean Idle engine will not require an Engine Shutdown System and will be allowed to 6 To comply with CARB emissions idle continuously. It is important that you do requirements your vehicle will either have not remove or deface this label. Do not the Certified Clean Idle label or an Engine block it from view. Please contact your Shutdown System (ESS). Some vehicles, authorized dealership if you need to however, are exempt from these replace this label. The dealership will be requirements because of their able to help you to determine whether or configurations (for example: fire truck not your vehicle's engine may be a service). candidate for a Certified Clean Idle label if it did not already have the label. Your vehicle may have either of these labels affixed to the vehicle to identify that If you have a PACCAR PX-6 or PX-8 its engine meets the strict low exhaust engine, your label will look like the image emission regulations instituted by the state of California (and other states that have

Y53-6096-1A1 (01/17) 227 INFORMATION - Clean Idle

If you have a Cummins engine, your label Fahrenheit, or if the engine is performing a will look like the image below. parked regeneration. The will alert you when the ESS shutdown timer reaches the last 30 seconds before the engine shuts down. The last 30 seconds prior to engine shutdown is the only time the driver may reset the idle time by pressing on the accelerator. More detailed information may be available in the Engine Operator’s Manual provided with your vehicle. Engine Shutdown System If the vehicle’s engine does not meet the low exhaust emission standard it will have an Engine Shutdown System (ESS) to meet limited idle regulations implemented 6 by CARB and some additional states. These regulations require that the engine have an automatic system to restrict the idle time on certain vehicles. An Engine Shutdown System will shut down the engine after 5 minutes if the vehicle idles with the park brake set and the transmission in ‘neutral’ or ‘park’. The ESS will also allow the vehicle 15 minutes of idle time if the driver does not set the park brake and shifts the transmission to ‘neutral’ or ‘park’. The ESS, however, will not shut down the engine if the engine is operating in Power Take Off (PTO) mode, if the engine coolant is below 60 degrees

228 Y53-6096-1A1 (01/17) INFORMATION - Greenhouse Gas Certification Label

This vehicle may be equipped with of the GHG certification. The codes are components that are identified as translated in the following table: Greenhouse Gas Greenhouse Gas Certified components Certification Label (GHG). A label on the door is printed with codes that identify the components manufactured on the vehicle that are part Definition of greenhouse gas label identifiers. Emission Control Identifier Emissions Related Components

VSL, VSLS, VSLE, or VSLD Engine Software parameters that affect the Vehicle Speed Limiter

IRT5, IRTE Engine software parameters that affect the automatic engine shutdown timer

ATS Aerodynamic side skirts and/or fuel tank fairings

ARF Aerodynamic roof fairing ARFR Adjustable height aerodynamic roof fairing 6 TGR Gap reducing fairing (tractor to trailer)

LRRA, LRRD, or LRRS Greenhouse Gas (GHG) Tires

See Also Greenhouse Gas Certified Tires on page 209 Vehicle Emissions Limited Express Warranty on page 230

Y53-6096-1A1 (01/17) 229 INFORMATION - Vehicle Emissions Limited Express Warranty

correction of the Warrantable Emissions in materials and workmanship other than Failures relating to the original equipment those which cause non-compliance with Vehicle Emissions Limited tires. PACCAR MAKES NO OTHER U.S. and Canadian GHG regulations, Express Warranty VEHICLE EMISSIONS WARRANTIES subject to limitations and conditions RELATING TO THE ORIGINAL contained within the tire manufacturer’s EQUIPMENT TIRES, EXPRESS OR warranty agreement. You are responsible IMPLIED. WHERE PERMITTED BY LAW, for the safe operation and maintenance of Original Equipment Tires PACCAR EXPRESSLY DISCLAIMS ANY the vehicle and its tires. PACCAR does not PACCAR Inc warrants the tires installed as WARRANTY OF MERCHANTABILITY OR warrant wear and tear of the tires. original equipment on this vehicle only FITNESS FOR A PARTICULAR PURPOSE RELATING TO VEHICLE Greenhouse Gas (GHG) against defects in materials and Components Other Than Tires workmanship which cause the vehicle to EMISSIONS. PACCAR AND THE fail to comply with applicable U.S. and SELLING DEALER SHALL NOT BE This GHG vehicle Warranty applies to the Canadian greenhouse gas emission limits LIABLE FOR INCIDENTAL OR vehicle (hereafter, vehicle) certified with the ("Warrantable Emissions Failures"). This CONSEQUENTIAL DAMAGES US Environmental Protection Agency. vehicle emissions limited express warranty INCLUDING, BUT NOT LIMITED TO: 6 LOSS OF INCOME OR LOST PROFITS; Your Warranty Rights and relating to original equipment tires is valid Obligations for two (2) years or 24,000 miles (38,624 VEHICLE DOWNTIME; km), whichever occurs first. YOUR SOLE COMMUNICATION EXPENSES; This vehicle is warranted for components AND EXCLUSIVE REMEDY AGAINST LODGING AND/OR MEAL EXPENSES; that directly impact the manufacturers PACCAR Inc IS LIMITED TO THE REPAIR FINES; APPLICABLE TAXES OR greenhouse gas (GHG) certification with OR REPLACEMENT OF ORIGINAL BUSINESS COSTS OR LOSSES; the US Environmental Protection Agency. EQUIPMENT TIRES, SUBJECT TO ATTORNEY’S FEES; AND ANY LIABILITY PACCAR must warrant these components PACCAR’S TIME AND MILEAGE YOU MAY HAVE IN RESPECT TO ANY for the periods of time listed below LIMITATIONS LISTED ABOVE. This OTHER PERSON OR ENTITY RELATING provided there has been no abuse, neglect Vehicle Emissions Limited Express TO WARRANTABLE EMISSIONS or improper maintenance of the vehicle. If Warranty relating to original equipment FAILURES. This Vehicle Emissions Limited a GHG-related part on your vehicle is tires begins on the date of delivery of the Express Warranty relating to original found to have a defect in material or vehicle to the first purchaser or lessee and equipment tires is limited to emissions assembly, the part will be repaired or accrued time and mileage is calculated compliance only. The tires are separately replaced by PACCAR. when the vehicle is brought in for warranted by their manufacturer for defects

230 Y53-6096-1A1 (01/17) INFORMATION - Vehicle Emissions Limited Express Warranty

Manufacturer's Warranty Coverage component has failed due to abuse, reached for each system. Owner is neglect, improper maintenance, responsible for maintaining all physical This warranty coverage is provided for five unapproved modifications (both physical parts related to GHG-regulations in the as- years or 100,000 miles (160,000) km, components and computer programming) built configuration and in proper working whichever first occurs, from the date of or using non-Original Equipment order for the full regulatory useful life of delivery of the vehicle to the first purchaser replacement parts. If there are any 435,000 miles (700,000 km) for Class 8 or first lessee. Where a Warrantable questions regarding these warranty rights vehicles, 185,000 miles (300,000 km) for Condition exists, PACCAR will diagnose and responsibilities, please contact the Class 6-7, and 110,000 miles (177,000 km) and repair the vehicle, parts and labor vehicle OEM manufacturer at the customer for Class 5. included, at no cost to the first purchaser or center telephone number provided with the first lessee and each subsequent vehicle operating instructions. Prior to the Replacement Parts purchaser or lessee. This warranty does expiration of the applicable warranty, not override any extended warranty PACCAR recommends that any service Owner must give notice of any warranted purchased to cover specific vehicle parts used for maintenance, repair or failure to an authorized PACCAR dealer components. replacement of GHG components be new and deliver the vehicle to such facility for or genuine approved rebuilt parts and Owner's Warranty Responsibilities repair. Owner is responsible for incidental assemblies. The use of non-genuine costs such as: communication expenses, engine or vehicle replacement parts that 6 The vehicle owner is responsible for meals, lodging incurred by Owner or are not equivalent to the PACCAR engine performing required maintenance that is employees of Owner as a result of a or OEM vehicle manufacturer’s original listed in your engine and vehicle Warrantable Condition. Owner is part specification as built from the factory Operator’s Manuals. The owner is responsible for downtime expenses, cargo may impair the engine and vehicle responsible for presenting the vehicle to a damage, fines, all applicable taxes, all emissions control system from working or service location as soon as a problem business costs, and other losses resulting functioning effectively, and may jeopardize exists. Any warranty repairs should be from a Warrantable Condition. Owner is your GHG warranty coverage. In addition, completed in a reasonable amount of time. responsible for maintaining all emissions genuine vehicle or engine parts must be Retain all receipts covering maintenance related engine and vehicle computer replaced with the same material and on this equipment. PACCAR cannot deny program settings in accordance with function as the part assembled on the warranty solely for the lack of receipts or manufacturer specifications. This vehicle from the factory. The owner may for the failure to ensure the performance of responsibility includes GHG specific elect to have maintenance, replacement or all scheduled maintenance. PACCAR may settings that may not be altered before the repair of the emission control parts deny warranty coverage if a vehicle GHG-related expiration mileage has been performed by a facility other than an

Y53-6096-1A1 (01/17) 231 INFORMATION - Vehicle Emissions Limited Express Warranty

authorized PACCAR dealer and may elect from the purchase and use of this vehicle This warranty is void if the vehicle is to use parts other than new or genuine is limited to the repair or replacement of altered with parts that do not meet the approved rebuilt parts and assemblies for "warrantable failures", for replacement material and functional specifications as such maintenance, replacement or repair; parts that are similar in material and manufactured from the factory. Any however, the cost of such service or parts function to OEM specifications and subject alterations to vehicle or engine computer and subsequent failures resulting from to PACCAR’s time, mileage, and hour settings will void GHG warranty and such service or parts may not be fully limitations of the greenhouse gas warranty. potentially cause the vehicle to become warranted if the manufacturer determines The maximum time, mileage and hour non-compliant with the GHG regulation of that the replacement part is not of similar limitations of the warranty begin with the the EPA Clean Air Act. Any alterations to material and function as the OEM part Date of Delivery to the first purchaser or GHG specific settings prior to the GHG assembled to the vehicle at the factory. first lessee. The accrued time, mileage, or related expiration mileage for each system hours is calculated when the vehicle is will void GHG warranty and potentially PACCAR Responsibilities brought in for correction of warrantable cause the vehicle to become non- The warranty coverage begins when the failures. PACCAR is not responsible for compliant with the GHG regulation of the vehicle is delivered to the first purchaser or failures or damage resulting from what EPA Clean Air Act. This warranty is void if first lessee. Repairs and service will be PACCAR determines to be abuse, neglect certain GHG components are not properly 6 performed by any authorized PACCAR or uncontrollable acts of nature, including, maintained and thus cannot perform to dealer using new or genuine approved but not limited to: damage due to accident; their designed capability. PACCAR is not rebuilt parts and assemblies PACCAR will operation without adequate coolants or responsible for failures resulting from utilize replacement parts that are selected lubricants; overfueling; overspeeding; lack improper repair or the use of parts which and installed to support the GHG of maintenance of cooling, lubricating or are not genuine approved parts. PACCAR compliance certification. PACCAR will intake systems; improper storage, starting, is not responsible for the material and labor repair parts found by PACCAR to be warm-up, run-in or shutdown practices; costs of emission control parts and defective without charge for parts or labor unauthorized modifications to the vehicle assemblies replaced during Scheduled (including diagnosis which results in and its components. PACCAR is also not Maintenance of the engine as specified in determination that there has been a failure responsible for failures caused by incorrect PACCAR Operator’s Manuals. THIS of a warranted part). oil, fuel or diesel exhaust fluid or by water, WARRANTY, TOGETHER WITH THE dirt or other contaminants in the fuel, oil or EXPRESS COMMERCIAL WARRANTIES Warranty Limitations diesel exhaust fluid. Failure of replacement ARE THE SOLE WARRANTIES MADE BY Sole and exclusive remedy against parts used in repairs due to the above non- PACCAR IN REGARD TO THIS VEHICLE. PACCAR and the Selling Dealer arising warrantable conditions is not warrantable. THIS LIMITED GHG WARRANTY IS THE

232 Y53-6096-1A1 (01/17) INFORMATION - Vehicle Emissions Limited Express Warranty

SOLE WARRANTY MADE BY PACCAR Greenhouse Gas Certification Label on AND THE SELLING DEALER. EXCEPT page 229 FOR THE ABOVE LIMITED WARRANTY, PACCAR AND THE SELLING DEALER MAKE NO OTHER WARRANTIES, EXPRESS OR IMPLIED. PACCAR AND THE SELLING DEALER EXPRESSLY DISCLAIM ANY WARRANTY OF MERCHANTABILITY OR WARRANTY OF FITNESS FOR A PARTICULAR PURPOSE. PACCAR AND THE SELLING DEALER SHALL NOT BE LIABLE FOR INCIDENTAL OR CONSEQUENTIAL DAMAGES INCLUDING, BUT NOT LIMITED TO: LOSS OF INCOME OR LOST PROFITS; ENGINE OR VEHICLE DOWNTIME; THIRD PARTY DAMAGE, 6 INCLUDING DAMAGE OR LOSS TO OTHER ENGINES, VEHICLES OR PROPERTY, ATTACHMENTS, TRAILERS AND CARGO; LOSS OR DAMAGE TO PERSONAL CONTENTS; COMMUNICATION EXPENSES; LODGING AND/OR MEAL EXPENSES; FINES; APPLICABLE TAXES OR BUSINESS COSTS OR LOSSES; ATTORNEYS’ FEES; AND ANY LIABILITY YOU MAY HAVE IN RESPECT TO ANY OTHER PERSON OR ENTITY. See Also

Y53-6096-1A1 (01/17) 233 INFORMATION - Vehicle Emissions Limited Express Warranty

6

234 Y53-6096-1A1 (01/17) Index

Index

A Brakes, Trailer Anti-Lock Brake System 59

Aftertreatment System 123 C Aiming Headlights 179 Air Cleaners 191 Cab 15–17 Air Conditioner 77, 78 Cab Access 14 Air Disc Brakes 161 Cab Maintenance 165 Air Filter 191 Care of Display Screens on the Dashboard 168 Air Filter Restricton 63 Check Engine Oil Level 187 Air Intake System 190 Clutch 212 Air Tanks 158 Clutch Linkage 212 Altering the Electrical System 181 Clutch Pedal 212 Alternator 186 Coolant 171 Auto Slack Adjuster 162 Coolant Fill 171 Automatic Slack Adjuster Stroke Specification 164 Coolant Surge Tank 171 Axle, Traction Control 57, 58, 107 Cooling system maintenance 168 See also ATC Cooling System Overheating 31 AxleAuxiliary 117 Cranking Battery Specification 184 AxleDiff Lock 114 Cruise ControlCancel 102 AxleDifferential Lock 114 Cruise ControlChange Set Speed 102 AxleDual Range 115 Cruise ControlResume Set Speed 102 AxlePusher Tag 117 Cruise ControlSet Speed 102 AxleTwo Speed 115 Cruise ControlStandard 101 B D

Batteries 181 Daily Checks 26 BatteryJump start 34 Dash Switch 74 ® Bendix AD-IS Series Air Dryer 157 Diesel Exhaust Fluid (DEF) 68 Brake System 160 Diesel Exhaust Fluid (DEF) Lamp 61 Brake, Park Brake 59 Diesel Particulate Filter (DPF) Warning Lamp 61 Brake, ParkingManual release 38 Drive Axle Temperature 59 Brakes, Anit-Lock Brake System 59 Driver Information Display 68 Index

Drum Brake Inspection 162 Fuse box label 179 FuseInspect and replace 33 FuseLocation 34, 36 E

Electrical System 176 G Emissions 123 Emissions, High Exhaust System Temperature 60 General Safety Instructions 9 Emissions, Malfunction Indicator Lamp 60 Greenhouse Gas Certified Tires 209 Engine - Coolant Temperature 66 Guide to the Warning Symbols 55 Engine Fan 189 Engine is overheating 31 Engine Maintenance 186 H Engine Mounting 191 Engine Oil Temperature 62 Headlight 74 Engine, Check Engine 62 Heater and Air Conditioner Maintenance 196 Engine, Low Coolant Level 62 High Beam 75 Engine, Oil Pressure 62, 67 High Beam Flash 75 Engine, Overspeed Air Shutdown 63 How to Add Coolant to the Cooling System 172 Engine, Retarder (Brake) 63 How to Check for Air System Leaks 159 Engine, Stop Engine 63 How to inspect brake pads on disc brakes 161 Engine, Wait To Start 63 How to Replace Air Conditioner Filter 197, 198 Exhaust 123 How to Wash the Exterior of the Vehicle 167 Exhaust System 191 F I Ice 46 Fifth Wheel Bi-Annual Maintenance 193 Ignition timer 70 Fifth Wheel Monthly Maintenance 193 Illustrations 9 Fifth Wheel Slide Switch 87 inside outside engine air intake 87 Fifth Wheel Slide Unlocked Warning 61 Inspect Disc Brake Caliper for Running Clearance 162 Frame 192 Inspect Power Steering Fluid 154 Frame Fastener Torque Requirements 214 Inspecting Noise and Emission Components 200 Free Travel 212 Install Engine Belt 188 Front axle and Suspension 194 Installing Batteries 185 Front Spring Suspension U-Bolts, Grade 8 213 Instrument Cluster 52 Fuel Filter Restricton 64 Fuel Level 66 Fuel System 192 Fuel Water In Fuel (WIF) 64 Index

L R

Lights Marker Clearance 76 Raise 16 Lights, High Beam 64 Rear Axle Alignment 203 Low Air Alarm 30 Rear Axle and Suspension 201 Low Oil Pressure Lamp 31 Rear Axle Lubrication 203 Lower 17 Recovery Hitch 40 Lubricants 153 Recovery hitch capacities 44 Lubrication Specification Chart 216 Recovery hitch How to use tow pin 41 Recovery hitchBest practices 45 Recovery hitchManually lock a differential 42 M Recovery hitchPrepare axles 41 Removing Batteries 185 Mud 46 Returning to Service after Recovering 45 Right Hand Steer 124 Right Hand Steer Operation 74 N Roadside Assistance 30 Noise and Emission Control 199 S Noise Control System - Maintenance Log 219 Safety 7 Safety Alerts 8 O Safety Restraint System - Inspection 173 Sand 46 Oil Level 154 Seat Belt Fasten 64 Sliding Fifth Wheels 193 Slow Battery Charging 185 P Snow 46 Speedometer 65 Pipe and Hose Clamp Torque Values 221 Stability Control 57, 58 power distribution box 179 Steering Gear Lubrication 219 Power Steering Fluid 205 Steering Shaft Bolt Torque Specifications 206 Power Steering Fluid Filter 205 Steering System 204 Power Take Off 100 Stop Engine Lamp 30 PTO 100 Suspension Dump 64 Index

What is an Air Compressor 159 T What is an Air Dryer 156 What is Low Voltage Disconnect 176 Tachometer 66 What is the Air System 155 Tilt 15 What to do before starting the vehicle 23 Tire Inflation 64 Wheel Cap Nut Torque Specifications 215 Tires 207 Wheels 210 Topping Up the Engine Oil 188 Windshield Washer 77 Tow Pin 40 Windshield Wiper 76 Towing the Vehicle 46 Windshield Wiper/Washer 175 Traction Control 91 Windshield Wipers 74 Trailer Hand Brake 77 Transmission, Check 65 Transmission, Oil Temperature High 65 TransmissionMaintenance 211 Turbocharger 190 Turn Signal 74 Turn Signal, Left 65 Turn Signal, Right 65 U

Under hood air intake symbol 87 V

Vehicle Air Pressure 68 Vehicle ID Labels 224 Vehicle is stuck 46 Vehicle Light Bulb specifications 178 Vehicle Loading 24 Vehicle recovery 37 Vehicle stuck 37 Visual inspection while approaching the vehicle 25 W

Weekly Checks 25

Y53-6096-1A1 01/17 Printed in U.S.A. Peterbilt Motors Company, A PACCAR Company, P.O. Box 90208, Denton, Texas 76202