© 2017 PACCAR Inc. - All Rights Reserved This manual illustrates and describes the operation of features or equipment which may be either standard or optional on this vehicle. This manual may also include a description of features and equipment which are no longer available or were not ordered on this vehicle. Please disregard any illustrations or descriptions relating to features or equipment which are not on this vehicle.
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Contents Safety..................................... 1 Emergency..................................... 2 Controls..................................... 3 Driving..................................... 4 Maintenance..................................... 5 Information.....................................
Contents
Chapter 1 | SAFETY In this Chapter: Applies To...............................................................................................................................................7 Using this Manual...................................................................................................................................7 Safety Alerts...........................................................................................................................................8 Illustrations....
SAFETY - 1 Visual inspection while approaching the vehicle.................................................................................. 25 Weekly Checks.....................................................................................................................................25 Daily Checks........................................................................................................................................
SAFETY - Applies To 1 Applies To Using this Manual Y53-6096-1A1 (01/17) Please take the time to get acquainted with your vehicle by reading this Operator’s Manual. We recommend that you read and understand this manual from beginning to end before you operate this equipment. This manual contains useful information for the safe and efficient operation of this equipment.
SAFETY - Safety Alerts information, with an outline for performing safety checks and basic preventive maintenance inspections. We have tried to present the information you’ll need to learn about functions, controls, and operation— and to present it as clearly as possible. We hope you’ll find this manual easy to use. There will be times when you need to take this manual out of the glovebox. When you do, please be sure to return it when you are finished using it.
SAFETY - Illustrations Notes The illustrations are intended to show repair or replacement procedures. The procedure will be the same for all applications, although the illustration may differ. WARNING! Hot engine oil can be dangerous. You could be burned. Let the engine oil cool down before changing it. Failure to comply may result in death, personal injury, equipment or property damage.
SAFETY - General Safety Instructions 1 Keep in mind that even a well maintained vehicle must be operated within the range of its mechanical capabilities and the limits of its load ratings. See the Weight Ratings label on the driver's door edge. Every new vehicle is designed to conform to all Federal Motor Vehicle Safety Standards applicable at the time of manufacture. Even with these safety features, continued safe and reliable operation depends greatly upon regular vehicle maintenance.
SAFETY - General Safety Instructions Inhalation of fumes can cause death or personal injury. To protect the environment, liquid refrigerant systems must be properly emptied and filled using equipment that prevents the release of refrigerant gas. Federal law requires capturing and recycling refrigerant. • When moving or lifting any heavy equipment or parts, make sure to use proper techniques and assistance.
SAFETY - Data Recorder 1 CAUTION Corrosive chemicals can damage the engine. DO NOT use corrosive chemicals on the engine. Failure to comply may result in equipment, or property damage. California Proposition 65 Warning • Diesel engine exhaust and some of its constituents are known to the State of California to cause cancer, birth defects, and other reproductive harm.
SAFETY - A Special Word About Repairs WARNING! WARNING! Diesel engine exhaust and some of its constituents are known to the State of California to cause cancer, birth defects, and other reproductive harm. Other chemicals in this vehicle are also known to the State of California to cause cancer, birth defects or other reproductive harm. This warning requirement is mandated by California law (Proposition 65) and does not result from any change in the manner in which vehicles are manufactured.
SAFETY - Additional Sources of Information 1 Additional Sources of Information Major component suppliers also supply operation manuals specific to their products. Additional manuals and other pieces of literature are included in the glove box literature package. Look for information on products such as the engine, driver's seat, transmission, axles, wheels, tires, ABS/ESC, radio, 5th wheel, lane departure and adaptive cruise control.
SAFETY - Cab Tilting How to lock and unlock the cab doors 1 Cab Tilting Information on locking your vehicle. The vehicle has one key for cab doors, ignition, and the optional sleeper luggage compartment. Frame-mounted tool box locks and locking fuel tank caps each have separate individual keys. WARNING! WARNING! Jumping out of the cab or getting into the cab without proper care is dangerous. You could slip and fall, which could lead to death or personal injury. Keep steps clean.
SAFETY - Cab Tilting 1 WARNING! Tilt the cab by using the equipment provided on the vehicle or by a hoist with sufficient capacity. Tilting the cab with an improvised prop is an unsafe practice. Failure to use the proper cab tilting equipment may lead to death or personal injury. device ensures safety and eliminates danger of mishaps while driving. WARNING! Always ensure the locking safety bar is fully engaged before getting under a fully tilted cab.
SAFETY - Cab Tilting The raised cab with lockbar in place should appear like this when complete. 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.
SAFETY - Standard Seat 1 CAUTION Do not try to pump the cab down or hold it down with hydraulic force. If you do, cab damage will occur. 2. Place the control valve handle in the "Lower" position. The cab should settle down on the rear mounts. 5. Visually inspect the cab latch hooks to ensure they are closed. 6. Ensure that the control valve handle is in the “Lower” position when operating the vehicle. Standard Seat WARNING! Do not adjust the driver's seat while the vehicle is moving.
SAFETY - Standard Seat driving up or down a steep hill or in a sharp curve. Correct Use of Restraint Incorrect Use of Restraint Correct Placement of Lap Belt Lap Belt Too High on the Hip Correct Placement of Shoulder Belt Should Belt Incorrectly Under the Arm 1 Unbelted riders could be thrown into the windshield or other parts of the cab or could be thrown out of the cab. They could strike another person. Injuries can be much worse when riders are unbelted.
SAFETY - Standard Seat 1 Safety Restraint Belt Twisted • • • During Pregnancy Pregnant women should always wear combination lap/shoulder belts. The lap belt portion must be worn snugly and as low as possible across the pelvis. To avoid pressure on the abdomen, the belt must never pass over the waist. A properly worn seat belt may significantly reduce the risks to woman and baby in the event of a crash.
SAFETY - Standard Seat weaken them. Do, however, keep them clean by following the care label on the belts. Let them dry completely before allowing them to retract or be stowed away. • Make sure the seat belts and bunk restraint of the unoccupied passenger seat or bunk is fully wound up on its retractor or is stowed, so that the belt or restraint tongue is in its properly stowed position. This reduces the possibility of the tongue becoming a striking object in case of a sudden stop.
SAFETY - Standard Seat 1 Tether Belts This vehicle may have an external tether belt installed with a seat, instead of the internal tethering device. Tether belts are designed to restrain the seat in the event of a sudden stop or an accident. Internal tether belts do not require adjustment. Make sure that the tether belt is attached to the cab floor and seat frame. It should be routed through the buckle on each side. Often the attachments are made using a split-type hook.
SAFETY - What to do before starting the vehicle What to do before starting the vehicle Checks before you operate your vehicle. Safe Vehicle Operation Be sure to perform pre-trip inspections before starting and operating the vehicle. For your safety, as well as those around you, be a responsible driver: • If you drink alcohol, do not drive. • Do not drive if you are tired, ill, or under emotional stress. Safe driving is only possible with the proper concentration on the driving task.
SAFETY - Vehicle Loading 1 Emergency Equipment It is good practice to carry an emergency equipment kit in your vehicle.
SAFETY - Visual inspection while approaching the vehicle platform, occupants, fuel, and any load. Never exceed the GVWR of your vehicle. GCW GAWR Load Distribution is the actual combined weight, or Gross Combination Weight (GCW), of your vehicle and its load: vehicle, plus trailer(s), plus cargo. is the Gross Axle Weight Rating. This is the total weight that one axle is designed to transmit to the ground. You will find this number listed on the driver's door edge.
SAFETY - Daily Checks 1 Engine • • • • • • Belts Hoses Clamps Radiator Air Cleaner Aftertreatments System Components • Exhaust Pipes • Engine Air Pre-cleaner (Optional) For vocational vehicles with optional engine air pre-cleaner, check the purge valve at the bottom of the hood mounted engine air precleaner for any obstructions. Make sure the purge valve will open and close as needed to purge dirt and water from the engine intake air.
SAFETY - Daily Checks • Suspension Components - check for loose or missing fasteners. Check damage to springs or other suspension parts such as cracks, gouges, distortions, bulges or chafing. • Brake Lines and Hoses - check lines, linkages, chambers, parking and service brake operation. • Air System - What is the Air System? on page 155 • Steps and Grab Handles • Frame Mounted Tanks (Fuel, Diesel Exhaust Fluid, etc) - check underneath the vehicle for signs of fluid leaks.
SAFETY - Daily Checks 1 28 Y53-6096-1A1 (01/17)
Chapter 2 | EMERGENCY In this Chapter: Roadside Assistance............................................................................................................................30 How to Recover a Vehicle....................................................................................................................
EMERGENCY - Roadside Assistance Roadside Assistance 2 Call toll-free to talk to someone at the PACCAR Customer Center. question, they will direct you to a representative who can. Low Air Alarm These are actions that the operator should perform if the low air alarm on the dashboard instrument cluster turns on. 3. Place the transmission in neutral (park with automatic transmissions, if equipped) and set the parking brake. 4. Turn OFF the engine. 5.
EMERGENCY - Roadside Assistance WARNING! This should be considered an emergency. You should stop the vehicle as safely as possible and turn OFF the ignition. The vehicle must be serviced and the problem corrected before driving again. Failure to do so may cause severe engine or Diesel Particulate Filter damage, orcause an accident which may result in death or personal injury.
EMERGENCY - Roadside Assistance 2 If the engine coolant temperature warning lamp comes on and the audible alarm sounds showing an overheat condition, or if you have any other reason to suspect the engine may be overheating, DO NOT TURN OFF THE ENGINE unless a low water warning device indicates a loss of coolant.
EMERGENCY - Roadside Assistance CAUTION If the truck is equipped with power take off (PTO) equipment, the engine shutdown system can be deactivated when the PTO is operational; however, engine idle periods should not exceed five minutes whenever possible. Failure to comply may result in equipment or property damage. 2. Check to ensure the Oil Pressure Gauge reads normal. 3. Make sure the engine fan is turning by switching the Engine Fan Switch from AUTO to MAN (Manual). 4.
EMERGENCY - Roadside Assistance CAUTION 2 Before replacing a fuse, turn OFF all lights and accessories and remove the ignition key to avoid damaging the electrical system. 1. Turn OFF all lights and accessories and remove the ignition key to avoid damaging the electrical system. 2. Determine from the chart on the fuse panel which fuse controls that component. 3. Remove that fuse and see if it is blown. Fuse Puller If it is blown, replace it with a fuse of the same rating.
EMERGENCY - Roadside Assistance WARNING! Never remove or tamper with battery caps. Ignoring this could allow battery acid to contact eyes, skin, fabrics, or painted surfaces. Failure to comply may result in death, personal injury, equipment or property damage. WARNING! Never jump start a battery near fire, flames, or electrical sparks. Batteries generate explosive gases that could explode. Keep sparks, flame, and lighted cigarettes away from batteries.
EMERGENCY - Roadside Assistance have a large red + or P on the battery case, post, or clamp. 2 NOTE Always connect positive (+) to positive (+) and negative (-) to negative (-). 9. Attach the other end of the same cable to the positive (+) terminal of the good (booster) battery. 10. Attach the remaining jumper cable FIRST to the negative (-) terminal (black or N) of the good battery.
EMERGENCY - How to Recover a Vehicle How to Recover a Vehicle Follow these steps to properly recover a vehicle from a situation where the vehicle is unable to move on its own. CAUTION Connect recovery rigging only to hitches intended for that purpose. Do not attach to bumpers or brackets. Use only equipment designed for this purpose. Failure to comply may result in equipment damage. CAUTION Remove the drive axle shafts or lift the driving wheels off the ground before towing the vehicle.
EMERGENCY - How to Recover a Vehicle 5. 2 6. 7. 8. the Best Practices for Recovery Rigging? on page 45. Make sure the recovered vehicle's parking brakes are released. See Manually Release the Parking Brake on page 38. If you desire to use the recovered vehicle’s brakes, ensure that the vehicle’s air system is connected to that of the recovery vehicle.
EMERGENCY - How to Recover a Vehicle WARNING! 2 Do not disassemble a spring brake chamber. These chambers contain a powerful spring that is compressed. Sudden release of this spring may result in death or personal injury. WARNING! Releasing the spring brakes on an unsecured vehicle could lead to an accident. The vehicle could roll, which may result in death, personal injury, equipment or property damage.
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 sure the push rod (adapter push rod or service push rod) is retracting. Do not over-torque the release stud assembly. (S-Cam type maximum: 50 lb-ft, Wedge type maximum: 30 lb-ft). The spring brake is now mechanically released.
EMERGENCY - How to Recover a Vehicle WARNING! Do not use parts from other trucks or materials from other sources to repair a hitch or to replace a missing hitch. The parts provided for recovery are made of high strength materials and are specifically designed for vehicle recovery. Failure to use the correct factory equipment may result in an accident involving death or personal injury. CAUTION Connect recovery rigging only to hitches intended for that purpose. Do not attach to bumpers or brackets.
EMERGENCY - How to Recover a Vehicle WARNING! 2 An open air line on the recovered vehicle will cause a leak in the air system of the recovery vehicle if both vehicles’ brake systems are connected. This could cause a loss of system air, which can cause the service brakes not to function, resulting in the sudden application of the spring brakes causing wheel lock-up, loss of control, or overtake by following vehicles. You could be in an accident involving death or personal injury.
EMERGENCY - How to Recover a Vehicle CAUTION A recovered vehicle will have no operational brake system. Additionally, the rear axle spring brakes will probably be applied. • If you don’t desire to use the recovered vehicle’s brakes, ensure that you cage the spring brakes before attempting to move the vehicle. 2 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.
EMERGENCY - How to Recover a Vehicle Recovery Hitch Capacities 2 The maximum rated loads for vehicle recovery varies depending on the direction or angle of pull. These capacities are listed in the table below and are for the two hitches working together, simultaneously.
EMERGENCY - How to Recover a Vehicle What are the Best Practices for Recovery Rigging? Use these guidelines when recovering a vehicle with rigging and hitches. CAUTION Recovery pull maximums assume the tow rigging evenly distributes the load between both recovery hitches. See examples in Recovery Rigging for details. Serious damage to the vehicle may occur if rigging is not connected properly. CAUTION When recovering ditched or bogged vehicles, stay well below Maximum Capacities.
EMERGENCY - How to Recover a Vehicle What to do if the Vehicle is Stuck in Sand, Mud, Snow or Ice 2 WARNING! Do not spin the wheels faster than 35 mph (55 km/h). Spinning a tire at speedometer readings faster than 35 mph (55 km/h) can be dangerous. Tires can explode from spinning too fast. Under some conditions, a tire may be spinning at a speed twice that shown on the speedometer.
EMERGENCY - How to Recover a Vehicle WARNING! 2 Secure the roof, side and chassis fairings while towing from the rear. An unsecured fairing may come off of the vehicle during transit. Failure to secure the fairings while towing may cause an injury accident resulting in death or personal injury.
EMERGENCY - How to Recover a Vehicle 2 48 Y53-6096-1A1 (01/17)
Chapter 3 | CONTROLS In this Chapter: Getting to Know the Dash.................................................................................................................... 52 Gauges in the Center Cluster...............................................................................................................54 Left Hand Accessories Overhead........................................................................................................
CONTROLS - Information Display.............................................................................................................................. 69 Virtual Gauges......................................................................................................................................69 Engine Speed RPM Detail................................................................................................................... 70 Ignition Timer............................................
CONTROLS - Operate the Windshield Wipers........................................................................................................... 76 How to Spray Windshield Washer Fluid............................................................................................... 77 Trailer Brake Hand Valve..................................................................................................................... 77 Heating and Air Conditioning....................................................
CONTROLS - Getting to Know the Dash Getting to Know the Dash steer, dual sit and dual steer and right hand stand up configuration. Cab interior dashboard overview for Low Cab Forward applications with left hand 3 1. 2. 3. 4. 5.
CONTROLS - Getting to Know the Dash 6. Left Hand Side Electronic Switches 7. Arm Rest, Storage (Optional) Right Hand Stand Up Cab Station 1 2 3 Left Hand Drive Station 4 Right Hand Dual Drive Dual Sit Station Right Hand (Curb) Side Instrument Cluster for Dual Sit and Steer Applications 5 6 7 8 9 10 11 12 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12.
CONTROLS - Gauges in the Center Cluster Right Hand Standup Drive Station Right Hand (Curb) Side Instrument Cluster for Stand Up Applications 1 3 2 3 4 sequence. The total sequence should only take no more than 10 seconds to complete. Completing this sequence will indicate a successful Self Test. Have your instrumentation system checked by a qualified service technician if does not successfully complete.
CONTROLS - Left Hand Accessories Overhead Right Hand Overhead Acessories Left Hand Accessories Overhead These accessories are located in the left hand side overhead compartment of the low cab forward application. Left Hand Overhead Acessories 1. Radio 2. Air Conditioner 3. Map Light Right Hand Accessories Overhead for Dual Sit Steer Applications These accessories are located in the right hand side overhead compartment of the low cab forward application and dual sit and steer configuration.
CONTROLS - Guide to the Warning Symbols Symbol Name 3 56 Color Standard or Optional Axle, Stability Control Yellow OPT Axles, Traction Control Yellow OPT 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
CONTROLS - Guide to the Warning Symbols Symbol Name Color Standard or Optional Engine, Retarder (Brake) Yellow OPT Engine, Stop Engine Red STD Engine, Wait To Start Yellow OPT Fifth wheel, Slide Unlocked Red STD 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 OP
CONTROLS - Guide to the Warning Symbols • Illuminates during the power-on selftest when the ignition is turned ON. It turns off after a few seconds if no system problems are detected. If an ATC problem is detected, the ATC warning lamp will turn on and stay on. • Illuminates when the ATC is regulating wheel spin and turns off after the traction control event has ended. • Flashes continuously when the ATC/ Deep Snow & Mud switch is turned on, indicating that this feature is active.
CONTROLS - Guide to the Warning Symbols NOTE For more information about the stability control system installed on your vehicle, please refer to additional material supplied with this operator manual, included in your glove box informational packet. Axle, Front Driven This icon will appear when the front driven axle is engaged. Axle, Oil Temperature (Forward or Rear) axle and type of lubricant. Very high temperatures signal a need to have your axle(s) lubrication checked.
CONTROLS - Guide to the Warning Symbols Illuminates during normal operating conditions to indicate a problem with the Trailer ABS System. This should be checked by an authorized dealer as soon as possible. 3 NOTE Tractors/Trucks and trailers built after 03/01/2001 must be able to turn on an InCab Trailer ABS Warning Lamp (per U.S. FMVSS121). The industry chose Power Line Communication (PLC) as the standard method to turn it on.
CONTROLS - Guide to the Warning Symbols Emissions, Engine Derate The aftertreatment system requires attention and as a result is derating the output of the engine. Diesel Exhaust Fluid (DEF) Gauge Engine aftertreatment system includes a diesel particulate filter and DPF warning lamp. 3 Diesel Exhaust Fluid (DEF) Lamp The operator should perform a stationary regeneration of the DPF and check the DEF fluid level. Seek service at the next available opportunity if the warning icon stays on.
CONTROLS - Guide to the Warning Symbols This icon will appear when the switch is in the UNLOCKED position. Engine, Check Engine Engine, Coolant Temperature Engine, Oil Pressure This warning will appear when the engine coolant temperature has reached a value that needs attention. If oil pressure drops below the minimum psi a red warning light in the gauge will turn on, the Stop Engine light will come on and an audible alarm tone will sound.
CONTROLS - Guide to the Warning Symbols Low Oil Pressure Lamp on page 31 Check Engine Oil Level on page 187 switch is turned on. (Engine retarders are an option.) Voltmeter Engine, Stop Engine Engine, Wait To Start This warning icon will appear when the system needs some time before attempting 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.
CONTROLS - Guide to the Warning Symbols CAUTION Continued operation with the Air Filter Restriction Gauge reading 25 in. H2O may cause damage to the engine. Inspect the filter and replace if necessary. Holes in the paper element render an air cleaner useless and may cause the Air Filter Restriction Gauge to give a false reading, even if the element is clogged. Replace the element if it is damaged. 3 engine. Consult the engine manufactures manual or engine dealer for fuel restriction specifications.
CONTROLS - Introduction Illuminates when tire pressures need to be checked. (Tire Pressure Monitoring System is an optIion.) Transmission, Oil Temperature High On the pages that follow you will find descriptions of some of the gauges on your instrument panel. Transmission, Check Illuminates when the oil in the main transmission becomes too hot. Illuminates when transmission has recorded a fault code. This icon may also appear in the Transmission Display menu of the Driver Performance Center.
CONTROLS - Tachometer Tachometer Engine speed information. 3 The Tachometer measures the engine speed in revolutions per minute (rpm). The rpm detail is also available as a viewable screen in the instrumentation cluster as a virtual gauge. The tachometer is a useful gauge when attempting to drive efficiently. It will let you match driving speed and gear selection to the operating range of your engine. If the engine speed gets too high, you can select a higher gear to lower the rpm's.
CONTROLS - Engine, Oil Pressure WARNING! Diesel fuel in the presence of an ignition source could cause an explosion. A mixture of gasoline or alcohol with diesel fuel increases this risk of explosion. Do not remove a fuel tank cap near an open flame. Use only the fuel and/or additives recommended for your engine. Failure to comply may result in death, personal injury, equipment or property damage. CAUTION Use only Ultra Low Sulfur Diesel (ULSD) Fuel, as recommended by engine manufacturers.
CONTROLS - Diesel Exhaust Fluid (DEF) Diesel Exhaust Fluid (DEF) 3 The diesel exhaust fluid gauge shows the approximate amount of DEF fluid in the DEF tank. Each gauge indicates the amount of air pressure in each system in pounds per square inch (psi). On vehicles equipped with metric air pressure gauges, the gauge face plate includes a kPa (major) scale and psi (minor) scale. NOTE CAUTION Use Diesel Exhaust Fluid only. Failure to do so may damage components of the Diesel Particulate Filter (DPF).
CONTROLS - Information Display done by navigating the menu via the Menu Control Switch. Information Display The Driver Information Display is located at the top of the instrument cluster. 4. Clock alarm sounds 5. Driver or passenger door is opened 6. Hazard warning lamp switch is on The various functions may be accessed by navigating through Menu Screens using the MCS. The bullets in the Menu Bar allow access to each item by pushing the MCS when the desired bullet is highlighted. WARNING! 1.
CONTROLS - Engine Speed RPM Detail 3 Engine Speed RPM Detail RPM reading of actual engine RPM (Accessible while parked or driving). This function allows the driver to set a timer to shut off the truck. After the timer is set, the ignition key may be turned to the off position and removed. The engine will continue to run for the programmed time. The ignition timer may be set for up to 30 minutes. Trip Information Engine RPM between the chevron markers indicates efficient engine operating conditions.
CONTROLS - Truck Information While moving, this menu will only display instantaneous fuel economy. Engine Make Model Engine Controller Software Version Governed Speed Limit 3 Engine Power Transmission Make Model Truck Information This menu provides information about the vehicle such as serial numbers.
CONTROLS - Active Warnings screen they are in. (Does not indicate a fault code.) To turn alarm ON/OFF: Clock This information is accessible when the vehicle is parked or driving. 3 This information is available for Automated Transmissions and is accessible when the vehicle is parked or driving. Refer to the Automated Transmission Operator’s Manual for additional information. Active Warnings This information is accessible when the vehicle is parked or driving.
CONTROLS - Menu Control Switch 4. Rotate the MCS knob to change the minutes. Scrolling above “59” or below “ 00” will increment or decrement the hour, respectively. 5. Press the button above the MCS to return to the settings menu. How to Set Units of Measure 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 "Language". 2. Press the MCS. 3. Rotate the MCS to display either English, Spanish or French. 4.
CONTROLS - Dual Station Switch 3. Station Selector (for Dual Steer Applications) 4. Fog Lights 5. Mirror Control 6. Cab Lighting Dimmer Control 7. Differential Lock 8. Differential Lock 9. Lift Axle 10. Lift Axle 11. Lift Axle 3 Dual Station Switch side of the cab cannot be used when right hand operation is in effect. Vehicle operation will revert back to the left hand drive position when the ignition is turned to the OFF position.
CONTROLS - How to Turn on High Beams 2. Release the signal stalk 3. The turn signal will cancel when the turn is complete. Each time the turn indicator is activated the audible warning emits a short beep. How to Turn on High Beams How to Momentarily Flash High Beams The high beam function is operated by the same steering column lever for the turn signals. High beams will not turn on if the headlights are turned off.
CONTROLS - How to Flash Marker and Clearance Lights NOTE The “flash to pass” functionality of the headlight switch is not available for vehicles manufactured with High Intensity Discharge (HID) headlamps. Please check with local regulations regarding restrictions on using high beam flashing. 3 NOTE Continued pressing of the high beam flash will not keep the high beams on.
CONTROLS - How to Spray Windshield Washer Fluid How to Spray Windshield Washer Fluid This vehicle is equipped with a functrion to wash the windshield and simulatenously engage the wipers. CAUTION If the electric pump is operated for a long period (more than 15 seconds) with a dry reservoir, the pump motor may be damaged. If you need to use the windshield wipers washer: 1. Push the outer knob in. • Press and hold will activate the washer fluid and wipers.
CONTROLS - Air Conditioner Control Panel WARNING! Exhaust fumes from the engine contain carbon monoxide, a colorless and odorless gas. Do not breathe the engine exhaust gas. A poorly maintained, damaged or corroded exhaust system can allow carbon monoxide to enter the cab. Entry of carbon monoxide into the cab is also possible from other vehicles nearby. Failure to properly maintain your vehicle could cause carbon monoxide to enter the cab, resulting in death or personal injury.
CONTROLS - Air Conditioner Control Panel Symbols for the air conditioning control panel Image Function 3 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. 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.
CONTROLS - How to Manually Control the Air Conditioner for the Cab How to Manually Control the Air Conditioner for the Cab 3 Information on controls to set cab heating and air conditioning. Temperature Control Set Point Air Conditioner Button 80 The cab temperature is set using the temperature control dial. The operating range is 60°F (16°C) and 84°F (28°C). Adjustments of 2° increments. The button inside the temperature control dial engages the A/C compressor.
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 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
CONTROLS - Dash Switches Title 3 82 Color Standard or Optional Engine, Overspeed Air Shutdown (Test) Amber OPT Engine, Overspeed Air Shutdown (Manual) None OPT Engine, Remote Throttle Amber OPT 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,
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 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
CONTROLS - Dash Switches Title 3 Color Standard or Optional Trailer, Belly Dump Gate Rear Red OPT Trailer, Dump Gate Red OPT Trailer, Hotline Green OPT 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 Diff Lock.
CONTROLS - Dash Switches Axle, Inter-Axle Differential Locked (Tandem) differential. In addition, a vehicle with Tridrive will have an interaxle differential lock switch. See Also Axle, Inter-Axle Differential Locked (Tandem) on page 85 Turn switch on to engage Inter-Axle Differential Lock. If your vehicle is equipped with a Low Voltage Disconnect (LVD) feature, the LVD is integrated into the main load center. Brakes, ABS Off-Road 3 Axle, Two Speed Turn switch on to engage ABS Off-Road mode.
CONTROLS - Dash Switches Cab Dimmer Switch 3 This switch is used to alter the brightness of the instrument panel lights. NOTE The Headlamp Switch is an ON or OFF switch. The panel lights are on full intensity during the day and go to Dimmer mode when headlamps are on. Engine, Brake On/Off Engine, Cruise Control Set/Resume Turn switch on to activate Engine Brake system.
CONTROLS - Dash Switches Engine, Heater Engine, Overspeed Air Shutdown (Test) Only operate the under hood intake air switch when outside temperatures are below 32° F (0° C). Engaging the under hood air intake while temperatures are above freezing may result in engine damage. Turn switch on to activate the Engine Heater. Engine, Remote Throttle Turn switch on to activate Remote Throttle Control. Engine, Overspeed Air Shutdown (Manual) Turn switch on to engage the Engine Overspeed Air Shutdown system.
CONTROLS - Dash Switches Turn switch on to “Unlock” Fifth Wheel Slide mechanism. The switch is guarded to protect you from accidentally activating or releasing the lock. Fuel Heater Ignition Key Switch The ignition key switch (located to the left of the steering column) has four positions: ACC (Accessories), OFF, ON, and START. WARNING! 3 Do not move the fifth wheel while the tractor-trailer is in motion. Your load could shift suddenly, causing you to lose control of the vehicle.
CONTROLS - Dash Switches Lights, Daytime Running (Override) headlights operate normally. Also, during engine cranking the DRL is temporarily turned off. Lights, Dome This switch overrides the normal operation 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 brakes are dissengaged. The override switch will turn the DRL off in these instances.
CONTROLS - Dash Switches Lights, Hazard 3 This switch operates the emergency flashers. With the switch in the ON position, the emergency flasher makes all four turn signals (front and rear) flash simultaneously. The flasher works independently of the ignition switch. You should always use the flasher if the vehicle is disabled or parked under emergency conditions. WARNING! Use your Hazard Warning Light System any time you have to stop off the road or on the side of the road, day or night.
CONTROLS - Dash Switches Lights, Park Light Momentarily push switch in to engage Traction Control (TC). switch) will go out immediately even though PTO disengagement may not have occurred. Pintle Hook NOTE Lights, Spot 3 Actual PTO engagement/disengagement may be delayed momentarily since it is controlled by the air system and mechanical movement. Turn switch on for Park Lights. When the Park Lights are on the dash lights, side and tail lights are also on.
CONTROLS - Dash Switches Power Take-off (PTO), Rear 3 Your vehicle may be equipped with a dash mounted switch that controls the rear PTO engagement/disengagement. Suspension, Axle, Pusher Suspension, Dump Suspension, Air Retention Turn switch on to deflate suspension air bags. The switch is guarded to protect you from accidentally deflating the suspension. Suspension, Third Axle Lift WARNING! Turn switch on to lower Single or Forward Pusher Axle.
CONTROLS - Dash Switches Trailer, Axle Lift Forward Turn switch on to open Trailer Dump Gate. Turn switch on to lift Forward Trailer Axle. Trailer, Belly Dump Gate Center Turn switch on to open Trailer Rear Belly Dump Gate. 3 Trailer, Hotline Trailer, Axle Lift Rear Turn switch on to lift Rear Trailer Axle. Turn switch on to open Trailer Center Belly Dump Gate. Trailer, Belly Dump Trailer, Belly Dump Gate Front Turn switch on to open Trailer Belly Dump.
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.
Chapter 4 | DRIVING In this Chapter: Starting and Operating......................................................................................................................... 96 How to Use Engine Start Switch on Right Hand Drive.........................................................................96 Starting and Warming Up..................................................................................................................... 96 Engine Operations.........................................
DRIVING - Starting and Operating Starting and Operating 4 Since each vehicle is custom-equipped, all engine operation instructions in this manual are general. You will want to consult the manual for your engine to find out details about your specific engine’s needs. You may need to use a slightly different procedure from the one outlined here. NOTE 1. Press and hold ENGINE START when using the right hand drive position to start the engine. 2.
DRIVING - Starting and Warming Up the engine still won’t start after a couple of tries, check the fuel lines for possible fuel starvation or air leaks. Starting failure may mean fuel isn’t reaching the injectors. 6. As soon as the engine starts, begin to watch the oil pressure gauge. Check your engine manufacturer’s manual for the right pressure for your engine. If the oil pressure doesn’t rise within a few seconds, stop the engine. Find out what is wrong before restarting the engine. 7.
DRIVING - Starting and Warming Up Engine Warm Up The purpose of engine warm-up is to allow oil film to be established between pistons and liners, shafts and bearings while your engine gradually reaches operating temperature. 1. After you’ve started your engine, idle it at approximately 600 rpm while you check: 4 a. oil pressure b. air pressure c. alternator output 2. After a few minutes of idling at 600 rpm, increase your idle speed to 900 or 1,000 rpm. Continue your warm-up.
DRIVING - Starting and Warming Up WARNING! To reduce the chance of personal injury, vehicle damage and/or death from overheated engines, which can result in a fire, never leave the engine idling without an alert driver present. If the engine should overheat, as indicated by the engine coolant temperature light, immediate action is required to correct the condition. Continued unattended operation of the engine, even for a short time, may result in serious engine damage or a fire.
DRIVING - Engine Operations Engine Operations Stationary Power Take Off Operation 4 The cruise control buttons for this vehicle may be used to control the engine rpm when the vehicle is stationary and the operator wants to use the Power Take Off (PTO) on the engine. Use the cruise control options in the same manner as with the vehicle in motion, but instead of setting vehicle speed, the engine speed (rpm) is set instead. 1. Ensure parking brakes are applied. 2. Ensure transmission is in Neutral. 3.
DRIVING - Engine Operations radiator to increase cab heater temperature in cold climates. CAUTION The use of a winterfront can result in excessive engine coolant, oil, and charge air (intake) temperatures, which can lead to overheating and possible engine damage. CAUTION Engine Control Display Your vehicle may come with an optional Engine and Driver Information Display. This instrument records information on engine diagnostics, scheduled maintenance, driving conditions, and general trip information.
DRIVING - Engine Operations pressed since the vehicle has been started. In vehicles with Eaton transmissions, the cruise control switches may be located on the shift control knob. How to Use Set Cruise Control Speed When Driving Information on using the cruise control. 4 This vehicle may have cruise control switches located on the steering wheel instead of the switches on the dash board. The instructions are still the same. these instructions do not apply to Adaptive Cruise Control.
DRIVING - Transmission When turning the system off, the previous set speed is removed from memory. The operator will have to manually reset the cruise speed. Transmission How to Use the Hyrdaulic Clutch Certain vehicles have a hydraulic clutch to shift a manual transmission. CAUTION Be careful not to apply the clutch brake while the vehicle is moving. The purpose of the clutch brake is to stop the transmission so that you can shift into a starting gear without grinding gears.
DRIVING - Transmission oil and air pressure are correct and all other parts and systems are in proper working condition: 1. For vehicles with a clutch pedal, locate the clutch pedal and engage the clutch brake. 2. Shift into a low gear. 4 CAUTION Always use first gear or a low speed range to start the vehicle in motion. The use of a higher gear or speed range forces undue strain on the engine, clutch, other transmission components, and may cause damage. 3.
DRIVING - Transmission How to Shift using Double Clutch Method Whether you are upshifting or down shifting, it is best to double clutch. Double clutching is easier on the transmission and on the engine, helping your vehicle match engine speed with driveline speed and achieving clash-free shifts. To double clutch: 1. Push the clutch pedal down to disengage the clutch. 2. Move the gear shift lever to neutral. 3. Release the pedal to engage the clutch.
DRIVING - Brakes Auxiliary Transmission Information about using the auxiliary transmission. If you have an auxiliary transmission, see your transmission manufacturer’s manual for its proper operation. 4 Brakes Air Brake System This vehicle’s brake system functions with the use of compressed air generated from the engine’s air compressor. The compressed air is stored in various air tanks to ensure that air pressure is available whenever the driver needs it.
DRIVING - Brakes Parking brakes work in reverse action of the regular brakes. When the parking brakes are engaged, air is exhausted from the spring chambers, which allows the spring to engage the brakes. This design also provides a safety function if a brake circuit has a leak and loses air. In such a scenario, the parking brakes will apply. The vehicle’s parking brake controls are the yellow diamond shaped knob on your dash board.
DRIVING - Brakes WARNING! Do not rely on an anti-lock brake system that is functioning improperly. You could lose control of the vehicle resulting in a severe accident, causing death or personal injury. If your ABS lamp goes on while you are driving or stays on after the self-check, your anti-lock system might not be working. The ABS may not function in an emergency. You will still have conventional brakes, but not anti-lock brakes. If the lamp indicates a problem, have the ABS checked.
DRIVING - Brakes Special Trailer ABS (Without PLC) Option If a trailer does not have PLC, but it does have ABS that is powered through an optional second trailer connector (ISO 3731) and that trailer ABS is designed to control the Trailer ABS Warning Lamp in the cab and the vehicle has been ordered with the option to turn on this lamp for these types of trailers, then this lamp will turn on when that trailer ABS has a system problem. This should be checked by a dealer as soon as possible.
DRIVING - Brakes vehicle speed, thereby reducing the tendency to roll over. RSP Example 4 rear axle) situation. Generally, shorter wheelbase vehicles (tractors, for instance) have less natural yaw stability, while longer wheelbase vehicles (straight trucks, for instance) have greater natural yaw stability. Factors that influence yaw stability are: wheelbase, suspension, steering geometry, weight distribution front to rear, and vehicle track width. to spin and jackknife.
DRIVING - Brakes illuminate whenever the ATC system detects drive wheel spin. The lamp will remain illuminated as long as wheel spin is detected and the ATC system is applying the drive wheel brakes or reducing engine torque. Engine torque or vehicle speed should be reduced to eliminate wheel spin and prevent excessive application of the ATC system.
DRIVING - Brakes WARNING! While the off road mode can improve vehicle control and shorten stopping distances, some steering ability may be reduced on certain surfaces resulting from the momentarily sliding tires. Always operate your vehicle at safe operating speeds. Failure to do so may cause you to lose control of the vehicle and could result in an accident or personal injury. 4 modified to allow short periods (0.25 seconds) of locked-wheel cycles.
DRIVING - Brakes deviation between expected and actual yaw rates. • Gusty winds are strong enough to cause significant side forces on the vehicle and any towed vehicles. To maximize the effectiveness of ESC: • Loads must be properly secured and evenly distributed at all times.
DRIVING - Axle and Suspension WARNING! Do not use any of the vehicle’s retarders in any situation that requires an immediate stop and/or in situations of poor traction (such as wet, icy or snow covered roads). Trying to use the retarder instead of the service brakes may cause a loss of vehicle control, which may result in an accident involving death or personal injury. 4 WARNING! The service brakes must be used in an emergency. The retarder alone might not stop you fast enough to prevent an accident.
DRIVING - Axle and Suspension switches may be available that can lock the interaxle driveline and/or any combination of the forward rear or rear-rear driving axles. The interaxle differential switch allows each axle to turn independently. In certain situations, engaging the interaxle differential lock relieves stress on the rear axles and reduces tire wear. Engaging this switch will also provide better traction in slippery or loose gravel conditions.
DRIVING - Axle and Suspension WARNING! Never shift the axle when moving downhill. Engine driveline disengagement may occur, eliminating engine retardation and allowing the wheels to spin faster than the current speed of the engine. This may require severe braking to slow the vehicle down and can result in an accident. Failure to comply may result in death, personal injury, equipment or property damage.
DRIVING - Axle and Suspension 3. To make the axle downshift, release and depress the accelerator quickly to increase the engine rpm. The axle will shift to LOW range. 4. You are now in the LOW axle range for rough terrain and heavy loads. Shift the transmission normally to maintain the desired speed. Operation of the auxiliary axles includes the proper maintenance of the system and calibration of its controls.
DRIVING - Axle and Suspension Auxiliary Axle Pressure Regulator Information on using the auxiliary axle pressure regulator. 4 Vehicles with liftable auxiliary axles will have knobs available to adjust the pressure in the auxiliary axle suspension. These knobs are in addition to the tag and pusher axle switches that control the axle position. Adding more pressure to the auxiliary axle will increase the pressure the auxiliary axle pushes down.
DRIVING - Axle and Suspension NOTE Axle Creep ratings MUST NOT be exceeded. CAUTION Always lower the axles as soon as possible after receiving a load. Never exceed 5 miles per hour when driving with a load with the auxiliary axle(s) raised/unloaded. Failure to lower the axle(s) can overload the frame and remaining axles, and could cause equipment damage. CAUTION Do not modify the air system and/or control functionality on a factory installed auxiliary axle(s).
DRIVING - Axle and Suspension obtain the desired load. Once the desired load or load range is achieved, document the pressure-toload ratio or setting for future use. 4 These instructions are general in nature. For more specific instructions, review the pusher or tag suspension manufacturers maintenance manual or contact the nearest authorized dealer. 1. Park loaded vehicle on level surface with wheels blocked. 2. Release vehicles spring brakes.
DRIVING - Axle and Suspension 2. Locate the air suspension ride height valve 3. Ensure that the tractor is fully laden during this procedure. Do not use these procedures on a vehicle that is not laden (bobtail). 4. Ensure the air supply and delivery plumbing of the height control valve is consistent with the following illustrations. 5. Loosen the fasteners mounting a height control valve to its bracket. Y53-6096-1A1 (01/17) 6.
DRIVING - Axle and Suspension Air Ride Height Data These are factory settings for ride height of the rear air suspension. 4 1. Ride Height 2. Centerline of suspension Single Axle Laden Ride Height inches (mm) Air Trac 11.00 (279) Low Air Leaf 6.50 (165) Single Axle UnLaden Ride Height - inches (mm) Air Trac 11.39 (289) Low Air Leaf Built Before April 2004 8.75 (222) Low Air Leaf Built After April 2004 6.75 (171) 122 Tandem Axle Laden Ride Height inches (mm) Air Leaf 11.
DRIVING - Aftertreatment System What to do if an Air Spring Ruptures If an air spring is ruptured, drive the vehicle to a safe stop off the highway to investigate the problem. WARNING! Do not continue to drive with ruptured air springs. The air loss can cause the spring brakes to apply allowing your brakes to drag and burn up the linings, which could lead to an accident causing death or personal injury. Do not continue to operate the vehicle in this condition.
DRIVING - Dual Steer Operation Dual Steer Operation 4 Dual steer vehicles are equipped with dualcontrol electronic shift controls that may have an auto neutral control and a shift shock eliminator feature. Follow the procedures below to operate these types of vehicles. Driving Tips and Techniques This section covers additional driving tips and techniques on how to drive your vehicle more efficiently. Coasting WARNING! 1. Bring the vehicle to a complete stop by using the foot brake pedal 2.
DRIVING - Driving Tips and Techniques NOTE Often these recommendations are secondary to maintaining an adequate and safe speed relative to the surrounding traffic and road conditions. Operate the engine within the optimum engine rpm range and do not allow the rpm's to exceed the maximum governed speed. See your Engine Operation and Maintenance manual for information regarding engine rpm. When the engine is used as a brake to control vehicle speed (e.g.
DRIVING - Stopping the Vehicle • injection nozzles defective or uncalibrated • improperly inflated tires • wheel bearings improperly adjusted • clutch improperly adjusted or worn (slipping) • fuel leaks 4 Wrong driving habits must be corrected and the recommendations on economic driving should be followed.
DRIVING - Stopping the Vehicle Final Stopping Procedures WARNING! Diesel fuel in the presence of an ignition source could cause an explosion. A mixture of gasoline or alcohol with diesel fuel increases this risk of explosion. Do not remove a fuel tank cap near an open flame. Use only the fuel and/or additives recommended for your engine. Failure to comply may result in death, personal injury, equipment or property damage.
DRIVING - Stopping the Vehicle 4 4. Secure the vehicle. Close all the windows and lock all the doors.
Chapter 5 | MAINTENANCE In this Chapter: Maintenance Schedule.......................................................................................................................131 New Vehicle Maintenance Schedule..................................................................................................152 Lubricants...........................................................................................................................................153 Checking Oil Level.......................
MAINTENANCE - Windshield Wiper/Washer.................................................................................................................. 175 Electrical System................................................................................................................................176 Engine Maintenance.......................................................................................................................... 186 Fuel System..................................................
MAINTENANCE - Maintenance Schedule Maintenance Schedule Preventive maintenance program begins with the daily checks. Routine vehicle checks can help avoid many large, expensive, and time consuming repairs. The vehicle will operate better, be safer, and last longer. Neglect of recommended maintenance can void your vehicle’s warranty. Some maintenance operations demand skills and equipment you may not have. For such situations, please take your vehicle to an authorized Service Center.
MAINTENANCE - Maintenance Schedule WARNING! Never start or let the engine run in an enclosed, unventilated area. Exhaust fumes from the engine contain carbon monoxide, a colorless and odorless gas. Carbon monoxide can be fatal if inhaled. Failure to comply may result in death, personal injury, equipment or property damage. 5 The following pages contain a table of maintenance tasks with the related intervals for each task on the right side of the table.
MAINTENANCE - Maintenance Schedule Preventative Maintenance Intervals I A B C D E At first 15,000 mi/24,000 km or at first PM 15,000 mi/24,000 km/ Monthly 30,000 mi/48,000 km 60,000 mi/96,000 km/ 6 Months 120,000 mi/ 192,000 km/ Annually 240,000 mi/ 384,000 km Maintenance Schedule System Frame Component Fifth Wheel Task Check the kingpin lock and plate for wear and function: lubricate (NLGI #2 grease).
MAINTENANCE - Maintenance Schedule System Front Axle Front Axle (Dana) 5 134 Component Task I Total Vehicle Alignment Check and adjust as required. Steering Knuckle Spindles, Thrust Bearings, Kingpins, Drawkeys, Tie Rod Ends, Steering Stops, and Bushings. Inspect for wear and damage and endplay. Shim or replace as required; see Front Axle and Suspension on page 194. Kingpin Bushings, Thrust Bearings, and Tie Rod Ball Ends Lubricate with approved grease.
MAINTENANCE - Maintenance Schedule System Front Suspension Component Task I A B C 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.
MAINTENANCE - Maintenance Schedule System Drive Axle (Dana) Component Axle Housing Task 5 136 A B C Visually inspect for damage or leaks. • Check oil level. Check "cold." Torque the drain plug. • Drain the lubricant while warm. Flush each unit with clean flushing oil. Change the lubricant. Air Shift Unit I Check the lubricant level. D E See manufacturer's service requirements. • Remove the housing cover and drain the lubricant. Wash the parts thoroughly and dry in air.
MAINTENANCE - Maintenance Schedule System Drive Axle (Meritor Line Haul / ON HIGHWAY) Component Axle Housing Task I A B Check the "cold" fill level at the differential carrier plug for a pinion angle of less than 7 degrees, or at the axle bowl plug for a pinion angle of greater than 7 degrees. Tighten the plug to 35-50 lb-ft (47-68 Nm) • Visually inspect for damage or leaks.
MAINTENANCE - Maintenance Schedule System Drive Axle (Meritor City Delivery / OFF HIGHWAY) Component Axle Housing Task Drive Axle (SISU) 138 A Check the "cold" fill level at the differential carrier plug for a pinion angle of less than 7 degrees, or at the axle bowl plug for a pinion angle of greater than 7 degrees. Tighten the plug to 35-50 lb-ft (47-68 Nm) • Visually inspect for damage or leaks. • Drain and replace the lubricant.
MAINTENANCE - Maintenance Schedule System Rear Suspension Drum Brakes (All) Component Task 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.
MAINTENANCE - Maintenance Schedule System Disc Brakes (Bendix®) 5 140 Component Task I A B C Brake Pads Inspect: replace as required. • 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.
MAINTENANCE - Maintenance Schedule System Hub, Drum, and Hubcap Component Task Hubs (non-LMS) Check the bearing endplay and adjust as required; see 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 I A B C D • • Clean the components and check for excessive wear or damage. Change the oil and seal; see Wheels on page 210.
MAINTENANCE - Maintenance Schedule System Main and Auxiliary Transmission Component Main and Auxiliary Transmission and Transfer Case Task Inspect for visible damage, signs of overheating, and leaks. I A • • Check the drain plugs for tightness. 5 Auxiliary Transmission • 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.
MAINTENANCE - Maintenance Schedule System Clutch Cooling Component Task I A B Clutch Hydraulic Fluid Replace fluid and bleed system. Clutch Release Bearing Lubricate. • Inspect and adjust when necessary (no adjustment required for SOLO type clutches) • C 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.
MAINTENANCE - Maintenance Schedule System Tires and Wheels Component Tires 144 Check inflation pressure; see Tires on page 207. I A B C D E Weekly "cold" using calibrated gauge. Inspect for cuts, irregular wear, missing lugs, sidewall damage, etc. • Inspect the wheel disc for any cracks or surface irregularities. Inspect the rim edge and bead seat area for damage. Replace any damaged wheels - DO NOT ATTEMPT TO REPAIR.
MAINTENANCE - Maintenance Schedule System Power Steering Component Task I A B C 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.
MAINTENANCE - Maintenance Schedule System Steering Components 5 Fuel and Tanks Component I A B C Steering Linkage Check all joints for excessive lash: replace as required; 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.
MAINTENANCE - Maintenance Schedule System Driveshafts Component Models SPL-90, 1710 and 1810 Slip Member and Ujoints Task Lubricate * Inspect Model SPL-100 Slip Member and U-joints Models SPL-140XL/ 170XL/250XL Slip Members and U-joints (ON HIGHWAY and LINE HAUL) Models SPL-140XL/ 170XL/250XL Slip Members and U-joints (OFF HIGHWAY and CITY) Lubricate * • C D E • U-joint inspections should be performed every time a vehicle comes in for scheduled maintenance.
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.
MAINTENANCE - Maintenance Schedule System Electrical and Lights Component Task I A B C Headlamps Check the aim and adjust as required. 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.
MAINTENANCE - Maintenance Schedule System Cab Structure, Doors and Hoods Heating and Air Conditioning Component Task I A B C Hood Lubricate the lower hood pivot (only if lube fittings are present). • Hinges and Latch Lubricate with silicone spray. • Body and Cab Holddown Bolts Check the condition and tightness. Air Conditioner Operate the system.
MAINTENANCE - Maintenance Schedule System Aftertreatment System Component Task System Check for leaks and proper support; see Noise and Emission Control on page 199. Diesel Particulate Filter Clean filter. Diesel Exhaust Fluid Tank Inspect the tank, straps, brackets, hoses and fittings for abrasion damage, leaks, tightness and fully engaged connectors. I A B C D E • Refer to the Engine Maintenance Manual. • Diesel Exhaust Fluid Supply Module Replace filter.
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/ Frequency 5 Steering Shaft U-Bolts. (OFF-HIGHWAY) Wheel Mounting First Day First 50-100 mi/ 80-160 km First 500 mi/800 km First 2,000 mi/ 3,218 km • • Front Axle U-Bolt Torque • Charge Air Cooler and Air Intake Pipe Clamps, retorque fasteners.
MAINTENANCE - Lubricants Lubricants In this section you will find the basic information you need to do the routine lubrication your vehicle requires. Of course you will want to schedule service more frequently if you are operating under severe conditions such as extreme heat or cold, with very heavy loads, off-road, etc. For any special service requirements, consult your service manuals and your lubricant supplier.
MAINTENANCE - Checking Oil Level NOTE Use only an exact replacement DPF in exhaust systems. Using a noncompliant DPF as a replacement could violate these standards and also void the emission system’s warranty. with the filler opening. Use care when checking the oil level with a finger. Just because you can reach the oil level with a finger, does not mean the oil level is correct.
MAINTENANCE - What is the Air System? parts in the gear. This could result in worn components. The mixture of two different fluids, although harmless to individual internal components, may initiate a chemical reaction that produces a new compound that will attack seals and other internal components. Do not mix different fluids. What is the Air System? Important safety information about your vehicle's air system.
MAINTENANCE - What is an Air Dryer? WARNING! Completely bypassing a Bendix® ADIS air dryer will bypass the system’s pressure protection valves. This could lead to loss of air pressure or damage to the vehicle’s air system, which could cause an accident involving death or personal injury. Always adhere to the manufacturer’s procedure if it is necessary in an emergency to temporarily bypass an ADIS series air dryer. Failure to comply may result in death, personal injury, equipment or property damage.
MAINTENANCE - What is an Air Dryer? enter the brake system. It provides clean, dry air to the components of the brake system, which increases the life of the system and reduces maintenance costs. NOTE Because no two vehicles operate under identical conditions, maintenance and maintenance intervals will vary. Experience is a valuable guide in determining the best maintenance interval for any one particular operation.
MAINTENANCE - Air Tanks dryer replacement should be made with an identical component. WARNING! Use of an air dryer brand or model that differs from what was originally installed could cause the air system to not perform correctly unless the full air system design is reviewed and modifications are made to comply with Federal Motor Vehicle Safety Standard (FMVSS) 121 Air Brake Systems.
MAINTENANCE - How to Check for Air System Leaks Periodically Clean filter screens ahead of the valves by removing the screens and soaking them in solvent. Blow them dry with pressurized air before reinstalling them. • Maintain the air compressor to prevent excessive oil bypass. • Replace worn seals in valves and air motors as they are needed. Your authorized dealer carries rebuild kits for most units.
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 to maintain for the air compressor: • Inspect compressor air filter element, if so equipped, and replace element if clogged. Check compressor mounting and drive for alignment and belt tension. Adjust if necessary. • Remove compressor discharge valve cap nuts and check for presence of excessive carbon.
MAINTENANCE - Brake System WARNING! Do not use any replacement part in the brake system unless it conforms exactly to original specifications. A nonconforming part in your vehicle's brake system could cause a malfunction resulting in an accident causing death or personal injury. Sizes and types are so related to one another that a seemingly unimportant change in one may result in a change in how well the brakes work for you on the road.
MAINTENANCE - Brake System 3. Looking from the ground up at the bottom of the caliper and rotor, compare the relative position of two notches; one located on the caliper and the other on the carrier. 4. Take a measurement from between these two notches and compare them to the specifications to determine if the pads need to be replaced. 5 Have a qualified mechanic perform a detailed inspection if the notches are not found.
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 specification to determine if the automatic slack adjusters need replacing.
MAINTENANCE - Brake System 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 brakes) 1" - 1 3/4" (25.4-44.
MAINTENANCE - Cab Maintenance Cab Maintenance General recommendations for cleaning the exterior and interior of the cab. Cab exterior and interior components need maintenance to ensure longevity and safe operations. WARNING! Always allow hot surfaces to cool down before attempting to work near them. Failure to comply may result in death or personal injury. WARNING! Handle cleaning agents carefully. Cleaning agents may be poisonous. Keep them out of the reach of children.
MAINTENANCE - Cab Maintenance remover will get rid of heavy deposits of road grime. To prevent spotting, wipe aluminum surfaces dry after washing. • Under corrosive conditions, such as driving on salted roads, clean aluminum parts with steam or high pressure water from a hose. A mild soap solution will help. Rinse thoroughly. 5 To maintain the tailpipe quality finish, wash the tailpipe with a soft cloth, mild soap and water or glass cleaner.
MAINTENANCE - Cab Maintenance formulated for this purpose. Test the cleaner on a hidden place to make sure it does not affect the fabric adversely. Follow the instructions on the container. Other interior surfaces may be cleaned using a mixture of mild soap and lukewarm water or an automotive interior cleaner, used on its intended surface (i.e. use leather conditioner on leather surfaces, etc.).
MAINTENANCE - Cooling System Maintenance before applying the car wash and wax solution. • Do not wash the vehicle in direct sunshine. • Do not spray water directly into the cab vents. 2. Using soapy water, wash the vehicle with a clean soft cloth or a soft brush made for automotive cleaning. • Use cool or warm water and a mild, household type soap. Strong industrial detergents and cleaning agents are not recommended.
MAINTENANCE - Cooling System Maintenance provides freezing and boiling point protection. WARNING! Coolant is toxic. DO NOT get the fluid in eyes. If contact occurs, flood eyes with large amounts of water for 15 minutes. Avoid prolonged or repeated contact with skin. In case of contact, immediately wash skin with soap and water. DO NOT take internally. If swallowed, seek immediate medical attention. DO NOT induce vomiting.
MAINTENANCE - Cooling System Maintenance ELC Condition Below Minimum 5 Recommended Levels Above Maximum Desired ELC/ Water Ratio 0% 10% 15% 20% 25% 30% 35% 40% 45% 50% 55% 60% 65% 70% 75% 80% 85% 90% 100% Freeze Point °F (°C) +32 (0) +25 (-4) +20 (-7) +15 (-9) +10 (-12) +5 (-15) -5 (-21) -12 (-24) -23 (-31) -34 (-37) -50 (-46) -65 (-54) -75 (-59) -84 (-64) -70 (-57) -55 (-48) -43 (-42) -30 (-34) -5 (-21) Coolant Extender blank filter at the interval specified in
MAINTENANCE - Cooling System Maintenance Cooling System Sealing Additives Cooling System Soluble Oils OK OK 1 1 1. Do not use sealing additives. CAUTION The use of sealing additives in the cooling system can cause damage to the engine. Sealing additives can plug various areas of the radiator, EGR system and oil cooler. The plugging of the cooling system can hamper heat transfer, causing internal engine damage. Do not use sealing additives in the cooling system.
MAINTENANCE - Cooling System Maintenance WARNING! Removing the fill cap on a hot engine can cause scalding coolant to spray out and burn you badly. If the engine has been in operation within the previous 30 minutes, be very careful in removing the fill cap. Protect face, hands, and arms against escaping fluid and steam by covering the cap with a large, thick rag. DO NOT try to remove it until the surge tank cools down or if you see any steam or coolant escaping.
MAINTENANCE - Safety Restraint System - Inspection NOTE Do not overfill a cooling system. Excess coolant may result in overflow, loss of antifreeze, and reduced corrosion protection. 1. If your cooling system is built with drain valves in the upper engine coolant pipe, open them before filling the surge tank. 2. Close any open coolant drains in the system. 3. Remove the surge tank fill cap (do not remove the surge tank pressure cap). 4.
MAINTENANCE - Safety Restraint System - Inspection WARNING! It is important to remember that any time a vehicle is involved in an accident, the entire seat belt system must be replaced. Unexposed damage caused by the stress of an accident could prevent the system from functioning properly the next time it is needed. Failure to comply may result in death or personal injury. 5 Seat Belt Inspection Points 2. Web cut or frayed at D-loop web guide. 3. Comfort Clip cracked or damaged. 4.
MAINTENANCE - Windshield Wiper/Washer WARNING! Replace the entire belt system (retractor and buckle side) if replacement of any one part is necessary. Unexposed damage to one or more components could prevent the system from functioning properly the next time it is needed. Failure to comply may result in death or personal injury. 1. Check the web wear in the system.
MAINTENANCE - Electrical System annually or every 60,000 miles (96,000 km). CAUTION Do not use antifreeze or engine coolant in the windshield washer reservoir, damage to seals and other components will result. WARNING! Before attempting any work on the batteries or electrical system, remove all jewelry. If metal jewelry or other metal comes in contact with electrical circuits, a short circuit may occur causing you to be injured, as well as electrical system failure and damage.
MAINTENANCE - Electrical System WARNING! Do not use the Spare Battery A and B circuits or other circuits that are controlled by the LVD to power electronic engine controls, ABS circuits, or safety/work related lighting. Before adding any device to the vehicle's electrical system, consult your nearest authorized dealer or read the contents of TMC RP136. Failure to do so may cause equipment damage or lead to personal injury.
MAINTENANCE - Electrical System Vehicle Light Bulb Specifications 5 Bulb Location Type of Bulb Notes Headlight Halogen H5054-LL (long life version not required) Headlight (Optional) N/A LED Light Rear tail light/ Turn Signal N/A LED lighting Interior map/dome/ indirect light N/A LED lighting NOTE Do not replace factory installed halogen headlamps with LED headlamps.
MAINTENANCE - Electrical System Aiming Headlights Fuses, Circuit Breakers and Relays Please have an authorized dealership aim the headlights. Fuses, circuit breakers, and relays are located in the Power Distribution Box which is located under the panel between the seats and closest to the rear window. The headlights were properly aimed at the factory to meet safety specifications. If the headlights need to be adjusted, please have an authorized dealership aim the headlights.
MAINTENANCE - Electrical System 5 180 Y53-6096-1A1 (01/17)
MAINTENANCE - Electrical System Altering the Electrical System Refer to a wiring diagram for your chassis before adding electrical options to ensure proper electrical system performance. WARNING! Do not replace a fuse with a fuse of a higher rating. Doing so may damage the electrical system and cause a fire. Failure to comply may result in death, personal injury, equipment or property damage. WARNING! Never install a circuit breaker in a circuit that is designated as "fuse only" circuit(s).
MAINTENANCE - Electrical System WARNING! Electrical damage or battery explosion can occur when improperly charging batteries. Failure to comply may result in death, personal injury, equipment or property damage. CAUTION Properly secure battery tie downs and battery box cover when reinstalling batteries after service. Do not over tighten. Over tightening can crack the battery case which can lead to equipment damage. WARNING! Batteries release gases that are flammable.
MAINTENANCE - Electrical System guidelines carefully when recharging a battery: • Before attempting any service in the electrical installation, disconnect the battery negative cable. • Allow no sparks or open flame anywhere near the charging area. • Charge a battery only in a wellventilated area, such as outdoors or in a fully open garage which contains no pilot lights or other flames. Gases generated during the charging process must be allowed to escape.
MAINTENANCE - Electrical System Cranking Battery Specification Replacement batteries must meet the following specifications.
MAINTENANCE - Electrical System Removing Batteries Installing Batteries Information on removing batteries. Follow the procedure below to reinstall main batteries on the vehicle: After accessing the battery, these steps can be used to remove them from the vehicle. 1. Be sure all switches on the vehicle are turned OFF. 2. Wait 2 minutes after turning ignition off then disconnect negative ground cable first. 3. Disconnect positive cable. 4. Unscrew the holding plate bolts with open end wrench.
MAINTENANCE - Engine Maintenance NOTE Some vehicles may have an ultra capacitor mounted in the battery box. These devices have a similar shape to a battery but have two positive posts and one negative posts. Do not attach battery chargers to these devices to recharge the vehicles batteries. Connect directly to the conventional two post charging batteries to charge them. 5 NOTE Follow the instructions that come with your battery charger. 1.
MAINTENANCE - Engine Maintenance WARNING! Never start or let the engine run in an enclosed, unventilated area. Exhaust fumes from the engine contain carbon monoxide, a colorless and odorless gas. Carbon monoxide can be fatal if inhaled. Failure to comply may result in death, personal injury, equipment or property damage. WARNING! Never idle your vehicle for prolonged periods of time if you sense that exhaust fumes are entering the cab. Investigate the cause of the fumes and correct it as soon as possible.
MAINTENANCE - Engine Maintenance Engine, Oil Temperature on page 62 Engine, Oil Pressure on page 62 5. Place the dipstick back into the holder. 6. Pull the dipstick out again and check the oil level. The oil level should always be between the 2 marks on the dipstick. Topping Up the Engine Oil Engine Oil Dip Stick Markings replacement, please see engine Operator’s Manual included with this chassis. 2. After topping up, wait 1 minute and check the oil level again. 3.
MAINTENANCE - Engine Maintenance automatic tensioner so that the idler pulley swings toward the belt routing. The following figure shows an example of the rotation direction to release the tensioner. WARNING! Do not work on or near the fan with the engine 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 position. In AUTO, it could engage suddenly without warning.
MAINTENANCE - Engine Maintenance will typically emit a squeal or a growl when the engine is at operating temperature and the fan clutch is engaged. If noise is detected, have the fan bearings inspected by an authorized dealership. Engine Fan Blade 5 Verify that there is enough fan blade clearance with the fan shroud. Around the fan shroud, the recommended distance is 1 in. (25 mm) from front edge of any fan blade-to-radiator side member. Minimum clearance is 3/4 in. (19 mm).
MAINTENANCE - Engine Maintenance lead to severe and expensive damage to your vehicle. mirrors, the mirror must be pivoted to provide access for servicing the filter element. Air Cleaners The following service information is basic to all air cleaner makes and models. WARNING! Engine Mounting Do not use air cleaner components as grab handles. These components may break if you are using them to support your weight. Failure to comply may result in personal injury or damage to vehicle components.
MAINTENANCE - Fuel System • Check for complete insertion of motor mount. Replace as necessary. • New leg to mount flange head bolts should be torqued to 210-230 lb-ft (284-311 Nm). Use only the fuel and/or additives recommended for your engine. Failure to comply may result in death, personal injury, equipment or property damage. WARNING! CAUTION Fuel System 5 Important information on your vehicle's fuel system. If anyone ever pours gasoline into your fuel tank, drain the entire system.
MAINTENANCE - Frame • Disconnect all electronic devices. It is not possible to list all of the electronics that could be affected, but a few examples include the following: alternator, engine Electronic Control Unit (ECU), transmission ECU, ABS ECU, navigation devices, diagnostic devices, and monitoring devices. • Disconnect battery cables and insulate them from the vehicle. • Do not use the ECU or engine ground stud for the ground of the welding probe.
MAINTENANCE - Front Axle and Suspension side of the fifth wheel plate. Use a water resistant lithium-base grease. Kingpin Lubrication Suspension Lubrication NOTE The plate must be lifted up slightly to relieve the weight of the bracket while applying grease. 5 Front Axle and Suspension Lubrication and inspection of front axle assemblies. Axle Lubrication Refer to the axle manufacturer's operator's manual for lubrication specifications and service intervals. 194 Lubricate with approved lubricant.
MAINTENANCE - Front Axle and Suspension Inspection Suspension U-Bolts For all vehicles, mandatory maintenance procedures include retightening all U-bolts and inspecting the suspension for loose fasteners, abnormal wear, or damage. However, even with proper maintenance, the service life of leaf springs is affected by many factors, such as: fatigue, vehicle gross weight, type of load, road conditions, and vehicle speed. Check for cracks, wear marks, splits, or other defects on the surface of the spring.
MAINTENANCE - Heater and Air Conditioner Maintenance Frame Fastener Torque Requirements on page 214 Suspension U-Bolts, Grade 8 on page 213 Heater and Air Conditioner Maintenance 5 Important information to know about maintaining the air conditioner for a Low Cab Forward vehicle. The combination heater-air conditioner provides comfort for those in the cab through accurate control of the cab environment in all weather conditions.
MAINTENANCE - Heater and Air Conditioner Maintenance Heater death, personal injury, equipment or property damage. CAUTION During extreme cold weather, do not blow hot defroster air onto cold windshields. This could crack the glass. Turn the Air Flow Control Dial to Defrost and adjust the fan speed accordingly while the engine warms. If the engine is already warm, move the Temperature Control Dial to cool, then gradually increase the temperature when you see that the windshield is starting to warm up.
MAINTENANCE - Heater and Air Conditioner Maintenance 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.
MAINTENANCE - Noise and Emission Control 1 Environmental Protection Agency (EPA) emissions and noise regulations. To maintain conformance with the regulations, these components need to be functional and properly maintained.
MAINTENANCE - Noise and Emission Control • Removing or rendering engine speed governor inoperative so as to allow engine speed to exceed manufacturer's specifications. • Modifying ECU parameters. • Exhaust System • Removing or rendering inoperative exhaust system components. • Fuel System 5 • Removing or rendering engine speed governor inoperative, allowing engine speed to exceed manufacturer's specifications. • Removing of air signal attenuator on engines equipped with this device.
MAINTENANCE - Rear Axle and Suspension suitable reinforcing plates to ensure that the insulators will remain in position. Exhaust System • Check for exhaust leaks, which would indicate a leaking manifold gasket; replace gasket if necessary. • Check cap screws for tightness, including those at the flanges. Refer to the engine manufacturer's service manual for proper tightening sequence and torque values. Joints and Clamps • Check for leaks, and tighten as necessary.
MAINTENANCE - Rear Axle and Suspension WARNING! Do not operate the vehicle if the suspension U bolts are not properly tightened. Loose U bolts will cause the axle to not be properly secured to the suspension, which could cause loss of vehicle control and an accident. Loose U bolts can also cause uneven tire wear and poor alignment. Failure to comply may result in death, personal injury, equipment or property damage.
MAINTENANCE - Rear Axle and Suspension vehicle manufacture. The values listed in the at the back of this chapter (Specification Reference Charts), are for cadmium plated or phosphate and oil fasteners only. U-bolts are difficult to tighten unless you have the right equipment. If you cannot tighten them correctly yourself, be sure to have them checked and tightened regularly by an authorized mechanic.
MAINTENANCE - Steering System • Bushing replacement. • Excessive or abnormal tire wear. Steering System The steering system consists of a power steering pump, gearbox and reservior. WARNING! 5 Do not operate the vehicle if the steering system is not working properly. You could lose control of your vehicle if the steering system is not in good working condition, which could result in a serious accident. For driving safety, visually check the steering gear and components.
MAINTENANCE - Steering System Power Steering Fluid Have the power steering fluid and filters changed at an authorized dealer. CAUTION When adding fluid, be sure to use fluid of the same type. While many fluids have the same description and intended purpose, they should not be mixed due to incompatible additives. Mixing incompatible fluids may lead to equipment damage. NOTE Before removing reservoir cover, wipe outside of cover so that no dirt can fall into the reservoir.
MAINTENANCE - Steering System Steering Shaft Bolt Torque Specifications Fastener torque specifications for steering shaft. For off–highway vehicles, tighten the U– bolts after the first day or two of operation. Then check weekly. The following are common torque specifications for most steering shafts.
MAINTENANCE - Driveline Driveline General lubrication information for drivelines. See the driveshaft manufacturer's operator's manual for lubrication specifications and service intervals. you can stop depends in large measure on how much friction you get between the road and your tires. In addition, keeping your tires in good condition is essential to the safe, efficient operation of your vehicle.
MAINTENANCE - Tires an inaccurate reading. So never deflate a warm tire to the specified pressure. WARNING! Do not operate a vehicle with underinflated tires. The extra heat caused by underinflation can cause sudden tire failure such as a tire fire or blow out, which can cause an accident resulting in death or personal injury. Low pressure may affect control at the front wheels, which could result in an accident involving death or personal injury.
MAINTENANCE - Tires Matching Tires Be sure to buy matched tires for your vehicle, especially on the rear axles. Mismatched tires can cause stress between axles and cause the temperature of your axle lubricant to get too hot. Matched tires will help your driveline last longer and will give you better tire mileage. WARNING! Do not mismatch tires, it can be dangerous. Never mix tires of different design such as steel belted radials and bias ply tires, etc.
MAINTENANCE - Wheels Resistance codes (LRR) identify which tires are certified. NOTE The tires installed on this vehicle at the factory as original equipment may be certified for Greenhouse Gas and Fuel Efficiency regulations. Replacement tires must be of equal or lower rolling resistance level (TRRL or Crr). Consult with your tire supplier(s) for appropriate replacement tires.
MAINTENANCE - Transmission Maintenance Disc Wheels WARNING! Improperly mounting and demounting tire and rim assemblies is dangerous. Failure to observe proper precautions could cause the tire rim assembly to burst explosively, causing death or personal injury. See the wheel manufacturer's literature for the proper way to mount and demount your tires and rims. Follow their precautions exactly.
MAINTENANCE - Mechanical Clutch Mechanical Clutch The clutch in this vehicle is actuated via a combination of mechanical linkages from the cab to the transmission. Free Pedal Travel 5 Free pedal travel is the distance the clutch pedal moves by applying only slight pressure. During free pedal the release yoke in the transmission moves until its bearing pads contact the release bearing. This movement of the release yoke is called free travel.
MAINTENANCE - Specification Reference Charts Suspension U-Bolts, Grade 8 Torque specifications for suspension ubolts. Tighten all U-Bolts with a torque wrench. Torque specifications apply to the following fasteners with lightly lubricated threads. Chevron Zinc Lubricant or SAE 20/30 oil should be used on U-Bolt threads. Torque requirements apply to manufacturer proprietary suspensions. All other suspensions must refer and adhere to original manufacturers shop manual.
MAINTENANCE - Specification Reference Charts Frame Fastener Torque Requirements Torque specifications for standard and metric frame fasteners, including the fifth wheel. 5 Use ESNA Style Lock Nut, with nylon insert. Lubricate nylon insert nut lightly with SAE 20/30 oil. Tighten all frame fasteners with a torque wrench. Torque specifications apply to the following fasteners with lightly lubricated threads.
MAINTENANCE - Specification Reference Charts Wheel Cap Nut Torque Specifications Torque specifications for wheel cap nuts, including standard and metric fasteners. At the first scheduled lube interval, have all wheel cap nuts torqued to their specified value. After that, check wheel cap nuts at least once a week. procedure for the wheels on your truck. This is a job you may not be able to do yourself. You need the right torquing equipment to do it.
MAINTENANCE - Specification Reference Charts Lubrication Specification Chart *Consult manufacturer or lubricant supplier for special details. NOTE The responsibility for meeting these specifications, the quality of the product, and its performance in service rests with the lubricant supplier. 5 Lubricant Symbol Key Type Application ATF MD3 or MERCON®-approved automatic transmission fluid BB High temperature ball bearing grease.
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.
MAINTENANCE - Specification Reference Charts Application 5 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 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-pilote
MAINTENANCE - Specification Reference Charts Steering Gear Lubrication The following recommendations are for general purpose steering systems (both TRW and Sheppard).
MAINTENANCE - Specification Reference Charts Component Recommended Interval (Miles) Inner Fender Shields 50,000 Cab Skirts Fasteners 50,000 Air Intake System Integrity Element 5,000 Clutch Type Fan Drive 10,000 Date & R.O. No. Repair Facility & Location Work Performed Date & R.O. No.
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 Plastic Air Intake Pipes Constant Torque CT-L 4.
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...........................................................................................................................................
INFORMATION - Consumer Information Consumer Information How to Order Replacement Parts Replacement parts may be obtained from an authorized dealership. When you order, it is IMPORTANT that you have the following information ready: • • • • Your name and address. Serial number of the truck. The name of the part you need. The name and number of the component for which the part is required. • The quantity of parts you need. • How you want your order shipped.
INFORMATION - Vehicle Identification Labels located on the driver's side door edge or on the driver's side door frame. • Right frame rail, top flange, about 3 ft. from the front end • Cab back, left-hand rear panel, lower edge • Tire, Rim, and Weight Rating Data label (truck) • Components and Weights label • Noise Emission label • Paint Identification label Certification Labels Your vehicle information and specifications are documented on labels.
INFORMATION - Vehicle Identification Labels Noise Emission Label WARNING! Do not exceed the specified load rating. Overloading can result in loss of vehicle control, either by causing component failures or by affecting vehicle handling. Exceeding load ratings can also shorten the service life of the vehicle. Failure to comply may result in death or personal injury. NOTE GVW is the TOTAL SCALE WEIGHT the vehicle is designed to carry.
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.
INFORMATION - Clean Idle If you have a Cummins engine, your label will look like the image below. Engine Shutdown System 6 Fahrenheit, or if the engine is performing a parked regeneration. The check engine light 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.
INFORMATION - Greenhouse Gas Certification Label Greenhouse Gas Certification Label Definition of greenhouse gas label identifiers. This vehicle may be equipped with components that are identified as Greenhouse Gas Certified components (GHG). A label on the door is printed with codes that identify the components manufactured on the vehicle that are part of the GHG certification.
INFORMATION - Vehicle Emissions Limited Express Warranty Vehicle Emissions Limited Express Warranty Original Equipment Tires 6 PACCAR Inc warrants the tires installed as original equipment on this vehicle only against defects in materials and workmanship which cause the vehicle to fail to comply with applicable U.S. and Canadian greenhouse gas emission limits ("Warrantable Emissions Failures").
INFORMATION - Vehicle Emissions Limited Express Warranty Manufacturer's Warranty Coverage This warranty coverage is provided for five years or 100,000 miles (160,000) km, whichever first occurs, from the date of delivery of the vehicle to the first purchaser or first lessee. Where a Warrantable Condition exists, PACCAR will diagnose and repair the vehicle, parts and labor included, at no cost to the first purchaser or first lessee and each subsequent purchaser or lessee.
INFORMATION - Vehicle Emissions Limited Express Warranty authorized PACCAR dealer and may elect to use parts other than new or genuine approved rebuilt parts and assemblies for such maintenance, replacement or repair; however, the cost of such service or parts and subsequent failures resulting from such service or parts may not be fully warranted if the manufacturer determines that the replacement part is not of similar material and function as the OEM part assembled to the vehicle at the factory.
INFORMATION - Vehicle Emissions Limited Express Warranty SOLE WARRANTY MADE BY PACCAR AND THE SELLING DEALER. EXCEPT 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.
INFORMATION - Vehicle Emissions Limited Express Warranty 6 234 Y53-6096-1A1 (01/17)
Index Index A Aftertreatment System 123 Aiming Headlights 179 Air Cleaners 191 Air Conditioner 77, 78 Air Disc Brakes 161 Air Filter 191 Air Filter Restricton 63 Air Intake System 190 Air Tanks 158 Altering the Electrical System 181 Alternator 186 Auto Slack Adjuster 162 Automatic Slack Adjuster Stroke Specification 164 Axle, Traction Control 57, 58, 107 See also ATC AxleAuxiliary 117 AxleDiff Lock 114 AxleDifferential Lock 114 AxleDual Range 115 AxlePusher Tag 117 AxleTwo Speed 115 Brakes, Trailer Anti-L
Index Drum Brake Inspection 162 E Electrical System 176 Emissions 123 Emissions, High Exhaust System Temperature 60 Emissions, Malfunction Indicator Lamp 60 Engine - Coolant Temperature 66 Engine Fan 189 Engine is overheating 31 Engine Maintenance 186 Engine Mounting 191 Engine Oil Temperature 62 Engine, Check Engine 62 Engine, Low Coolant Level 62 Engine, Oil Pressure 62, 67 Engine, Overspeed Air Shutdown 63 Engine, Retarder (Brake) 63 Engine, Stop Engine 63 Engine, Wait To Start 63 Exhaust 123 Exhaust S
Index L R Lights Marker Clearance 76 Lights, High Beam 64 Low Air Alarm 30 Low Oil Pressure Lamp 31 Lower 17 Lubricants 153 Lubrication Specification Chart 216 Raise 16 Rear Axle Alignment 203 Rear Axle and Suspension 201 Rear Axle Lubrication 203 Recovery Hitch 40 Recovery hitch capacities 44 Recovery hitch How to use tow pin 41 Recovery hitchBest practices 45 Recovery hitchManually lock a differential 42 Recovery hitchPrepare axles 41 Removing Batteries 185 Returning to Service after Recovering 45 Rig
Index T Tachometer 66 Tilt 15 Tire Inflation 64 Tires 207 Topping Up the Engine Oil 188 Tow Pin 40 Towing the Vehicle 46 Traction Control 91 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 Veh
Y53-6096-1A1 01/17 Printed in U.S.A. Peterbilt Motors Company, A PACCAR Company, P.O.
