Stoneridge Electronics 32476 Remote Control Transmitter User Manual

Stoneridge Electronics Remote Control Transmitter

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32476 User Manual HTML Version

User manual

Operator’s Manual

Contents

Safety

Emergency

Controls

Driving

Maintenance

Information

Index

Contents

This manual illustrates and describes the operation of features or equipment which may be either standard or optional on

this vehicle. This manual may also include a description of features and equipment which are no longer available or were

not ordered on this vehicle. Please disregard any illustrations or descriptions relating to features or equipment which are

not on this vehicle.

PACCAR reserves the right to discontinue, change specications, or change the design of its vehicles at any time without

notice and without incurring any obligation.

The information contained in this manual is proprietary to PACCAR. Reproduction, in whole or in part, by any means is strictly

prohibited without prior written authorization from PACCAR Inc.

Truck Model Example

SAFETY

INTRODUCTION

About the Manual . . . . . . . . . . . . . . . . 1-3

SafetyAlerts.................. 1-3

Vehicle Safety ................. 1-5

A Special Word About Repairs . . . . . . . . . . 1-7

Additional Sources of Information . . . . . . . . . 1-8

CAB AND FRAME ACCESS

Safety.................... 1-10

Door Lock and Keys. . . . . . . . . . . . . . 1-11

Remote Keyless Entry (RKE) . . . . . . . . . . 1-12

Climbing onto the Deck Plate . . . . . . . . . . 1-13

GETTING TO YOUR ENGINE

Hood Hold Downs. . . . . . . . . . . . . . . 1-15

HoodTilt................... 1-16

Hood Hold-Open Device . . . . . . . . . . . . 1-17

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

SAFETY

SEATS AND RESTRAINTS

Introduction . . . . . . . . . . . . . . . . . 1-19

Safety Restraint Belts . . . . . . . . . . . . . 1-22

Tether Belts . . . . . . . . . . . . . . . . . 1-25

Komfort-Latch® Feature . . . . . . . . . . . . 1-26

During Pregnancy. . . . . . . . . . . . . . . 1-28

Belt Damage and Repair . . . . . . . . . . . . 1-28

Sleeper Bunks and Restraints . . . . . . . . . 1-29

Safety Restraint Tips . . . . . . . . . . . . . 1-31

START-UP

Introduction . . . . . . . . . . . . . . . . . 1-33

Safe Vehicle Operation . . . . . . . . . . . . 1-33

Vehicle Loading. . . . . . . . . . . . . . . . 1-34

Emergency Equipment . . . . . . . . . . . . 1-36

Driver's Check List . . . . . . . . . . . . . . 1-36

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

INTRODUCTION

About the Manual

Congratulations! Your selection of a

Kenworth truck was a wise investment.

Kenworth trucks are recognized as

the industry standard for quality and

reliability.

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 your truck. This manual

explains the safe, efcient operation

and maintenance of your Kenworth.

NOTE

After you’ve read this manual, it should

be stored in the cab for convenient

reference and remain with this truck

when sold.

Your Kenworth may not have all the

features or options mentioned in this

manual. Therefore, you should pay

careful attention to the instructions that

pertain to just your vehicle. In addition,

if your vehicle is equipped with special

equipment or options not discussed in

this manual, consult your dealer or the

manufacturer of the equipment.

All information contained in this

manual is based on the latest

production information available at the

time of publication. Kenworth Truck

Company reserves the right to make

changes at any time without notice.

Safety Alerts

Please read and follow all of the

safety alerts contained in this manual.

They are there for your protection

and information. These alerts can

help you avoid injury to yourself, your

passengers, and help prevent costly

damage to the vehicle. Safety alerts

are highlighted by safety alert symbols

and signal words such as "WARNING",

"CAUTION", or "NOTE". Please do not

ignore any of these alerts.

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

INTRODUCTION

1 WARNING CAUTION

Example:

WARNING!

The safety message following this

symbol and signal word provides a

warning against operating procedures

which could cause death or personal

injury. They could also cause

equipment or property damage. The

alert will identify the hazard, how to

avoid it, and the probable consequence

of not avoiding the hazard.

WARNING!

Do not carry additional fuel containers

in your vehicle. Fuel containers, either

full or empty, may leak, explode, and

cause or feed a re. Do not carry ex-

tra fuel containers. Even empty ones

are dangerous. Failure to comply may

result in death or personal injury.

CAUTION

The safety alert following this symbol

and signal word provides a caution

against operating procedures which

could cause equipment or property

damage. The alert will identify the

hazard, how to avoid it, and the

probable consequence of not avoiding

the hazard.

Example:

CAUTION

Continuing to operate your vehicle

with insufcient oil pressure will cause

serious engine damage. Failure to

comply may result in equipment or

property damage.

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

INTRODUCTION

NOTE

The alert following this symbol and

signal word provides important

information that is not safety related

but should be followed. The alert

will highlight things that may not be

obvious and is useful to your efcient

operation of the vehicle.

Example:

NOTE

Pumping the accelerator will not assist

in starting the engine.

Vehicle Safety

WARNING!

Do not drink alcohol and drive. Your

reexes, perceptions, and judgment

can be affected by even a small

amount of alcohol. You could have a

serious or even fatal accident, if you

drive after drinking. Please do not

drink and drive or ride with a driver

who has been drinking. Failure to

comply may result in death, personal

injury, equipment or property damage.

Do not text and drive. Your reaction

time, perceptions and judgment can

be affected while texting or using any

other form of mobile messaging while

driving. Failure to comply may result

in death, personal injury, equipment or

property damage.

WARNING!

Make sure your vehicle is in top

working condition before heading

out on the road, it is the responsible

driver's duty to do so. Inspect the

vehicle according to the Driver's Check

List beginning on page 1-36.

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. Follow

the maintenance recommendations

found in Preventive Maintenance on

page 5-9. This will help preserve your

investment.

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.

Safe driving is only possible with the

proper concentration on the driving

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

INTRODUCTION

task. Keep distraction to a minimum to

improve your concentration. Examples

of distractions may include radio

controls, GPS navigation controls,

cellular telephone calls, cellular text

messages, reading or reaching for

something on the oor. Minimizing

your distractions will improve safe

driving and will help avoid an accident

involving death or personal injury.

Be aware of local regulations that may

prohibit the use of cellular telephones

while driving. In addition to being an

unsafe practice, it may be against local

or federal ordinances to use cellular

devices while operating the vehicle.

This manual is not a training manual.

It cannot tell you everything you need

to know about driving your vehicle. For

that you need a good training program

or truck driving school. If you have not

been trained, get the proper training

before you drive. Only qualied drivers

should drive this vehicle.

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.

• Other chemicals in this vehicle

are also known to the State of

California to cause cancer, birth

defects or other reproductive

harm.

• Battery posts, terminals, and

related accessories contain lead

and lead compounds, chemicals

known to the State of California

to cause cancer and reproductive

harm. Wash hands after handling.

Data Recorder

California Vehicle Code - Section

9951- Disclosure of Recording Device

Your vehicle may be equipped with one

or more recording devices commonly

referred to as “event data recorders

(EDR)” or “sensing and diagnostic

modules (SDM)”. If you are involved in

an accident, the device(s) may have

the ability to record vehicle data that

occurred just prior to and/or during the

accident. For additional information on

your rights associated with the use of

this data, contact

• the California Department of Motor

Vehicles - Licensing Operations

Division

– or –

• http://www.dmv.ca.gov/

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

INTRODUCTION

Environmental Protection

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 re-

quirement is mandated by California

law (Proposition 65) and does not re-

sult from any change in the manner in

which vehicles are manufactured.

Some of the ingredients in engine

oil, hydraulic oil, transmission and

axle oil, engine coolant, diesel fuel,

air conditioning refrigerant (R12,

R134a, and PAG oil), batteries, etc.,

may contaminate the environment if

spilled or not disposed of properly.

Contact your local government agency

for information concerning proper A Special Word About

disposal. Repairs

WARNING!

Do not attempt repair work without suf-

cient training, service manuals, and

the proper tools. You could be killed

or injured, or you could make your ve-

hicle unsafe. Do only those tasks you

are fully qualied to do.

Your dealer’s service center is the best

place to have your vehicle repaired.

You can nd dealers all over the

country with the equipment and trained

personnel to get you back on the road

quickly—and keep you there.

Your vehicle is a complex machine.

Anyone attempting repairs on it needs

good mechanical training and the

proper tools. If you are sure you

have these requirements, then you

can probably perform some repairs

yourself. However, all warranty repairs

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

INTRODUCTION

must be performed by an authorized

service facility. If you aren’t an

experienced mechanic, or don’t have

the right equipment, please leave all

repairs to an authorized service facility.

They are the ones equipped to do the

job safely and correctly.

Maintenance Manuals. If you do

decide to do any complex repair work,

you’ll need the maintenance manuals.

Order them from your authorized

dealer. Please provide your Chassis

Serial Number when you order, to be

sure you get the correct manuals for

your vehicle. Allow about four weeks

for delivery. There will be a charge for

these manuals.

Final Chassis Bill of Material. A

complete, non-illustrated computer

printout listing of the parts used to

custom-build your vehicle is available

through the dealer from whom you

purchased your vehicle.

WARNING!

Modifying your vehicle can make it un-

safe. Some modications can affect

your vehicle's electrical system, stabil-

ity, or other important functions. Be-

fore modifying your vehicle, check with

your dealer to make sure it can be

done safely. Improper modications

can cause death or personal injury.

Additional Sources of

Information

Installed Equipment - Operator's

Manuals

Major component suppliers also supply

operation manuals specic 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/ESP (if applicable), radio, 5th

wheel, lane departure and adaptive

cruise control. If you are missing these

pieces of literature, ask your Dealer

for copies.

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

INTRODUCTION

Other Sources

Another place to learn more about

trucking is from local truck driving

schools. Contact one near you to learn

about courses they offer.

Federal and state agencies such

as the department of licensing also

have information. The Interstate

Commerce Commission can give

you information about regulations

governing transportation across state

lines.

(04/13) Y53-1200-1B1 1-9

CAB AND FRAME ACCESS

CAB AND FRAME

ACCESS

Safety

WARNING!

Always reinstall steps before entering

the cab or accessing the deck plate.

Without steps you could slip and fall.

Failure to comply may result in death

or personal injury.

Be careful whenever you get into or out

of your vehicle’s cab. Always maintain

at least three points of contact with

your hands on the grab handles and

your feet on the steps.

Jumping out of the cab or getting into

the cab without proper caution is dan-

gerous. You could slip and fall, which

could lead to death or personal injury.

Keep steps clean. Clean any fuel, oil,

or grease off of the steps before enter-

ing the cab. Use the steps and grab

handles provided, and always keep at

least three points of contact between

your hands and feet and the truck. Al-

ways face toward the vehicle when

entering or exiting the cab and look

where you are going.

WARNING!

The following picture shows the best

way to enter and exit a Conventional

Cab.

1-10 Y53-1200-1B1 (04/13)

CAB AND FRAME ACCESS

Door Lock and Keys

Door Lock

Doors can be locked from the inside by

using the lock button. Close the door

then push the button down to lock.

Doors automatically unlock when you

open them from inside, and can be

locked from the outside with the key or

the optional remote keyless entry key

fob.

WARNING!

To reduce the chance of death or per-

sonal injury, always lock the doors

while driving. Along with using the lap

shoulder belts properly, locking the

doors helps prevent doors from inad-

vertently opening and occupants from

being ejected from the vehicle.

Keys

To lock or unlock the doors from

outside the cab, insert the key in the The same key ts your ignition, doors,

lock. Turn the key toward the rear to and sleeper luggage compartment.

lock; forward to unlock.

Frame-mounted tool box locks and

locking fuel tank caps each have

individual keys.

(04/13) Y53-1200-1B1 1-11

CAB AND FRAME ACCESS

1 Remote Keyless Entry (RKE)

(Optional)

This vehicle may be equipped with a

Remote Keyless Entry (RKE) system

that adds security and convenience

to your vehicle. The system will

lock or unlock the driver’s door and

passenger’s door with the key fob and

alert you with parking lights when the

selected doors are locked or unlocked.

The system includes two key fobs that

provide secure rolling code technology

that prevents someone from recording

the entry signal.

NOTE

FCC ID: 2ADG6-32476

IC: 12459A-32476

This device complies with Part 15 of

the FCC Rules and with RSS-210 of

Industry Canada.

Operation is subject to the following

two conditions:

(1)

This device may not cause harmful

interference, and

(2)

This device must accept any in-

terference received, including interfer-

ence that may cause undesired oper-

ation.

Changes or modifications not expres-

sively approved by the party respon-

sible for compliance could void the

user's authority to operate the equip-

ment. The term “IC:” before the radio

certification number only signifies that

Industry Canada technical specifica-

tions were met.

Operation

To Unlock the Driver’s Door

Press the UNLOCK button once. The

driver's door will unlock and the parking

lights will come on for 40 seconds.

To Unlock the Passenger’s Door

Press the UNLOCK button once and

press again within 5 seconds. The

passenger door will unlock.

To Lock All Doors

Press the LOCK button. The doors will

lock and the parking lights will come

on for 2 seconds. If the doors are open

they will not lock. The range of the

RKE system should be approximately

30 ft. This will be reduced if it is

operated close to other RF sources

such as TV/radio transmitters and cell

towers.

1-12 Y53-1200-1B1 (04/13)

CAB AND FRAME ACCESS

Batteries

The key fob uses one CR2032,

3V battery. Batteries should last

approximately three years, depending

on use. Consistently reduced range

is an indicator that the battery needs

replacement. Batteries are available

at most discount, hardware, and drug

stores.

The battery can be accessed by

removing the cover of the key fob.

After a new battery is installed, the

key fob must be synchronized with the

vehicle.

Synchronization

The key fob may need to be

synchronized to the truck when the

battery is replaced or when the key fob

has not been used for an extended

period of time.

To Synchronize A Key Fob:

1. Hold the key fob near the receiver

which is located behind the

speedometer and tachometer.

2. Press and hold both the Lock and

Unlock buttons at the same time

for approximately 7 seconds.

3. When the key fob is

resynchronized, the doors

will lock then immediately unlock.

4. If the fob fails to synchronize,

it could be programmed to a

different truck or could have failed.

Contact your dealer to re-program

your key fob.

Climbing onto the Deck

Plate

WARNING!

When you are climbing onto and off

the deck plate, maintain at least three

points of contact with your hands on

the grab handles and your feet on the

steps. Always face toward the vehicle

when entering or exiting the cab and

look where you are going. Failure to

comply may result in death or personal

injury.

When stepping onto a surface to enter

the cab or access the deck plate, only

use the steps and grab handles in-

stalled and designed for that purpose.

Failure to use the proper steps and

grabhandles could cause a fall which

may result in death or personal injury.

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

CAB AND FRAME ACCESS

WARNING!

Keep steps clean. Clean any fuel,

oil, or grease off the steps before en-

tering the cab or accessing the deck

plate. Stepping on a slippery surface

can cause a fall which may result in

death or personal injury.

Always reinstall steps before entering

the cab or accessing the deck plate.

Without steps you could slip and fall.

Failure to comply may result in death

or personal injury.

The following pictures show you the

right way to get on and off the area

behind your cab.

NOTE

Hold handles as you step up.

Maintain three points of contact.

Any alteration (adding bulkheads,

headache racks, tool boxes, etc.) be-

hind the cab that affects the utilization

of installed grab handles, deck plates,

or frame access steps should com-

ply with Federal Motor Carrier Safety

Regulation 399.

1-14 Y53-1200-1B1 (04/13)

GETTING TO YOUR ENGINE

GETTING TO YOUR 1. Hood Latch in the Closed Position

ENGINE

Hood Hold Downs

Hood hold downs keep a hood from

opening unexpectedly.

CAUTION

A hood not latched securely could

open during operation and cause ve-

hicle damage. Be sure to latch the

hood securely.

(04/13) Y53-1200-1B1 1-15

GETTING TO YOUR ENGINE

2. Pull Latch to Open 3. Pull Up to Separate Hood Tilt

To open your hood, unlock the hood

hold downs by unlatching them. Put

one or both hands on the top of the

hood front. Tilt the hood forward by

pulling at the top of the hood, pivoting

on the foot placed on the bumper

and using the foot on the ground for

stability. Keep pulling on the hood

until you are certain that the hood hold

open device is engaged. When closing

the hood, be sure that you maintain

the same points of contact (top of hood

and bumper) to control the movement

of the hood as it closes.

WARNING!

A pivoting hood could hurt someone or

be damaged itself. Before opening or

closing the hood, be sure there are no

people or objects in the way. Failure to

stand in a position of safety can cause

death or personal injury.

1-16 Y53-1200-1B1 (04/13)

GETTING TO YOUR ENGINE

Pull with hand from here

Hood Hold-Open Device

The hood is equipped with a hood

hold-open device. In order for the hood

hold-open device to become engaged,

the vehicle hood must be fully open.

Once the vehicle hood is fully open,

the hold-open latch will automatically

engage and will need to be disengaged

by the operator.

The release lever for the hood hold

open device is located near the front

hinge of the hood. Press the lever in to

disengage the hood hold open device.

Press in to disengage

(04/13) Y53-1200-1B1 1-17

GETTING TO YOUR ENGINE

WARNING!

Before opening or closing the hood,

make sure your footing is secure and

stable. Failure to do so may cause

the hood to close uncontrollably which

may result in death or personal injury.

Always ensure the hood hold-open

latch is engaged to keep the hood fully

open any time anyone gets under the

hood for any reason. Failure to do so

may cause the hood to close uncon-

trollably which may result in death or

personal injury.

Before closing the hood, be sure the

area is clear—no people or objects are

in the way. Failure to do so may result

in death or personal injury.

1-18 Y53-1200-1B1 (04/13)

SEATS AND RESTRAINTS

SEATS AND

RESTRAINTS

Introduction

This section covers the operation

and safe use of your seats. For

further information on features and

adjustment of the seat, see the

manufacturer's Service and Operation

Manual included with the vehicle.

Seat Adjustment

WARNING!

Do not adjust the driver's seat while

the vehicle is moving. The seat could

move suddenly and unexpectedly and

can cause the driver to lose control of

the vehicle. Make all adjustments to

the seat while the vehicle is stopped.

After adjusting the seat and before

driving off, always check to ensure that

the seat is rmly latched in position.

Failure to comply may result in death,

personal injury or property damage.

Before driving or riding in vehicle,

ensure that there is adequate head

clearance at maximum upward travel

of seat. Injury may occur if head

clearance is not adequate. Failure to

comply may result in death or personal

injury.

Suggested Control Setting Order:

1. Seat fore/aft position

2. Seat height

3. Thigh support

4. Seat bottom angle

5. Seat back recline angle

6. Lumbar

7. Adjust steering wheel

8. Adjust mirrors

The suspension seat in this vehicle will

have the following controls to adjust

the seat to the operator’s specic

needs.

(04/13) Y53-1200-1B1 1-19

SEATS AND RESTRAINTS

1. Seat heater/cooler

2. Seat thigh support up/down

3. Seat bottom angle adjustment

WARNING!

CAUTION

Seat heaters should not be used if the

operator or passenger has difculty in

sensing and reacting to an increased

temperature of the seat. The heater

function may result in personal injury.

Do not use the seat heater for more

than 10 minutes at one time. Always

turn off the seat heaters when they

are not needed. Overuse of the seat

heater may decrease the capacity of

the vehicle’s batteries and may result

in poor starting and potential equip-

ment damage.

1-20 Y53-1200-1B1

1. Seat fore/aft

2. Express down

3. Suspension stiffness

4. Seat height up/down

5. Lumbar and bolster* controls

6. Recline adjustment

7. Armrest angle adjustment

*This is an optional feature and may vary

depending on the vehicle.

(04/13)

SEATS AND RESTRAINTS

Do not drive or ride with your seat back

in the reclined position. You could be

injured by sliding under the seat belts

in a collision. Failure to comply may

result in death or personal injury.

WARNING!

Lumbar (and bolster support if

available) are provided for superior

support to the back during operation.

Lower support is standard and the

optional functions include upper

lumbar and bolster functions. Pressing

on the “+” symbol of the button will

add support in the area. Pressing the

opposite side of the button will release

pressure and will reduce support in the

area.

1. Lower and Upper* lumbar adjustment

2. Bolster* adjustment

*This is an optional feature and may vary

depending on the vehicle.

The seats in this vehicle are equipped

with a switch that locks out the fore-aft

isolator function in the seat. When

locked, the seat will not move back

and forth. It will be rigidly xed and

only allowed to move up and down

with the vehicle’s movements.

(04/13) Y53-1200-1B1 1-21

SEATS AND RESTRAINTS

Passenger Seat Swivel (Optional)

This vehicle may be equipped with a

swivel function on the passenger seat.

This function allows the passenger

seat to rotate and face towards the

inside of the cab.

WARNING!

Always ensure that the passenger

seat is locked into the forward-facing

position when the vehicle is in mo-

tion. Locking the swivel seat into the

forward facing position maximizes vis-

ibility to the surrounding area. Failure

to comply creates a safety hazard that

may result in death or personal injury.

1-22

WARNING!

Do not use the swivel function while a

passenger is in the seat and the vehi-

cle is in motion. The seat belt will not

provide proper protection if the pas-

senger is not facing forward and the

vehicle is in an accident. Failure to

comply may result in death or personal

injury.

Y53-1200-1B1

Safety Restraint Belts

Safety belts have proven to be the

single most effective means available

for reducing the potential for either

death or personal injury in motor

vehicle accidents. Unbelted riders

could be thrown into the windshield

or other parts of the cab or could be

thrown out of the cab. They could

strike another person. Injuries can be

(04/13)

SEATS AND RESTRAINTS

much worse when riders are unbelted. above the speedometer/tachometer Lap/Shoulder Belt 1

Always fasten your seat belt and be

sure anyone riding with you does the

same. Therefore, read the following

instructions and always observe user

warnings pertaining to safety belts.

WARNING!

Do not drive vehicle without your seat

belt and your riders belts fastened.

Riding without a safety belt properly

fastened can lead to death or personal

injury in an emergency.

In vehicles equipped with passenger

seat swivel function, the seat belts will

only perform their intended function

when the seat is facing forward. Fail-

ure to comply can lead to death or per-

sonal injury in an emergency.

WARNING!

Your vehicle is equipped with a seat belt

indicator in the warning light display

(see “Seat Belt, Fasten” on page 3-41).

The combination lap-shoulder belt is

equipped with a locking mechanism.

The system adjusts automatically to a

person's size and movements as long

as the pull on the belt is slow.

Hard braking or a collision locks the

belt. The belt will also lock when

driving up or down a steep hill or in a

sharp curve.

To fasten the belt:

1. Grasp the belt tongue.

2. Pull belt in a continuous slow

motion across your chest and lap.

3. Insert belt tongue into buckle on

inboard side of seat.

4. Push down until the tongue is

securely locked with an audible

click.

(04/13) Y53-1200-1B1 1-23

SEATS AND RESTRAINTS

5. Pull belt to check for proper

fastening and adjustment, as

follows:

• Pull shoulder section to make sure

belt ts snugly across the chest

and pelvis.

• There should be less than 1 inch

(25 mm) gap between the body

and the belt.

• The shoulder belt must be

positioned over the shoulder, it

must never rest against the neck

or be worn under the arm.

• Make sure any slack is wound up

on the retractor and that the belt

is not twisted.

To unfasten the belt:

1. Push in the release button on the

buckle.

2. The belt will spring out of the

buckle.

If the belt is locked, lean the body back

to remove any tension in the belt. After

releasing the belt, allow the belt to

retract completely by guiding the belt

tongue until the belt comes to a stop.

1-24 Y53-1200-1B1 (04/13)

SEATS AND RESTRAINTS

Safety Restraint Belts

Lap Belt Shoulder Belt

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

WARNING! Tether Belts Internal tether belts do not require

Proper seat belt adjustment and use This vehicle may have an external adjustment.

is important to maximize occupant tether belt installed with a seat, instead

safety. Failure to wear or adjust the of the internal tethering device. Tether

safety belt properly may result in death belts are designed to restrain the seat

or personal injury. in the event of a sudden stop or an

accident.

(04/13) Y53-1200-1B1 1-25

SEATS AND RESTRAINTS

WARNING!

Do not remove, modify, or replace

the tether belt system with a different

tether system. A failed or missing

tether belt could allow the seat base

to fully extend in the event of an acci-

dent. Failure to comply may result in

death or personal injury.

Failure to adjust tether belts properly

can cause excessive movement of

the seat in an accident. Tether belts

should be adjusted so that they are

taut when the seat is in its most up-

ward and forward position. Failure to

comply may result in death or personal

injury.

WARNING!

To adjust an external tether belt:

• Make sure that the tether belt is

attached to the cab oor and seat

frame. It should be routed through

the buckle on each side.

• Often the attachments are made

using a split-type hook. Make sure

both halves of the hook are around

the anchor bracket.

• To lengthen the tether, turn the

buckle to a right angle to the

webbing. Then pull the buckle.

To shorten the tether, pull on the

strap.

Komfort-Latch® Feature

Your vehicle includes a feature

designed to eliminate cinching and

provide improved safety and comfort.

Cinching is the condition where a belt

becomes continually tighter around

you during a rough, bouncy ride. The

need for this feature increases with

rough road conditions, particularly over

long distances.

To eliminate cinching, simply activate

the Komfort-Latch feature located

on the seat belt webbing at the

appropriate time:

1. Adjust the seat to its proper driving

position.

2. Latch the seat belt.

3. If available, adjust the seat belt

height adjuster to a comfortable

driving position.

1-26 Y53-1200-1B1 (04/13)

SEATS AND RESTRAINTS

WARNING!

Do not set the Komfort Latch with too

much slack. Too much slack may re-

duce the effectiveness of the seat belt.

Failure to comply may result in death

or personal injury.

4. While seated appropriately, push

the "on" button to engage the

Komfort Latch.

5. Learn forward in the seat until you

hear a "click."

6. Return to normal driving position,

and the Komfort Latch maintains

the preset amount of tension relief.

To disengage the mechanism:

1. Unbuckle the seat belt

2. Press the “OFF” button of the

Komfort Latch or tug on the

shoulder strap. Komfort-Latch®

related problem exists, but the vehicle

can still be safely driven. Vehicle

should be serviced to correct the

problem but the situation should not be

considered an emergency.

15. Engine, Ether Start

Illuminates when ether start switch is

on.

16. Engine, Engine Fan

Illuminates when fan is active.

17. Engine, Heater

Illuminates when Engine Heater switch

is on.

18. Engine, Low Coolant Level

Illuminates with an audible alarm

indicating critically low coolant level.

The vehicle must be serviced to correct

the problem but the situation should

not be considered an emergency.

19. Engine, Overspeed Air

Shutdown (EOAS)

Illuminates when the Engine

Overspeed Air Shutdown system is

activated.

20. Engine, Retarder (Brake)

Illuminates when the engine retarder

(compression brake or exhaust brake)

switch is turned on. (Engine retarders

are an option.)

21. Engine, Stop Engine

Illuminates and an audible alarm tone

will sound when a major engine system

problem exists.

WARNING!

The illumination of the Stop Engine

Light should be considered an emer-

gency. You should stop the vehicle as

safely as possible and turn OFF the ig-

nition. The vehicle must be serviced

and the problem corrected before driv-

ing again. Failure to do so may cause

severe engine damage or cause an

accident involving death or personal

injury.

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

WARNING SYMBOLS

22. Engine, Wait To Start

Illuminates when engine grid heater is

on. (Cummins ISL engines)

23. Fuel, Water In Fuel (WIF)

Illuminates when water has been

detected in the fuel.

24. Lane Departure Warning (LDW)

Illuminates when optional LDW system

is not able to track the vehicle's

position within the lane.

NOTE

For vehicles equipped with Lane De-

parture Warning, please refer to Lane

Departure Warning Driver's Guide for

additional information.

25. Lights, High Beam

Illuminates when the high beams are

on. This icon will ash with audible

alarm if the headlamps are left on

when the door is open. In addition, this

icon will ash, but without an audible

alarm, if there is a problem with the

low beam headlights or the low beam

headlight wiring. In such event, the

high beam headlights will turn on at

50% normal brightness.

26. Power Take-off (PTO)

Illuminates when the PTO is engaged.

NOTE

Do not drive vehicle with PTO en-

gaged.

27. Power Take-off (PTO), Pump

Mode

Illuminates with remote throttle

application. Indicates pump mode is

active.

28. Refrigerator

Illuminates to indicate that the

refrigerator is on and ignition is off.

29. Seat Belt, Fasten

Illuminates when the ignition key is

turned on as a reminder to fasten your

seat belt.

30. Suspension Dump

Illuminates when suspension air bags

are deated.

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

WARNING SYMBOLS

31. Tire Ination

Illuminates when tire pressures need to

be checked. (Tire Pressure Monitoring

System is an option.)

32. Transmission, Auxiliary

Illuminates to indicate auxiliary

transmission is in neutral.

33. Transmission, Check

Illuminates when transmission

has recorded a fault code. This

icon may also appear in the

Transmission Display menu of the

Driver Performance Center. If the user

is in this display menu, the icon does

not indicate a fault code.

34. Transmission, Retarder

(may include BrakeSaver when

applicable)

Illuminates when BrakeSaver (export

only) or Transmission Retarder is

active.

35. Transmission, Service

Transmission (Allison only)

Illuminates when Allison 1000/2000

transmission requires service.

36. Turn Signal, Left

Blinks when the left turn signal or the

hazard light function is operating.

37. Turn Signal, Right

Blinks when the right turn signal or the

hazard light function is operating.

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

OPTIONAL GAUGES

Introduction

Listed here are gauges that may or

may not be on your dashboard or

the center instrument cluster. For

vehicles with a telematic navigation

screen, optional gauges will be part of

the screen functions. Please refer to

the navigation system supplement for

further details about its functions and

how it works.

Axle, Pusher Air Pressure

The Pusher Axle Air Pressure gauge(s)

indicate the air pressure in the pusher

axle(s) suspension air bags. This icon

may have a numeral above the image

of the wheel to indicate which pusher

axle if there are multiple pusher axles

on the vehicle.

Axle, Tag Air Pressure

The Tag Axle Air Pressure gauge

indicates the amount of air pressure in

the tag axle suspension air bags. This

icon may have a numeral above the

image of the wheel to indicate which

pusher axle if there are multiple pusher

axles on the vehicle.

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

OPTIONAL GAUGES

Fuel Filter Restriction Air Filter Restriction

Pressure Indicator or Gauge

3 This gauge tells you the condition

of the fuel lter by indicating the

restriction from the fuel lter to the fuel

pump. Check the engine manual for

proper restriction. Replace the lter

with an approved lter only. Do not

substitute the wrong micron element.

NOTE

The maximum allowable restriction

could vary according to the type or

make of engine. Consult the en-

gine manufacturers manual or engine

dealer for fuel restriction specica-

tions.

CAUTION

This gauge indicates the condition of

the engine air cleaner and is measured

by inches of water (H2O). A clean lter

should register 7 in. H2O (may vary

with system design) and a lter whose

life is over will register approximately

25 in. H2O.

Continued operation with the Air Filter

Restriction Gauge reading 25 in. H2O

may cause damage to the engine. In-

spect the lter and replace if neces-

sary. Holes in the paper element ren-

der an air cleaner useless and may

cause the Air Filter Restriction Gauge

to give a false reading, even if the ele-

ment is clogged. Replace the element

if it is damaged.

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

OPTIONAL GAUGES

Engine, Oil Pressure Engine, Oil Temperature Manifold Pressure Gauge

It is important to maintain oil pressure

within acceptable limits. If oil pressure

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.

The Engine Oil Temperature gauge

indicates the engine oil temperature.

If the oil temperature exceeds the

maximum limits, a red warning

light in the gauge will turn on. Do

not exceed maximum engine oil

temperature recommended by the

engine manufacturer. (See the Engine

Operation and Maintenance Manual

for details.)

Your manifold pressure gauge

indicates the power your engine is

putting out by showing the amount of

turbo boost. If the pressure indicated

by your manifold pressure gauge goes

down, there may be something wrong

with your engine. Have it checked by a

qualied service person.

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

OPTIONAL GAUGES

Fuel Pressure Gauge

Your vehicle may also have a fuel

pressure gauge.

WARNING!

Do not carry additional fuel containers

in your vehicle. Fuel containers, either

full or empty, may leak, explode, and

cause or feed a re, possibly causing

death or personal injury. Do not carry

extra fuel containers, even empty ones

are dangerous.

3-46

Transmission Temperature

Gauge

Your Transmission Temperature

Gauge indicates the temperature of

the oil in your transmission. Watch

this gauge to know when your

transmission is overheating. If it is,

have it checked by an authorized

service representative.

Maximum transmission temperature

may vary, depending upon the

transmission and type of lubricant.

Check your transmission’s owner’s

manual.

Y53-1200-1B1

Drive Axle Temperature

Gauge (Forward and Rear)

These gauges indicate the temperature

of the lubricant in your vehicle’s axle(s).

These temperatures will vary with

the kind of load you are carrying and

the driving conditions you encounter.

Maximum axle temperature may vary,

depending upon the axle and type

of lubricant. Very high temperatures

signal a need to have your axle(s)

lubrication checked.

Depending on the vehicle

conguration, there may be a

drive axle temperature gauge for

more than just the forward and rear

(04/13)

OPTIONAL GAUGES

driver. The icon will have an X over

the representative axle to indicate

which axle the temperature is being

displayed in the gauge.

CAUTION

Driving with very hot temperatures in

your rear drive axles can cause se-

rious damage to axle bearings and

seals. Have your axle lubrication

checked if you notice a sign of over-

heating.

Suspension Load Air

Pressure, #1, #2

Suspension Load Air Pressure #1

Suspension Load Air Pressure #2

The Suspension Load Air Pressure

gauge indicates the amount of air

pressure in the air suspension air bags.

When the vehicle is equipped with dual

leveling valves, the #1 gauge indicates

the air pressure in the driver's side air

bags. The #2 gauge indicates the air

pressure in the passenger's side air

bags.

Tractor Brake Application

Air Pressure

The Tractor Brake Application Air

Pressure gauge indicates the amount

of air pressure applied to the tractor

brakes. 3

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

OPTIONAL GAUGES

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

Pressure Temperature

The Trailer Air Tank Air Pressure

The Trailer Brake Application Air gauge indicates the amount of air

Pressure gauge indicates the amount pressure in the trailer brake air tank.

of air pressure applied to the trailer

brakes during brake foot valve and/or

hand brake control valve applications.

The Transfer Case Oil Temperature

gauge indicates the temperature of

the oil in the transfer case. If the oil

temperature exceeds maximum limits,

a red warning light in the gauge will

turn on. Do not exceed maximum

oil temperature recommended by the

manufacturer. (See the Transfer Case

Operation and Maintenance Manual

for details.)

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

OPTIONAL GAUGES

Transmission Oil Transmission Retarder Oil

Temperature, Auxiliary Temperature

The Auxiliary Transmission Oil

Temperature gauge indicates the

temperature of the oil in the auxiliary

transmission.

NOTE

Watch this gauge to know when the

transmission is overheating.

Do not exceed maximum oil

temperature recommended by the

manufacturer. (See the Transmission

Operation and Maintenance Manual

for details.)

The Transmission Retarder Oil

Temperature gauge indicates

the temperature of the oil in the

transmission retarder.

NOTE

Watch this gauge to know when the

transmission is overheating.

Do not exceed maximum oil

temperature recommended by the

manufacturer. (See the Transmission

Operation and Maintenance Manual

for details.)

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

SWITCHES

Dash Switches

This custom vehicle will have a wide

variety of switch controlled equipment.

However, this particular vehicle may

not have every switch identied in this

section of the operator manual.

Some air device switches on the

dash may require that the vehicle

either be at a specic speed, park

brakes set or another device to be

on or off for the air device to operate.

Dash Switches

The instrument display will display

information regarding what needs to

change in order for the air device to

operate as expected.

Some of these switches control air

system functions and may require the

vehicle’s ignition to be in the ACC

or ON position for switch to maintain

control via air pressure. If the switch

requires ignition power, it will allow that

air circuit to lose pressure (deactivate)

once the ignition is turned off. To

activate that function again, the ignition

needs to be turned to the ACC or ON

position and the switch needs to be

re-engaged. Some of the switches that

control air functions will not disengage

when the vehicle ignition is turned off.

If the ignition is turned off, air pressure

will be maintained in the circuit for

that control switch. The few switches

that do not require ignition power are

described accordingly after the Dash

Switch table.

The Dash Switch table provides a

complete list of icons that may be

found on the switch.

Symbol Name Symbol Color Standard Option Page

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

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

3-60.

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

SWITCHES

Symbol Name Symbol Color Standard Option Page

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

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

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

6. Axle, Inter-Axle Differential Locked (Tandem) Amber ● See Axle, Inter-Axle Differential Locked

(Tandem) on page 3-60.

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

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

9. Batteries, Low Voltage Disconnect (LVD) None ● See Batteries, Low Voltage Disconnect (LVD)

on page 3-60.

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

SWITCHES

Symbol Name Symbol Color Standard Option Page

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

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

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

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

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

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

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

3-61.

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

SWITCHES

Symbol Name Symbol Color Standard Option Page

17. Engine, Cruise Control Set/Resume None ● See Engine, Cruise Control Set/Resume on

page 3-61.

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

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

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

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

3-62.

22. Engine, Overspeed Air Shutdown (Test) Amber ● See Engine, Overspeed Air Shutdown (Test)

on page 3-62.

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

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

SWITCHES

Symbol Name Symbol Color Standard Option Page

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

3-62.

25. Exhaust, Diesel Particulate Filter (DPF)

Regeneration None ● See Exhaust, Diesel Particulate Filter (DPF)

Regeneration on page 3-62.

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

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

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

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

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

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

SWITCHES

Symbol Name Symbol Color Standard Option Page

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

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

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

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

3-64.

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

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

3-64.

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

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

SWITCHES

Symbol Name Symbol Color Standard Option Page

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

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

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

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

3-65.

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

3-65.

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

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

3-65.

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

SWITCHES

Symbol Name Symbol Color Standard Option Page

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

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

3-66.

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

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

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

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

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

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

SWITCHES

Symbol Name Symbol Color Standard Option Page

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

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

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

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

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

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

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

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

SWITCHES

Symbol Name Symbol Color Standard Option Page

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

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

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

3-67.

62. Transmission, Transfer Case Amber ● See Transmission, Transfer Case on page

3-67.

63. Transmission, Transfer Case 2 Speed Amber ● See Transmission, Transfer Case 2 Speed on

page 3-67.

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

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

SWITCHES

1. Axle Diff-Lock - Dual

Turn switch on to engage Front

and Rear Axle Diff Lock.

2. Axle Diff-Lock -Forward Rear

Turn switch on to engage Forward

Rear Axle Diff Lock.

3. Axle Diff Lock - Steer

Turn switch on to engage Front

Axle Diff Lock.

4. Axle Diff-Lock Rear Rear

Turn switch on to engage Rear

Rear Axle Diff Lock.

5. Axle Diff Lock - Single Rear

Turn switch on to engage Single

Rear Axle Diff Lock.

6. Axle, Inter-Axle Differential

Locked (Tandem)

Turn switch on to engage Inter-Axle

Differential Lock.

7. Axle, Two Speed

If equipped, the two speed axle

switch allows you to select axle high

and low ranges. The low range

(Off) provides maximum torque for

operating off-highway. The high

range (On) is a faster ratio for

highway speeds. This switch does

not require ignition power to maintain

the desired switch setting.

8. Back Up Alarm Mute

Turn switch on to mute Back

Up Alarm.

NOTE

The mute function use is discouraged.

Only use mute when legally required.

9. Batteries, Low Voltage

Disconnect (LVD)

If your vehicle is equipped with a Low

Voltage Disconnect (LVD) feature,

the LVD module is located inside

the driver's side kick panel.

10. Brakes, ABS Off-Road

Turn switch on to engage ABS

Off-Road mode. See Anti-Lock

Braking System on page 4-21.

11. Brakes, Parking Brake Valve

Pull yellow knob to activate parking

brakes. See Parking Brake Valve

on page 4-23.

12. Cab Dimmer Switch

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.

13. Dump Truck Gate

Turn switch on to open Dump

Truck Gate.

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

SWITCHES

14. Engine, Brake Level

In the up position there will be 100%

engine retarding. In the middle

position there will be 60% engine

retarding. In the down position there

will be 33% engine retarding.

For more information on when

and how to use the engine brake

in your vehicle, see the engine

brake owner’s manual for additional

engine brake information.

15. Engine, Brake On/Off

Turn switch on to activate Engine

Brake system.

For more information on when

and how to use the engine brake

in your vehicle, see the engine

brake owner’s manual for additional

engine brake information.

16. Engine, Cruise Control On/Off

Turn switch on to activate Cruise

Control System.

17. Engine, Cruise Control

Set/Resume

The Cruise Control Set/Resume

switch allows you to SET the desired

speed or RESUME the desired

speed after the cruise control function

has been interrupted.

WARNING!

Do not operate the cruise control when

operating on road surfaces with poor

traction (wet, icy, or snow covered

roads) or in heavy trafc. Accelera-

tions caused by the normal operation

of the cruise control could cause you

to lose control of the vehicle resulting

in an injury accident.

18. Engine, Ether Start (optional)

Momentarily push switch in to

activate the Ether Start system.

19. Engine Fan Override

The engine fan switch allows you

to control the engine fan manually

or automatically. Please refer to

Engine Fan Control on page 4-12

for more information on how to

operate this switch.

WARNING!

Do not work on or near the fan with the

engine running. Anyone near the en-

gine fan when it turns on could be se-

riously injured. If it is set at MANUAL,

the fan will turn on any time the igni-

tion key switch is turned to the ON po-

sition. In AUTO, it could engage sud-

denly without warning. Before turning

on the ignition or switching from AUTO

to MANUAL, be sure no workers are

near the fan.

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

SWITCHES

CAUTION

The fan or equipment near it could be

damaged if the fan turns on suddenly

when you do not expect it. Keep all

tools and equipment away from the

fan.

Do not operate the engine fan in the

MANUAL position for extended peri-

ods of time. The fan hub was de-

signed for intermittent operation. Sus-

tained operation will shorten the fan

hub’s service life as well as reduce fuel

economy.

20. Engine Heater

Turn switch on to activate the

Engine Heater.

21. Engine, Overspeed Air

Shutdown (Manual)

Turn switch on to engage the

Engine Overspeed Air Shutdown

system. A system reset will be

required before re-starting engine.

See EOAS system manufacturer's

instruction manual for details.

22. Engine, Overspeed Air

Shutdown (Test)

Hold down switch and increase

engine RPM to test that Engine

Overspeed Air Shutdown system

functions correctly. A system

reset will be required before

restarting engine. See EOAS

system manufacturer's instruction

manual for details.

23. Engine, Remote Throttle

Turn switch on to activate Remote

Throttle Control.

24. Engine, Under Hood Air Intake

Operate this switch to control

whether the engine intake is from

under the hood or fresh air from

the air inlet grille.

25. Exhaust, Diesel Particulate

Filter (DPF) Regeneration Switch

Manually controls the diesel

particulate lter regeneration process.

Refer to Engine Aftertreatment

Controls Operator's Manual for

additional information.

26. Fifth Wheel Slide

Turn switch on to “Unlock” Fifth

Wheel Slide mechanism.

The switch is guarded to protect

you from accidentally activating

or releasing the lock.

NOTE

Vehicles having an air slide fth wheel

have a fth wheel slider lock controlled

by a switch on the instrument panel.

By placing the switch in the unlock po-

sition you can slide the fth wheel to

various positions to adjust weight dis-

tribution.

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

SWITCHES

WARNING!

Do not move the fth wheel while the

tractor-trailer is in motion. Your load

could shift suddenly, causing you to

lose control of the vehicle. Never op-

erate the vehicle with the switch in the

UNLOCK position. Always inspect the

fth wheel after you lock the switch to

be sure the fth wheel slide lock is en-

gaged. Failure to comply may result

in death, personal injury, equipment or

property damage.

27. Fuel Heater

Turn switch on to activate Fuel Heater.

28. Generic, Air, Accessory

Provides accessory air to the

end of frame connection when

switch is turned on.

NOTE

The generic air accessory switch is de-

signed by the original equipment man-

ufacturer to reset when the ignition

power is turned off. When ignition is

turned off, this circuit will exhaust air

pressure.

SPARE 29. Generic, Spare

Turn switch on to power customer

installed accessory.

30. Lights, Auxiliary

Turn switch on for Auxiliary Lights.

31. Lights, Beacon

Turn switch on for Beacon Light(s).

32. Lights, Daytime Running

Lights (DRL) (with optional

over-ride switch)

Three controls (or conditions)

will affect whether the system

is ON or OFF:

• headlight (master) switch

• engine cranking

• parking brake

If the headlight switch is turned

OFF, the DRL system engages

automatically after the engine starts

and you release the parking brake.

If the headlight switch is ON, the

DRL system is overridden, and

headlights operate normally. Also,

during engine cranking the DRL

is temporarily turned off.

WARNING!

Do not use daytime running lights

(DRL) during periods of darkness or

reduced visibility. Do not use DRL as a

substitute for headlights or other lights

during operations that require lighting

of your vehicle. Failure to comply may

result in death, personal injury, equip-

ment or property damage.

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

SWITCHES

33. Lights, Dome NOTE

Turn switch on for Cab Dome Lights.

Across the U.S.A. and Canada,

34. Lights, Exterior Lights Self Test State/Provincial requirements vary as

This switch will engage a program to when high beams and fog lights can

which will illuminate exterior light for

the operator to verify functionality. and cannot be used together. Some

Please refer to Exterior Lights Self states allow only four lights to be used

Test on page 3-77 for more detail together, while some allow more. How

on how to use the program. your lights are arranged will affect

whether you can operate headlights

35. Lights, Flood

and fog lights concurrently—always

Flood Lights.

Turn switch on for cab mounted

comply with the state or provincial re-

quirements where you are driving.

36. Lights, Flood ISO 3732 Spare

Turn switch on for trailer mounted 38. Lights, Hazard

Flood Lights. With the switch in the ON position,

37. Lights, Fog the emergency asher makes all four

turn signals (front and rear) ash

Turn switch on for Fog Lights. simultaneously. The asher works

independently of the ignition switch.

You should always use the asher

if the vehicle is disabled or parked

under emergency conditions.

WARNING!

Use your Hazard Warning Light Sys-

tem any time you have to stop off the

road or on the side of the road, day

or night. A hard-to-see vehicle can re-

sult in an injury accident. Another ve-

hicle could run into you if you do not

set your ashers and follow the place-

ment of emergency signals per FM-

CSR 392.22.

39. Lights, Headlight and

Parking Lights

Turn switch on for headlights. When

the Headlights are ON, side, and

tail lights are also on. This switch

also controls the park lights.

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

SWITCHES

CAUTION

If you have conrmed there is a prob-

lem in the low beam wiring circuit, pro-

ceed with caution to the next available

exit/turnoff and safely pull your vehi-

cle completely off the road and call for

assistance. Driving your vehicle with

the headlamps on high beam (at re-

duced intensity) for a prolonged period

could lead to an injury accident. Con-

tact your nearest dealer to have the

problem corrected as soon as possi-

ble.

40. Lights, Marker/Clearance

Turn switch on to control Cab and

Vehicle Marker/Clearance lights.

NOTE

An interrupt switch for the trailer

marker lights is mounted on the end

of the turn signal lever.

41. Lights, Marker/Clearance/Cab

Turn switch on to control Cab

Marker/Clearance lights separately

from the trailer.

42. Lights,

Marker/Clearance/Trailer

Turn switch on to control

Trailer Marker/Clearance lights

separately from the vehicle

marker/clearance lights.

43. Lights, Spot

Turn switch on for Spot Light.

44. Mud and Snow Traction Control

Momentarily push switch in to engage

Traction Control (TC).

45. Power Take-off (PTO)

Turn switch on to engage PTO.

Your vehicle may be equipped with

a dash mounted switch that controls

PTO engagement/disengagement.

When the operator activates the

switch for the PTO, the status

indicator lamp (located on the

switch) will immediately illuminate

even though PTO engagement

may not have occurred.

If the PTO is engaged and the

operator turns the switch OFF, the

PTO status indicator lamp (located

on the switch) will go out immediately

even though PTO disengagement

may not have occurred.

NOTE

Actual PTO engagement/ disengage-

ment may be delayed momentarily

since it is controlled by the air system

and mechanical movement.

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

SWITCHES

CAUTION

Increasing engine RPM before the

PTO is actually engaged could pre-

vent the PTO from engaging and/or

cause PTO damage.

46. Power Take-off (PTO), Forward

Turn switch on to engage

Forward PTO.

47. Power Take-off (PTO), Rear

Turn switch on to engage Rear PTO.

48. Roofdenser

Turn switch on for roof mounted

condenser fan.

49. Suspension, Axle, Pusher

Turn switch on to lower Single or

Forward Pusher Axle. This switch

does not require ignition power to

maintain the desired switch setting.

50. Suspension, Axle, Tag

Turn switch on to lower Tag Axle. This

switch does not require ignition power

to maintain the desired switch setting.

51. Suspension, Dump

Turn switch on to deate Suspension

Air Bags. The switch is guarded

to protect you from accidentally

deating the suspension. This switch

does not require ignition power to

maintain the desired switch setting.

WARNING!

CAUTION

Do not operate the Air Suspension De-

ate Switch (Dump Valve) while driv-

ing. Sudden deation while your vehi-

cle is moving can affect handling and

control and could lead to an accident.

Use this switch only when your vehicle

is not moving.

Operating a vehicle with air suspen-

sion bags either overinated or under-

inated may cause damage to drive-

line components. If a vehicle must

be operated under such conditions, do

not exceed 5 mph (8 km/h).

52. Suspension, Lift

Turn switch on to over-inate

Suspension Air Bags. Turn switch off

for normal suspension height.

53. Suspension, Third Axle Lift

Turn switch on to raise Third

Axle. This switch does not require

ignition power to maintain the

desired switch setting.

54. Pintle Hook

Turn switch on to remove the slack

from the Tow Hook.

55. Trailer, Axle (3rd Axle) Lift

Turn switch on to lift 3rd Trailer

Axle. This switch does not require

ignition power to maintain the

desired switch setting.

56. Trailer, Axle Lift Forward

Turn switch on to lift Forward

Trailer Axle. This switch does not

require ignition power to maintain

the desired switch setting.

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

SWITCHES

57. Trailer, Axle Lift Rear

Turn switch on to lift Rear Trailer

Axle. This switch does not require

ignition power to maintain the

desired switch setting.

58. Trailer, Belly Dump

Turn switch on to open Trailer

Belly Dump.

59. Trailer, Dump Gate

Turn switch on to open Trailer

Dump Gate.

60. Trailer Hotline

Turn switch on to supply electrical

power to trailer accessories.

61. Trailer, Suspension Air Dump

Turn switch on to deate Trailer Air

Suspension. This switch does not

require ignition power to maintain

the desired switch setting.

62. Transmission, Transfer Case

Turn switch on to shift the

Transfer Case.

63. Transmission, Transfer

Case 2 Speed

Turn switch on to shift the 2

Speed Transfer Case.

64. Winch Clutch

Turn switch on to engage

Winch Clutch.

Steering Column Controls

Introduction

1. Tilt Telescoping Lever

2. Turn Signal Lever

3. Trailer Hand Brake

NOTE

The ignition key must be turned to ON

for the signal/switch to operate.

The turn signal lever is mounted on the

left side of the steering column. The

lever controls several functions: turn

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

SWITCHES

signal, ID Clearance lights, high beam

and windshield wiper control.

1. Tilt/Telescoping Steering Column

Depending on your vehicle’s

conguration, you may have either

a Tilt/Telescoping or a xed steering

column.

• The tilt feature allows forward and

rearward movement of the wheel.

• The telescoping feature allows you

to move the wheel up and down.

To activate these features, locate the

Tilt/Telescoping lever.

WARNING!

Make all adjustments to the steer-

ing mechanism while the vehicle is

stopped. Adjusting the Tilt-Telescop-

ing Steering Wheel while the vehicle is

in motion could cause loss of control.

You wouldn’t be able to steer properly

and could have an accident resulting

in death or personal injury.

To adjust the steering wheel, PUSH

and HOLD the lever down fully. Push

or pull the wheel to the desired height

and angle, then PUSH the lever back

into the locked position.

Steering Column Locked

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

SWITCHES

2. Turn Signal/High Beam Switch

NOTE

The ignition key must be turned to ON

for the signal/switch to operate.

The lever-action turn signal/high beam

switch is located on the left side of

the steering column.Each time a turn

indicator is activated the buzzer emits

a short beep.

Turn Signals

Steering Column Unlocked

Turn Signal

• To signal a right turn, push the

lever forward (clockwise).

(04/13) Y53-1200-1B1

• To signal a left turn, pull the lever

back (counterclockwise).

• Each time the turn indicator is

activated the audible warning

emits a short beep.

NOTE

If the vehicle turn signals and turn sig-

nal indicators in the dash gauge clus-

ter ever begin ashing at an acceler-

ated rate (115 cycles per minute) when

the turn signal lever is in the OFF (cen-

ter) position, or when a Right/Left turn

has been selected, the problem may

be related to a failed turn signal switch

or turn signal module. In either case,

the problem is not a failed bulb. Con-

tact your nearest authorized dealer to

have the problem corrected as soon as

possible.

3-69

SWITCHES

WARNING!

After you complete a turn, shut the

system off by returning the lever to

the “OFF” (center) position. Failure

to shut off a turn signal could confuse

other drivers and result in an injury ac-

cident. An indicator light in the instru-

ment panel will ash until the turn sig-

nal is turned off.

High Beam

NOTE

The headlights must be ON for the

high beam switch to operate.

• To switch your headlights to lower

or higher beam, gently pull the turn

signal lever, toward the steering

wheel, until you hear the switch

click and the beam changes.

The blue indicator light in the

instrument panel will be ON when

the high beam is being used.

• To return to previous beam: pull

the lever towards the steering

wheel again.

• The high beams can be

momentarily ashed with or

without the headlights being on.

To ash the high beams, gently

push the headlight lever away from

the steering wheel to momentarily

turn on the lights.

NOTE

Continued pressing of the high beam

ash will not keep the high beams on.

NOTE

The “ash to pass” functionality of the

headlight switch is not available for

vehicles manufactured with High In-

tensity Discharge (HID) headlamps.

Please check with local regulations

regarding restrictions on using high

beam ashing.

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

SWITCHES

Windshield Wipers/Washer

Your vehicle is equipped with a

two-speed, intermittent windshield

wiper system. The windshield wiper

system is integrated with the exterior

lights so that the low beam headlights

will turn on when the windshield wipers

Flash to pass turn on.

To override this function, turn

the headlights on and then off

again and the low beams will turn

off. Permanently overriding this

functionality is attainable via the

Settings Menu in the instrument cluster

ID and Clearance Lights Flash display. Go to Settings - > Wiper

Interlock and turn this value to OFF.

A seven-position rotary wiper switch

(located on the turn signal lever)

operates the windshield wipers and

washer. Rotate the end of the turn

signal lever to change the wiper mode.

(04/13) Y53-1200-1B1

NOTE

The ignition key must be turned to ON

or ACC for the wiper/washer switches

to operate.

Wiper/Washer

The rst position after OFF is the

intermittent #1 cycle. The next

positions are intermittent #2, #3, and

#4. The last two positions are wiper

low speed and wiper high speed.

To wash the windshield:

Push the rotary wash/wipe knob in

(towards steering column), hold for

more than 0.8 seconds and then

release. hold the knob in to extend

3-71

SWITCHES

the washing cycle. after the lever

is released, the wipers will shut off

automatically or resume the wiper’s

setting speed.

To activate the wipers for one swipe

without activating the washer (“mist”

function), push the turn signal lever

in (towards the steering column) and

release in less than 0.5 seconds. The

wipers will perform a single swipe and

then resume the wiper’s setting speed.

WARNING!

Clean blades regularly with a damp

cloth to remove road lm and wax

build-up. Do not drive with worn or

dirty wiper blades. They can reduce

visibility, making driving hazardous

which may lead to an injury accident

resulting in death or personal injury.

CAUTION

Do not use antifreeze or engine

coolant in the windshield washer

reservoir - damage to seals and other

components will result.

If the electric pump is operated for a

long period (more than 15 seconds)

with a dry reservoir, the pump motor

may be damaged.

Check the windshield washing uid

level daily. If necessary, ll to top.

Clean all inside and outside windows

regularly. Use an alcohol-based

cleaning solution and wipe dry with

either a lint-free or a chamois cloth.

Avoid running the wiper blades over a

dry windshield to prevent scratching

the glass. Spray on washer uid rst.

A scratched windshield will reduce

visibility.

3. Trailer Brake Hand Valve

This hand valve, mounted on the

steering wheel column, provides air

pressure to apply the trailer brakes

only. It operates independently of

the foot treadle valve. See Using the

Brake System on page 4-21, for more

instructions on proper use of the Trailer

Brake Hand Valve.

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

SWITCHES

Steering Wheel Controls

(Optional)

CAUTION

Under no circumstances should you

attempt to service the steering wheel,

clockspring, or any of the electrical

wiring in the multiplex system, or any

steering components (steering col-

umn, steering driveline or steering

gear). Tampering with these com-

ponents may result in an inoperable

multiplex system.

This vehicle may be equipped with an

optional steering wheel with audio and

cruise control button mounted on the

spokes of the steering wheel.

1. Left Switch Pod

2. Horn

3. Right Switch Pod

System Description

The steering wheel contains controls

for commonly used functions so that

the operator does not have to take

their hands off of the steering wheel to

operate.

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

SWITCHES

Operating the System

Horn - Depressing the bottom center

bar activates the electric horn.

Cruise Control -Vehicles with

steering wheel controls will have cruise

control options on the right hand of the

wheel instead of the switches on the

dashboard. These optional switches

for cruise control include a third switch

to allow the operator to accelerate or

coast while maintaining cruise control

operation. For complete operating

instructions, see Cruise Control on

page 4-35.

3-74

Left Switch Pod

1. Audio Volume +/-

2. Audio Seek +/-

3. Audio Mute/Mode

Right Switch Pod

1. Cruise Control

On/Off/Cancel

2. Cruise Control Set/Resume

3. Cruise Control

Accelerate/Coast

Y53-1200-1B1 (04/13)

SWITCHES

Do not operate the cruise control when

operating on road surfaces with poor

traction (wet, icy, or snow covered

roads) or in heavy trafc. Accelera-

tions caused by the normal operation

of the cruise control could cause you

to lose control of the vehicle resulting

in an injury accident.

WARNING!

Horn

To use the electric horn, press the

button in the center of the steering

wheel, which is the standard location

for electric horns. Your vehicle may be

equipped with air horns. To operate,

pull on the lanyard extending from the

overhead header panel.

Door Mounted Controls

Introduction

If your vehicle is equipped with power

mirrors, the mirror controls will be

located on the driver side door pad.

Mirrors can be adjusted in 4 directions.

1. Mirror Heat Switch

2. Power Mirror Switch

3. Mirror Selector Switch

4. Power Door Lock Switch

5. Power Window Switch

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

SWITCHES

Adjust all mirrors before driving. Ad-

justing the mirrors while driving can

cause you to take your eyes off the

road, which could result in an accident.

Failure to do so could lead to serious

injury or equipment damage.

WARNING!

To provide good visibility, adjust the

mirror so the side of your vehicle

appears in the inboard part of the

mirror.

WARNING!

Convex mirrors can distort images

and make objects appear smaller and

farther away than they really are. You

could have an accident if you are too

close to another vehicle or other ob-

ject. Keep plenty of space between

your vehicle and others when you

turn or change lanes. Remember that

other objects are closer than they may

appear.

1. Mirror Heat Switch

Your vehicle may be equipped with

optional heated mirrors. Mirror heat

is controlled by the mirror heat switch

button, which is part of the mirror

switch module located on the driver

side door pad.

NOTE

The Mirror Heat switch also controls

the optional hood mounted mirror

heat.

2. Power Mirror Switch

If your vehicle is equipped with power

mirrors, the directional controls for

both mirrors are located near the top of

the driver side door trim pad.

1. Move the mirror selector switch

(3) to the right or left from the

neutral center position to select

the desired mirror for adjustment.

2. Depress the mirror directional

control pad (2) in one of its four

arrow directions to adjust the

mirror in/out or up/down.

NOTE

After mirror adjustments have been

completed, return the mirror selector

switch back (3) to the center (neutral)

position to prevent unintentional ad-

justments to the mirrors.

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

SWITCHES

4. Power Door Lock Switch

Power door lock rocker switches are

located on the door pads. To lock or

unlock both cab doors as well as a

sleeper door, depress any door lock

switch at the end that displays a closed

or open padlock symbol, respectively,

on the switch face.

5. Power Window Switch

Power window rocker switches are

located on the door pads. Depress

the switch to open the window or pull

up on the switch to close the window.

Release the switch to stop window

movement. The drivers side window

has an express down feature. Pushing

on the switch all the way down until the

switch bumps will activate the express

down feature. Release the button and

the window will continue to open until it

is completely open.

Exterior Lights Self Test

To start the Exterior Light Self-Test

(ELST) feature:

1. Park the vehicle and set the

parking brakes.

2. Insert the key into the ignition, start

the engine and allow the vehicle

to run through its own Power On

Self Test.

3. Press the momentary switch on

the dash to start the ELST.

This feature allows the operator to

verify and inspect exterior lighting

operation typically performed during a

pre-trip inspection. When the feature

is engaged, via a switch on the dash, it

will illuminate the:

• Park lights

• Side marker lights

• Hazard/turn signals

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

SWITCHES

• Lo beam headlamps

• First set of fog/driving lights

The test will turn those lights off and

then illuminate the:

• Park lights

• Side marker lights

• Hi beam headlamps

• Stop/Brake lights

After turning these lights off, the

system will resume testing the rst set

of lights. The light test will eventually

stop on its own. The operator may

interrupt the test by turning the vehicle

off or pressing the switch a second time

while the test is running. The operator

can verify the light functionality by

visibly watching the light from outside

the vehicle during the test or can read

the instrument cluster for any faults

displayed that are lighting related.

3-78 Y53-1200-1B1 (04/13)

HEATING AND AIR CONDITIONING

HEATING AND AIR

CONDITIONING

Cab Controls

1. Fan Control Dial 4. MAX Defrost Button 7. Temperature Sensor

2. AUTO Mode Button 5. Air Distribution Dial 8. Air Conditioner Button

3. Temperature Control Dial 6. Sleeper Override Button (for vehicles with a 9. Outside Air / Recirculation Air Button

sleeper)

(04/13) Y53-1200-1B1 3-79

HEATING AND AIR CONDITIONING

Introduction

Your vehicles heating and air

conditioning system operates in three

distinct modes; manual, automatic,

and maximum defrost. Each mode

provides the driver with the greatest

level of comfort and convenience while

maintaining the exibility of traditional

systems.

The recommended mode for all

conditions that do not require

windshield defrosting is the automatic

mode on page 3-83. This mode is

capable of maintaining cab comfort

under various driving conditions

without driver interaction.

The cab heater and A/C controls are

located together in the center of the

dash just to the right of the steering

column. The sleeper heater and A/C

controls are located in the sleeper

cabinet.

WARNING!

Do not drive with visibility reduced

by fog, condensation, or frost on the

windshield. Your view may be ob-

scured, which may result in death,

personal injury, equipment or prop-

erty damage. For clear visibility and

safe driving it is extremely important

for you to follow the instructions per-

taining to the function and use of the

ventilation/heating and defogging/de-

frosting system. If in doubt, consult

your dealer. Maximum heating output

and fast defrosting can be obtained

only after the engine has reached op-

erating temperature.

WARNING!

Exhaust fumes from the engine con-

tain carbon monoxide, a colorless and

odorless gas. Do not breathe the

engine exhaust gas. A poorly main-

tained, damaged or corroded exhaust

system can allow carbon monoxide to

enter the cab. Entry of carbon monox-

ide into the cab is also possible from

other vehicles nearby. Failure to prop-

erly maintain your vehicle could cause

carbon monoxide to enter the cab,

resulting in death or personal injury.

3-80 Y53-1200-1B1 (04/13)

HEATING AND AIR CONDITIONING

WARNING!

Never idle your vehicle for prolonged

periods of time if you sense that ex-

haust fumes are entering the cab. In-

vestigate the cause of the fumes and

correct it as soon as possible. If the ve-

hicle must be driven under these con-

ditions, drive only with the windows

open. Failure to repair the source of

the exhaust fumes may result in death,

personal injury, equipment or property

damage.

NOTE

Keep the engine exhaust system and

the vehicles cab ventilation system

properly maintained. It is recom-

mended that the vehicles exhaust

system and cab be inspected:

• By a competent technician every

15,000 miles,

• Whenever a change is noticed in

the sound of the exhaust system,

• Whenever the exhaust system,

underbody, or cab is damaged.

NOTE

To allow for proper operation of the ve-

hicle ventilation system, keep the in-

let grille at the base of the windshield

clear of snow, ice, leaves and other ob-

structions at all times.

CAUTION

Do not stay in the vehicle with the en-

gine running or idling for more than 10

minutes with the vehicle's Heater and

A/C ventilation system in RECIRC or

at LOW FAN SPEED. Even with the

ventilation system on, running the en-

gine while parked or stopped for pro-

longed periods of time is not recom-

mended.

NOTE

When idling for short periods of time:

• Set the heating or cooling system

to Heat or A/C

• Set the fan to Medium or High

speed

• Set the controls to FRESH AIR

(04/13) Y53-1200-1B1 3-81

HEATING AND AIR CONDITIONING

NOTE

If you are required to idle your vehi-

cle for long periods of time, install an

auxiliary heater or automatic idle con-

trol. These auxiliary devices can re-

duce fuel consumption and save you

money.

NOTE

If you are parked next to idling vehi-

cles, move your vehicle or do not stay

in your vehicle for prolonged periods of

time.

Manual Control Mode

The manual mode is the default mode

when the heating and air conditioning

system is turned on. The fan speed,

air temperature, and air outlets

are selected using the dials on the

controller.

Adjusting the settings:

Step 1: To adjust the fan speed,

turn the fan control dial clockwise to

increase speed or counterclockwise

to decrease speed. Setting the fan

dial to “O” turns the HVAC system off.

Step 2: To adjust the temperature

setting, turn the temperature control

dial to the desired temperature. The

system automatically adjusts the

outlet air temperature to achieve

the desired cab temperature.

Step 3: To adjust the air distribution,

turn the air distribution dial to the

desired position as indicated by the

graphics.

For vehicles with a sleeper, the

cab control can be used to

activate/deactivate the sleeper

HVAC using the button inside the

mode dial.

The temperature of the air from the

vents will uctuate as the vehicle

works to achieve the chosen cab

temperature. Note that in manual

mode the system does not engage

the A/C compressor automatically. To

engage the air conditioning, press the

button inside the temperature dial. To

engage recirculation of cab air, press

the button inside the fan speed dial.

3-82 Y53-1200-1B1 (04/13)

HEATING AND AIR CONDITIONING

Automatic Control Mode

Your vehicle’s air conditioning system

is equipped with an automatic button

that provides complete cab climate

control without driver interaction. When

selected, the system will manipulate

the air distribution, air temperature, fan

speed, A/C compressor, and cab air

recirculation to achieve the comfort

level selected on the temperature dial.

The button that enables automatic

mode is labeled AUTO. The system

will remain in automatic mode until the

driver adjusts the dials on the control.

Adjust the temperature knob and the

system will respond to obtain the

selected comfort level as quickly as

possible.

Using the automatic mode:

Step 1: Turn on HVAC by rotating

fan speed control clockwise.

Step 2: To engage automatic

mode, press the AUTO button.

Step 3: To adjust cab temperature,

rotate the temperature dial to the

desired temperature. The system

automatically adjusts to achieve the

desired cab temperature.

The system will achieve the comfort

level associated with the selected

temperature on the temperature dial.

Therefore, depending on the specic

environmental conditions, the air

temperature can be slightly higher or

lower than the set point. This is a

normal function of the AUTO mode and

is not to mistaken for a malfunctioning

system.

The AUTO function uses a sun light

sensor to measure the amount of

sunlight entering the cab. This sensor

is located at the base of the windshield

on the driver’s side of the instrument

panel. Do not block this sensor.

1 Sunlight Sensor

Partial Automatic

During AUTO mode the operator may

override any setting and operate in

a partial automatic mode. This can

be done via the dials and/or buttons

(04/13) Y53-1200-1B1 3-83

HEATING AND AIR CONDITIONING

on the HVAC control. In the partial

automatic mode, the AUTO button

indicator will cease to be illuminated.

Instead, the indicator of the adjusted

setting will illuminate.

For example, if the driver adjusts the

fan dial while in AUTO mode, the

fan dial indicator will illuminate and

fan speed will adjust to the setting of

the dial. However, the temperature

and air outlet settings will continue to

function automatically. Similarly, if user

adjusts the air distribution setting while

in AUTO mode, the air distribution

dial indicator will illuminate and the

distribution will adjust to the setting

of the dial. The fan and temperature

settings will continue to function

automatically.

Economy Function

An economy function is also available

in partial automatic mode. In this mode

the system will operate in AUTO mode

without the use of the A/C compressor.

The operator may select economy

by initiating AUTO mode and then

pressing the A/C button to disengage

the compressor. The indicators for A/C

compressor and AUTO mode do not

illuminate while operating in economy

mode.

MAX Defrost Mode

The heating and air conditioning

system provides for one touch

windshield defrosting. Certain driving

conditions will cause fog or ice to form

on the windshield. By pressing the

MAX defrost button, the HVAC system

will automatically adjust the blower

speed, air temperature, and air outlet

distribution to maximize clearing of the

windshield. The system will remain in

this mode until the driver presses the

button again or adjusts the dials.

Note that the air temperature in MAX

defrost mode will be set to the warmest

temperature setting. This setting helps

to clear the windshield of ice and fog

more quickly. Outside air mode and

A/C compressor are also active to

maximize performance.

3-84 Y53-1200-1B1 (04/13)

HEATING AND AIR CONDITIONING

Buttons and Dials

Fan Speed Control Dial

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.

Fan Speed Adjustment

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.

Outside Air/Recirculation Air

Button

Air Distribution Dial

The mode of air distribution inside the

cab is set using the air distribution

dial. Five icons on the dial indicate

the primary mode options. The driver

may also select a secondary mode in

between the primary modes indicated

by points on the dial. Airow is

provided to the side windows in all

modes.

Panel Vents

Panel and Floor Vents

Floor Vents

Floor and *Defrost Vents

*Defrost Vents

*Automatically engages outside air and A/C

compressor.

Power to the sleeper HVAC unit can

be toggled using the button inside the

air distribution dial. When activated,

the indicator on the button illuminates.

The sleeper HVAC unit will function to

the settings of the sleeper control.

Sleeper Override Button (for

vehicles with a sleeper)

(04/13) Y53-1200-1B1 3-85

HEATING AND AIR CONDITIONING

Temperature Control Dial

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.

Temperature Control Set Point

The button inside the temperature

control dial engages the A/C

compressor. When activated the

indicator on the button will illuminate.

During AUTO mode, the A/C button

indicator will remain illuminated at all

times even though the compressor

may be cycling.

Air Conditioner Button

NOTE

Fan control dial must also be in the

ON position to engage the A/C com-

pressor. A/C engages automatically in

AUTO, defrost and oor/defrost.

Operating Tips

Defrosting and Defogging the

Windshield

The cab windshield and side windows

can be cleared of ice and fog in two

ways. The rst is to use the MAX

defrost mode (See MAX defrost

section). The second is to manually

adjust the air distribution dial to the

defrost position.

3-86 Y53-1200-1B1 (04/13)

HEATING AND AIR CONDITIONING

CAUTION

During extreme cold weather, do not

blow hot defroster air onto cold wind-

shields. This could crack the glass.

Turn the Air Flow Control Dial to

Defrost and adjust the fan speed ac-

cordingly 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. Failure to comply

may result in equipment damage.

Manual Windshield

Defrosting/Defogging

The manual defrost/defogging mode

differs from the MAX defrost mode

by allowing the driver to select an air

temperature other than full heat. This

allows the driver to maintain a constant

cab temperature while defrosting

the windshield. Note however that

performance may be reduced.

Step 1: Adjust the fan speed to high by

rotating the fan control dial clockwise.

Step 2: Set the air distribution

dial to the defrost mode setting.

This automatically engages the

outside air and A/C compressor.

Step 3: Adjust the temperature dial to

add heat as needed. For maximum

performance, adjust the temperature

to maximum heat by rotating the

temperature dial clockwise.

The driver may also use the

oor/defrost setting on the air control

dial to maintain a clear windshield while

providing heat to the oor. This setting

may be helpful in conditions where the

windshield re-fogs. To increase the

effectiveness of the defroster, engage

the A/C compressor.

(04/13) Y53-1200-1B1 3-87

HEATING AND AIR CONDITIONING

For Maximum Cooling

Step 1: Adjust the fan speed to high by

rotating the fan control dial clockwise.

Step 2: Set the air distribution

dial to the panel setting.

Step 3: Adjust the air temperature

to maximum cool by rotating the

temperature dial counterclockwise.

Step 4: Engage the A/C compressor

by pressing the air conditioner button.

Step 5: Set the air source to

recirculation mode by pressing the

outside air / recirculation air button.

The button indicator light should be

illuminated.

For Maximum Heating

Step 1: Adjust the fan speed to high by

rotating the fan control dial clockwise.

Step 2: Set the air distribution

dial to the oor setting.

Step 3: Adjust the air temperature

to maximum heat by rotating the

temperature dial clockwise.

NOTE

The engine must be at operating tem-

perature for maximum heating. If op-

erating in AUTO mode, heating airow

is not allowed until the engine warms

sufciently to provide required coolant

temperatures.

Air Dehumidication

The HVAC system can be used to

reduce the humidity level of the cab

and clear fog from the windshield.

Step 1: Adjust fan speed to

the desired airow setting.

Step 2: Engage the A/C compressor

by pressing the air conditioner button.

Step 3: Set the air source to outside

air mode by pressing the outside

air / recirculation air button. The

button indicator light should NOT be

illuminated.

NOTE

That the A/C compressor may not en-

gage when the outside temperature is

below 34ºF (1ºC).

3-88 Y53-1200-1B1 (04/13)

HEATING AND AIR CONDITIONING

Cab Air Distribution

Equal distribution of air is important

in maintaining a constant cab interior

temperature. For best performance, all

vents should remain open to allow the

AUTO mode to function properly.

To maintain the selected cab

temperature the AUTO mode may

provide an air temperature from the

vents that differs from the temperature

set point. To ensure proper operation,

it is recommended that the driver

redirects the air instead of adjusting

the temperature set point or closing

the vent. The system may have

difculties in obtaining the desired

cabin temperature if the temperature

setting is repeatedly changed.

Outside Air / Recirculation Air

Selecting air recirculation mode

completely isolates the cab interior

from the outside air. This mode is

helpful in preventing dust, pollen,

and odors from entering the cab.

Additionally, recirculation mode can

reduce the amount of time needed

to cool down the vehicle while in

maximum cool down. Note that the

mode may increase fogging on the

windshield. A coarse air lter is

provided for recirculation air and is

located under the IP.

The outside air mode provides for

100% outside air into the cab. This

mode is helpful with windshield

defogging. A pleated air lter located

under hood provides ltration for dust,

pollen, and debris. If equipped, your

vehicle may also provide for ember

ltration or ne particulate ltration.

Sleeper Heater - A/C

Controls (optional)

Sleeper Controls

1. Fan Control Dial

2. Temperature Control Dial

3. Air Conditioner Button

Unlike the cabin air temperature

controls, the sleeper temperature

control will alter the air temperature

based on the knob setting. The

temperature control is not keyed

to specic temperatures. Turning

counterclockwise means cooler than

it is now. Clockwise means warmer

than it is now. Once the desired

(04/13) Y53-1200-1B1 3-89

HEATING AND AIR CONDITIONING

temperature is reached, the system

will maintain it automatically.

A separate switch on the dash HVAC

unit will send power to the “bunk” or

sleeper control unit The button on the

cab HVAC unit must be pressed and

in the on mode to use the sleeper

controls.

The sleeper control unit has three

controls:

1. Air Speed Control

2. Air Conditioner Compressor

On/Off

3. Air Temperature Control

NOTE

The sensor is located on the sleeper

heater - A/C control panel and mea-

sures the sleeper air temperature at

the panel. There will be a time de-

lay between temperature control ad-

justment and sleeper air temperature

change. Also, be careful of any heat

source, which could affect the air tem-

perature by the sensor. Avoid hanging

items (e.g. shirt, jacket, etc.) which

could block the air ow to the sensor.

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

ACCESSORIES

Sleeper Alarm Clock

1. Alarm - press to turn on the

alarm

Increase value of setting

Decrease value of setting

time/date and or alarm

setting

2. Snooze - press to snooze

the alarm bell

7. Select - press to choose the

setting being changed while

9. Active alarm icon - alarm

is activated when this icon

3. Dimmer/brighter - press to

make display brighter

adjusting the either the time

or the alarm

appears

4. Dimmer/darker - press to

make display less bright

8. Time and Alarm value

setting - press to change

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

ACCESSORIES

Setting System Time

NOTE

The year “2010” will display when set-

ting the clock for the rst time or if bat-

tery power had been lost.

1. Press the MODE button until the

screen begins ashing.

2. Use the UP and DOWN buttons to

adjust the value.

3. Press the SEL button to adjust

the next setting and use the UP

and DOWN buttons to change the

value.

4. Repeat this for all settings. The

alarm clock will scroll in the

following order each time you

press the SEL button.

a. Year

b. Month

c. Day

Setting System Alarm

d. Hours

1. Press the MODE button twice until

e. Minutes the screen displays the AL icon.

5. To exit and save your settings, 2. Use the UP and DOWN buttons to

press the MODE button once you adjust the setting.

have set the minutes.

3. Press the SEL button to adjust

the next setting and use the UP

and DOWN buttons to change the

setting.

4. Repeat this for all areas. The

alarm clock will scroll in the

following order each time you

press the SEL button.

a. Hours

b. Minutes

5. To exit and save your settings,

press the MODE button once you

have set the minutes.

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

ACCESSORIES

Turning the Alarm On/Off

Press the ALM button to turn the alarm

on and off. The icon (9) will illuminate

when the alarm is active.

When time reaches the set time

the alarm will ring. If the snooze

button is not pressed, the alarm will

continue ringing for 15 minutes then

will automatically stop. Pressing any

other button except SNZ (2) will turn

the alarm off.

Snooze Operation Dim Control Operation

When the alarm is ringing press the Press the DIM+ or DIM- buttons (3, 4)

SNZ button (2) to silence the alarm for to change the brightness of the display.

9 minutes. The small bell icon (9) will

ash until the alarm is shut off. The

snooze button can be used as many

times as desired.

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

ACCESSORIES

Radio (Option)

As an option, your vehicle has either

an AM/FM Stereo Receiver, which may

or may not have a CD, or may have

the stereo system integrated with your

Navigation and telematics unit.

Other radio options include a bluetooth

or satellite receiver.

For instructions on how to operate your

particular radio, see the supplemental

operating manual for those units.

Cigarette Lighter and

Ashtray (Option)

NOTE

The cigarette lighter will operate with

the ignition key in either the OFF, ACC

(accessory), or ON position.

This vehicle comes standard with two

cupholders and power ports located

in the center of the dashboard. This

vehicle may have the optional ashtray

insert (for the cupholder) and the

optional cigarette lighter in a power

port.

To operate, push in on the knob end

of the lighter. After a few moments,

the lighter will automatically pop out,

glowing hot and ready to use. After

use, insert the lighter back into the

socket without pushing all the way in.

The socket of the cigarette lighter may

be used to operate 12 volt, 15 ampere

appliances, such as a hand spotlight

or small vacuum cleaner.

WARNING!

Do not place paper or other com-

bustible substances in an ashtray, it

could cause a re. Keep all burnable

materials, besides smoking materials,

out of the ashtray. Failure to comply

may result in death, personal injury,

equipment or property damage.

Do not exceed the voltage/amperage

capacity of the cigarette lighter. It

could result in a re. Follow all warn-

ings and instructions in the operator's

manual for the appliance you are us-

ing. Failure to comply may result in

death, personal injury, equipment or

property damage.

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

ACCESSORIES

Cab Storage

Glove Box

A glove box is provided to store

important documents, the vehicle

literature set (including this Operator's

Manual) and other related materials.

WARNING!

Do not drive with the glove box open,

it can be dangerous. In an accident

or sudden stop, you or a passenger

could be thrown against the cover and

be injured. To reduce the risk of per-

sonal injury during an accident or sud-

den stop, keep the glove box closed

when the vehicle is in motion.

You can choose from a variety of other

interior storage options to store your

personal supplies or small tools:

- center console

- map pocket on the door

- overhead storage compartments

Do not carry loose objects in your cab,

it can be dangerous. In a sudden

stop, or even going over a bump in the

road, they could y through the air and

strike you or a passenger. You could

be injured or even killed. Secure all

loose objects in the cab before moving

the vehicle. Carry any heavy objects

such as luggage in the exterior storage

compartment and close it securely.

WARNING!

Appliances

If your vehicle is equipped with a

television, or other appliance, be sure

they are compatible with your vehicle's

electrical system. Secure them in the

cab so they cannot come loose in a

sudden stop.

WARNING!

In a sudden stop or collision a heavy

object in your cab could strike you or

anyone with you. You could be injured

or even killed. Secure any appliance

(such as a radio, or TV) you add to

your sleeper or cab.

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

ACCESSORIES

Ignition Key Switch

The ignition key switch (located to the

left of the steering column) has four

positions: ACC (Accessories), OFF,

ON, and START.

OFF: In this position all accessories

are OFF (except those listed below)

and you can remove the key.

The following lights and accessories

have power when the key is in the OFF

position:

• brake lights

• emergency hazard asher

• dome and courtesy lamps (on

doors)

• electric horn

• cigarette lighter

• tail lights

• marker lamps

• headlights

• radio station memory

• instrument lights

• auxiliary power

• instrument panel memory settings

ACC (Accessory): With the key in this

position you can play the radio, defrost

mirrors (if equipped with mirror heat)

or use other accessories.

ON: In the ON position all circuits are

energized. Panel warning lights will

light and the buzzer will sound until

(1) the engine is started, (2) normal oil

operating pressure is reached, and (3)

air brake system pressure is above

65 psi (441 kPa). In this position, the

ignition key cannot be removed.

START: Turn the key to this position

to start your engine. Release the

key after the engine has started. For

complete engine starting procedures,

see Operating The Engine on page

4-5.

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

ACCESSORIES

Vehicle Telematic System

Your vehicle may be equipped with

an onboard telematics system. This

system is a Global Positioning Satellite

(GPS)-linked computer. It receives

input from multiple sources to locate

your vehicle. Read and understand

the Supplemental Telematics and

Navigation System Owner’s Manual

and observe the Warnings, Cautions,

and Notes that follow before using the

system.

WARNING!

Verify legal weight and height restric-

tions for the route suggested by the

telematic system. Failure to verify

height restrictions could lead to caus-

ing death, personal injury or property

damage. Failure to verify weight re-

strictions could result in a trafc infrac-

tion.

WARNING!

Only glance at the system monitor

while driving. Prolonged periods of

viewing while driving could result in an

accident involving death or personal

injury.

Do not program the telematic system

while driving. Always stop your ve-

hicle when programming or changing

the settings on the telematic system.

Programming the system while driving

can cause you to take your eyes off

the road, which could result in an ac-

cident involving death, personal injury

or equipment damage.

WARNING!

CAUTION

Regardless of how and where the nav-

igation system directs you, it is your re-

sponsibility to operate the vehicle in a

safe and legal manner. Failure to com-

ply may result in death, personal injury,

equipment or property damage.

Ensure the volume level of all audio

devices is set to a level that still allows

you to hear outside trafc and emer-

gency vehicles. Failure to comply may

result in death, personal injury, equip-

ment or property damage.

Do not rely on the telematic system

to route you to the closest emergency

services. Not all emergency services

are in the database.

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

ACCESSORIES

NOTE

The map database is the most cur-

rent available at the time of produc-

tion. The database is designed to pro-

vide you with route suggestions and

does not take into account the relative

safety of a suggested route or of fac-

tors that may affect the time required to

reach your destination. See the Sup-

plemental Navigation System Owner’s

Manual for more information.

Care of the Display Screen

From time to time it may be necessary

to clean the display screen. To clean

the screen, dampen a clean, soft,

lint-free cloth with water only. A mild

glass cleaner that does not contain

alcohol or ammonia may also be

used. Cleaners that contain alcohol

and/or ammonia will eventually dry-out,

crack and "yellow" the screen. Wipe

the screen gently back and forth. You

can also use a commercial cleaner

especially designed for LCD screens.

Screen Display On/Off

1. Press and hold the POWER/LIGHT

button for approximately 1 second.

2. After the display has been turned

on, the following Warning/Informational

screen will appear:

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

ACCESSORIES

Warning/Informational Screen

WARNING

Do not let this device distract you while

driving. Always concentrate on you

driving. Distractions could cause an

accident resulting in injuries to you or

others.

IMPORTANT

Disclaimer: Map data may be inaccurate and

navigation routes may not be available for

larger size vehicles.

Regardless of how and where the navigation

system directs you, it is your responsibility

to operate the vehicle in a safe and legal

manner.

Note: Before using this system, read

the Owner's Manual and learn how it

operates. Some functions of this syste

will not operate when the truck is moving.

3. After reading the information, touch

the TT

Tin the upper right corner of the

screen with your nger indicating you

acknowledge and understand the

information. The MENU screen will Passenger Side 'down'

automatically appear next. Mirror

4. To turn the system off, press and

hold the POWER/LIGHT button for 3

seconds.

Disclaimer

The vehicle manufacturer is not

responsible for erroneous map data,

misrouting or any downtime or other

damages associated with or arising out

of the use of the Navigation System. A mirror is located above the

passenger door that provides a quick

view of the blind spot created by the

passenger door.

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

ACCESSORIES

Rotate the mirror up or down to get the

desired view.

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

STARTING AND OPERATING

Introduction .................. 4-5

Normal Weather ................ 4-5

Cold Weather ................. 4-6

Engine Block Heater (Option). . . . . . . . . . . 4-6

Engine Warm-up ................ 4-7

Ether Metering Equipment . . . . . . . . . . . 4-10

OPERATING THE ENGINE

Stationary PTO Operation . . . . . . . . . . . 4-12

Engine Fan Control .............. 4-12

Winterfronts................. 4-13

Engine Control Display . . . . . . . . . . . . 4-14

OPERATING THE TRANSMISSION

Operating Hydraulic Clutch (Manual Transmission) 4-15

Operating Manual Transmissions . . . . . . . . 4-15

Putting the Vehicle in Motion . . . . . . . . . . 4-16

Automatic and Automated Transmissions . . . . 4-19

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

STARTING AND OPERATING

Auxiliary Transmission . . . . . . . . . . . . . 4-20

More Transmission Tips . . . . . . . . . . . . 4-20

OPERATING THE BRAKE SYSTEM

Introduction . . . . . . . . . . . . . . . . . 4-21

Retarders . . . . . . . . . . . . . . . . . . 4-33

CRUISE CONTROL

Cruise Control Switch . . . . . . . . . . . . . 4-35

Adaptive Cruise Control (Optional) . . . . . . . 4-37

AXLE

Differential Lock . . . . . . . . . . . . . . . 4-40

Dual Range (Two-Speed) Rear Axle . . . . . . . 4-41

Auxiliary Axles -Pusher or Tag . . . . . . . . . 4-43

SUSPENSION

Air Suspension Height/Air Pressure . . . . . . . 4-49

Driving with Deated Air Springs . . . . . . . . 4-50

AFTER-TREATMENT SYSTEM

Introduction . . . . . . . . . . . . . . . . . 4-51

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

STARTING AND OPERATING

DRIVING TIPS AND TECHNIQUES

Introduction ................. 4-52

Coasting................... 4-52

Descending a Grade ............. 4-53

Engine Overspeed .............. 4-53

Fuel - Excess Consumption . . . . . . . . . . 4-55

SLEEPER BUNKS

SleeperBunk................. 4-58

STOPPING THE ENGINE

Before Stopping the Engine . . . . . . . . . . 4-60

Refueling .................. 4-60

Refuel Before the Final Stop . . . . . . . . . . 4-61

Final Stop .................. 4-62

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

STARTING AND OPERATING

STARTING AND

OPERATING

Introduction

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 nd out details about

your specic engine’s needs. You

may need to use a slightly different

procedure from the one outlined here.

Below are instructions for both

normal-temperature starting and

cold-weather starting.

Normal Weather

When the outside temperature is

above 50° F (10° C), you can use the

following procedure:

1. Set the parking brake.

2. Put your main transmission in

Neutral.

3. Disengage (depress) the clutch

(with manual transmission).

4. Turn the key switch to ON.

CAUTION

Never operate the starter motor while

the engine is running. The starter and

ywheel gears could clash or jam, se-

verely damaging them.

NOTE

Some starters are equipped with over-

crank protection. Check the “Engine

Operation and Maintenance Manual”

for details.

5. Turn the ignition key to the START

position. If the engine does not

start within 30 seconds, release

the ignition switch. To avoid

overtaxing the starter motor or

the batteries, don’t use the starter

for more than 30 seconds. Let

the starter motor cool and the

batteries recover for two minutes

before trying again.

If 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

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

STARTING AND OPERATING

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. Slowly engage (release) the clutch

after the engine has started.

8. Wait for the oil pressure gauge to

reach normal operating pressure

before operating the vehicle or

idling faster than 1000 rpm.

Cold Weather

In cold weather, fast engine starting

helps relieve the loads on the electrical

system and cranking motor. Using the

special cold starting equipment will

help starting. If you follow a few simple

guidelines, you will extend the service

life of your engine:

• Keep the electrical system in top

condition.

• Use the best quality fuel of the

recommended grade.

• Use recommended engine

lubricating oil.

• For manual transmissions and

auxiliary transmissions, leave the

transmission in neutral and allow

the transmission lubricating oil

to warm up (approximately 3-5

minutes) before operating vehicle.

Engine Block Heater

(Option)

To preheat the engine before starting,

plug the optional engine block heater

into a properly grounded AC electrical

source. Do not start the engine with

the heater plugged in.

WARNING!

Engine block heaters can cause res

which may result in death, injury

and/or property damage if not properly

maintained and operated. Regularly

inspect the engine block heater wiring

and connector for damaged or frayed

wires. Do not use the heater if there

are any signs of problems. Contact

your authorized dealer or the manu-

facturer of the heater if you are in need

of repairs or information.

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

STARTING AND OPERATING

Always unplug heater before starting

the engine. Damage to the cooling

system could occur if the heater is not

turned OFF (unplugged).

CAUTION

Depending on engine make, when the

temperature falls below -10° F (-24°

C), the block heater is required.

• Use a solution of half ethylene

glycol antifreeze and half water for

best heater performance. Do not

exceed 65 percent concentration

of antifreeze, as a shortened

heater life will result. See Engine

Cooling System on page 5-72, for

more information.

• After servicing the cooling system,

operate the vehicle for a day or two

before using the heater. Trapped

air inside the engine needs time

to escape.

Engine Warm-up

Engine

The purpose of engine warm-up is to

allow oil lm to be established between

pistons and liners, shafts and bearings

while your engine gradually reaches

operating temperature.

Warm-up Procedure

1. After you’ve started your engine,

idle it at approximately 600 RPM

while you check:

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 1000 RPM.

Continue your warm-up. This

procedure allows oil to warm and

ow freely while pistons, liners,

shafts, and bearings expand

slowly and evenly. In extremely

cold temperatures, you may have

to increase idle speed.

NOTE

In colder climates where the tem-

perature is often below freezing, the

warm-up for turbocharged engines is

especially important. Chilled external

oil lines leading to the turbocharger

will slow the oil ow until the oil warms,

reducing oil available for the bearings.

Watch the engine oil temperature or

pressure gauge for a warming trend

before increasing engine idle speed

(RPM).

3. Continue the engine warm-up until

the coolant temperature reaches

at least 130° F (54° C). At this

temperature, you can use partial

throttle. Wait until the coolant

temperature is at least 160° F (71°

C) before operating at full throttle.

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

STARTING AND OPERATING

WARNING!

Exhaust fumes from the engine con-

tain carbon monoxide, a colorless and

odorless gas. A poorly maintained,

damaged, or corroded exhaust system

can allow carbon monoxide to enter

the cab or sleeper. Failure to prop-

erly maintain your vehicle could cause

carbon monoxide to enter the cab and

cause death or personal injury.

Never idle your vehicle for prolonged

periods of time if you sense that ex-

haust fumes are entering the cab. In-

vestigate the cause of the fumes and

correct it as soon as possible. If the ve-

hicle must be driven under these con-

ditions, drive only with the windows

slightly open. Failure to repair the

source of the exhaust fumes may lead

to death or personal injury.

WARNING!

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. If you must

use a winterfront:

• Refer to the “Engine Operation

and Maintenance Manual”

for operating restrictions and

recommendations.

• Use only a winterfront available

from your dealer that is

compatible with an EPA-compliant

engine cooling system. These

winterfronts are specically

designed for use with new grill

snap patterns.

NOTE

Keep the engine exhaust system and

the vehicle’s cab/sleeper ventilation

system properly maintained. It is rec-

ommended that the vehicle’s exhaust

system and cab/sleeper be inspected:

• By a competent technician every

15,000 miles,

• Whenever a change is noticed in

the sound of the exhaust system,

• Whenever the exhaust system,

underbody, cab or sleeper is

damaged.

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

STARTING AND OPERATING

NOTE

• Do not stay in the vehicle with

the engine running or idling

for more than 10 minutes with

the vehicle’s Heater and A/C

ventilation system in RECIRC

or at LOW FAN SPEED. Even

with the ventilation system On,

running the engine while parked

or stopped for prolonged periods

of time is not recommended.

• If other vehicles are parked next

to you idling, move your vehicle

or do not stay in your vehicle for

prolonged periods of time.

Idling the Engine

Under most circumstances, idling

your engine for long periods merely

wastes fuel. In severe arctic weather

conditions, however, you may need

longer idling to be sure all parts of your

engine are fully lubricated.

WARNING!

To reduce the chance of death or per-

sonal injury and/or vehicle damage

from overheated engines, which can

result in a re, never leave the engine

idling without an alert driver present.

If the engine should overheat, as indi-

cated by the engine coolant tempera-

ture 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 re.

CAUTION

Do not allow your engine to idle, at

low rpm's (400–600 rpm), longer than

ve minutes. Long periods of idling

after the engine has reached operat-

ing temperatures can decrease engine

temperature and cause gummed pis-

ton rings, clogged injectors, and pos-

sible engine damage from lack of lu-

brication. The normal torsional vibra-

tions generated can also cause trans-

mission wear. 4

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

STARTING AND OPERATING

Transmission

In cold weather [below 32° F (0°

C)], you may nd shifting sluggish

when you rst start up. Transmission

warm-up is especially important at

this time, but it is always a good

idea to warm-up your transmission

before starting out on the road. To

warm-up the transmission, follow these

procedures.

To warm-up the transmission

lubricating oil during engine warm-up,

with a single transmission (manual and

automatic):

1. Put the transmission in Neutral.

2. Release the clutch pedal (manual

only) and operate the transmission

in neutral for 3 to 5 minutes prior

to operating the transmission in

either forward or reverse range.

3. If you have a two-transmission

combination:

Ether Metering Equipment

a. Put the main transmission in

gear.

b. Put the auxiliary transmission Ether starting uid is ammable and

in Neutral. This will allow poisonous. Do not smoke near ether

the transmission countershaft or ether equipment, do not ingest

to turn, agitating the oil and ether uid and wear safety goggles

warming it. when handling ether uid. Follow all

safety literature provided with your

ether equipment. Failure to take these

precautions may result in death, per-

sonal injury.

WARNING!

Do not move or relocate the ether

cylinder or tubing from its original

installation. It must be mounted to pro-

tect it from engine exhaust heat and

from moving parts which could dam-

age it. Failure to comply may result in

death, personal injury, equipment or

property damage.

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

STARTING AND OPERATING

Do not store the spare cylinder in the

cab. Failure to comply may result in

death, personal injury, equipment or

property damage.

WARNING!

Do not smoke when testing, installing,

or servicing an ether starting unit.

Service it in a well-ventilated area away

from heat, open ames, or sparks.

If swallowed, do not induce vomiting.

Call a physician immediately.

Wear goggles to avoid getting uid in

your eyes. Avoid getting it on your skin

and avoid breathing the fumes. If uid

does get in your eyes or fumes irritate

your eyes, ush for 15 minutes with

large amounts of clean water. Contact

an eye specialist.

In warm weather, when you will not

need the ether starting system, remove

the ether bottle from your truck and

store it safely. Return the protective

cap to the bottle mounting connector.

For more helpful starting information,

refer to the engine manual that came

with your vehicle.

Ether injected into the engine cylinder

during cold weather startup will help

the engine start faster. Using ether

during cold weather startup will result

in reduced demands on the batteries

and the starter motor.

When you turn the ignition switch to the

START position, the cranking motor

and the ether system are engaged.

When needed, starting uid is released

from a pressurized cylinder, ows

through a valve and tubing, and sprays

from a nozzle in you engine’s air intake

system.

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

OPERATING THE ENGINE

OPERATING THE

ENGINE

Stationary PTO Operation

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 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.

Setting Idle Speed

1. Ensure parking brakes are applied.

2. Ensure transmission is in Neutral.

3. Engage PTO per the

manufacturer's operating

instructions.

4. Move the ON/OFF switch to the

"ON" position.

5. Toggle the SET/RESUME switch

to obtain the desired engine rpm.

Cancelling Cruise Control

You can cancel cruise control in any

of these ways:

• Tap the brake pedal.

• Tap the clutch pedal.

• Move the ON/OFF switch to the

"OFF" position.

Engine Fan Control

The engine fan can be turned ON

using a switch that is mounted on the

accessory switch panel. This lets you

set the fan to manual or automatic

operation.

• With the ignition key turned ON

and the fan switch in the MANUAL

position, the engine fan will be ON

regardless of engine temperature.

• With the engine fan switch in the

AUTO position, the engine fan will

automatically turn ON when the

engine computer sends a signal

requiring the engine fan to be on.

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

OPERATING THE ENGINE

WARNING!

CAUTION

Do not work on or near the fan with the

engine running. Anyone near the en-

gine fan when it turns on could be in-

jured. 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 with-

out warning. Before turning on the ig-

nition or switching from AUTO to MAN-

UAL, be sure no workers are near the

fan.

The fan or equipment near it could be

damaged if the fan turns on suddenly

when you do not expect it. Keep all

tools and equipment away from the

fan.

NOTE

Do not operate the engine fan in the

MANUAL position for extended peri-

ods of time. The fan hub was de-

signed for intermittent operation. Sus-

tained operation will shorten the fan

hub's service life as well as reduce fuel

economy.

Winterfronts

A winterfront or other air ow restriction

device may be mounted in front of

the radiator to increase cab heater

temperature in cold climates.

CAUTION

A winterfront should only be used at

temperatures below 40°F (4°C). Use

of a winterfront above 40°F (4°C) can

decrease life of cooling module com-

ponents. Remove winterfront as soon

as the ambient temp reaches 41°F

(5°C). The use of a winterfront above

40°F (4°C) can result in excessive

engine coolant, oil, and charge air

(intake) temperatures, which can lead

to overheating and possible engine

or coolant module damage and emis-

sions non-compliance.

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

OPERATING THE ENGINE

NOTE

The winterfront is designed to min-

imize the temperature differences

across the radiator and reduce the

possibility of cooling module damage.

Aftermarket winterfronts may not pro-

vide the proper airow distribution and

could cause cooling module damage.

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. The specic

features of your display may vary

depending on engine make.

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

OPERATING THE TRANSMISSION

OPERATING THE

TRANSMISSION

Operating Hydraulic Clutch

(Manual Transmission)

Manual transmissions will also have a

clutch pedal situated to the left of the

brake pedal. Pressing down on the

clutch pedal will disengage the clutch

and will allow the transmission gears

to be shifted.

At the beginning of the pedal stroke,

there will be about ½ inch (13 mm) of

movement before any resistance is

felt. As the pedal is pressed further, the

operator will feel increased resistance

as the clutch is disengaged. After

the clutch has been fully disengaged,

there will be another 1 - 1 1/2 inches

(25 -40 mm) of pedal travel which will

engage the clutch brake. At this full

stroke, the pedal will feel like it cannot

be pressed anymore.

If the transmission is not shifting

smoothly into gear while the clutch

pedal is completely pressed to the

oor, then it is time to have the clutch

and hydraulic system inspected and

serviced.

CAUTION

Do not push the clutch pedal com-

pletely to the oor when shifting while

the vehicle is in motion. using the

clutch brake while shifting a vehicle in

motion will damage the clutch brake. A

non functioning clutch brake will make

shifting very difcult when the vehicle

is stationary.

If the clutch pedal is pressed

completely to the oor and the

transmission is not shifting, then it is

time to have the clutch adjusted or

serviced.

Operating Manual

Transmissions

The transmission shift pattern for

your vehicle may be located on the

shift control knob. In addition to

understanding the shift pattern and

its location, you should read the

transmission manufacturer’s manual

provided with your vehicle before

operating the vehicle.

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

OPERATING THE TRANSMISSION

Putting the Vehicle in Motion

After making sure the vehicle's oil

and air pressure are correct and all

other parts and systems are in proper

working condition:

1. Fully depress the clutch pedal (for

manual transmission) until the

clutch brake makes contact.

a. The total stroke of the clutch

pedal is about 6 inches (152

mm). The rst ½ inch (13

mm) is free travel. After the

free travel comes the release

stroke, which is the part that

fully releases the clutch. The

last ½ inch (13 mm) engages

the clutch brake.

b. Always start out in a low

gear. Starting in higher gears,

even with a light load, will

cause a very jumpy start and

excessive wear.

CAUTION

Always use rst 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 en-

gine, clutch, other transmission com-

ponents, and may cause damage.

2. Evaluate the road surface

conditions and terrain your vehicle

is on. Select a gear low enough to

let your vehicle start forward with

the throttle at idle.

3. Push the parking brake valve

handle (Yellow) against the dash

panel to release the brakes.

4. Release the clutch pedal (manual

only), then gradually accelerate to

permit smooth starting,

5. Do not allow your vehicle

to roll (even a little) in the

opposite direction during clutch

engagement. If you need to

start up on an incline, apply your

service brakes before you release

the parking brake. Then release

your service brakes as you engage

the clutch and apply throttle.

For further instructions on

operating your transmission, see

the transmission manufacturer's

Driver/Operator's Instruction Manual.

If you have a misaligned gear condition

in your vehicle's transmission and

cannot start, gradually release the

clutch, allowing the drive gear teeth to

line up properly. Then the drive gear

can roll enough to allow the teeth to

line up properly and complete the shift.

The best engine performance and

maximum economy is obtained if gears

are properly selected. This efciency

is achieved by always selecting gears

within optimum engine RPM, which is

where maximum torque and power are

obtained. For further information, see

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

OPERATING THE TRANSMISSION

More Driving Tips and Techniques on

page 4-52.

Shifting Gears in a New Vehicle

Shift carefully in a new vehicle. The

transmission may be a little stiff at

rst. Avoid gear clashing, by closely

following these procedures.

When you are operating a new vehicle

or one that has been exposed to cold

weather, you want the transmission

lubricant (uid) to circulate and coat

the contacting surfaces of the gears.

Metal contacting metal in moving

parts may seriously damage your

transmission, do not drive in one

gear for long periods of time until the

transmission lubricant has a chance to

coat all contacting surfaces.

Clutch Brake and Travel

The clutch brake is used for stopping

transmission gears, allowing you to

easily shift into rst gear or reverse

without grinding gears. Approximately

the last ½ inch (13 mm) of clutch pedal

travel activates the clutch brake.

To apply the clutch brake (while the

vehicle is stopped) fully depress the

clutch pedal to stop the gears. With

the throttle at idle, select rst gear

then release the clutch pedal to let the

vehicle start forward, until the clutch is

fully engaged. See the transmission

manufacturer's Driver/Operator's

Instruction Manual for further details.

If the transmission has a butt-tooth

condition and you cannot engage a

gear, gradually release the clutch.

Then the drive gear can roll enough to

allow the teeth to line up properly and

complete the shift.

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

OPERATING THE TRANSMISSION

During Normal Driving

If you want to shift directly into any gear

other than rst or reverse, depress the

clutch pedal only far enough to release

the clutch. Fully depressing the pedal

applies the clutch brake and could

cause gear hang-up.

CAUTION

Be careful not to apply the clutch brake

while the vehicle is moving. The pur-

pose of the clutch brake is to stop the

transmission so that you can shift into

a starting gear without grinding gears.

Applying the clutch brake when the ve-

hicle is moving will render the clutch in-

operative.

Double Clutching

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. This lets you control

the RPM of the mainshaft gears,

allowing you to match the RPM of

the mainshaft gears to those of the

output shaft.

a. Upshifts: let the engine and

gears slow down to the RPM

required for the next gear.

b. Downshifts: press accelerator,

increase engine and gear

speed to the RPM required in

the lower gear.

4. Now quickly press the pedal to

disengage the clutch and move

the gear shift lever to the next gear

speed position.

5. Release the pedal to engage the

clutch.

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

OPERATING THE TRANSMISSION

Automatic and Automated

Transmissions

An automatic or automated

transmission makes shifting much

easier. It remains important to

completely understand how to operate

the transmission to optimize its

efciency. Please read the manual

for your automatic or automated

transmission included with your

vehicle.

For automated transmissions, there is

no “park” position. So you will need to

apply the parking brake before leaving

the cab.

Hill Hold

The hill hold feature is available as

an option with certain automated

transmissions. This feature holds the

vehicle while on a hill to allow the

operator to release the service brakes

and press the accelerator. This feature

will hold the vehicle if the vehicle is

attempting to go up a hill from a stop in

either drive or reverse.

WARNING!

Do not leave the cab of your vehi-

cle without applying the parking brake.

The truck could roll and cause an acci-

dent resulting in death or personal in-

jury. Always apply the parking brake

before you leave the cab.

WARNING!

If your vehicle has an automated trans-

mission, be aware that it can roll back-

wards when stopped on a hill or grade,

or when starting from a stop on a hill

or grade. Failure to comply may result

in death, personal injury, equipment or

property damage. Observe the follow-

ing guidelines:

• When stopped on a hill or grade,

press the brake pedal.

• When starting from a stop on a

hill or grade, quickly remove your

foot from the brake pedal and

rmly press on the accelerator

pedal.

(04/13) Y53-1200-1B1 4-19

OPERATING THE TRANSMISSION

Auxiliary Transmission

If you have an auxiliary transmission,

see your transmission manufacturer’s

manual for its proper operation.

More Transmission Tips

Riding the Clutch

The clutch is not a footrest. Do not

drive with your foot resting on the

clutch pedal. It will allow your clutch to

slip, causing excessive heat and wear,

damage could result.

Release Bearing Wear

When you must idle your engine for any

period of time, shift your transmission

to neutral and disengage the clutch

(take your foot OFF of the pedal). This

helps prevent unnecessary wear to

your clutch release bearing, and it is

less tiring for you, too.

Tips

• Always use the clutch when

making upshifts or downshifts.

• Always select a starting gear

that will provide sufcient gear

reduction for the load and terrain.

• Never downshift when the vehicle

is moving too fast.

• Never slam or jerk the shift lever

to complete gear engagement.

• Never coast with the transmission

in neutral and the clutch

disengaged.

• To provide smooth gear

engagements while shifting,

use proper coordination between

shift lever and clutch.

Double clutching is a very effective

means to increase the service life of

your transmission. Double clutching

refers to a technique where the clutch

pedal is used twice per shift instead of

once. It also requires that you adjust

the engine rpm in the middle of the

shift which ultimately synchronizes the

gears during shifting. Synchronizing

reduces wear on the gears. See

Double Clutching on page 4-18.

4-20 Y53-1200-1B1 (04/13)

OPERATING THE BRAKE SYSTEM

OPERATING THE

BRAKE SYSTEM

Introduction

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.

Compressed air is delivered to the

brake system through the valve at

the brake pedal and is controlled

with various valves and braking

circuits. The brake system is designed

with separate front, rear and (when

applicable) trailer circuits so that if one

circuit is compromised and loses air,

the other circuits will not be affected.

Safety valves in each circuit will protect

the other circuits in the event that a

circuit loses air.

The air compressor on the engine will

typically provide 100-130 psi (690-896

kPa) to the air tanks. The vehicle

is also designed with an air dryer,

which removes moisture from the

compressed air in order to protect all

components in the air system.

The brake system may be further

enhanced by additional devices

such as brake proportioning valves,

Anti-lock braking systems or sensors

designed to let you know if your brake

pads need to be serviced.

Certain conditions may result in the

brake surfaces getting wet. Brake

surfaces that are wet do not perform

as well as when they are dry. There

may be situations where wet brake

surfaces cannot be avoided. In such

situations, apply the brakes while in

motion, to dry the brake surfaces.

Certain conditions may result in your

brake surfaces becoming overheated

(above 800° F or 427° C). Overheated

brakes will damage linings and

drum surfaces, ultimately decreasing

braking performance. Refer to

Retarders and Descending a grade to

avoid overheating the brakes.

This vehicle may be equipped with

an anti-lock braking system (ABS).

This ABS reduces the possibility of

wheel lock-up. If a wheel is about

to lock during braking, the ABS will

automatically adjust air pressure to the

brake chambers on the appropriate

wheel(s) to prevent wheel lock-up. The

ABS is automatically turned on when

the ignition switch is turned on.

(04/13) Y53-1200-1B1 4-21

OPERATING THE BRAKE SYSTEM

WARNING!

The Anti-Lock Brake System is a crit-

ical vehicle safety system. For the

safety of you and others around you,

have the vehicle submitted for peri-

odic preventive maintenance checks

as well as having any suspected prob-

lems immediately checked by an au-

thorized dealer. Failure to properly

maintain your brake system can lead

to serious accidents. Failure to com-

ply may result in death, personal injury,

equipment or property damage.

WARNING!

Do not drive through water deep

enough to wet brake components, as

it may cause the brakes to work less

efciently than normal. The vehicle's

stopping distance may be longer than

expected, and the vehicle may pull

to the left or right when brakes are

applied, which could contribute to an

accident involving death or personal

injury.

Do not rely on an anti-lock brake sys-

tem that is functioning improperly. You

could lose control of the vehicle re-

sulting 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 work-

ing. The ABS may not function in an

emergency. You will still have conven-

tional brakes, but not anti-lock brakes.

If the lamp indicates a problem, have

the ABS checked.

WARNING!

Vehicles without anti-lock brake

systems (ABS) are typically equipped

with a bobtail brake proportioning

system. When a trailer is not

connected, the drive axle brake

application pressure will automatically

be limited by the proportioning system.

When driven in a bobtail mode,

these tractors will require greater

4-22 Y53-1200-1B1 (04/13)

OPERATING THE BRAKE SYSTEM

brake pedal application to provide the Parking Brake

equivalent braking to a bobtail tractor

not equipped with a proportioning

system.

(04/13) Y53-1200-1B1

1. Normal Run Position

2. Trailer Park with Vehicle

Released

3. System Park or Trailer

Charge with Vehicle Parked

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. If the vehicle is

equipped to tow a trailer, then there will

be an additional red octagon shaped

knob for the trailer parking brakes.

Parking brakes will be engaged when

either of these knobs are pulled OUT.

(If one knob is pulled out, the other

knob will automatically pop out.)

Pushing IN a knob will disengage

the respective parking brakes. If you

push in the yellow knob only, you

will disengage the vehicle’s parking

4-23

OPERATING THE BRAKE SYSTEM

brakes but will not disengage the trailer

parking brakes (if applicable). Either

knob will pop back out if the system

pressure is not above 60 psi (414 kPa).

The instrument panel display will

provide a message any time the

parking brakes (vehicle or the trailer)

are set and the vehicle is put into

motion.

Trailer ABS

Power Line Communication (PLC)

North American on-highway vehicles

are equipped with a separate electrical

circuit to power the anti-lock brake

system (ABS) on towed vehicle(s).

In most cases, the ABS power will

be supplied through the Auxiliary

circuit on the primary 7-way trailer

light line connector. If the vehicle

was manufactured with a switchable

Auxiliary circuit for trailer accessories,

an additional 7-way connector would

have been provided for trailer ABS

power. In either case, the ABS

power line on the vehicle will be PLC

equipped.

Do not splice into the non-switchable

Auxiliary circuit on the primary 7-way

trailer light line. Doing so may cause

the trailer ABS to malfunction. This cir-

cuit is dedicated for trailer ABS power.

To add a switchable auxiliary circuit,

contact a dealership.

CAUTION

Vehicles and trailers built after

3/1/01 must be able to turn on an

In-Cab Trailer ABS Warning Lamp

(per Federal Motor Vehicle Safety

Standards (FMVSS) 121). The industry

chose Power Line Communication

(PLC) as the standard method to turn

it on.

NOTE

Trailers not equipped with PLC can not

turn on the In-Cab Trailer ABS Warn-

ing Lamp.

4-24 Y53-1200-1B1 (04/13)

OPERATING THE BRAKE SYSTEM

NOTE

For doubles or triples, the lamp does

not distinguish between trailers. An

ABS problem in any of the trailers

will activate the Trailer ABS Warning

Lamp.

NOTE

If you change the intended service in

any way (i.e. number of axles, multiple

trailers, add switchable trailer acces-

sories, etc.) from the date the vehicle

was manufactured, you should con-

tact your trailer manufacturer and/or

trailer anti-lock brake manufacturer

to determine if the power available at

the 7-way trailer light line is adequate.

Failure to do so might result in insuf-

cient power to the trailer ABS system,

which may affect its operation.

CAUTION

The center pin of the 7-way trailer light

line may be constantly powered for

ABS. Make sure it will not accidently

turn on trailer equipment.

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. The Trailer

ABS Warning Lamp will not turn on for

the power-on test when connected to

these types of trailers.

NOTE

Very few trailers built before 3/1/01

have this option. Trailers built after

3/1/01 are built with PLC technology.

(04/13) Y53-1200-1B1 4-25

OPERATING THE BRAKE SYSTEM

Advanced ABS with Stability

Control

This vehicle may be equipped

with an optional Electronic Stability

Program (ESP). ESP is a feature for

ABS-equipped vehicles that reduces

the risk of rollovers, jackkning, and

other loss of control situations. ESP

features include Roll Stability Program

(RSP) and Yaw Control.

During operation, the ECU of the

Bendix® Advanced ABS system

constantly compares performance

models to the vehicle’s actual

movement, using the wheel speed

sensors of the ABS system, as well

as lateral, yaw, and steering angle

sensors. If the vehicle shows a

tendency to leave an appropriate travel

path, or if critical threshold values are

approached, the system will intervene

to assist the driver.

Roll Stability Program

Bendix® Roll Stability Program (RSP),

an element of the overall ESP system,

addresses rollover conditions. In the

case of a potential roll event, the ECU

will override the throttle and quickly

apply brake pressure at all wheel ends

to slow the vehicle combination. The

level of braking application during an

RSP event will be proportional to roll

risk.

A Real World Example of How the

RSP System Operates

Excessive speed for road conditions

creates forces that exceed the

threshold at which a vehicle is likely to

rollover on a higher-friction surface.

The system automatically reduces

engine torque and applies the service

brakes (based on the projected rollover

risk) to reduce the vehicle speed,

thereby reducing the tendency to roll

over.

RSP Example

4-26 Y53-1200-1B1 (04/13)

OPERATING THE BRAKE SYSTEM

Yaw Stability

Yaw stability counteracts the tendency

of a vehicle to spin about its vertical

axis. During operation, if the friction

between the road surface and the tires

is not sufcient to oppose lateral (side)

forces, one or more of the tires can

slide, causing the truck/tractor to spin.

These yaw events are referred to as

either “under-steer” (where there is a

lack of vehicle response to steering

input due to tire slide on the steer axle)

or “over-steer” (where the tractor's

rear end slides out due to tire slide

on the 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 inuence yaw stability

are: wheelbase, suspension, steering

geometry, weight distribution front to

rear, and vehicle track width.

Yaw Control

Yaw Control responds to a wide

range of low- to high-friction surface

scenarios including rollover, jackknife

and loss of control. In the case of

vehicle slide (over-steer or understeer

situations), the system will reduce the

throttle and then brake one or more

of the “four corners” of the vehicle

(in addition to potentially applying

the trailer brakes), thus applying a

counter-force to better align the vehicle

with an appropriate path of travel. For

example, in an over-steer situation,

the system applies the “outside”

front brake; while in an under-steer

condition, the “inside” rear brake is

applied.

A Real World Example of How Yaw

Control Operates

Excessive speed exceeds the

threshold, creating a situation where a

vehicle is likely to spin and jackknife.

The Bendix® Yaw Control system

reduces engine throttle and selectively

applies brakes to reduce the vehicle

speed, thereby reducing the tendency

to jackknife.

Yaw Control Example

(04/13) Y53-1200-1B1 4-27

OPERATING THE BRAKE SYSTEM

ESP May Reduce the Vehicle Speed

Automatically

To minimize unexpected deceleration

and reduce the risk of a collision the

operator must:

• Avoid aggressive driving

maneuvers, such as sharp

turns or abrupt lane changes at

high speeds, which might trigger

the stability system.

• Always operate the vehicle safely,

drive defensively, anticipate

obstacles and pay attention

to road, weather, and trafc

conditions. ABS, ATC, and ESP

stability systems are no substitute

for prudent, careful driving.

Towing Doubles or Triples May

Reduce the Effectiveness of

Stability Systems

ESP is designed and optimized for

trucks and for tractors that tow single

trailers. If a tractor equipped with

ESP is used to power multiple trailer

combinations (known as “doubles” or

“triples”) the effectiveness of the ESP

system may be greatly reduced.

WARNING!

Exercise extreme care when tow-

ing doubles or triples with a vehicle

equipped with Electronic Stability Pro-

gram. Excessive speed and aggres-

sive maneuvers, such as sharp turns,

sudden steering inputs or abrupt lane

changes should be avoided because

these maneuvers could cause loss of

vehicle control possibly resulting in an

accident involving death or personal

injury.

Limitations of Stability Systems

The ESP stability system’s

effectiveness may be greatly reduced

if:

• The load shifts due to improper

retention, accident damage or the

inherently mobile nature of some

loads (for example, hanging meat,

live animals or partially laden

tankers).

• The vehicle has an unusually high

or off-set center of gravity (CG).

• One side of the vehicle drops off

the pavement at an angle that is

too large to be counteracted by a

reduction in speed.

• The vehicle is used to haul double

or triple trailer combinations.

• If very rapidly winding steering

inputs are inputted at high speeds.

4-28 Y53-1200-1B1 (04/13)

OPERATING THE BRAKE SYSTEM

• There are mechanical problems

with suspension leveling of the

tractor or trailer resulting in uneven

loads.

• The vehicle is maneuvering on a

high banked road creating either

additional side forces due to the

weight (mass) of the vehicle or a

deviation between expected and

actual yaw rates.

• Gusty winds are strong enough

to cause signicant side forces

on the vehicle and any towed

vehicles.

To Maximize the Effectiveness of

ESP

• Loads must be properly secured

and evenly distributed at all times.

• Drivers need to exercise extreme

caution at all times, and avoid

sharp turns, sudden steering

inputs or abrupt lane changes at

high speeds, particularly if:

a. the vehicle hauls loads that

could shift,

b. the vehicle or load has a high

or off-set center of gravity

(CG) when loaded, or

c. the vehicle tows doubles or

triples.

Truck Chassis Modications

The ESP system was specically

calibrated and validated only for

your vehicle’s original factory-built

conguration. If your vehicle’s chassis

components are altered (for example;

a wheelbase extension or reduction,

tag axle addition or removal, tractor to

truck conversion or steering system

component change) the ESP system

must be disabled immediately by a

qualied mechanic.

WARNING!

Failure to disable ESP “Electronic Sta-

bility Program” when modifying a vehi-

cle could result in a loss of vehicle con-

trol possibly resulting in an accident in-

volving death or personal injury.

(04/13) Y53-1200-1B1 4-29

OPERATING THE BRAKE SYSTEM

WARNING!

For vehicles equipped with ESP “Elec-

tronic Stability Program” do not re-

place the vehicle’s steering wheel with

an aftermarket or different part num-

ber than originally supplied. Using a

different steering wheel could cause

ESP to malfunction causing a loss of

vehicle control possibly resulting in an

accident involving death or personal

injury.

4-30

Steering Angle Sensor

Re-Calibration

Whenever maintenance or repair

work is performed to the steering

mechanism, linkage, gear, adjustment

of the wheel track, or if the steering

angle sensor is replaced or the steering

wheel is changed or re-centered, the

Steering Angle Sensor must be

re-calibrated.

WARNING!

If the Steering Angle Sensor is not

re-calibrated, the Yaw Control system

will not function properly. A uncali-

brated sensor could result in a loss of

control of your vehicle which can lead

to an accident involving death or per-

sonal injury.

Y53-1200-1B1

Optional ATC Functions

Wheel Spin Control (option)

Your truck/tractor ABS may have an

acceleration slip regulation (ASR)

or automatic traction control (ATC)

feature. This feature is controlled by a

switch as shown in the next illustration.

Either of these features is monitored by

a warning lamp located on the switch.

Wheel Spin Control Warning Lamp

The Traction Control warning lamp on

page 3-37 will briey illuminate and

then go out when the ignition switch

is rst turned on. The traction control

warning lamp will illuminate whenever

the ASR or ATC system detects drive

wheel spin. The lamp will remain

illuminated as long as wheel spin is

(04/13)

OPERATING THE BRAKE SYSTEM

detected and the ASR or 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 ASR/ATC

system. Except for checking for proper

illumination of the ABS and traction

control warning lamps when rst

starting the vehicle, and for monitoring

these lamps while driving, no special

operating procedures are required.

For detailed system description, see

literature for your specic ABS that

was provided with your vehicle.

This feature helps improve traction

when vehicles are on slippery surfaces

or surfaces with poor traction (i.e.

mud or snow) by reducing drive wheel

overspin. Wheel spin control works

automatically in two different ways:

• If a drive wheel starts to spin,

wheel spin control applies air

pressure to brake the wheel. This

transfers engine torque to the

wheels with better traction.

• If all drive wheels spin, wheel spin

control reduces engine torque to

provide improved traction.

Wheel spin control turns itself on and

off, you do not have to select this

feature. If drive wheels spin during

acceleration, the ASR Warning Lamp

comes on, indicating wheel spin control

is active.

Do not allow the ASR Warning Lamp

to remain on continuously for an

extended length of time. Extended,

continuous use of the ASR/ATC can

cause overheating of the drive wheel

brakes.

Deep Snow and Mud Switch (option)

A deep snow and mud switch is

included with Wheel Spin Control. The

Deep Snow and Mud feature is helpful

during acceleration. This function

increases available traction on extra

soft surfaces like snow, mud or gravel,

by slightly increasing the permissible

wheel spin. When this function is in

use, the ASR Warning Lamp blinks

continuously.

Off-Road ABS Function Switch

(option)

Your vehicle may be equipped with

a separate switch to activate an

Off-Road ABS function. This function

is NOT to be used for On-Highway

driving but is intended to be used

to improve stopping performance in

Off-Highway conditions (e.g. loose

gravel and mud). The Off-Road ABS

function is accomplished by allowing a

“wedge” of material to build-up in front

of momentarily locked wheels.

Features and Benets

• Changes the ABS control limits to

allow for a more aggressive ABS

function while off-road.

(04/13) Y53-1200-1B1 4-31

OPERATING THE BRAKE SYSTEM

• Improves vehicle control and

helps reduce stopping distances

in off-road conditions or on poor

traction surfaces such as loose

gravel, sand, and dirt.

• Allows retarders to function

independently of the ABS function.

• If your vehicle does not have an

engine retarder, the Off- Road

ABS switch will function the same.

CAUTION

Never drive your vehicle on improved

roads/highways with the Off-Road

ABS function turned on. When you

drive your vehicle onto an improved

road surface or highway, immediately

turn off the Off-Road ABS switch.

Failure to do so will cause the ABS

system to not function properly in an

ABS event under 25 mph and could

result in an accident or personal injury.

While the off-road mode can improve

vehicle control and shorten stopping

distances, some steering ability may

be reduced on certain surfaces result-

ing 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.

WARNING!

How the Off-Road ABS Function

Works

• The ABS lamp ashes slowly

during off-road mode engagement.

This is done to alert you of a

modication to the ABS control

software.

• At speeds above 25 mph, the ABS

controller operates in the normal

on-highway mode.

• At speeds between 10 and 25

mph, the ABS control software is

modied to allow short periods

(0.25 seconds) of locked-wheel

cycles.

• At speeds below 10 mph, the ABS

control software is turned off to

allow locked wheels.

• When the Off-Road ABS function

is enabled, the Retarder Disable

output is turned off. That is,

the engine retarders are left to

function without ABS intervention.

For additional information, see the

Off-Road ABS pamphlet in your

vehicle’s glove box.

4-32 Y53-1200-1B1 (04/13)

OPERATING THE BRAKE SYSTEM

Retarders

Various retarders are available, which

function against the engine, driveline,

or transmission. These are devices

that use your engine’s power to slow

down your vehicle. They save wear

and tear on your service brakes and

can be a safety feature, too, because

they can keep your brakes from

overheating.

Ideally, you should always slow your

vehicle with your retarder (where

permitted by law) and use your service

brakes only for stopping completely.

Operating this way will greatly prolong

the life of your brakes.

WARNING!

Do not use any of the vehicle’s re-

tarders 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 re-

tarder instead of the service brakes

may cause a loss of vehicle control,

which may result in an accident involv-

ing death or personal injury.

The service brakes must be used in an

emergency. The retarder alone might

not stop you fast enough to prevent an

accident. Failure to comply may result

in death, personal injury, equipment or

property damage.

The retarder is NOT intended as the

primary brake for the vehicle, nor is

it an emergency brake. The retarder

only helps the service brakes by using

pressure to slow the drivetrain. Use

the service brakes for quick stops.

Do not use the retarder when operating

on road surfaces with poor traction

(such as wet, icy, or snow covered

roads or gravel). Retarders can

cause the wheels to skid on a slippery

surface.

(04/13) Y53-1200-1B1 4-33

OPERATING THE BRAKE SYSTEM

Driving Bobtail or with an Unloaded

Trailer

We recommend that you do not use

your engine retarder to slow down

when you are bobtailing or pulling an

empty trailer.

WARNING!

Using an engine retarder can cause a

wheel lockup. The trailer is not load-

ing the tires enough to give the traction

you may need. When you are bobtail

or unloaded, you can have a serious

accident if your wheels lock suddenly

during braking. You could be killed or

injured. Don’t use your retarder when

you are driving bobtail or with an un-

loaded trailer.

Transmission Retarder

If you have this option, it will act

like a brake to slow your vehicle

without using the brakes. Take your

foot off the throttle and operate the

retarder switch. When you do not

need full retarder effect, you can

apply it intermittently (off and on)

to cause gradual or partial slowing.

Continuous application of your retarder

will cause your hydraulic uid to get

hotter. Intermittent application will help

prevent overheating.

WARNING!

Do not rely on your automatic trans-

mission hydraulic retarder to stop your

vehicle. If your engine shuts down, the

vehicle’s retarder will cease to operate

which, may lead to an accident involv-

ing death or personal injury. Always

be ready to suddenly apply the service

brakes.

4-34 Y53-1200-1B1 (04/13)

CRUISE CONTROL

Cruise Control Switch

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. See Steering Wheel Controls

on page 3-73 to determine where the

cruise control switches are located.

For information about the Adaptive

Cruise Control, see Adaptive Cruise

Control on page 4-37.

• To Turn On:

Press the ON/OFF button.

• To Turn Off:

Press the ON/OFF button. Any

previous speed settings are cleared.

Using Cruise Control While Driving

Setting Cruise Speed

1. Ensure that the vehicle speed is

above the minimum cruise control

speed (19 mph (30 km/h) for

PACCAR MX engine and 30 mph

(48 km/h) for Cummins engines)

and the engine speed is above

1100 rpm.

2. Press the "ON/OFF" button.

3. Accelerate the vehicle to the

desired cruise speed.

4. Press the "SET" button to set the

cruise speed.

NOTE

Cruise Control may not hold the set

speed going down hills. If the speed

increases going down a hill, use the

brakes to slow down. This will cancel

Cruise Control.

Changing the Cruise Set Speed

For vehicles with cruise control buttons

on the steering wheel, the cruise

speed may be changed by using the

+/- button. The pressing and holding

the + button will increase speed while

pressing and holding the - button will

decrease speed. For vehicles with

dash mounted cruise control switches,

changing the speed is done through

the "Set/Resume" button. To increase

the speed, press and hold the Set

button. To decrease the speed, press

and hold the "Resume" button.

Cancelling Cruise Control

You can cancel cruise control in any

of these ways:

• Tap the brake pedal.

• Tap the clutch pedal.

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

CRUISE CONTROL

• Press the ON/OFF button if the

vehicle has dash board mounted

cruise control switches or the

CANCEL button if the vehicle has

cruise control switches on the

steering wheel.

Resuming Cruise Control

1. If you tapped the brake or

clutch pedal, the cruise control

remembered the previously set

cruise speed. To resume that

set speed, accelerate above the

minimum cruise control speed and

press the "RESUME" button.

2. If you pressed the "OFF" button

(or the steering wheel mounted

"CANCEL" button) or turned the

ignition key OFF, this cleared the

system memory and you will need

to set a new cruise speed.

4-36

Using Cruise Control for Stationary

PTO Operation

Setting Idle Speed

1. Ensure parking brakes are applied.

2. Ensure transmission is in Neutral.

3. Engage PTO per the

manufacturer's operating

instructions.

4. Press the "ON" button.

5. Press the "SET" button to obtain

the desired engine rpm.

Cancelling Cruise Control

You can cancel cruise control in any

of these ways:

• Tap the brake pedal.

• Tap the clutch pedal.

Y53-1200-1B1

• Press the "OFF" button (or

the steering wheel mounted

"CANCEL" button).

NOTE

Cruise control functions and features

may vary depending upon which en-

gine you have. For specic expla-

nation of your cruise control, see the

cruise control or engine manual in-

cluded with your vehicle.

This vehicles electronic system will

perform a ‘rationality check’ every time

the vehicle is started. This check is

to ensure that the service brakes are

working before allowing cruise control

to function. This safety feature is

designed to ensure that a driver is able

to cancel the cruise set speed by using

the service brake pedal. The system

will not allow cruise control operation if

it does not pass the ‘rationality check.’

The instrument cluster will prompt you

to press the service brake pedal if it

(04/13)

CRUISE CONTROL

has not been pressed since the vehicle

has been started.

In vehicles with Eaton transmissions,

the cruise control switches may be

located on the shift control knob.

(04/13)

Adaptive Cruise Control

(Optional)

This vehicle may have an Adaptive

Cruise Control with Braking (ACB)

system that enhances the cruise

control function. The adaptive cruise

control system uses a radar sensor to

detect the following distance to vehicles

in front. The system will attempt to

maintain either a safe distance or the

vehicle speed depending on what is

selected by the driver. If a following

distance conict occurs the system

will alter the vehicles throttle position,

apply engine braking, and even apply

vehicle foundation brakes in attempt to

maintain the following distance. The

driver should always remain alert and

ultimately is the one still responsible

for safe vehicle control.

When the system is active and

controlling the speed and distance, the

screen will show the following display.

Y53-1200-1B1

The information in the instrument

cluster will provide various visual

and audible information. The audible

sounds may be a steady beep or

a repeating beep depending on the

situation. The following illustrations

are provided with the beeping

characteristics.

Level 3 (Green) Following Distance

Alert

This warning is active when the

following distance is less than what

is set in the system. This is the

least severe of all the warning tones.

The system will emit a single beep

4-37

CRUISE CONTROL

repeating at a rate of 42 tones per

minute.

Level 2 (Amber) Following Distance

Alert

This warning is active when the

following distance is less than what is

set in the system. This warning is more

severe than the Level 3 Following

Distance Alert. The system will emit a

double beep repeating at a rate of 80

tones per minute (40 double beeps per

minute).

Level 1 (Red) Following Distance

Alert

This warning is active when the

following distance is less than what

is set in the system. This warning

tone is the most severe following

distance alert. The system will emit

a continuous beep repeating at a

rate of 188 tones per minute and a

popup “WARNING Following Distance:

Increase Gap to Vehicle Ahead.”

Brake Command Warning

This is the most severe warning issued.

When the system uses the foundation

brakes the level 1 warning will appear

on the screen accompanied with a

"Collision Alert BRAKE" message.

The warning is active when the driver

must take immediate evasive action by

applying more braking power and/or

steering clear of the vehicle ahead to

avoid a potential collision. The system

will emit a solid beep for a 3 second

duration.

Stationary Object Alert

The system can also detect stationary

objects in the vehicles path. The

operator needs to take control of the

vehicle to avoid the stationary object.

The icon will be accompanied with a

pop-up message but no audible sound.

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

CRUISE CONTROL

WARNING!

The Wingman® ACB sensor may not

be able to detect vehicles and objects

with limited metal surfaces (such as

recreational vehicles, horse-drawn

buggies, motorcycles, logging trail-

ers, etc.). Failure to understand the

system limitation may result in death,

serious injury, and/or property dam-

age.

Fault Alert

This warning is presented to alert

the operator that the ACB system is

malfunctioning and will be disabled.

The operator will need to resume

control of the vehicle’s throttle and

brakes. The system will remain

disabled until the fault is corrected.

(04/13)

Y53-1200-1B1 4-39

AXLE

Differential Lock

The vehicle may be equipped with

switches to lock the either of the rear

axle differentials. Depending on how

the vehicle is specied, a combination

individual 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.

In the LOCK position, continuous

operation on paved, dry surfaces, put

stress on the axles, and can possibly

damage the internal gears. The switch

has a guard to prevent accidental

operation of the switch.

Locking the differentials is typically

used during ice or snow conditions

and without tire chains, unpaved roads

that have loose sand, mud or uneven

surfaces. Look ahead and predict

when the differential needs to be

locked. Stop the vehicle and lock the

differentials before approaching.

While using the differential in the

locked position, do not exceed 25 mph

(40 km/h). When disengaging the

differential lock, reduce the throttle to

prevent drivetrain damage.

WARNING!

Do not put the differential lock in the

LOCK position while the wheels are

spinning freely (slipping), you could

lose control of the vehicle or cause

axle damage. Switch to LOCK only

when the wheels are not spinning.

Failure to comply may result in death,

personal injury, equipment or property

damage.

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

AXLE

Dual Range (Two-Speed)

Rear Axle

Your vehicle may be equipped with a

two-speed or dual range axle (option).

You can select two rear axle ratios for

operating under heavy loads or rough

terrain as well as for over the road

hauling.

The Low Range provides maximum

torque for hauling heavy loads or

traveling over rough terrain. The High

Range is a faster ratio for highway

speeds and general over the road

conditions. A switch on the accessory

switch panel controls the Dual Range

Rear Axle. You will notice that the

switch has a guard to protect you from

activating it accidentally. Always park

your vehicle with the range selector in

LOW.

Dual Range Axle Operation

Important tips on operating a Dual

Range Axle with Interaxle Differential:

• Shift the axle with the inter-axle

differential in the unlocked position

only.

• When you are driving with poor

traction, lock the differential. When

you have the differential locked,

drive with the axle in LOW range

only.

• When you are driving on a surface

with good traction, keep the

interaxle differential unlocked. You

can drive with the axle in the LOW

or HIGH range.

• Always UNLOCK the inter-axle

differential before shifting the axle

speed range.

CAUTION

If you shift the axle range with the in-

ter-axle differential in LOCK, you could

seriously damage the axles. Never

shift the axle range with the differen-

tial locked.

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

AXLE

Starting-Up

1. Unlock the inter-axle differential

before starting.

2. Put the Range Selector in the

LOW range. Shift the transmission

to start the vehicle moving.

3. When you are driving on rough

terrain and secondary roads, or

under a very heavy load, keep the

axle in the LOW range. Shift the

transmission to maintain proper

road speed.

WARNING!

Never shift the axle when moving

downhill. Engine driveline disengage-

ment 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.

Proper shifting of the axle depends on

the synchronization of engine/driveline

and wheel speed. When you shift

the axle, the connection between the

engine and wheels is momentarily

disengaged while the gearing is

synchronized. Normally when the axle

is shifted the speed of the engine, axle,

and wheels adjust, allowing for proper

gear engagement.

When going downhill the wheels will

not slow down, but will tend to speed

up, which makes gear synchronization

almost impossible. As a result, the

axle is neither in HIGH nor LOW range

and all engine/driveline retardation is

lost. Without engine retardation it is

more difcult to slow the vehicle down

and greater stress is put on the brake

system.

CAUTION

To avoid damaging your vehicle shift

the axle at slower travel speeds until

you are used to driving with a dual

range axle.

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

AXLE

LOW to HIGH (Cruising)

When you go from rough terrain to

highway driving, shift the axle to the

HIGH range following this procedure:

1. Be sure the differential is

UNLOCKED.

2. Maintain your vehicle speed

(accelerator depressed) and move

the Range Selector lever to HIGH.

3. Keep driving with the accelerator

depressed until you want the axle

to shift.

4. To make the axle shift, release the

accelerator until the axle shifts.

You are now in the HIGH axle

range for highway speeds. Shift

the transmission normally to reach

your desired cruising speed.

(04/13)

HIGH to LOW (Rough Terrain)

If you need to downshift the axle for

more power or you are driving on

rough terrain:

1. Maintain your vehicle speed

(accelerator depressed) and move

the Range Selector lever to LOW.

2. Keep driving with the accelerator

depressed until you want the axle

to downshift.

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.

Y53-1200-1B1

Auxiliary Axles - Pusher or

Tag

Adjustable auxiliary axles (commonly

known as Pusher or Tag axles) can

add to the productivity of the vehicle by

increasing the load capabilities of the

vehicle when they are in the deployed

(down) position. There are different

congurations of axles with different

functionality (liftable versus steerable).

Without the extra axle, the excessive

weight can reduce the service life

of vehicle components such as, but

not limited to, the frame rail, axles,

suspension and brakes.

Operation of the auxiliary axles

includes the proper maintenance of the

system and calibration of its controls.

Operating the auxiliary axles will also

require a rm understanding of the

4-43

AXLE

Gross Axle Weight Rating (GAWR)

and the load that is being carried. See

Vehicle Loading on page 1-34.

The vehicle will have switches on the

dash to control the position of the

auxiliary axles. In certain situations,

however, the system will override the

controls to protect the axle system.

Any liftable and steerable auxiliary

axles will rise off of the ground when

the parking brakes are engaged or

when the vehicle is put in reverse.

If the liftable auxiliary axle is not a

steerable axle, then it will remain in the

down position when activated by the

dash mounted switch.

Operating the auxiliary liftable axles

must be performed in a manner that

does not exceed the axle creep rating.

Axle creep ratings are weight and

speed limits that are allowed while

the vehicle is fully loaded (in excess

of the vehicle’s standard GAWR) and

the axle is in its up position. Axle

creep ratings are assigned by the

axle manufacturer and are based on

axle model and intended service of

the vehicle. Contact an authorized

dealership if you are unable to identify

the axle creep rating of this vehicle.

• Liftable/steerable (axle lift

calibration required)

• Liftable/non-steerable (axle lift

calibration required)

• Non-liftable (some suspensions

require dump valve calibration)

WARNING!

Do not operate or park the vehicle

with auxiliary axles in the down/loaded

position when vehicle is unladen, or

is being unloaded. Raise or dump air

into driver-controlled auxiliary axle(s)

prior to unloading vehicle. Failure

to do so can result in loss of vehicle

control or rollaway that may result in

death, personal injury, equipment or

property damage.

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

AXLE

Axle Creep Rating Denition

Creep Ratings

Low speed, off-highway (work site)

axle loads, which exceed the standard

gross axle weight rating (GAWR) of a

particular axle.

Operator's using vehicles equipped

with liftable auxiliary axles must

consider creep ratings when any

liftable axle is unloaded or in the raised

position. Liftable auxiliary axles should

only be raised (or unloaded) to improve

maneuverability in an off-road use or

when vehicle is unloaded.

NOTE

Axle Creep ratings MUST NOT be ex-

ceeded.

Contact your dealer or axle

manufacturer to determine what

the creep rating is for your particular

axle(s) and conguration. Creep

ratings are generally limited to the

following:

• Tandem rear axles only

• Straight trucks only

• Maximum spring mount

centers per axle manufacturers

specications

• Maximum tire static loaded radius

(SLR) per axle manufacturers

specications

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 re-

maining axles, and could cause equip-

ment damage.

WARNING!

Never operate the vehicle with more

pressure in the lift axles than is nec-

essary to carry the load, as deter-

mined by the calibration procedure

described. Failure to do so can result

in loss of traction and stability at the

steer and/or drive axles and can result

in increased braking distance, which

could cause loss of vehicle control

resulting in an accident. Failure to

comply may result in death, personal

injury, equipment or property damage.

Do not modify the air system and/or

control functionality on a factory in-

stalled auxiliary axle(s). Modifying the

factory operation of the pusher and/or

tag axle(s) will void your warranty, and

can cause equipment damage.

CAUTION

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

AXLE

CAUTION

Liftable/Steerable or

Liftable/Non-Steerable Pusher

and/or Tag Axle Calibration

Procedure

Below are some general instructions

on how to adjust and calibrate the air

control valve for the auxiliary axles to

obtain the proper load distribution of

the axle(s). For additional operating

and maintenance instructions, see the

pusher or tag suspension manufacturer

literature in the glove box or contact

them directly.

A change in tire size on either the aux-

iliary axles or the drive/steer axles can

change the calibration of the auxiliary

axles. If tires are installed with a differ-

ent loaded radius, the calibration pro-

cedure must be repeated. Failure to

do so can cause equipment damage.

NOTE

This procedure must be performed

prior to placing the vehicle into ser-

vice.

Setting the Pressure-to-Load Ratio

To obtain the desired axle load

distribution, you must correlate the

suspension air gauge pressure to the

actual axle load by scaling the axle

weight(s) and adjusting the pressure

to obtain the desired load. Once the

desired load or load range is achieved,

document the pressure-to-load ratio or

setting for future use.

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

AXLE

General Calibration Guidelines

These instructions are general in

nature. For more specic instructions,

review the pusher or tag suspension

manufacturers maintenance manual or

contact the nearest authorized dealer.

NOTE

Perform this procedure at or near a

weight scale. Procedure can be per-

formed while parked on the weight

scale if scale is available.

1. Park loaded vehicle on level

surface with wheels blocked.

2. Release vehicles spring

brakes. (Do not release for

Liftable/Non-Steerable pusher or

tag axles).

3. Lower the pusher/tag axles with

the axle lift control ip valve. (For

some non-liftable axles, inate air

suspension).

4. Adjust the amount of load on

each axle by turning the pressure

regulator clockwise to increase

the load or counterclockwise

to decrease the load. (The

suspension manufacturer

may publish pre-established

Pressure-to-Load Ratio Pressure

Settings to assist you in achieving

an estimated ground load).

5. After setting the pressure to obtain

the desired axle load, verify proper

ground loading with the weight

scale.

NOTE

Exceeding local, state or federal

weight limits may result in citations.

Contact your local commercial weight

enforcement ofce for limits in your

area.

Operation guidelines

NOTE

Steerable-pusher and/or tag axle(s)

will raise when the transmission is

shifted into reverse or when the park-

ing brakes are applied.

Maximizing Drive Axle Traction

Adjust the pressure regulator control

knob to a lower pressure until desired

traction is obtained. By reducing air

pressure at pusher or tag axle, load

will be transferred to drive axles. Do

not overload drive axles.

Coupling to a Loaded Trailer

Inate air springs of the auxiliary axles

to the desired pressure after coupling

to a loaded trailer while still maintaining

proper traction of the drive axles.

Unloading Operation

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

AXLE

Always deate air springs of the

auxiliary axles before attempting to

unload vehicle. This allows maximum

traction of the drive axles to control the

vehicle.

Non-liftable (Non-steerable) Axles

Some suspensions require dump valve

calibration.

Example: Neway dead axles do not

lift, but the air can be dumped out of

them to unload them when empty. Air

pressure is controlled via an adjustable

regulator. These axles need to be

calibrated for load.

Contact your authorized dealer or

axle/suspension manufacturer for

dump valve calibration procedures.

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

SUSPENSION

Air Suspension Height/Air

Pressure

Your vehicle may have an air

suspension and a deation switch

which allows the air in the suspension

to be exhausted from a switch on the

dash. The normal purpose of this

feature is to allow you to lower the

vehicle for loading.

A guard on the switch prevents

you from accidentally deating the

suspension.

CAUTION

Operating a vehicle with air suspen-

sion bags either overinated or under-

inated may cause damage to drive-

line components. If a vehicle must

be operated under such conditions, do

not exceed 5 mph (8 km/h). Failure to

comply may result in equipment dam-

age.

Suspension Air Pressure Gauge

The Suspension Air Pressure gauge

(option), see Optional Gauges on page

3-43, which indicates the amount of air

pressure in the air suspension springs

in pounds per square inch (psi). Air

pressure in the spring is related to

the rear axle load. The greater the

rear axle load, the greater the air

pressure in the air bags. Therefore,

the air pressure displayed will vary,

depending upon the rear axle load. 4

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

SUSPENSION

Driving with Deated Air control arm to center in the closed

Springs position.

If an air spring is ruptured, there will

be enough air pressure to drive the

vehicle to a safe stop off the highway

2. The air system can then be

pumped up to normal pressure for

continued operation.

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 caus-

ing death or personal injury. Do not

continue to operate the vehicle in this

condition.

You can get to a repair facility if you do

the following:

1. Remove the height control link

connected to the axle and to

the suspension air valve control

arm. This will cause the air valve

WARNING!

Do not drive the vehicle if the air pres-

sure is less than 100 psi (690 kPa).

Driving the vehicle with less than 100

psi (690 kPa) could make the brakes

unsafe to use which could cause an

accident involving death or personal

injury.

Operating a vehicle with air suspen-

sion bags either overinated or under-

inated may cause damage to drive-

line components. If a vehicle must

be operated under such conditions, do

not exceed 5 mph (8 km/h).

CAUTION

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

AFTER-TREATMENT SYSTEM

AFTER-TREATMENT

SYSTEM

Introduction

This vehicle will has an exhaust

After-Treatment System (ATS), to

control vehicle exhaust emissions,

which consist of a Diesel Particulate

Filter (DPF), Selective Catalyst

Reduction (SCR), Regeneration

Switch and warning lights. The DPF

will trap soot from the engine exhaust

gases. The SCR uses Diesel Exhaust

Fluid to reduce the levels of NOx in

the engine exhaust. The ATS will

periodically clean (regenerate) the

DPF. Please refer to the Exhaust

Aftertreatment System Supplement

provided with the vehicle for more

detailed description of functionality and

warnings.

(04/13) Y53-1200-1B1 4-51

DRIVING TIPS AND TECHNIQUES

DRIVING TIPS AND

TECHNIQUES

Introduction

This section covers additional driving

tips and techniques on how to drive

your vehicle more efciently.

Coasting

WARNING!

Do not coast with the transmission in

neutral or with the clutch pedal de-

pressed - it is a dangerous practice.

Coasting in neutral may result in dam-

age to your drivetrain when you try

to re-engage the transmission. You

could lose control of the vehicle which

can lead to an accident involving death

or personal injury.

Do not coast with the transmission

in neutral or with the clutch pedal

depressed. Besides being illegal and

dangerous, coasting is also expensive.

It causes premature failure or damage

to the clutch and transmission and

overloads the brake system.

Coasting with the transmission

in neutral also prevents proper

transmission component lubrication.

During coasting the transmission is

driven by the rear wheels, and the

countershaft gear (which lubricates

the transmission components by oil

splash) will only be turning at idle

speed.

4-52 Y53-1200-1B1 (04/13)

DRIVING TIPS AND TECHNIQUES

Descending a Grade

WARNING!

Do not hold the brake pedal down too

long or too often while going down a

steep or long grade. This could cause

the brakes to overheat and reduce

their effectiveness. As a result, the

vehicle will not slow down at the usual

rate. To reduce the risk of an accident

which could cause death or personal

injury, before going down a steep or

long grade, reduce speed and shift the

transmission into a lower gear to help

control your vehicle speed. Failure to

follow procedures for proper downhill

operation could result in loss of vehi-

cle control.

Engine Overspeed

CAUTION

To avoid engine damage, do not let the

engine rpm go beyond the maximum

governed rpm—valve damage could

result if overspeed conditions occur.

NOTE

Often these recommendations are

secondary to maintaining an adequate

and safe speed relative to the sur-

rounding trafc 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., while

driving down a grade), do not allow

the engine rpm to exceed maximum

governed speed.

Under normal load and road conditions

operate the engine in the lower end of

the range.

(04/13) Y53-1200-1B1 4-53

DRIVING TIPS AND TECHNIQUES

Use of Tachometer

The tachometer is an instrument that

aids in obtaining the best performance

of the engine and manual transmission,

serving as a guide for shifting gears.

Refer to the Engine Operation and

Maintenance manual for optimum

engine rpm.

• If the engine rpm moves beyond

the maximum governed speed,

indicating an overspeed condition,

apply the service brake or shift to

a higher gear to bring engine rpm

within the optimum speed range.

• When driving downhill: shift to a

lower gear, use the engine brake

(if so equipped), and use the

service brake, keeping the engine

speed below 2,100 rpm.

When the engine speed reaches

its maximum governed speed, the

injection pump governor cuts off fuel

to the engine. However, the governor

has no control over the engine rpm

when it is being driven by the vehicle's

transmission, for example, on steep

downgrades. Apply service brakes or

shift to a higher gear.

Fuel economy and engine performance

are also directly related to driving

habits:

• The best results in trip time and

fuel economy are obtained while

driving the vehicle at a steady

speed.

• Shift into higher or lower gears (or

apply the service brake) to keep

engine rpm near the lower end of

the optimum operating range.

• Avoid rapid acceleration and

braking.

Optimal Engine Speed

WARNING!

Do not look at the Instrument Clus-

ter Display for prolonged periods or at

it repeatedly in a short period of time

while the vehicle is moving. Extended

glance durations to instrument cluster

and or overly frequent glances inside

the vehicle can cause a loss of at-

tention to the situations on the road-

way and vehicle’s road position, which

could lead to an accident and possible

death or personal injury or equipment

damage.

The tachometer displays a green bar

just below the most efcient engine

speed for the vehicle. The placement

and size of this bar is dependent on

the engine as installed at the factory.

The driver’s general goal should

be to select a gear that keeps the

tachometer needle positioned over

the green light as much as possible

4-54 Y53-1200-1B1 (04/13)

DRIVING TIPS AND TECHNIQUES

during steady state driving. In addition

to proper maintenance and good

driving habits, this visual cue can help

minimize the fuel consumption.

1. Optimal Engine Speed

Indicator

Use of Instrument Cluster Display

The Instrument cluster display

provides information to help the driver

optimize vehicle efciency. Refer to

Instrumentation Cluster Information on

page 3-14 for details. A driver will nd

the section describing Trip Information

and the RPM Detail useful.

Fuel - Excess Consumption

The vehicle's fuel consumption is

connected to three important factors:

maintenance, driving habits, and

general condition of the road, trafc

conditions, and vehicle load.

(04/13) Y53-1200-1B1 4-55

DRIVING TIPS AND TECHNIQUES

Maintenance

Proper maintenance will keep the

vehicle running like new even after

long periods of use. The driver must

perform the daily and weekly checks

of the vehicle.

Maintenance factors affecting fuel

consumption:

• air and/or fuel lters partially

clogged

• engine valves out of adjustment

• injection pump improperly

synchronized

• injection nozzles defective or

uncalibrated

• improperly inated tires

• wheel bearings improperly

adjusted

• clutch improperly adjusted or worn

(slipping)

• fuel leaks

Driving Habits

Wrong driving habits must be

corrected and the recommendations

on economic driving should be

followed.

Driving factors affecting fuel

consumption:

• excessive speed and unnecessary

fast acceleration

• long periods of idling

• driving with foot resting on the

(manual transmission) clutch

pedal

4-56 Y53-1200-1B1 (04/13)

DRIVING TIPS AND TECHNIQUES

General Condition

Other factors affecting fuel

consumption are related to loads

and type of roads on which the vehicle

operates. It is not always possible to

choose the most adequate road, but

it must be kept in mind that the ideal

road is the one that allows a steady

speed in high gear, without requiring

frequent braking and acceleration.

The following general conditions

can affect fuel consumption:

• overload

• unbalanced load

• very high load

• inadequate roads

• trafc conditions

(04/13) Y53-1200-1B1 4-57

SLEEPER BUNKS

Sleeper Bunk

If your vehicle has an upper and lower

bunk, the upper bunk can be folded up

out of the way to provide you with more

dressing area in the sleeper cab. The

lower bunk has storage underneath

it to stow your luggage and other

belongings. The upper bunk weight

limit is 320 lb. (145 kg).

WARNING!

Be sure the restraint system is used

when anyone is occupying the sleeper

while the vehicle is moving. In an ac-

cident, an unrestrained person lying in

a sleeper bunk could be injured. He or

she could be thrown from the bunk.

Always keep the lower bunk in its down

(latched) position while the vehicle is

moving. If left open, stored items could

become loose during an accident and

strike you. Before you move the vehi-

cle, check to be sure the lower bunk

is latched securely. Failure to comply

may result in death or personal injury.

• Before you move the vehicle,

check to be sure the lower

bunk is latched securely.

WARNING!

To Lower Upper Bunk: pull on the

lanyard in the upper left corner of the

bunk to release the bunk. This will free

it from the anchored position and allow

you to lower the bunk.

To Raise Upper Bunk: fold the

upper bunk up and push it against the

retaining latch until you hear a click.

Pull on the bunk to be sure it is latched

securely.

WARNING!

Be sure the latch that holds the upper

bunk in the folded position is working

properly so the bunk will not fall down.

If the bunk falls, you could be injured.

Be sure to stow away all loose belong-

ings before you move your vehicle. Do

not store objects on the bunks, they

could cause damage or injury in an ac-

cident. Failure to comply may result

in death, personal injury, equipment or

property damage.

WARNING!

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

SLEEPER BUNKS

WARNING!

Be sure the restraint system is used

when anyone is occupying the sleeper

while the vehicle is moving. In an ac-

cident, an unrestrained person lying in

a sleeper bunk could be injured. He

or she could be thrown from the bunk.

Failure to comply may result in death

or personal injury.

Be sure no one ever rides unsecured

in the upper bunk. That person could

be thrown out in an accident and could

be injured. Do not use the upper bunk

while you are moving. Failure to com-

ply may result in death or personal in-

jury.

WARNING!

Sleeper Occupant Restraint

The sleeper restraint is stored in a

compartment on the rear sleeper cab

wall.

WARNING!

Failure to properly use the sleeper re-

straint when an individual is located

in the sleeper bunk and the vehicle is

moving can result in death or personal

injury.

See Sleeper Bunks and Restraints on

page 1-29, for more information on

cab/seat restraint systems.

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

STOPPING THE ENGINE

Before Stopping the Engine

A hot engine stores a great amount of

heat. It doesn’t cool down immediately

after you shut it off. Always cool your

engine down before shutting it off. You

will greatly increase its service life.

Idle the engine at 1000 RPM for

ve minutes. Then low idle for thirty

seconds before shutdown. This will

allow circulating coolant and lubricating

oil to carry away heat from the cylinder

head, valves, pistons, cylinder liners,

turbocharger, and bearings. This

way you can prevent serious engine

damage that may result from uneven

cooling.

Turbochargers

This cooling-down practice is

especially important on a turbocharged

engine. The turbocharger contains

bearings and seals that are subjected

to hot exhaust gases. While the

engine is operating, heat is carried

away by circulating oil. If you stop the

engine suddenly, the temperature of

the turbocharger could rise as much as

100°F (55°C) above the temperature

reached during operation. A sudden

rise in temperature like this could

cause the bearings to seize or the oil

seals to loosen.

Refueling

Air inside the fuel tanks allows water

to condense in the tank. To prevent

this condensation while the vehicle is

parked for extended periods of time,

ll the tanks to 95 percent of capacity.

Never ll to more than 95 percent

capacity as this provides room for

expansion resulting from temperature

extremes. When refueling, add

approximately the same amount to

each fuel tank on vehicles with more

than one tank.

WARNING!

Do not carry additional fuel containers

in your vehicle. Fuel containers, either

full or empty, may leak, explode, and

cause or feed a re. Do not carry ex-

tra fuel containers, even empty ones

are dangerous. Failure to comply may

result in death, personal injury, equip-

ment or property damage.

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

STOPPING THE ENGINE

Diesel fuel in the presence of an ig-

nition source (such as a cigarette)

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 ame. Use only the fuel and/or

additives recommended for your en-

gine. Failure to comply may result in

death, personal injury, equipment or

property damage.

WARNING!

Specication: Use only Ultra

Low Sulfur Diesel (ULSD) Fuel,

as recommended by engine

manufacturers. If you need further

information on fuel specications,

consult the Engine Operation and

Maintenance Manual.

Location of Fuel Shut-Off Valves

If your vehicle is equipped with shut-off

valves for the take-off and return lines,

they are located on the fuel lines

entering the top of the fuel tank. Fuel

shut-off valves for the fuel crossover

line are on the bottom of the fuel tank,

at the crossover line connection.

Refuel Before the Final Stop

Air space in your fuel tanks allows

water to condense there. To prevent

this condensation while you are

stopped, ll your tanks to 95% of

capacity.

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

STOPPING THE ENGINE

Final Stop

To make sure your vehicle is ready

to go after a long stop (such as over

night), please follow the suggestions

below. Your vehicle will be easier to

get going when you are ready, and

it will be safer for anyone who might

be around it. Please remember, too,

that in some states it is illegal to leave

the engine running and the vehicle

unattended.

4-62

Final Stopping Procedures

1. Set the parking brake before leaving

the driver’s seat. To hold your vehicle

while it is parked, don’t rely on:

• Air Brakes

• Hand Control Valve for Trailer

Brakes

• Engine Compression

WARNING!

Using the trailer hand brake or air

brakes to hold a parked vehicle is

dangerous. Because they work with

air pressure, these brakes could come

loose. Your vehicle could roll, causing

an accident involving death or per-

sonal injury. Always set the parking

brakes. Never rely on the trailer hand

brake or truck air brakes to hold a

parked vehicle.

Y53-1200-1B1

2. If you are parked on a steep grade,

block the wheels.

Suitable wheel chocks are at a

minimum an 18-inch (46 cm) long 4x4.

Blocked Wheels

3. Drain water from the air reservoirs.

While the engine and air supply

system are still warm, drain moisture

from the air reservoirs. Open the

reservoir drains just enough to drain

the moisture. Don’t deplete the entire

(04/13)

STOPPING THE ENGINE

air supply. Be sure to close the drains

before leaving the vehicle.

Opening Drains

4. Secure the vehicle. Close all the

windows and lock all the doors.

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

MAINTENANCE

PREVENTIVE MAINTENANCE SCHEDULE

Introduction .................. 5-9

Maintenance Schedule . . . . . . . . . . . . 5-12

LUBRICANT SPECIFICATIONS

Introduction ................. 5-35

Engine ................... 5-35

Master Lubrication Index . . . . . . . . . . . . 5-38

Fuller Transmission Lubrication . . . . . . . . . 5-41

Allison Transmission Lubrication . . . . . . . . 5-43

Spicer Transmission Lubrication . . . . . . . . 5-43

Oil Changes ................. 5-44

Meritor Axle Lubrication . . . . . . . . . . . . 5-45

Eaton/Dana Axle Lubrication . . . . . . . . . . 5-46

Wheel Bearing Lubrication . . . . . . . . . . . 5-47

Universal Joint Lubrication . . . . . . . . . . . 5-47

Steering Gear Lubrication . . . . . . . . . . . 5-48

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

MAINTENANCE

AIR SYSTEM

Introduction . . . . . . . . . . . . . . . . . 5-49

Air Dryer . . . . . . . . . . . . . . . . . . . 5-52

Air Tanks . . . . . . . . . . . . . . . . . . 5-54

Air Gauges and Air Leaks . . . . . . . . . . . 5-55

Air Compressor . . . . . . . . . . . . . . . . 5-56

BRAKE SYSTEM

Brake Adjustment . . . . . . . . . . . . . . . 5-58

CAB

Exterior Maintenance . . . . . . . . . . . . . 5-63

Cleaning, Protecting and Weather Stripping . . . 5-64

Safety Restraint System - Inspection . . . . . . 5-68

Windshield Wiper/Washer . . . . . . . . . . . 5-71

COOLING SYSTEM

Cooling system maintenance . . . . . . . . . 5-72

Engine (Block) Heater . . . . . . . . . . . . . 5-75

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

MAINTENANCE

ELECTRICAL

Electrical System . . . . . . . . . . . . . . . 5-77

LightBulbs.................. 5-78

Bulb Specications .............. 5-79

Fuses, Circuit Breakers and Relays . . . . . . . 5-80

Fuse Inspection and Replacement . . . . . . . 5-84

Adding Electrical Options . . . . . . . . . . . 5-84

Batteries................... 5-85

Battery Care ................. 5-89

Battery Charging ............... 5-89

Electrical and Alternator Precautions . . . . . . 5-91

Remote Keyless Entry . . . . . . . . . . . . . 5-92

ENGINE

Engine Maintenance ............. 5-93

Engine Lubrication .............. 5-94

Accessory Drive Belts . . . . . . . . . . . . . 5-97

Engine Fan ................. 5-98

Air Intake System . . . . . . . . . . . . . . . 5-99

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

MAINTENANCE

Turbocharger . . . . . . . . . . . . . . . . . 5-99

Air Cleaners . . . . . . . . . . . . . . . . . 5-100

ServiSignal™ Mini Indicator . . . . . . . . . . 5-101

Exhaust System . . . . . . . . . . . . . . . 5-101

Engine Mounting . . . . . . . . . . . . . . . 5-101

FUEL SYSTEM

Location of Fuel Shut-off Valves. . . . . . . . . 5-103

Specication . . . . . . . . . . . . . . . . . 5-103

Fuel Filters . . . . . . . . . . . . . . . . . . 5-103

FRAME

Introduction . . . . . . . . . . . . . . . . . 5-104

FRONT AXLE AND SUSPENSION

Axle Lubrication . . . . . . . . . . . . . . . 5-108

Inspection . . . . . . . . . . . . . . . . . . 5-109

Wheel Alignment . . . . . . . . . . . . . . . 5-109

U-Bolt Torque . . . . . . . . . . . . . . . . 5-110

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

MAINTENANCE

HEATER AND AIR CONDITIONER

Introduction ................. 5-112

Air Filters .................. 5-113

Heater.................... 5-115

Air Conditioner ................ 5-116

NOISE AND EMISSION CONTROL

Noise Emission Warranty . . . . . . . . . . . 5-117

Inspection and Maintenance Instructions . . . . . 5-118

Noise Control System - Maintenance Log . . . . 5-124

REAR AXLE AND SUSPENSION

General Maintenance . . . . . . . . . . . . . 5-125

Visual Inspection ............... 5-126

Rear Suspension Fasteners . . . . . . . . . . 5-127

Rear Axle Lubrication . . . . . . . . . . . . . 5-128

Rear Axle Alignment ............. 5-130

STEERING SYSTEM

PowerSteering................ 5-131

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

MAINTENANCE

Fluid Level and Rell . . . . . . . . . . . . . 5-132

Steering Shaft . . . . . . . . . . . . . . . . 5-133

DRIVELINE

Driveshaft Maintenance . . . . . . . . . . . . 5-135

U-Joints . . . . . . . . . . . . . . . . . . . 5-135

TIRES AND WHEEL

Tires . . . . . . . . . . . . . . . . . . . . 5-136

Wheel Mounting and Fastening . . . . . . . . . 5-142

Wheel Replacement with Disc Brake Option . . . 5-144

Disc Wheels . . . . . . . . . . . . . . . . . 5-145

WHEEL BEARING

Wheel Bearing Adjustment . . . . . . . . . . . 5-146

TRANSMISSION MAINTENANCE

Introduction . . . . . . . . . . . . . . . . . 5-147

Transmission Lubricants . . . . . . . . . . . . 5-148

Automatic Transmissions . . . . . . . . . . . 5-149

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

MAINTENANCE

CLUTCH

Introduction ................. 5-150

Clutch Hydraulic Fluid . . . . . . . . . . . . . 5-150

Clutch Adjustment .............. 5-151

Clutch Adjustment – Normal Wear . . . . . . . 5-151

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

PREVENTIVE MAINTENANCE SCHEDULE

PREVENTIVE

MAINTENANCE

SCHEDULE

Introduction

Preventive maintenance program

begins with the daily checks. See

Driver’s Check List on page 1-36

for these routine 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.

WARNING!

Before attempting any procedures

in the engine compartment, stop the

engine and let it cool down. Hot com-

ponents can burn skin on contact.

Failure to comply may result in death,

personal injury, equipment or property

damage.

If the engine must be operating to in-

spect, be alert and cautious around the

engine at all times. Failure to com-

ply may result in death, personal injury,

equipment or property damage.

WARNING!

If work has to be done with the en-

gine running, always (1) set the park-

ing brake, (2) block the wheels, and (3)

ensure that the shift lever or selector

is in Neutral. Failure to comply may

result in death, personal injury, equip-

ment or property damage.

Exercise extreme caution to prevent

neckties, jewelry, long hair, or loose

clothing from getting caught in the fan

blades or any other moving engine

parts. Failure to comply may result

in death, personal injury, equipment or

property damage.

WARNING!

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

PREVENTIVE MAINTENANCE SCHEDULE

WARNING!

Disconnect the battery ground strap

whenever you work on the fuel sys-

tem or the electrical system. When

you work around fuel, do not smoke

or work near heaters or other re haz-

ards. Keep an approved re extin-

guisher handy. Failure to comply may

result in death, personal injury, equip-

ment or property damage.

Always support the vehicle with ap-

propriate safety stands if it is neces-

sary to work underneath the vehicle. A

jack is not adequate for this purpose.

Failure to comply may result in death,

personal injury, equipment or property

damage.

WARNING!

When working underneath the vehi-

cle without appropriate safety stands

but with the wheels on the ground (not

supported), make sure that (1) the ve-

hicle is on hard level ground, (2) the

parking brake is applied, (3) all wheels

are blocked (front and rear) and (4) re-

move the ignition key so that the en-

gine cannot be started. Failure to com-

ply may result in death, personal injury,

equipment or property damage.

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!

The following pages contain a table

of maintenance tasks with the related

intervals for each task on the right

side of the table. The top of the table

displays a guide to a maintenance

interval and its schedule. Some

tasks are dependent on the vehicle

application. These tasks will be

shown as separate tasks and will have

the words “ON HIGHWAY”, “CITY

DELIVERY” or “OFF-HIGHWAY”

after the description. These tasks

are differentiated because they are

dependent on the vehicle’s operating

environment.

On highway is dened for applications

where the vehicle is NOT used off of a

paved road during normal operation.

City Delivery is dened for applications

where frequent start and stopping is

required during normal operation and

the highway is used infrequently and

for short periods of time.

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

PREVENTIVE MAINTENANCE SCHEDULE

Off highway is dened for applications

where the vehicle may be driven off

the pavement on a regular basis, even

if it is an infrequent basis and/or for a

brief time period.

Please contact an authorized

service dealership if there are

questions regarding which interval

to follow. Consult the supplier for

specic recommendations where

discrepancies develop between these

recommendations in this table and

component supplier recommendations.

• Engine lubricating oil change

intervals aren’t listed here. Refer

to your engine’s operating manual

for recommendations. For specic

information on maintenance

procedures consult your vehicle

maintenance manual.

• The initial ll of drive axle lubricant

must be changed before the end

of the rst scheduled maintenance

interval. Refer to Oil Changes on

page 5-44 before you put a new

vehicle into service.

• The initial ll of lubricant in

manual transmissions must be

changed before the end of the rst

maintenance interval. See Fuller

Transmission Lubrication on page

5-41 for specic information.

• If your vehicle is equipped with an

automatic transmission, consult

the owner’s manual for it that came

with your vehicle to obtain lubricant

check and change intervals.

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

PREVENTIVE MAINTENANCE SCHEDULE

Maintenance Schedule

New Vehicle Maintenance Schedule

Operation\Frequency First Day

After First Miles (km)

50 – 100

(80 – 160) 500 (800) 2,000

(3218) 3,000

–5,000

(4800

–8000)

Steering Shaft U-Bolts. (OFF-HIGHWAY) See Steering System on page 5-131. X

Wheel Mounting. See Wheel Mounting and Fastening on page 5-142. X

Front Axle U-Bolt Torque. See Front Spring Suspension U-Bolts on page 5-110. X

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

Rear Suspension Fasteners. See Rear Suspension Fasteners on page 5-127. X

Transmission Lubrication.

1. For Fuller transmission, see Fuller Transmission Lubrication on page 5-41.

2. For Allison transmission, see Allison Transmission Lubrication on page 5-43.

3. For Spicer transmission, see Spicer Transmission Lubrication on page 5-43.

Axle Lubrication.

1. For Meritor axle, see Meritor Axle Lubrication on page 5-45.

2. For Eaton/Dana axle, see Eaton/Dana Axle Lubrication on page 5-46.

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

PREVENTIVE MAINTENANCE SCHEDULE

PREVENTIVE MAINTENANCE (PM) INTERVALS

SYSTEM COMPONENT MAINTENANCE TASK Recommended PM Interval

I A B C D E

Frame Fifth Wheel Check the kingpin lock and plate for wear and function;

lubricate (NLGI #2 grease). X

Inspect fth wheel operation (shown on page 5-127) X

Frame Fasteners Check for tightness; tighten to the specied torque value as

required (shown on page 5-104). X

Crossmembers and

Mounting Brackets Inspect for cracks and loose fasteners. Replace or tighten to

the specied torque value as required (shown on page 5-104). X

Engine Mounting Inspect engine mounts every 60,000 miles (96,560 km) (shown

on page 5-101). Contact an authorized vehicle OEM dealership

if engine mounts need servicing.

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

PREVENTIVE MAINTENANCE SCHEDULE

PREVENTIVE MAINTENANCE (PM) INTERVALS

SYSTEM COMPONENT MAINTENANCE TASK Recommended PM Interval

I A B C D E

Front Axle

(Meritor) Total Vehicle Alignment Check and adjust as required. X X

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 (shown on page 5-131). X

Kingpin bushings, thrust

bearings, and tie rod ball

ends

Lubricate with approved grease. X

Drawkeys Tighten nuts X X

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

PREVENTIVE MAINTENANCE SCHEDULE

PREVENTIVE MAINTENANCE (PM) INTERVALS

SYSTEM COMPONENT MAINTENANCE TASK Recommended PM Interval

I A B C D E

Front Axle

(Dana) Total Vehicle Alignment Check and adjust as required. X X

Kingpin bushings, thrust

bearings, and tie rod ball

ends (ON HIGHWAY)

Lubricate with approved grease. X

Kingpin bushings, thrust

bearings, and tie rod ball

ends (OFF-HIGHWAY)

Lubricate with approved grease. X

Steering knuckle spindles,

thrust bearings, kingpins,

drawkeys, tie rod ends,

steering stops, and

bushings (ON HIGHWAY)

Inspect for wear and damage and for endplay. Shim or replace

as required. X

Steering knuckle spindles,

thrust bearings, kingpins,

drawkeys, tie rod ends,

steering stops, and

bushings (OFF-HIGHWAY)

Inspect for wear and damage and for endplay. Shim or replace

as required. X 5

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

PREVENTIVE MAINTENANCE SCHEDULE

PREVENTIVE MAINTENANCE (PM) INTERVALS

SYSTEM COMPONENT MAINTENANCE TASK Recommended PM Interval

I A B C D E

Front

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

corrosion. X

Spring Pins and Shackles Inspect for worn parts and excessive joint clearance. Shim

or replace as required. X

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. X

Check for proper function. X

U-bolts (ON HIGHWAY) Check the general condition and the tightness of the nuts.

Tighten the nuts to the specied torque value as required

(shown on page 5-111).

X X

U-bolts (OFF HIGHWAY) Check the general condition and the tightness of the nuts.

Tighten the U-bolts after the rst day or two of operation.

Then tighten the nuts to the specied torque value as required

(shown on page 5-111).

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

PREVENTIVE MAINTENANCE SCHEDULE

PREVENTIVE MAINTENANCE (PM) INTERVALS

SYSTEM COMPONENT MAINTENANCE TASK Recommended PM Interval

I A B C D E

Drive Axle

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

Check oil level. Check “cold.” Torque the drain plug. X

Drain the lubricant while warm. Flush each unit with clean

ushing oil. Change the lubricant. See information on page 5-45

Air Shift Unit Check the lubricant level. X

Remove the housing cover and drain the lubricant. Wash the

parts thoroughly and dry in air. X

Breather Clean or replace. X

Lube Pump (ON HIGHWAY) Remove the magnetic strainer and inspect for wear particles.

Wash in solvent and dry in air. X

Lube Pump (OFF

HIGHWAY) Remove the magnetic strainer and inspect for wear particles.

Wash in solvent and dry in air. X

Lube Filter (ON HIGHWAY) Change. X

Lube Filter (OFF

HIGHWAY) Change. X

Magnetic drain plug and

breather (ON HIGHWAY) Clean or replace. X

Magnetic drain plug and

breather (OFF HIGHWAY) Clean or replace. X

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

PREVENTIVE MAINTENANCE SCHEDULE

PREVENTIVE MAINTENANCE (PM) INTERVALS

SYSTEM COMPONENT MAINTENANCE TASK Recommended PM Interval

I A B C D E

Drive Axle

(Meritor) Axle Housing Check the “cold” ll 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 N.m.)

Visually inspect for damage or leaks. X

Drain and replace the lubricant. See information on page 5-44

Lubricant lter Change the lter. X

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

Input shaft and pinion shaft Check and adjust the endplay. X

Axle shaft Tighten the rear axle ange nuts to the specied torque value. X

Interaxle differential Check the operation. X

Drive Axle

(SISU) Axle Housing Change the oil in the differential carrier and the hubs, and clean

the magnetic oil drain plugs. X X

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

Visually inspect for damage or leaks. X X

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

Breather Check the breather for proper operation. X

Lube Filter Clean the suction lter for the optional pressure lubrication

system. X

S-cam brakes Overhaul the brakes; degrease all moving parts; check the

bushings and seals for wear. X

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

PREVENTIVE MAINTENANCE SCHEDULE

PREVENTIVE MAINTENANCE (PM) INTERVALS

SYSTEM COMPONENT MAINTENANCE TASK Recommended PM Interval

I A B C D E

Rear

Suspension U-bolts Check the torque. Tighten to specied torque value as required

(shown on page 5-128). X X

Frame and crossmember

bolts Check the torque. Tighten to specied torque value as required

(shown on page 5-106). X

Mounting brackets and

fasteners Check the condition and the fastener torque. Tighten to the

specied torque value as required (shown on page 5-106). X X

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

PREVENTIVE MAINTENANCE SCHEDULE

PREVENTIVE MAINTENANCE (PM) INTERVALS

SYSTEM COMPONENT MAINTENANCE TASK Recommended PM Interval

I A B C D E

Drum Brakes

(All) Slack adjusters Check the push rod travel and check the control arm for cracks.

Adjust at reline (shown on page 5-61). X

Lubricate (NLGI #2 grease). X

Brake camshaft bearing Check for excessive camshaft paly in the axial and radial

directions. Max allowable play is 0.003 in. Lubricate (NLGI

#2 grease).

Brake treadle valve Clean the area around the treadle, boot, and mounting plate.

Check the pivot and mounting plate for integrity. Check the

plunger boot for cracks. Lubricate roller pin, pivot pin, and

plunger (NLGI #2 grease).

Brake air system Check air lines and ttings for leaks (shown on page 5-49).

Adjust routing as required to prevent chang. Check tank

mounting and condition.

Clean or replace the inline lters. X

Brake lining Inspect; replace as required. X

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

PREVENTIVE MAINTENANCE SCHEDULE

PREVENTIVE MAINTENANCE (PM) INTERVALS

SYSTEM COMPONENT MAINTENANCE TASK Recommended PM Interval

I A B C D E

Disc Brakes

(Bendix®) Brake pads Inspect; replace as required. X

Brake disc/rotor Inspect for visible cracks, heat checking, galling, or scoring of

surface. Check for runout (max allowable is 0.002 in.). X

Caliper sliding function Ensure caliper slides freely with no obstructions or excessive

play. X

Caliper slide pins Inspect protective caps of the guide pins for damage or

cracking. X

System operation Check operation; inspect as per manufacturer’s service

literature. X

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

PREVENTIVE MAINTENANCE SCHEDULE

PREVENTIVE MAINTENANCE (PM) INTERVALS

SYSTEM COMPONENT MAINTENANCE TASK Recommended PM Interval

I A B C D E

Hub, Drum,

and Hubcap Hubs (non-LMS) Check the bearing endplay and adjust as required (shown on

page 5-47). X

Hubs (non-LMS) with

outrunner seals Clean the components and check for excessive wear or

damage. Change the oil and seal (shown on page 5-47). X

Hubs (non-LMS) with

standard seals Clean the components and check for excessive wear or

damage. Change the oil and seal (shown on page 5-47). X

Hub seals (all) Check for leaks; replace as required. X

LMS Hubs (Dana) Inspect for leaks. Check the bearing endplay and adjust as

required (shown on page 5-47). X

LMS Hubs (Dana) with

Synthetic Lubricant Service the bearings, seals and oil. This interval may be

different depending on the results of the regular inspection.

(shown on page 5-47).

500,000 miles/ 800,000 km

LMS Hubs (Dana) with

Mineral Lubricant Service the bearings, seals and oil. This interval may be

different depending on the results of the regular inspection.

(shown on page 5-47).

350,000 miles/ 560,000 km

Brake drums Inspect for visible cracks, heat checking, galling or scoring of

the braking surface, and for severe corrosion on the outside

surface. Check for out-of-round or oversize condition [0.080 in.

(2 mm) more than the original diameter]. Replace as required.

Hubcaps Clean the sight window. Check the center plug, mounting

ange, and ll plug for leaks and for proper installation.

Replace broken or damaged parts. Check the lubricant level

and add as required.

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

PREVENTIVE MAINTENANCE SCHEDULE

PREVENTIVE MAINTENANCE (PM) INTERVALS

SYSTEM COMPONENT MAINTENANCE TASK Recommended PM Interval

I A B C D E

Main and

auxiliary

transmission

Main and auxiliary

transmission and transfer

case

Inspect for visible damage, signs of overheating, and leaks. X X

Check the drain plugs for tightness. X

Mounting Brackets and

Fasteners Check the condition of the fasteners and their torque. Tighten

to the specied torque value as required. X

Oil cooler Clean the ns (air-to-oil type) and body. Check the hose

condition and for leaks; replace as required. X

Main and aux. transmission Check the oil level; rell as required. X

Main and auxiliary

transmission (ON

HIGHWAY)

Drain lubricant while warm. Flush each unit with clean ushing

oil. 500,000 miles/ 800,000 km

Main and auxiliary

transmission (OFF

HIGHWAY)

Drain lubricant while warm. Flush each unit with clean ushing

oil. X X

Auxiliary

transmission Cotta Transfer Case

TR2205

Fabco Transfer Case

TC142/TC143/TC170/

TC270

Marmon-Harrington

Transfer Case

MVG2000/MVG2000SD

Inspect: Check oil level; inspect for leaks and any visible

damage. X

Initial oil change: Drain oil while warm; ush case with gear

oil-compatible uid; clean magnetic drain plug; rell. Do not

ush the case with any solvent.

X X

Change oil. X

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

PREVENTIVE MAINTENANCE SCHEDULE

PREVENTIVE MAINTENANCE (PM) INTERVALS

SYSTEM COMPONENT MAINTENANCE TASK Recommended PM Interval

I A B C D E

Air Intake Air intake piping, mounting,

and charge air cooler Check the system for broken pipes, leaks, joint integrity,

cleanliness, and proper support (shown on page 5-99). X

Cold starting aids Check for leaks and proper operation (shown on page 4-10). X

Air cleaner Replace the engine intake air cleaner element (shown on page

5-100). When required by air restriction

indicator or required by the engine

manufacturers operator manual.

Clutch Clutch hydraulic uid Replace uid and bleed system. X

Clutch release bearing Lubricate. X

Inspect and adjust when necessary (no adjustment required

for SOLO type clutches) X

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

PREVENTIVE MAINTENANCE SCHEDULE

PREVENTIVE MAINTENANCE (PM) INTERVALS

SYSTEM COMPONENT MAINTENANCE TASK Recommended PM Interval

I A B C D E

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

Extended Life Coolant

(ELC) Check the freeze point (shown on page 5-73). X

Check for contamination using test strips (shown on page 5-72). X

Replace blank water lter if applicable. X

Perform lab analysis (shown on page 5-72).

If lab analysis shows coolant is unsuitable for continued use:

Flush, drain, and rell (shown on page 5-72).

Add ELC Extender (shown on page 5-72).

Flush, drain, and rell with new coolant (shown on page 5-72). X

Fan clutch Check for air leaks. (shown on page 5-98).

Check the fan drive bearings (turn the sheave in both directions

to check for worn hub bearings).

X X

Solenoid valve Check the fan drive for proper engagement and disengagement. X X

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

PREVENTIVE MAINTENANCE SCHEDULE

PREVENTIVE MAINTENANCE (PM) INTERVALS

SYSTEM COMPONENT MAINTENANCE TASK Recommended PM Interval

I A B C D E

Tires and

Wheels Tires Check ination pressure (shown on page 5-136). Weekly “cold” using calibrated gauge

Inspect for cuts, irregular wear, missing lugs, sidewall damage,

etc. X

Disc wheels 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.

Demountable rims Inspect the mounting ring, rim gutter, side ring, and lock ring for

damage; replace as required. X

Wheel nuts and studs Check the tightness of the fasteners and tighten the fasteners

to the specied torque as required (shown on page 5-142). X

Inspect for damaged hex corners, stripped or damaged

threads, and excessive corrosion; clean or replace as required. X

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

PREVENTIVE MAINTENANCE SCHEDULE

PREVENTIVE MAINTENANCE (PM) INTERVALS

SYSTEM COMPONENT MAINTENANCE TASK Recommended PM Interval

I A B C D E

Power

Steering Reservoir Check the uid level (shown on page 5-48). X

Reservoir (ON HIGHWAY) Drain, replace the lter, and rell (shown on page 5-48). X X

Reservoir (OFF HIGHWAY) Drain, replace the lter, and rell (shown on page 5-48). X X

Steering gear Check the lash of the sector shaft; adjust as required. X

Grease the trunnion bearing (EP NLGI #2 lithium-based,

moly-lled, HD grease). X

Grease the input shaft seal (EP NLGI #2 lithium-based,

moly-lled, HD grease). X

Power assist cylinder Lubricate the ball joints. Inspect for leaking rod seals, damaged

ball joint boots, and damage to cylinder rod or barrel. X

Hoses and tubes Check for leaks and chang. X

Steering linkage Check all joints for excessive lash; replace as required (shown

on page 5-131). X

Draglink tube clamp and

ball socket Check the torque; tighten to specied torque value as required. X X

Pitman arm clamp bolt and

nut Check the torque; tighten to specied torque value as required. X X

Steering intermediate shaft Check the torque on the pinch bolt and nut. X X

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

PREVENTIVE MAINTENANCE SCHEDULE

PREVENTIVE MAINTENANCE (PM) INTERVALS

SYSTEM COMPONENT MAINTENANCE TASK Recommended PM Interval

I A B C D E

Power

Steering Steering intermediate shaft

U-joints (ON HIGHWAY) Lubricate [EP NLGI #2 HD grease, +325° F to -10° F (+163° C

to -23° C) range]. X X

Steering intermediate shaft

U-joints (OFF HIGHWAY or

CITY DELIVERY)

Lubricate [EP NLGI #2 HD grease, +325° F to -10° F (+163° C

to -23° C) range]. X X

Draglink and tie rod arm ball

sockets (ON HIGHWAY) Lubricate (EP NLGI #2 lithium-based, moly-lled, HD grease). X X

Draglink and tie rod arm ball

sockets (OFF HIGHWAY or

CITY DELIVERY)

Lubricate (EP NLGI #2 lithium-based, moly-lled, HD grease). X X

Fuel and Tanks Fuel tanks Inspect tanks, brackets, hoses, and ttings for correct location,

tightness, abrasion damage, and leaks; repair or replace as

required.

Fuel tank breathers Check for proper function; clean the drain hoses. X

Fuel tank straps Check the strap tightness; tighten to proper torque value as

required:

Aluminum tank: 30 Lb. ft. (41 N.m.)

Cylindrical Steel tank: 8 Lb. ft. (11 N.m.)

X X

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

PREVENTIVE MAINTENANCE SCHEDULE

PREVENTIVE MAINTENANCE (PM) INTERVALS

SYSTEM COMPONENT MAINTENANCE TASK Recommended PM Interval

I A B C D E

Driveshafts Models SPL-90, 1710 and

1810 slip member and

U-joints

Lubricate*. X X

Inspect. U-joint inspections should be

performed every time a vehicle comes

in for scheduled maintenance.**

Model SPL-100 slip

member and U-joints Lubricate*. X

Inspect. U-joint inspections should be

performed every time a vehicle comes

in for scheduled maintenance.**

Models

SPL-140/140HD/170/

170HD/250/250HD slip

members and U-joints (ON

HIGHWAY and LINEHAUL)

Lubricate*. X

Inspect. U-joint inspections should be

performed every time a vehicle comes

in for scheduled maintenance.** 5

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

PREVENTIVE MAINTENANCE SCHEDULE

PREVENTIVE MAINTENANCE (PM) INTERVALS

SYSTEM COMPONENT MAINTENANCE TASK Recommended PM Interval

I A B C D E

Driveshafts Models

SPL-140/140HD/170/

170HD/250/250HD slip

members and U-joints (OFF

HIGHWAY)

Lubricate*. X

Inspect. U-joint inspections should be

performed every time a vehicle comes

in for scheduled maintenance.**

Models

SPL-140XL/170XL/250XL

slip members and U-joints

(ON HIGHWAY and LINE

HAUL)

Lubricate*. 350,000 mi (560,000 km) 1st interval

and then every 100,000 mi (160,00

km) after that.

Inspect. U-joint inspections should be

performed every time a vehicle comes

in for scheduled maintenance.**

Models

SPL-140XL/170XL/250XL

slip members and U-joints

(OFF HIGHWAY and CITY)

Lubricate*. X

Inspect. U-joint inspections should be

performed every time a vehicle comes

in for scheduled maintenance.**

*Use only Spicer Driveshaft approved lubricants when greasing Spicer U-joints.

**Refer to Spicer Driveshaft service manual DSSM-0100 (3264-SPL) for detailed instructions.

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

PREVENTIVE MAINTENANCE SCHEDULE

PREVENTIVE MAINTENANCE (PM) INTERVALS

SYSTEM COMPONENT MAINTENANCE TASK Recommended PM Interval

I A B C D E

Battery Boxes,

Tool Boxes,

and Steps

Battery cables Check the condition of the cables, cushion clamps, nylon tie

straps, and routing. Replace a cushion clamp if the rubber has

deteriorated. Repair or tighten terminals, and secure cables to

prevent chang. Replace damaged cables (cuts, cracks, or

excessive wear) (shown on page 5-77).

Batteries (ON HIGHWAY

and LINE HAUL) Check for cracks and damage, electrolyte level, condition of

terminals, and tightness of holddowns (shown on page 5-77). X

Batteries (OFF-HIGHWAY) Check for cracks and damage, electrolyte level, condition of

terminals, and tightness of holddowns (shown on page 5-77). X

Battery box and tray (ON

HIGHWAY and LINE HAUL) Check the box integrity. Clean the drain tube and check for acid

leaks. Check condition of all equipment mounted under the box. X

Battery box and tray

(OFF-HIGHWAY) Check the box integrity. Clean the drain tube and check for acid

leaks. Check condition of all equipment mounted under the box. X

Battery Cable Fasteners Check battery cable fasteners and tighten as necessary to

10-15 Lb. ft. (13.6-20.3 N.m.) as specied on the battery label. X

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

PREVENTIVE MAINTENANCE SCHEDULE

PREVENTIVE MAINTENANCE (PM) INTERVALS

SYSTEM COMPONENT MAINTENANCE TASK Recommended PM Interval

I A B C D E

Electrical and

lights Headlamps Check the aim and adjust as required. X

Warning lights in light bar Check at the ignition start position to verify bulbs and driver

information display function (shown on page 3-30). X

Turn, Stop, Reverse lights

and signals Visual check. X

Alternator Check operation and output. X

Check tightness of the pulley nut. X

Check the tension of the drive belt (shown on page 5-97). X

Check tightness of the terminal hex nuts. X

Starter Check torque on hex nuts. X

ECM connector Check the tightness of the ECM connector. X

Wheel sensors Check for damaged sensors and connectors, and worn or

frayed wires. X

Fuel and diesel exhaust

uid tank sending unit Check the mounting screws and electrical connections for worn

or damaged wires and connectors. X X

Power supply harnesses

(engine, transmission, etc.) Check for worn or damaged insulation, corroded terminals,

frayed wires, and oil or uid leaks on the connectors or wiring. X

Wash to remove excess grease. X

Cab structure,

doors and

hoods

Hood Lubricate the lower hood pivot (only if lube ttings are present). X

Hinges and latch Lubricate with silicone spray. X

Body and cab holddown

bolts Check the condition and tightness. X

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

PREVENTIVE MAINTENANCE SCHEDULE

PREVENTIVE MAINTENANCE (PM) INTERVALS

SYSTEM COMPONENT MAINTENANCE TASK Recommended PM Interval

I A B C D E

Heating

and Air

Conditioning

Air conditioner Operate the system. X

Heater and air conditioner Perform the checks listed shown on page 5-112. X

Full operational and diagnostic check. X

Cabin fresh air lter (ON

HIGHWAY) Inspect and clean, replace if necessary, as shown on page

5-113. X

Cabin fresh air lter

(OFF-HIGHWAY) Inspect and clean, replace if necessary, as shown on page

5-113. X

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

Sleeper air lter Inspect and clean, replace if necessary, as shown on page

5-114. X

Recirc cab air lter (ON

HIGHWAY) Please contact an authorized dealer when the service interval

is required to inspect the cabin recirculation air lter. X

Recirc cab air lter

(OFF-HIGHWAY) Please contact an authorized dealer when the service interval

is required to inspect the cabin recirculation air lter. X

Aftertreatment

System System Check for leaks and proper support (shown on page 5-117). X

Diesel particulate lter Clean lter. Refer to the Engine Maintenance

Manual.

Diesel exhaust uid tank Inspect the tank, straps, brackets, hoses and ttings for

abrasion damage, leaks, tightness and fully engaged

connectors.

Diesel exhaust uid supply

module Replace lter. Refer to the Engine Maintenance

Manual.

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

PREVENTIVE MAINTENANCE SCHEDULE

PREVENTIVE MAINTENANCE (PM) INTERVALS

SYSTEM COMPONENT MAINTENANCE TASK Recommended PM Interval

I A B C D E

Air Air compressor governor Replace air strainer. X

Air lines Check condition and routing to prevent chang. X

System Lubricate (shown on page 5-49). X

Inline lters Replace elements or clean with solvent. X

Air dryer Perform the checks listed (shown on page 5-49). X

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

Air dryer (OFF HIGHWAY) Overhaul. X

Engine Basic Engine Maintenance and service interval recommendations are detailed in the engine manufacturer’s

Operations and Maintenance Manual included with the vehicle. The engine manufacturer’s

recommendations vary depending engine model. Information is also available from authorized dealers,

the engine manufacturer’s authorized service centers, and the engine manufacturer’s web site.

Safety Three-point Safety Belt

System Inspect. 20,000 miles/32,000km

If the vehicle is exposed to severe

environmental or working conditions,

more frequent inspections may be

necessary.

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

LUBRICANT SPECIFICATIONS

LUBRICANT

SPECIFICATIONS

Introduction

WARNING!

Handle lubricants carefully. Vehicle lu-

bricants (oil and grease) can be poi-

sonous and cause death, personal in-

jury or sickness. They can also dam-

age the paint on the vehicle.

In this section you will nd 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. Please remember:

one key to keeping your truck running

at top economy and in prolonging

its life is proper lubrication servicing.

Neglecting this essential aspect of

vehicle care can cost time and money

in the long run.

CAUTION

Do not mix different types of lubricants.

Mixing lubricants (oil and grease) of

different brands or types could dam-

age vehicle components; therefore,

drain (or remove) old lubricants from

the unit before relling it.

Engine

Proper engine lubrication depends

on the outside temperatures where

you will be driving. Use the oil

recommended for the conditions you

are most likely to be operating in. You

will nd a complete engine lubrication

service guide in the Engine Operation

Manual that came with your vehicle.

The engine operator manual contains

specic maintenance tasks that you or

a qualied service technician need to

perform to maintain the engine.

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

LUBRICANT SPECIFICATIONS

WARNING!

Exhaust fumes from the engine con-

tain carbon monoxide, a colorless and

odorless gas. A poorly maintained,

damaged, or corroded exhaust system

can allow carbon monoxide to enter

the cab or sleeper. Failure to prop-

erly maintain your vehicle could cause

carbon monoxide to enter the cab and

cause death, personal injury or serious

illness.

Never idle your vehicle for prolonged

periods of time if you sense that ex-

haust fumes are entering the cab. In-

vestigate the cause of the fumes and

correct it as soon as possible. If the ve-

hicle must be driven under these con-

ditions, drive only with the windows

slightly open. Failure to repair the

source of the exhaust fumes may lead

to death, personal injury or serious ill-

ness.

NOTE

Keep the engine exhaust system and

the vehicle’s cab ventilation system

properly maintained. It is recom-

mended that the vehicle’s exhaust

system and cab be inspected:

• By a competent technician every

15,000 miles/ 24,000 km,

• Whenever a change is noticed in

the sound of the exhaust system,

• Whenever the exhaust system,

underbody, cab or sleeper is

damaged.

NOTE

Use only an exact replacement parts

in Aftertreatment exhaust system. Us-

ing a noncompliant replacement part

could violate emissions requirements

and also void the emission system’s

warranty.

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

LUBRICANT SPECIFICATIONS

Pipe and Hose Clamps

Use the following table for torque

specications to check pipe and hose

clamps.

Pipe and Hose Clamp Torque Values

APPLICATION APPROVED CLAMP TORQUE

Nm Lb-In

Radiator and Heat Exchanger Hoses Constant-Torque CT-L 10.2-12.5 90-110

Heater Hoses Constant Tension not required not required

Air Intake Pipes Hi-Torque HTM-L 11.3-14.2 100-125

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

Charge Air Intake Hoses Flex Seal 667 7.9-11.3 70-100

B9296 6-7 50-60

Fuel, Oil and Water Heat Exchangers (for

hoses less than 9/16 diameter) Miniature 3600L 1.1-1.7 10-15

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

LUBRICANT SPECIFICATIONS

Master Lubrication Index

Lubricant Symbol Key

ATF MD3 or MERCON®-approved automatic transmission uid

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

CB Engine oil for mild to moderate requirements

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

CD Engine oil meeting API “Five engine test sequence”

CD50 SAE50W synthetic transmission uid

CE Engine oil meeting severe duty service requirements for direct-injection turbocharged engines

CJ-4 Engine oil for PACCAR MX and Cummins EGR engines

CL Multipurpose chassis grease

EP Extreme Pressure Lubricant (Lithium 12-hydroxystearate base NGLI 2)

GL Straight mineral gear lubricant

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

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

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

DOT3 or DOT4 Brake Fluid

5 NOTE

The responsibility for meeting these

specications, the quality of the prod-

uct, and its performance in service

rests with the lubricant supplier.

For oil reservoir with side ller plugs

(transmission, axles, steering gear

boxes, transfer cases, etc.) the oil

must be level with the ller opening. Use care when checking the oil level

with a nger. Just because you can

reach the oil level with a nger, does

not mean the oil level is correct.

1 Improper Oil Level

2 Proper Oil Level

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

LUBRICANT SPECIFICATIONS

Component Lubrication Index

Universal Joints EP*

Drive Shaft Splines CL*

Steering Column CL

Alternator Bearing BB*

Fan Hub BB*

Power Steering Reservoir ATF

Steering Drag Link CL

Steering Knuckles CL

Spring Pins CL

Clutch Release Bearings BB

Brake Shoe Anchor Pins HT

Brake Cam Bearings HT

Slack Adjusters CL

Starter Bearings CC

Turbocharger Aneroid CC

Water Pump BB*

Suspension Fittings (other than threaded pins and bushings) EP

Steering Axle: Grease Fittings on Steering Arm; Tie Rod Ends; Drag

Link; King Pins EP

Steering Shaft Grease Fittings EP

Brake Treadle Hinge and Roller Engine oil

Lock Cylinders Lock lubricant

Door Hinges Not required - Teon bushings

Door Latches and Striker Plates Polyethylene grease stick

Door Weatherstrip Silicone lubricant

Hub-piloted Aluminum Wheels Coat the wheel pilot or hub pads with Freylube #3 lubricant (light colored)

or Chevron Zinc lube. Do not get lubricant on the face of the wheel or

the hub.

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

LUBRICANT SPECIFICATIONS

Component Lubrication Index

Manual Transmission Hydraulic Clutch DOT3 or DOT4 (Brake Fluid)

*Consult manufacturer or lubricant supplier for special details.

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

LUBRICANT SPECIFICATIONS

Fuller Transmission

Lubrication

Fuller transmissions are designed so

that the internal parts operate in a

bath of oil circulated by the motion of

gears and shafts. Grey iron parts have

built-in channels where needed to

help lubricate bearings and shafts. All

parts will be amply lubricated if these

procedures are closely followed:

1. Maintain oil level; check it

regularly.

2. Change oil regularly.

3. Use the correct grade and type of

oil.

4. Buy oil from a reputable dealer.

Lubrication Change and Inspection

Off-Highway Use

Refer to the Eaton Fuller transmission

manual for servicing information.

Highway Use

• Refer to the Eaton Fuller

transmission manual for servicing

information.

• Refer to the oil change vs.

temperature chart that follows for

special oil change information. The

“intermittent peak temperature”

is the maximum temperature

observed for a short time in a

fully loaded vehicle performing

normally.

CAUTION

Exceeding the recommended oil

change intervals may be harmful to

the life of the transmission and the

transmission oil cooler. 5

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

LUBRICANT SPECIFICATIONS

Recommended Lubricants

Type Grade (SAE) Ambient Temperature

Heavy Duty Engine Oil MIL-L-2104B, C, or D;

API - SF, or API-CD

50 Above 10° F (-12° C)

40 Above 10° F (-12° C)

30 Below 10° F (-12° C)

Mineral gear oil with rust and oxidation inhibitor

API-GL-1 90 Above 10° F (-12° C)

80W Below 10° F (-12° C)

Synthetic Lubricant* 50 All

*See your dealer for approved brands.

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

LUBRICANT SPECIFICATIONS

Allison Transmission

Lubrication

Lubrication Change and Inspection

• Refer to your transmission

manual (furnished separately) for

lubrication information.

• Refer to the Allison Transmission

manual for servicing information.

Spicer Transmission

Lubrication

It is extremely important to use the

proper lubricants and maintain the

correct oil levels in Spicer units. This

will ensure proper lubrication and

operating temperatures in these units.

Recommended Lubricants

The lubricants listed below are

recommended, in order of preference,

for use in all Spicer mechanical

transmissions, auxiliaries, and

transfer cases. Do not use extreme

pressure additives such as those

found in multipurpose or rear axle-type

lubricants. These additives are not

required in Spicer transmissions,

and may in some cases create

transmission problems. Multipurpose

oils, as a group, have relatively poor

oxidation stability, a high rate of sludge

formation, and a greater tendency to

react with or corrode the steel and

bronze parts. 5

Type Grade (SAE) Ambient Temperature

Heavy Duty Engine Oil MIL-L-2104D or

MIL-L-46152B, API-SF or API-CD (MIL-L-2104B

or C or MIL-L-46152 designations are

acceptable)

30, 40, or 50 Above 0° F (-18° C)

30 Below 0° F (-18° C)

Mineral gear oil (R and O type) API-GL-1 90 Above 0° F (-18° C)

80 Below 0° F (-18° C)

Synthetic Engine Oil meeting MIL-L-2104D or

MIL-L-46152B, API-SF or API-CD CD50

CD30

All

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

LUBRICANT SPECIFICATIONS

Type Grade (SAE) Ambient Temperature

*Synthetic Gear Oil Meeting MIL-2105C or

API-GL5 EP75W90

EP75W140

All

*EP Gear Oils are not recommended when lubricant operating temperatures are above 230° F (110° C).

Oil Changes

CAUTION

When adding oil, types and brands of

oil should not be intermixed because

of possible incompatibility, which could

decrease the effectiveness of the lubri-

cation or cause component failure.

An initial oil change and ush should

be performed after the transmission

has been placed in actual service.

This change should be made any time

after 3000 miles (4800 km) but never

longer than 5000 miles (8000 km) of

over-the-road service. In off-highway

use, the change should be made after

24 hours but before 100 hours of

service have elapsed.

Relling

Remove all dirt around ller plug. Rell

with new oil of the grade recommended

for the existing season and prevailing

service. Fill to the bottom of the

level testing plug positioned on the

side of the transmission. Do not

overll the transmission. Overlling

usually results in oil breakdown due

to excessive heat and aeration from

the churning action of the gears. Early

breakdown of the oil will result in heavy

varnish and sludge deposits that plug

up oil ports and build up on the splines

and bearings. Overow of oil can also

escape onto clutch or parking brakes.

When adding oil, do not mix different

types of oil.

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

LUBRICANT SPECIFICATIONS

Meritor Axle Lubrication

NOTE

Axles utilized in 100% off-highway use

are not eligible for Meritor’s Advanced

Lube Rear Drive Axle program.

Under Meritor’s Advanced Lube Rear

Drive Axle program, the axles listed

below are exempt from an initial

lubricant change:

AVAILABLE ADVANCED LUBE AXLES

RS-17-145 RS-23-180 RT-40-145 RT-44-145P

RS-19-145 RS-26-180 RT-40-145P RT-46-160

RS-21-145 RS-30-180 SQ-100A RT-46-160P

RS-23-160 RT-34-145 SQ-100AP RT-52-160

RS-23-161 RT-34-145P RT-44-145 RT-52-160P

Meritor rear axles that do not appear

on the list above will continue to

require an initial drain at 3000-5000

miles (4800-8000 km). •

particular axle for lubricant

specications.

See your dealer for

Meritor-approved lubricant

• Refer to the following chart for

lubricant change intervals:

• Refer to the Meritor Field brands.

Maintenance Manual for a

Application Type Of Lubricant Mileage Interval

On Highway Synthetic 240,000 mi. (384,000 km)

Synthetic with Pump and Filter 500,000 mi. (800,000 km)

Mineral Base 120,000 mi. (192,000 km)

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

LUBRICANT SPECIFICATIONS

Application Type Of Lubricant Mileage Interval

City Delivery Synthetic 120,000 mi. (192,000 km)

Synthetic with Pump and Filter 240,000 mi. (384,000 km)

Mineral Base 120,000 mi. (192,000 km)

Off Highway Synthetic 120,000 mi. (192,000 km)

Synthetic with Pump and Filter 120,000 mi. (192,000 km)

Mineral Base 120,000 mi. (192,000 km)

• Change the lubricant lter every

120,000 miles (192,000 km). Top

off the lubricant level with a similar

lubricant.

Eaton/Dana Axle Lubrication

• The original mineral-based

lubricant must be drained within

3000-5000 miles (4800-8000

km) on all Eaton axles. This

initial change is very important

because it ushes out break-in

contaminants that might otherwise

cause premature wear.

• No initial drain is required on

Eaton axles that are factory lled

with an Eaton-approved synthetic

lubricant.

• Mineral-based lubes must be

drained within the rst 5000 miles

(8000 km) if converting to an

Eaton-approved synthetic lube.

• Change the lubricant within the

rst 5000 miles (8000 km) of

operation after a carrier head

replacement, regardless of the

lubricant type.

• Refer to the Eaton Field

Maintenance Manual for a

particular axle for lubricant

specications.

• See your dealer for

Eaton-approved lubricant brands.

• Refer to the chart below for

lubricant change interval.

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

LUBRICANT SPECIFICATIONS

Type of Lubricant On-Highway Mi. (km) Maximum Change Interval On/Off Highway Severe

Service Mi. (km) Maximum Change Interval

Mineral-Based 120,000 (192,000) Yearly 60,000 (96,000) Yearly

Eaton-Approved Synthetic 240,000 (384,000) 2 Years 120,000 (192,000) Yearly

Eaton-Approved Synthetic

in axle with extended drain

interval option

350,000 (560,000)

Wheel Bearing Lubrication

Oil-lubricated Driven Hubs

Use hypoid oil, A.P.I.-GL-5 SAE

75W-90FE synthetic gear lubricant

or equivalent. A minimum of 1 quart

(921 ml) of oil is required for proper

lubrication of each drive hub. Add oil

through the ller hole in the hub; if

none, add oil through the differential

ller hole. (Note: Remember to replace

vent plug or threaded ller plug when

done.) Allow time for the oil to seep

through the bearings when initially

lling a hub. Maintain the differential

oil level by adding oil until its surface is

even with the bottom of the ller hole

(see illustration on page 5-38).

Oil-lubricated Nondriven Hubs

Use CD50 synthetic transmission uid

SAE 50W or equivalent. A minimum of

9 oz. (270 ml) of lubricant is required

for proper lubrication of an LMS™ hub;

10-13 oz. (295-400 ml) is required for

a non-LMS hub, depending on wheel

design. Allow time for the uid to seep

through the bearings when initially

lling a hub. When properly lled, the

uid level will lie between the uid level

line and 1/4” above the line.

NOTE

Remember to replace vent plug when

done.

Universal Joint Lubrication

Refer to the Spicer Universal Joints

and Driveshafts service manual and

lubrication specications.

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

LUBRICANT SPECIFICATIONS

Steering Gear Lubrication

Fluid Rell

The following recommendations are

for general purpose steering systems

(both TRW and Sheppard).

• For normal temperatures, use

Automatic Transmission Fluid

(ATF) Type E or F or Dexron® III.

• For cold temperatures of -22º F

(-30º C) and above use ATF Type

• For extremely cold temperatures

between -22º F (-30º C) and -40º

F (-40º C) use ATF Type B.

Inspection

NOTE

Before removing reservoir cover, wipe

outside of cover so that no dirt can fall

into the reservoir.

1. Check the uid level; add uid if

required.

2. Check uid for contamination,

discoloration, or burnt smell;

correct source of such problems

before replacing uid and lter.

When adding uid, be sure to use uid

of the same type. While many u-

ids have the same description and in-

tended purpose, they should not be

mixed due to incompatible additives.

Mixing incompatible uids may lead to

equipment damage.

CAUTION

If incompatible (insoluble) uids are

mixed in a power steering system,

air bubbles can be produced at the

interface of the two uids. This can

cause cavitation, which reduces the

lubrication between moving parts in

the gear. This could result in worn

components.

The mixture of two different uids,

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 uids.

5-48 Y53-1200-1B1 (04/13)

AIR SYSTEM

Introduction

WARNING!

Do not attempt to modify, alter, repair

or disconnect any component of the

air system. Repairs or modications

to the air system, other than what is

described in this section, should only

be performed by an authorized dealer.

Failure to comply may result in death

or personal injury.

WARNING!

Prior to the removal of any air system

component, always block and hold the

vehicle by a secure means other than

the vehicle's own brakes. Depleting

air system pressure may cause the

vehicle to roll unexpectedly result-

ing in an accident causing death or

personal injuries. Keep hands away

from chamber push rods and slack

adjusters, they may apply as system

pressure drops.

After completing any repairs to the air

system, always test for air leaks, and

check the brakes for safe operation

before putting the vehicle in service.

Failure to comply may result in death,

personal injury, equipment or property

damage.

WARNING!

Never connect or disconnect a hose

or line containing air pressure. It may

whip as air escapes. Never remove a

component or pipe plug unless you are

certain all system pressure has been

depleted. Failure to comply may result

in death, personal injury, equipment or

property damage.

Never exceed recommended air pres-

sure and always wear safety glasses

when working with air pressure. Never

look into air jets or direct them at any-

one. Failure to comply may result in

death, personal injury, equipment or

property damage.

WARNING!

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

AIR SYSTEM

WARNING!

Never attempt to disassemble a com-

ponent until you have read and un-

derstood recommended procedures.

Some components contain power-

ful springs and injury can result if

not properly disassembled. Use only

proper tools and observe all precau-

tions pertaining to use of those tools.

Failure to comply may result in death,

personal injury, equipment or property

damage.

Completely bypassing a Bendix®

AD-IS air dryer will bypass the sys-

tem’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 involv-

ing death or personal injury. Always

adhere to the manufacturer’s proce-

dure if it is necessary in an emergency

to temporarily bypass an AD-IS-series

air dryer. Failure to comply may result

in death, personal injury, equipment or

property damage.

WARNING!

The operation of the vehicle’s braking

system and many vehicle accessories

depends upon the storage and

application of a high-pressure air

supply.

Your vehicle’s compressor takes

outside air and compresses it, usually

to 100-120 psi (689-827 kPa). The

compressed air then goes to the

reservoirs to be stored until needed.

When you operate your air brakes, the

stored compressed air ows into the

chambers where it is used to apply

your truck and trailer brakes. That is

why, when you push down on your

brake pedal, you don’t feel the same

amount of pressure on the pedal that

you do when you apply the brakes on

your car. All you are doing on your

truck is opening an air valve to allow

air to ow into the brake chambers.

Contamination of the air supply system

is the major cause of problems in

air-operated components such as

brake valves, and suspension height

control valves. To keep contaminants

to the lowest possible level, follow

these maintenance procedures.

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

AIR SYSTEM

WARNING!

If the supply and service tanks are

not drained at the recommended fre-

quency, water could enter the air lines

and valves. This could cause corro-

sion or blockage, which could compro-

mise the brake system safety and po-

tentially cause an accident involving

death or personal injury.

Daily Periodically

• Drain moisture from the supply • Clean lter screens ahead of the

and service air tanks. valves by removing the screens

and soaking them in solvent. Blow

• Operate air devices to circulate them dry with pressurized air

lubricants within the unit. before reinstalling them.

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

AIR SYSTEM

Twice a Year

• Maintain the air compressor to

prevent excessive oil by-pass.

See your maintenance manual for

details.

• Replace worn seals in valves and

air motors as they are needed.

Air Dryer

The function of the air dryer is to collect

and remove air system contaminants in

solid, liquid and vapor form before they

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 un-

der identical conditions, maintenance

and maintenance intervals will vary.

Experience is a valuable guide in de-

termining the best maintenance inter-

val for any one particular operation.

Every 900 operating hours or 25,000

miles (40,200 km) or every three (3)

months check for moisture in the air

brake system by opening air tanks,

drain cocks, or valves and checking for

presence of water.

NOTE

A small amount of oil in the system

may be normal and should not, in it-

self, be considered a reason to replace

the desiccant cartridge. Oil stained

desiccant can function adequately.

A tablespoon of water found in the

air tank would point to the need for a

desiccant cartridge change. However,

the following conditions can also

cause water accumulation and should

be considered before replacing the

desiccant cartridge.

• Air usage is exceptionally high

and not normal for a highway

vehicle. This may be due to

accessory air demands or some

unusual air requirement that

does not allow the compressor

to load and unload (compressing

and non-compressing cycle) in a

normal fashion or it may be due to

excessive leaks in the air system.

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

AIR SYSTEM

• In areas where more than a 30°

F (17° C) range of temperature

occurs in one day, small amounts

of water can accumulate in

the air brake system due to

condensation. Under these

conditions, the presence of small

amounts of moisture is normal

and should not be considered as

an indication that the dryer is not

performing properly.

• An outside air source has been

used to charge the air system.

This air did not pass through the

drying bed.

Overhaul

Maintenance intervals typical for

on-highway operation would be 2 - 3

years, 350,000 miles or 10,800 hours.

Maintenance intervals typical for high

duty cycle usage such as transit bus,

refuse hauler, dump truck, cement

mixers and off-highway operation

would be 1 year, 100,000 miles or

3,600 hours.

NOTE

Review the warranty policy before per-

forming any maintenance procedures.

An extended warranty may be voided

if unauthorized maintenance is per-

formed during this period.

Bendix® AD-IS Series Air Dryer

Your vehicle may be equipped with a

Bendix® AD-IS series air dryer. Any

air dryer replacement should be made

with an identical component.

WARNING!

If a different air dryer brand or model is

installed on the vehicle other than what

was originally installed, it could cause

the air system to not perform correctly

unless the full air system design is

reviewed and modications made to

comply with Federal Motor Vehicle

Safety Standards (FMVSS) 121 - Air

Brake Systems. Failure to abide by

this warning and maintain compliance

to FMVSS 121 could cause loss of

vehicle control and may lead to death

or serious personal injury.

The AD-IS Series air dryer has

incorporated into its design various

components that have typically been

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

AIR SYSTEM

installed separately on the vehicle (see

below for components/areas affected):

• Pressure protection valves

• Safety valve

• Governor and plumbing

• Plumbing of the front and rear

service air tanks

• Plumbing to accessory systems

These components are required to

meet the Federal Motor Vehicle Safety

Standards (FMVSS 121 - Air Brake

Systems). As the Warning above

states, any other type of air dryer

installed in the place of an AD-IS Series

will require changes, modications

and/or additions to your vehicle’s air

system to maintain compliance with

FMVSS 121.

Air Tanks

To eject moisture from the air system

tanks, pull the line that is connected to

the moisture ejection valve. Continue

pulling until the air comes out free of

water.

Daily: The supply and service air

tanks, must be drained on a daily

basis. Operate air devices daily to

circulate lubricants within the unit.

Periodically: Clean lter screens

ahead of the valves by removing the

screens and soaking them in solvent.

Blow them dry with pressurized air

before reinstalling them.

WARNING!

CAUTION

If the supply and service air tanks are

not drained at the recommended fre-

quency, water could enter the air lines

and valves. This could cause corro-

sion or blockage, which could compro-

mise the brake system safety and po-

tentially cause an accident. Failure to

comply may result in death, personal

injury, equipment or property damage.

Do not use penetrating oil, brake uid,

or wax-based oils in the air system.

These uids may cause severe dam-

age to air system components.

• 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.

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

AIR SYSTEM

Air Gauges and Air Leaks

Your vehicle comes with air pressure

gauges for two separate systems,

Primary and Secondary: the Primary

gauge indicates pressure in the rear

braking system; the Secondary gauge

indicates pressure in the front braking

system. Each gauge indicates the

amount of air pressure in pounds per

square inch (psi).

WARNING!

Do not operate the vehicle if leakage

in the air system is detected. Con-

duct the following procedure and con-

tact an authorized dealer (or any other

properly equipped service center) if

a leak is detected. Failure to check

the brakes or follow these procedures

could cause a system failure, increas-

ing the risk of an accident and may

result in death, personal injury, equip-

ment or property damage.

If the light and alarm do not turn off at

start-up, do not try to drive the vehicle

until the problem is found and xed. If

the pressure in either or both systems

is too low for normal brake operation,

i.e., the pointer of one gauge falls

below 65 psi (448 kPa), a warning light

on the gauge will glow and the audible

alarm will sound.

NOTE

Park brakes lock up at 60 psi (414

kPa), the audible alarm will sound at

65 psi (448 kPa).

Primary Air Pressure Gauge

Secondary Air Pressure Gauge

Follow the procedure below to

check the compressed air system

for leaks:

1. Periodically, or after maintenance

or replacement of air system

components:

2. Build up air pressure in the system

to the governor cutout point or until

120 psi (827 kPa) is reached.

3. Stop the engine and release the

service brakes.

4. Without applying the brake pedal,

observe the rate of air pressure

drop. This rate should not exceed

2.0 psi (14 kPa) per minute.

(04/13) Y53-1200-1B1 5-55

AIR SYSTEM

Air Compressor

5. Start the engine and build up the Operation

air pressure again.

6. Stop the engine, and apply the All compressors, regardless of make

brakes fully. Apply the brake pedal or model, run continuously while the

and hold it down for ve minutes. engine is running. System pressure

The pressure drop should not is controlled by the governor. The

exceed 3.0 psi (21 kPa) per governor acts in conjunction with

minute. the unloading mechanism in the

compressor cylinder block to start

7. If you detect excessive leakage and stop compression of air. The

(air pressure loss greater than 3.0 compressor is unloaded when the

psi (21 kPa) after ve minutes of system pressure reaches 120 psi (827

brake application), a leakage test kPa) and compression is reestablished

should be made at the air line when system pressure falls to 100 psi

connections and at all air brake (690 kPa).

control units. These tests should

determine where air is escaping.

5-56 Y53-1200-1B1

Preventive Maintenance

The following service checks are

provided for your information only and

should be performed by a certied

mechanic. Contact your dealer or the

engine manufacturer's Maintenance

Manual for further information on

servicing air compressors.

After completing any repairs to the air

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 lter

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

(04/13)

AIR SYSTEM

presence of excessive carbon. If

excessive carbon is found, clean

or replace the compressor cylinder

head. Also, check compressor

discharge line for carbon, and

clean or replace the discharge line

if necessary.

• Disassemble compressor and

thoroughly clean and inspect

all parts. Repair or replace

all worn or damaged parts, or

replace compressor with a factory

exchange unit.

CAUTION

When draining the engine cooling sys-

tem is required, to prevent damage

from freezing, the compressor must

also be drained at the cylinder head

and block. Engine damage could oc-

cur if the cooling system is not peri-

odically drained and maintained. See

Cooling System on page 5-72 for fur-

ther information.

(04/13) Y53-1200-1B1 5-57

BRAKE SYSTEM

Brake Adjustment

WARNING!

Do not work on the brake system with-

out the parking brake set and wheels

chocked securely. If the vehicle is not

secured to prevent uncontrolled vehi-

cle movement, it could roll and cause

death, serious personal injury or dam-

age to the vehicle.

To operate your vehicle safely

and protably, you need some

understanding of its brake systems.

For more on brakes, see the Index,

under Brakes.

Brake adjustment and brake balance

must be set carefully to (1) make

the most efcient use of the forces

available for braking and (2) allow

equal stopping forces at all wheels.

The air brake system of this vehicle

was congured for ONE of the follow-

ing operations: tractor or truck, and

complies with the respective portions

of FMVSS 121. A tractor shall not be

operated or congured as a truck, nor

shall a truck be operated or congured

as a tractor, without signicant modi-

cations to the air brake system in order

to retain compliance with FMVSS 121.

Contact your dealer for instructions.

CAUTION

Once a brake system is set to

specications, changing any one of

its components or any combination of

components may cause the system

to not work as well. All parts have

to work together to perform as they

should. Any replacement components

in your brake system should be exactly

equal to the original components.

Any changes from the original

specications can affect the whole

system. All of the following areas

are interrelated and must conform to

original specications:

• Tire Size

• Drum brakes

a. Cam Radius

b. Wedge Angle

c. Drum Radius

d. Brake Linings

e. Brake Chambers

f. Slack Adjusters

• Disc Brakes

a. Disc Rotors

5-58 Y53-1200-1B1 (04/13)

BRAKE SYSTEM

WARNING!

Do not use any replacement part in the

brake system unless it conforms ex-

actly to original specications. A non-

conforming part in your vehicle's brake

system could cause a malfunction re-

sulting 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.

If parts do not work together properly,

you could lose control of your vehicle,

which could cause a serious accident.

All vehicle operators should check

their brakes regularly.

WARNING!

Do not use brake linings with a thick-

ness below the specied minimum.

Such linings will have lining rivets

exposed that can damage the brake

drum and reduce brake efciency,

which could cause death, personal

injury or system failure.

Air Disc Brakes

Have brake pads inspected by a

qualied mechanic for wear at regular

intervals according to the Preventive

Maintenance Schedule on page 5-12.

In severe service or off-highway

applications inspect the linings more

frequently.

Regularly inspect for pad/rotor wear:

• Park on level ground and chock

the wheels.

• Temporarily release the parking

brakes.

• Compare the relative position

of two notches; one located on

the caliper and the other on the

carrier. See the illustration below

to determine if the brakes require

a detailed inspection by a qualied

mechanic.

(04/13) Y53-1200-1B1 5-59

BRAKE SYSTEM

• Have a qualied mechanic

perform a detailed inspection

if the notches are not found.

The pads and rotors should

be measured and compared

against the manufacturers

specications located in the brake

manufacturer’s service manual.

Caliper Detail

1. Brake Caliper Assembly

2. Location of Inspection

Grooves

3. Notches Line-Up (Time to

schedule inspection of Pads

and Rotors)

4. Brake Rotor

5. Brake Carrier Assembly

Regularly inspect caliper for Running

Clearance:

• Stop the vehicle on level ground

and let the brakes cool down. Hot

brake calipers can burn skin on

contact.

• Chock the wheels.

• Temporarily release the parking

brakes.

• Grab the caliper and move it. This

movement is Running Clearance.

• Proper Running Clearance is

0.08 inch (2 mm) of movement of

the brake caliper (approximately

the thickness of a nickel) in the

inboard/outboard direction.

• Have a qualied mechanic provide

further inspection if the caliper

does not move or appears to move

more than the specied clearance.

5-60 Y53-1200-1B1 (04/13)

BRAKE SYSTEM

Drum Brakes

Have brake drum linings and disc

brake pads inspected by a qualied

mechanic for wear at regular intervals

according to the maintenance

schedule. In severe service or

off-highway applications inspect the

linings more frequently.

Automatic Slack Adjusters

Periodically check the Brake Chamber

Stroke. Replace the slack adjuster if

proper stroke cannot be maintained.

Operational checks of automatic

slack adjusters

• Measure brake chamber stroke

with the spring brake released and

the air pressure no less than 100

psi (690 kPa).

• Brake Chamber Stroke is the

difference between the applied

and the retracted position of the

air chamber pushrod.

• A correctly installed and

functioning auto slack adjuster will

produce the following strokes:

Chamber Type Stroke

36 (rear brakes) 1-1/2" - 2-1/4"

(38 - 57 mm)

30 (rear brakes) 1-1/2" - 2"

(38 - 51 mm)

16, 20 and 24 (front

brakes) 1" - 1-3/4"

(25.4 - 44.4 mm)

Brake Chamber Stroke

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

BRAKE SYSTEM

WARNING!

Manual adjustment of automatic slack

adjusters is a dangerous practice that

could have serious consequences. It

gives the operator a false sense of se-

curity about the effectiveness of the

brakes. Contact the Service Depart-

ment at your dealership if the stroke

exceeds the above specications. A

stroke exceeding these values may in-

dicate a problem with the slack ad-

juster or the brake foundation.

5-62 Y53-1200-1B1 (04/13)

CAB

Exterior Maintenance

Painted Surfaces

Wash painted surfaces frequently to

remove grime and caustic deposits

which may stain the nish. See

Cleaning, Protecting, and Weather

Stripping on page 5-64.

Chrome and Aluminum Surfaces

To prevent rust, keep chromed parts

clean and protected with wax at all

times, especially in winter conditions

where the roads are salted.

• If necessary, use a commercial

chrome cleaner to remove light

rust.

• Chrome surfaces are best

cleaned with fresh water. Wipe

dry to preserve their luster. A

commercial chrome cleaner will

remove light rust. After cleaning,

wax at surfaces and apply a thin

coat of rust preventive lubricant

around bolts or other fasteners.

• Clean aluminum wheels and

bumpers with warm water. Tar

remover will get rid of heavy

deposits of road grime. To prevent

spotting, wipe aluminum surfaces

dry after washing.

• 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.

(04/13) Y53-1200-1B1 5-63

CAB

Tail Pipe Surface Cleaning

WARNING!

Always allow hot surfaces to cool

down before attempting to work near

them. Failure to comply may result in

death or personal injury.

To maintain your quality nish, wash

with a soft cloth, mild soap and water

or glass cleaner. A non-abrasive

chrome polish can be used sparingly

on hard to clean areas. Do Not clean

your high heat chrome using scouring

pads, abrasive chrome polish, highly

acidic chemical cleaners or any other

abrasive cleaners.

Stainless Steel

Even high quality stainless steel parts

can rust under prolonged exposure

to salt water, especially when the

salt-laden moisture is held against

the metal surface by road grime. It

is, therefore, important to frequently

clean salty moisture and grime from

stainless steel surfaces.

• If surface rust is encountered,

wash the surface and use a

commercial polishing compound

to clean off the rust, followed by a

coating of wax.

• Never use steel wool when

cleaning stainless steel because

minute particles of the steel wool

can embed in the surface of the

stainless steel and cause rust

staining.

Cleaning, Protecting and

Weather Stripping

Frequent washings of the vehicle

are required to remove grime and

contaminants that can stain and

oxidize paint and accelerate corrosion

of plated and polished metal surfaces.

Waxing offers added protection against

staining and oxidation. But to allow

enough time for your truck's nish to

cure, wait about 30 days after the date

of manufacture before waxing. Do not

apply wax in the hot sun and do not

friction burn the paint with a bufng

machine.

Occasionally spray weather-stripping

on doors and windows with silicone

compound to help preserve resiliency.

This is especially useful in freezing

weather to prevent doors and windows

from sticking shut with ice.

5-64 Y53-1200-1B1 (04/13)

CAB

Vehicle Cleaning

Precautions

WARNING!

Handle cleaning agents carefully.

Cleaning agents may be poisonous.

Keep them out of the reach of children.

Failure to comply may result in death,

personal injury, equipment or property

damage.

Do not use gasoline, kerosene, naph-

tha, nail polish remover or other

volatile cleaning uids. They may be

toxic, ammable or hazardous in other

ways. Failure to comply may result in

death, personal injury, equipment or

property damage.

WARNING!

Do not clean the underside of chas-

sis, fenders wheel covers, etc. with-

out protecting your hands and arms.

You may cut yourself on sharp-edged

metal parts. Failure to comply may re-

sult in death, personal injury, equip-

ment or property damage.

Moisture, ice, and road salt on brakes

may affect braking efciency. Test

the brakes carefully after each vehicle

wash. Failure to comply may result in

death, personal injury, equipment or

property damage.

• Observe all caution labels.

• Always read directions on the

container before using any

product.

• Do not use any solution that can

damage the body paint.

• Most chemical cleaners are

concentrates that require dilution.

• Only use spot removing uids in

well ventilated areas.

• Any vehicle is subjected to

deterioration from industrial

fumes, ice, snow, corrosive road

salt, etc., to name just a few

causes. A well-cared-for vehicle

can look like new many years

later. Regular and correct care

will contribute to maintaining the

beauty and the value of your

vehicle.

Your dealer has a number of

vehicle-care products and can advise

you on which ones to use for cleaning

the exterior and interior of your vehicle.

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

CAB

CAUTION

Do not aim the water jet directly at door

locks or latch. Tape the key holes to

prevent water from seeping into the

lock cylinders. Water in lock cylinders

should be removed with compressed

air. To prevent locks from freezing in

the winter, squirt glycerin or lock deicer

into the lock cylinders.

Washing the Exterior

1. Begin by spraying water over the

dry surface to remove all loose dirt

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.

° Do not use stiff brushes, paper

towels, steel wool, or abrasive

cleaning compounds because

they will scratch painted,

plated, and polished metal

surfaces.

3. Rinse surfaces frequently while

washing to ush away dirt that

might scratch the nishes during

the washing operation.

4. Wipe everything dry with a

chamois to avoid water spots.

° To prevent water spotting, dry

off the cosmetic surfaces with

a clean cloth or chamois.

5. Remove road tar with an

automotive type tar remover or

mineral spirits.

6. After cleaning and drying, apply a

quality automotive wax.

5-66 Y53-1200-1B1 (04/13)

CAB

NOTE

To allow enough time for your truck's

nish to cure, wait at least thirty days

after the date of manufacture before

waxing.

• Do not apply wax in the hot sun.

• Never dust off dry surfaces with a

cloth because it will scratch the

nishes.

Cleaning the Chassis

• Hose dirt and grime from the

entire chassis. Then, if an oil

leak develops, you will be able to

detect it easier.

• Corrosive materials used for ice

and snow removal and dust control

can collect on the underbody. If

these materials are not removed,

accelerated corrosion (rust) can

occur on underbody parts such as

fuel lines, frames, oor pan, and

exhaust system, even though they

have been provided with corrosion

protection.

At least every spring, ush these

materials from the under body with

plain water. Be sure to clean any

area where mud and other debris can

collect. Sediment packed in closed

areas of the frame should be loosened

before being ushed. If desired, your

dealer can do this service for you.

Cleaning Interior Vinyl and

Upholstery

• Wipe vinyl upholstery and lining

with a good commercial upholstery

cleaner. Do not use acetone or

lacquer thinner.

• Clean fabric upholstery with

upholstery shampoo specially

formulated for this purpose. Follow

instructions on the container.

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

CAB

Safety Restraint System -

Inspection

The seat belt system, including

webbing, buckles, latches, and

mounting hardware, endures heavy

use in heavy-duty vehicles, much more

than seat belt systems in passenger

cars. All users should be aware of the

factors contributing to this heavy use

and reduced belt life.

WARNING!

Failure to properly inspect and main-

tain restraint systems can lead to injury

or loss of life. Without periodic inspec-

tion and maintenance to detect unsafe

conditions, seat restraint components

can wear out or not protect you in an

accident.

Factors contributing to reduced seat

belt life:

Factors contributing to reduced seat

belt life:

• Heavy trucks typically accumulate

twice as many miles as the

average passenger car in a given

time period.

• Seat and cab movement in trucks

causes constant movement of the

belt due to ride characteristics

and seat design. The constant

movement of the belt inside

the restraint hardware and the

potential for the belt to come in

contact with the cab and other

vehicle parts, contributes to the

wear of the entire system.

• Environmental conditions, such as

dirt and ultraviolet rays from the

sun, will reduce the life of the seat

belt system.

Due to these factors, the three-point

safety belt system installed in your

vehicle requires thorough inspection

every 20,000 miles (32,000 km). If

the vehicle is exposed to severe

environmental or working conditions,

more frequent inspections may be

necessary.

Any seat belt system that shows cuts,

fraying, extreme or unusual wear,

signicant discoloration due to UV

(ultraviolet) exposure, abrasion to the

seat belt webbing, or damage to the

buckle, latch plate, retractor hardware

or any other obvious problem should

be replaced immediately, regardless

of mileage.

5-68 Y53-1200-1B1 (04/13)

CAB

WARNING!

It is important to remember that any

time a vehicle is involved in an acci-

dent, the entire seat belt system must

be replaced. Unexposed damage

caused by the stress of an accident

could prevent the system from func-

tioning properly the next time it is

needed. Failure to comply may result

in death or personal injury.

Inspection Guidelines

Follow these guidelines when

inspecting for cuts, fraying, extreme

or unusual wear of the webbing,

and damage to the buckle, retractor,

hardware, or other factors. Damage to

these areas indicates that belt system

replacement is necessary.

WARNING!

Replace the entire belt system (retrac-

tor and buckle side) if replacement of

any one part is necessary. Unexposed

damage to one or more components

could prevent the system from func-

tioning 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.

The webbing must be closely

examined to determine if it is

coming into contact with any sharp

or rough surfaces on the seat or

other parts of the cab interior.

These areas are typical places

where the web will experience

cutting or abrasion. Cuts, fraying,

or excessive wear would indicate

the need for replacement of the

seat belt system.

2. The pillar web guide (D-loop) is

the area where almost constant

movement of the seat belt

webbing occurs because of

relative movement between the

seat and cab.

3. Check the Komfort-Latch for

cracks or possible damage and

check for proper operation.

4. Check buckle and latch for proper

operation and to determine if

latch plate is worn, deformed, or

damaged.

5. Inspect the retractor web storage

device, which is mounted on the

oor of the vehicle, for damage.

The retractor is the heart of the

occupant restraint system and can

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

CAB

often be damaged if abused, even

unintentionally. Check operation

to ensure that it is not locked up

and that it spools out and retracts

webbing properly.

6. If tethers are used, be sure they

are properly attached to the

seat and, if adjustable, that they

are adjusted in accordance with

installation instructions. Tethers

must also be inspected for web

wear and proper tightness of

mounting hardware.

7. Mounting hardware should be

evaluated for corrosion, and for

tightness of bolts and nuts.

8. Check web in areas exposed to

ultraviolet rays from the sun. If the

color of the web in these areas is

gray to light brown, the physical

strength of the web may have

deteriorated due to exposure to

the sun's ultraviolet rays. Replace

the system.

Seat Belt Inspection Points

1 Web cut or frayed or

extremely worn at latch

area.

2 Web cut or frayed at D-loop

web guide.

3 Comfort Clip cracked or

damaged.

4 Buckle casting broken.

5 Retractor Web Storage for

damage. (located behind

trim panel)

6 Tethers for web wear and

proper tightness of mounting

hardware.

7 Mounting hardware for

corrosion, proper tightness

of bolts and nuts.

8 Web for deterioration, due

to exposure to the sun

WARNING!

Failure to adjust tether belts properly

can cause excessive movement of

the seat in an accident. Tether belts

should be adjusted so that they are

taut when the seat is in its most up-

ward and forward position. Failure to

comply may result in death or personal

injury.

Once the need for replacement of

the seat belt has been determined,

be certain it is only replaced with

5-70 Y53-1200-1B1 (04/13)

CAB

an authorized PACCAR Parts

replacement seat belt.

If the inspection indicates that any

part of the seat belt system requires

replacement, the entire system must

be replaced. An installation guide is

attached to every replacement belt.

Utilize the proper guide for your type of

seat, and follow the instructions very

closely. It is vitally important that all

components be reinstalled in the same

position as the original components

that were removed and that the

fasteners be torqued to specication.

This will maintain the design integrity

of the mounting points for the seat belt

assembly. Contact your dealer if you

have any questions concerning seat

belt replacement.

Windshield Wiper/Washer

The windshield wiper system is

maintenance free. Check wiper blades

annually or every 60,000 miles (96,000

km).

Washer Reservoir

CAUTION

Do not use antifreeze or engine

coolant in the windshield washer

reservoir, damage to seals and other

components will result.

Daily: Check reservoir water level,

located in the engine compartment. If

necessary, rell to the proper level.

(04/13) Y53-1200-1B1 5-71

COOLING SYSTEM

Cooling system

maintenance

Your engine’s cooling system is

standard with Extended Life Coolant

(ELC). ELC consists of a mixture of

ethylene glycol, water, and organic

acid technology chemical inhibitors.

ELC prevents corrosion and scale

formation as well as provides freezing

and boiling point protection.

CAUTION

The engine cooling system has very

specic maintenance and inspection

requirements. Failure to follow re-

quirements can damage the engine.

Engine damage can include but is not

limited to:

• Freezing

• Boiling

• Corrosion

• Pitted cylinder liners

This information is found in the engine

manufacturers owner’s manual. It is

the owner’s responsibility to follow all

requirements listed in the engine man-

ufacturers owner’s manual.

What to Check in an ELC-lled

Cooling System

ELC Concentration

Check the level of freeze/boilover

protection, which is determined by

the ELC concentration. Use a glycol

refractometer to determine glycol level.

Add ELC to obtain the ELC to water

ratio required to provide the protection

you need. Use the chart below to help

determine how much ELC you need

to add.

NOTE

Maximum recommended ELC con-

centration is 60% ELC and 40% water

by volume (a 60/40 coolant mixture).

The minimum recommended concen-

tration is 40%.

In an ELC-lled cooling system, the

freeze point should be maintained

between -30° F and -45° F (-34° C and

-43° C).

5-72 Y53-1200-1B1 (04/13)

COOLING SYSTEM

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)

(-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)

Items in bold are the recommended levels of concentration.

ELC Condition (Contamination and

Inhibitor Concentration)

Perform a visual inspection of the

ELC. It should have no cloudiness

or oating debris. Determine the

chemical inhibitor concentration level

by using an ELC-specic test kit or

test strips. Inhibitor concentration level

determines corrosion protection. If you

are concerned about possible coolant

quality, contamination, or mechanical

problems, submit a coolant sample for

analysis. Improper maintenance may

cause coolant degradation and could

result in damage to the cooling system

and engine components. Consult

your dealer or the ELC manufacturer’s

representative for recommended ELC

test kits, test strips, and laboratory

sample procedures.

ELC Extender

Add ELC extender if necessary at the

maintenance interval under “Cooling”.

Coolant Filter

If your vehicle came with a

non-chemical lter (“blank lter”),

replace it only with a blank lter at the

interval specied in the Preventive

Maintenance Schedule on page 5-12.

Never use lters that contain SCAs in

an ELC-lled system.

Topping Off

WARNING!

Removing the ll cap on a hot engine

can cause scalding coolant to spray

out and burn you badly. If the en-

gine has been in operation within the

previous 30 minutes, be very care-

ful in removing the ll cap. Protect

face, hands, and arms against escap-

ing uid 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. In any situation,

remove the cap very slowly and care-

fully. Be ready to back off if any steam

or coolant begins to escape.

(04/13) Y53-1200-1B1 5-73

COOLING SYSTEM

NOTE

If frequent topping off is necessary and

there are no visible signs of coolant

leaks when the engine is cold, check

for leaks with the engine operating at

normal temperature.

Top off the cooling system when

coolant does not rise to the level

indicated as ‘MIN’ on the surge tank.

The surge tank is translucent which

allows the coolant level to be seen.

Add coolant through the surge tank ll

cap. Do not remove the pressure cap

to ll the cooling system.

5-74

Surge Tank

NOTE

Do not use the pressure cap to ll the

surge tank with uid.

Proper Coolant Level

NOTE

Do not overll a cooling system. Ex-

cess coolant may result in overow,

loss of antifreeze, and reduced corro-

sion protection.

Y53-1200-1B1

• The minimum uid level is

determined by the line on the

surge tank indicated by the letters

“MIN”. This indicator is located

below the ll cap.

• The cooling system will need uid

if the surge tank level does not rise

to the “MIN” line regardless if the

system is hot or cold.

Relling Your Radiator

1. If your cooling system is built with

drain valves in the upper engine

coolant pipe, open them before

lling the surge tank.

2. Close any open coolant drains in

the system.

3. Remove the surge tank ll cap

(do not remove the surge tank

pressure cap).

4. Fill the system with premixed

coolant through the surge tank ll

cap. Pour coolant at a steady ow

(04/13)

COOLING SYSTEM

rate until the surge tank is full (to

the base of the ll neck). It may be

necessary to pause for 1 minute

and then re-ll if the uid level

dropped.

5. Close any drain valves that were

opened in Step 1.

6. Start the engine and idle at low

RPM.

7. During low rpm idle, air will purge

from the cooling system which will

lower the coolant level in the surge

tank. Continue to ll the surge

tank until the coolant level remains

approximately ½ in. above the

"MIN" line. This may take up to 2

minutes, depending on the outside

temperature.

8. Operate the engine throttle

until the operating temperature

stabilizes (when the thermostat

opens).

9. Fill the surge tank as necessary

to raise the coolant level to ½ in.

above the “MIN” level.

10. Operate the engine at high idle for

another 10 minutes and then ll

the surge tank again to ½" above

the “MIN” level.

11. Replace the surge tank ll cap.

Check the coolant level after each trip.

Add coolant as necessary. You may

nd your coolant level is not up to the

correct level soon after you have lled

the radiator. This may be because all

of the trapped air in the system has not

yet been purged. It takes a little time

for all the air to leave the system after

you ll your radiator.

Engine (Block) Heater

WARNING!

CAUTION

Do not use the heater if there are

any signs of problems. Engine block

heaters can cause res resulting in

death, personal injury, equipment

or property damage if not properly

maintained and operated. Regularly

inspect the engine block heater wiring

and connector for damaged or frayed

wires. Contact your authorized dealer

or the manufacturer of the heater if

you are in need of repairs or informa-

tion. Failure to comply may result in

death, personal injury, equipment or

property damage.

Always unplug the block heater be-

fore starting your engine. Damage to

the cooling system could occur if not

turned OFF (unplugged).

(04/13) Y53-1200-1B1 5-75

COOLING SYSTEM

Use a solution of half ethylene glycol

antifreeze and half water for best

heater performance. Do not use

more than 65 percent concentration of

antifreeze, as a shortened heater life

will result.

After servicing the cooling system,

operate the vehicle for a day or two

before using the heater. Trapped

air inside the engine needs time to

escape.

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

ELECTRICAL

Electrical System

WARNING!

CAUTION

Battery posts, terminals and related

accessories contain lead and lead

compounds, chemicals known to the

State of California to cause cancer

and reproductive harm. Wash hands

after handling.

Do not modify or improperly repair the

vehicles electrical system or power

distribution box. All electrical repairs

should be performed by an authorized

dealer. Improper repair or modica-

tions will void your warranty and/or

cause serious damage to your vehicle.

Low Voltage Disconnect (LVD)

Purpose

The LVD may increase battery life

and prevent unnecessary jump

start conditions by ensuring that an

unattended load does not deplete

the battery charge to a level that will

prevent you from starting your vehicle.

Operation

The LVD will disconnect non-vital

battery loads when battery voltage

drops below 12.3V for 3 minutes and

the key switch is in the ACC or OFF

position. During the last 2 minutes the

LVD will emit a slow audible beep. 30

seconds before disconnecting loads

the alarm will change to a fast beep.

The battery voltage must come back

up above a certain voltage before the

LVD will reset.

See an authorized dealer if the LVD

fails to reconnect loads during normal

operation.

Circuits Disconnected By LVD

• Cab Dome Lamps

• Cab Accessories

• Spare Battery A and B

NOTE

All LVD circuits are color-coded blue

on the central electrical panel cover

label.

(04/13) Y53-1200-1B1 5-77

ELECTRICAL

WARNING!

Do not use the Spare Battery A and

B circuits or other circuits that are

controlled by the LVD to power elec-

tronic 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 RP-136. Failure to do so may

cause equipment damage or lead to

personal injury.

NOTE

The determination of what cir-

cuits/loads that were connected to

the LVD was based upon the rec-

ommendation from Technology and

Maintenance Council (TMC) of the

American Trucking Association. To re-

view the recommended practice, see

TMC RP-136.

Light Bulbs

Headlight Replacement

Replacing a headlight bulb is

accomplished by accessing the rear

of the headlight via a access panel in

the front fender. Open the hood to get

access to this panel.

Once the panel is open, the headlight

bulb socket may be removed to replace

the bulb.

WARNING!

Optional HID headlights have high

voltage circuits and should only be

serviced by a trained technician. At-

tempting to service the HID ballast

without proper training may result in

severe electrical shock which could

lead to death or personal injury.

Access door

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

ELECTRICAL

Headlight Aiming Bulb Specications

1. Adjustment knob

2. Park/turn lamp

3. Low beam

4. High beam

The headlights were properly

aimed at the factory to meet safety

specications. If the headlights need to

be adjusted, please have an authorized

dealership aim the headlights.

Bulb Location Type of Bulb

Low Beam Halogen H11-LL (SAE), H7

(ECE) (long life

version not required)

Low Beam HID D1-S

High Beam Halogen HB3A – LL (long life

version not required)

Turn Signal/ Daytime

Running Lamp 4157 NAK (SAE),

PY27/7W (ECE)

Side Marker/Position

Lamp/Park Lamp 168(SAE), W5W

(ECE)

Rear tail light/ Turn

Signal Not applicable – LED

lighting

Interior

map/dome/indirect

light

Not applicable – LED

lighting

(04/13) Y53-1200-1B1 5-79

ELECTRICAL

Fuses, Circuit Breakers and

Relays

Fuses, circuit breakers, and relays are

located in the Power Distribution Box

to the left of the steering column behind

the clutch pedal. Additional fuses are

located in the engine compartment

(drivers side bulkhead) and also

in the sleeper under bunk storage

compartment.

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

ELECTRICAL

Engine Area Fuse Label

(04/13) Y53-1200-1B1 5-81

ELECTRICAL

In-Cab Fuse Label

5-82 Y53-1200-1B1 (04/13)

ELECTRICAL

Sleeper Fuse Label

(04/13) Y53-1200-1B1 5-83

ELECTRICAL

Fuse Inspection and

Replacement

If a fuse is blown, see What to do if

fuse or relay blows on page 2-6 for

more information.

Adding Electrical Options

WARNING!

CAUTION

Do not add a fuse with a rating higher

than 30 amps. Follow the circuit pro-

tection size/type recommended by the

component manufacturer. Installing

a fuse or circuit breaker greater than

designated may damage the electrical

system which could lead to equipment

damage and/or personal injury.

Follow all manufacturers' circuit pro-

tection recommendations for the com-

ponents and wires being added. Fail-

ure to comply may result in equipment

damage.

Fuse Puller

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

ELECTRICAL

NOTE

If you are unfamiliar with proper elec-

trical repair practices and procedures,

see your authorized dealer for assis-

tance.

NOTE

Easy addition of circuits is provided by

plug-in connectors that have a ground

and a power wire.

For proper electrical system

performance, refer to a wiring

diagram for your chassis before adding

electrical options.

WARNING!

Never install a circuit breaker in a

circuit that is designated as “fuse-

only” circuit(s). Fuse-only circuits are

marked with an * on the reverse side of

the Power Distribution Box cover. Us-

ing a circuit breaker in those fuse-only

circuits may cause the circuit to over-

heat when a short exists which could

lead to equipment damage and/or per-

sonal injury.

Batteries

Battery Access

The vehicle is originally equipped with

three or four batteries. Replacement

batteries must meet the following

specications: maintenance-free,

group 31 size, threaded stud, 12V/ 650

cold cranking ampere (CCA), and 160

minutes of reserve capacity.

The battery compartment is located on

the left side of the vehicle, under the

cab access steps.

1. Remove the 6 bolts that are

located in the 2 cab access step

plate.

2. Remove battery cover for access.

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

ELECTRICAL

In-Cab Battery Box

Your vehicle may be equipped

with Absorbed Glass Mat (AGM)

batteries located in the cab under the

passenger’s seat. The glass mat in

AGM batteries are designed to absorb

the battery acid inside the battery that

can leak or spill out in conventional

batteries. This design feature allows

batteries to be positioned in any

orientation without risk of leaking.

To access the batteries:

1. Remove 6 fasteners securing the

passenger side seat base to the

battery box assembly.

2. Remove the seat and seat base

as one unit to gain access to the

batteries.

WARNING!

Replace only with AGM (Group 31)

batteries. Use of other batteries could

result in acid leaks causing personal

injury in the event of a vehicle acci-

dent. Failure to comply may result in

death, personal injury, equipment or

property damage.

Battery cables and air/electrical har-

nesses are mounted to the bottom of

the oor. Do not drill or screw into oor

pan without rst checking the location

of the cables, harnesses or any other

component that might be damaged.

Damaging any component could result

in electrical shock which could cause

personal injury and/or loss of a critical

truck system. Failure to comply may

result in death, personal injury, equip-

ment or property damage.

WARNING!

Electrical damage or battery explosion

can occur when improperly charg-

ing batteries. Refer to the Charging

System on page 5-89 for appropri-

ate charging instructions. Failure to

comply may result in death, personal

injury, equipment or property damage.

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

ELECTRICAL

WARNING!

Batteries release gases that are

ammable. Batteries are equipped

with vent tubes and ash arrestors

which vent battery gases out of the

cab. Ensure all vent tubes, ash ar-

restors and grommets are properly

installed and ensure they are clear

and functioning properly. Failure to

reinstall or keep the vent tubes and

grommets clear or ensure the ash

arrestor(s) are functioning properly

could result in personal injury or equip-

ment damage. Failure to comply may

result in death, personal injury, equip-

ment or property damage.

Do not store other items in this battery

box. Failure to comply could result in

damage to the truck and/or batteries.

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 equip-

ment damage.

The Diesel Exhaust Fluid (DEF) sys-

tem purges to prevent damage from

freezing. If your vehicle is equipped

with battery disconnect switches, do

NOT disconnect battery power within

two minutes of switching the ignition

key off. Failure to comply may result

in vehicle or property damage.

CAUTION

Removing and Installing Batteries:

1. Be sure all switches on the vehicle

are turned OFF.

2. Wait 2 minutes after turning

ignition off then disconnect

negative ground cable rst.

3. Disconnect positive cable.

4. Unscrew bolt of holding plate with

open end wrench.

NOTE

Always dispose of automotive batter-

ies in a safe and responsible manner.

Contact your authorized dealer for dis-

posal standards. Call your local au-

thorized recycling center for informa-

tion on recycling automotive batteries.

(04/13) Y53-1200-1B1 5-87

ELECTRICAL

Follow the procedure below to reinstall

batteries on the vehicle:

NOTE

Make sure to reconnect the ground

(negative) cable last.

1. Place batteries in vehicle and

tighten bolt of holding plate.

2. Reconnect positive cable.

3. Reconnect ground (negative)

ground cable.

Battery replacement may alter or dis-

turb battery cable routing. Check to in-

sure battery cables are free from any

point of chafng. Failure to comply

may result in death, personal injury,

equipment or property damage.

WARNING!

Replacing Parts Removed for

Access

1. Replace battery cover.

2. Install 2 bolts in step strut. Torque

to 24-32 lb-ft (33-43 Nm).

3. Install fairing and install 4 bolts.

Torque to 6-7 lb-ft (8-9 Nm).

4. Install steps by installing 2 bolts in

each step. Torque to 24-32 lb-ft

(33-43 Nm).

WARNING!

Always reinstall the steps before en-

tering the cab. Without the steps you

could slip and fall, resulting in possible

injury to yourself.

WARNING!

Fairings not installed properly could

come loose and cause other motorists

to have an injury accident. It is impor-

tant that fairings be installed properly.

Failure to comply may result in death,

personal injury, equipment or property

damage.

Before attempting any work on the bat-

teries or electrical system, remove all

jewelry. If metal jewelry or other metal

comes in contact with electrical cir-

cuits, a short circuit may occur causing

you to be injured, as well as electrical

system failure and damage.

WARNING!

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

ELECTRICAL

Battery Care

Regular attention to the charging

system will help prolong the service

life of the batteries. Here are some

common causes of battery failure:

Overcharge: this condition results

from improper voltage regulator

adjustment. It results in overheating

of the battery, warped plates, and

evaporation of electrolyte.

Undercharge: the voltage regulator

is malfunctioning, the drive belt is

slipping, or your vehicle has undergone

long periods of standing idle or short

distance driving. These conditions

result in battery plates becoming

covered with a hard coating.

Vibration: loose battery hold-downs

may cause battery plate failure.

Short Circuits: these discharge the

battery by draining electricity.

Dirty or Loose Connections:

improper connections may stop the

ow of electrical power to and from the

battery.

Battery Charging

Except for using small trickle charges

to maintain battery condition, you

should have your vehicle's batteries

charged by a qualied service facility.

WARNING!

Batteries can injure you severely.

They contain acid, produce poisonous

and explosive gases, and supply lev-

els of electric current high enough to

cause burns. A spark or ame near

a battery on charge may cause it to

explode with great force. Never re-

move or tamper with the battery caps.

Failure to comply may result in death,

personal injury, equipment or property

damage.

To help reduce the risk of personal

injuries, follow these guidelines

carefully when recharging a battery:

• Before attempting any service

in the electrical installation,

(04/13) Y53-1200-1B1 5-89

ELECTRICAL

disconnect the battery negative

cable.

• Allow no sparks or open ame

anywhere near the charging area.

• Charge a battery only in a

well-ventilated area, such as

outdoors or in a fully open garage

which contains no pilot lights or

other ames. Gases generated

during the charging process must

be allowed to escape.

• Always make sure the battery

charger is OFF before connecting

or disconnecting the cable clamps.

• To avoid short circuits, damage

to the vehicle, or personal injury,

never place metal tools or jumper

cables on the battery or nearby.

Metal that accidentally comes in

contact with the positive battery

terminal or any other metal on the

vehicle (that is in contact with the

positive terminal), could cause a

short circuit or an explosion.

Charging Reminders

• Use protective eyewear.

• Keep all batteries away from

children.

• Never reverse battery poles.

• Never attempt to place the vehicle

in motion, or run the engine with

batteries disconnected.

• Keep the battery clean and dry.

• Look for any signs of damage.

• Battery terminals should not

be coated with improper

grease. Use petroleum jelly

or commercially available,

noncorrosive, nonconductive

terminal coatings.

• Never use a fast charger as a

booster to start the engine. This

can seriously damage sensitive

electronic components such

as relays, radio, etc., as well

as the battery charger. Fast

charging a battery is dangerous

and should only be attempted by

a competent mechanic with the

proper equipment.

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

ELECTRICAL

Slow Battery Charging

NOTE

Follow the instructions that come with

your battery charger.

• It is not necessary to remove the

battery from the compartment.

WARNING!

Charger cables must be connected

positive to positive (+ to +) and nega-

tive to negative (- to -). If connected

improperly, batteries could explode.

Failure to comply may result in death,

personal injury, equipment or property

damage.

(04/13)

Always make sure the battery charger

is OFF before connecting or discon-

necting the cable clamps. To reduce

the danger of explosions and result-

ing death or personal injury, do not

connect or disconnect charger cables

while the charger is operating.

1. Disconnect the battery cables.

WARNING!

2. Connect charger cables.

3. Start charging the battery at a rate

not over 6 amperes. Normally, a

battery should be charged at no

more than 10 percent of its rated

capacity.

4. After charging, turn OFF charger

and disconnect charger cables.

Y53-1200-1B1

Electrical and Alternator

Precautions

Take the following precautions to

avoid burning out alternator diodes:

• Do not start the engine

with alternator disconnected

(connections removed) from the

circuit.

• Before welding, disconnect all

electronic connections to the

vehicle batteries.

• Remove battery power cable and

insulate it from the vehicle.

• Do not run the engine with the

batteries disconnected.

• Do not disconnect the battery

cables or alternator connection

cables with the engine running.

• Never turn the ignition switch from

the ON position to the START

position with the engine running.

5-91

ELECTRICAL

• When charging the battery

(installed in the vehicle) disconnect

the battery cables.

• Do not reverse the cables of the

alternator, starter motor, or battery.

• Do not polarize the alternator. The

alternator should not be polarized

like a generator. To ensure correct

polarity, use a test lamp or a

voltmeter.

Remote Keyless Entry

The remote keyless entry system may

become inoperational due to a key

fob battery. If you have issues with

a key fob, replace the battery and

re-synchronize the key fob. In some

situations, the key fob may need to

be replaced and in others, a fuse may

have failed and may render both key

fobs inoperative.

Contact your dealer for more help if

a key fob does not work and it is not

because of a bad battery.

5-92 Y53-1200-1B1 (04/13)

ENGINE

Engine Maintenance

WARNING!

Exhaust fumes from the engine con-

tain carbon monoxide, a colorless and

odor less gas. Do not breathe the

engine exhaust gas. A poorly main-

tained, damaged or corroded exhaust

system can allow carbon monoxide to

enter the cab. Entry of carbon monox-

ide into the cab is also possible from

other vehicles nearby. Failure to prop-

erly maintain your vehicle could cause

carbon monoxide to enter the cab and

cause death or personal injury.

WARNING!

Never idle your vehicle for prolonged

periods of time if you sense that ex-

haust fumes are entering the cab. In-

vestigate the cause of the fumes and

correct it as soon as possible. If the ve-

hicle must be driven under these con-

ditions, drive only with the windows

open. Failure to repair the source of

the exhaust fumes may result in death,

personal injury, equipment or property

damage.

NOTE

Keep the engine exhaust system and

the vehicles cab ventilation system

properly maintained. It is recom-

mended that the vehicles exhaust

system and cab be inspected:

• By a competent technician every

15,000 miles,

• Whenever a change is noticed in

the sound of the exhaust system,

• Whenever the exhaust system,

underbody or cab is damaged.

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

ENGINE

Engine Lubrication

Refer to the engine manufacturer's

Engine Operation and Maintenance

Manual supplied with your vehicle for

information about draining and relling

engine oil, engine crank case capacity,

engine oil type, and changing oil lters,

etc.

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, per-

sonal injury, equipment or property

damage.

Inspection of the Engine Oil Level

NOTE

It takes approximately 15 minutes for

all the oil to run into the sump when the

engine is ‘warm.’ If the level is checked

immediately after switching off the en-

gine, the dipstick will show a low oil

level.

1. Make sure that the vehicle frame

rail is standing on a at and level

surface.

2. Make sure that the vehicle is

horizontal, both lengthwise and

crosswise. Check this carefully

on a vehicle with air suspension.

Note that the engine may be

inclined up to 4° depending on the

vehicle model and wheelbase.

3. Twist the dipstick handle to unlock

it, then pull the dipstick out of the

holder.

4. Wipe the dipstick clean with a

lint-free cloth.

5. Place the dipstick back into the

holder.

6. Pull the dipstick out again and

check the oil level. The oil level

should always be between the 2

marks on the dipstick.

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

ENGINE

7. Reinstall the dipstick and twist to Topping Up the Engine Oil Pipe and Hose Clamps

lock it in place. 1. Top up with oil, if necessary, via Use the following table for torque

the ller opening. Use the correct specications to check pipe and hose

grade in the correct quantity. For clamps.

oil replacement, please see engine

Operator’s Manual included with

this chassis.

2. After topping up, wait 1 minute and

check the oil level again.

3. Reinstall the oil ll cap and twist

to lock it in place.

1. Engine Oil High Level

2. Engine Oil Low Level

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

ENGINE

Pipe and Hose Clamp Torque Values

APPLICATION APPROVED CLAMP TORQUE

Nm Lb-In

Radiator and Heat Exchanger Hoses Constant-Torque CT-L 10.2-12.5 90-110

Heater Hoses Constant Tension not required not required

Air Intake Pipes Hi-Torque HTM-L 11.3-14.2 100-125

Charge Air Intake Hoses Flex Seal 667 7.9-11.3 70-100

B9296 6-7 50-60

Fuel, Oil and Water Heat Exchangers (for

hoses less than 9/16 diameter) Miniature 3600L 1.1-1.7 10-15

Exhaust Clamps Breeze V-Band 54 480

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

ENGINE

Accessory Drive Belts

You can extend the reliability and

service life of your vehicle's drive belts

with proper attention to installation,

and maintenance. Neglect could

cause belt failure. The result could be

the loss of the electrical or air system

as well as possible engine damage

from overheating. So it's a very good

idea to check your belts frequently and

replace them as soon as you detect

trouble.

Follow this procedure to install an

accessory drive belt:

1. Route the new belt around the

pulleys, and then rotate the

automatic tensioner so that the

idler pulley swings toward the

belt routing. The following gure

shows an example of the rotation

direction to release the tensioner.

2. Slip the belt around the idler

pulley attached to the automatic

tensioner.

3. Release the automatic tensioner.

4. Check the belt alignment on each

pulley. The belt must fall between

the anges of each pulley.

PACCAR MX Belt Routing

NOTE

See the engine manufacturer's opera-

tor's manual for further information on

replacing engine drive belts. 5

Cummins Belt Routing

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

ENGINE

Engine Fan

WARNING!

Do not work on the fan with the engine

running. The engine fan can engage

at any time without warning. Before

turning on the ignition, be sure that no

one is near the fan. Failure to comply

may result in death or personal injury.

Your truck may be equipped with an

On/Off or Viscous Fan Drive. Follow

these guidelines to check your engine

fan:

• Check the fan bearings for fan

hub bearing looseness, loss

of lubricant and any abnormal

conditions. (For example, fan

belt misaligned or excessive

wear/damage.) Before starting the

engine and with the engine off,

look and feel for looseness in the

fan hub.

• With the engine idling and the

hood open, stand at the front of

the vehicle. Listen for any noises

coming from the fan hub. Bearings

that have lost lubricant, and are

dry, 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.

Fan Drive and Blade

WARNING!

Do not work on the fan with the engine

running. The engine fan can engage

at any time without warning. Before

turning on the ignition be sure that no

one is near the fan. Failure to comply

may result in death or personal injury.

Fan Blade Clearance: 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).

• Rear edge of any blade must be

no closer than 3/8 in. (9 mm) to

the nearest engine component. If

this cannot be obtained, the fan

spacer or fan is not correct.

• The leading edge of any fan blade

must be 1 in. (25 mm) from the

inside edge of the shroud.

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

ENGINE

Air Intake System

Engine heat, vibration, and age

combine to loosen air intake

connections and cause cracks in

the tubing and elbows. Leaks in the

intake system allow abrasive dust to

enter the engine and quickly cause

expensive damage. During your daily

walk-around inspection, carefully

check all tubing, elbows, clamps,

supports and fasteners for condition

and tightness.

• Check the Charge-Air-Cooler for

air leaks annually. The air leaks

can be caused by cracked tubes

or header. For service see your

authorized dealer.

CAUTION

Do not use air intake pipes and con-

nections as a step or to pull yourself

up. This could loosen the connections

and open the system to unltered air

which could damage the engine.

Turbocharger

When servicing the air intake and

exhaust systems on a turbocharged

engine, check the items listed below.

WARNING!

Do not operate engine with tur-

bocharger intake piping disconnected.

A suction is created when the engine

is running. This suction could draw

your hand or anything else near it into

the impeller fan. You could be injured.

Always keep the intake piping con-

nected when you will be running the

engine.

Lubricating System: Check the oil

lines, housing, and connections. Look

for leaks, damage, or deterioration.

Leaks could mean you have damaged

oil lines or oil seals.

Manifold: With the engine operating,

check for leaking manifold or ange

gaskets.

High Frequency Vibration: Vibration

may indicate turbo rotor imbalance.

Have your dealer investigate this

immediately. If you detect any

deciencies, take the vehicle to an

authorized dealer for servicing. Delay

could lead to severe and expensive

damage to your vehicle.

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

ENGINE

Air Cleaners

The following service information is

basic to all air cleaner makes and

models.

CAUTION

Failure to replace air lter at proper

intervals may result in passage of

dirt/debris into the engine or the “dust-

ing” of an engine resulting in signicant

engine damage.

Service the air cleaner lter elements

as specied in the Preventive

Maintenance Schedule on page 5-12.

Your vehicle is equipped with an air

inlet restriction indicator. Service

the lter elements when the air

inlet restriction indicator locks in the

extreme Up position. Paper elements

require care and proper handling

because they are critical to engine

service life. If your vehicle has an

external air cleaner and cab-mounted

mirrors, the mirror must be pivoted to Replacing the Engine Air Intake

provide access for servicing the lter Filter

element. 1. Open hood.

2. Loosen a total of 4 screws.

(screws will not come out of the

housing)

3. Remove lid.

4. Remove lter.

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

ENGINE

ServiSignal™ Mini Indicator

The ServiSignal™ Mini Indicator is

installed on the air cleaner or air

induction piping so it has access to

clean ltered air. As the lter plugs

and restriction increases, a red ag

appears in the window. When it

reaches the red zone, the air lter

should be replaced. The indicator can

be reset by pressing the button at the

end of the indicator.

Exhaust System

The exhaust system is part of the

noise and emission control system.

Periodically check the exhaust for

wear, exhaust leaks, and loose or

missing parts. For details see Noise

and Emission Control on page 5-117.

Please refer to the Engine Operator's

Manual for more details on how to

maintain the emission's components in

the exhaust system.

Engine Mounting

Periodic Inspection: Inspect engine

mounts every 60,000 miles (96,560

km). Check for the following:

• Inspect both mount and leg

fasteners. Check for loose

or broken bolts. Replace as

necessary.

• Check mount and leg for fractures,

breaks or deformation. Replace

as necessary.

• Check for complete insertion

of motor mount. Replace as

necessary.

• New leg to mount ange head

bolts should be torqued to 210-230

Lb-Ft (284-311 Nm).

(04/13) Y53-1200-1B1 5-101

ENGINE

CAUTION

Do not re-torque or reuse existing

ange head bolts. These bolts are

factory set to the specied torque. If

bolts are loose or damaged, they must

be replaced with the new bolts. Fail-

ure to comply may result in equipment

or property damage.

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

FUEL SYSTEM

Location of Fuel Shut-off

Valves

Fuel shut-off valves for the fuel

crossover line are on the bottom of the

secondary fuel tank, at the crossover

line connection. They are optional on

the primary fuel tank.

Specication

Use only diesel fuel as recommended

by engine manufacturers.

WARNING!

CAUTION

A mixture of gasoline or alcohol with

diesel fuel in the presence of an igni-

tion source (such as a cigarette) could

cause an explosion resulting in death

or personal injury. Use only the recom-

mended diesel fuel.

If anyone ever pours gasoline into your

fuel tank, drain the entire system. Oth-

erwise, the pump and engine will be

damaged. Don’t try to dilute the gaso-

line by adding diesel fuel (See Warning

above).

Fuel Filters

See Engine Manufacturer’s Operator

Manual provided with this chassis

or the instructions provided with a

Fleetguard lter.

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

FRAME

Introduction

WARNING!

Do not cut, splice or weld frame rails or

drill through the top or bottom anges

of the rails. These operations could af-

fect frame rail strength leading to a fail-

ure resulting in an accident. Rail fail-

ures resulting from such modications

are not warrantable. Failure to com-

ply may result in death, personal injury,

equipment or property damage.

Emergency Welding

WARNING!

Frame welding is NOT recommended.

The high heat of welding nullies the

special heat treatment of the rails,

greatly reducing the tensile strength

of the frame rail. If a frame member

becomes cracked from overloading,

fatigue, surface damage or a collision,

the only permanent repair is to replace

the damaged frame member with a

new part.

In an emergency, a temporary repair

may be performed. Observe the

following precautions to protect

electronic systems during welding

operations. Emergency welding

procedures are further explained in the

maintenance manuals. Please refer to

the ordering information on the back

cover to obtain a maintenance manual.

Welding Precautions

In the event of emergency welding of a

frame rail and when welding any other

part of your truck or any component

attached to your truck, observe the

following precautions before welding:

• 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.

• Ensure that the ground connection

for the welder is as close to the

5-104 Y53-1200-1B1 (04/13)

FRAME

weld point as possible. This

ensures maximum weld current

and minimum risk to damage

of electrical components on the

vehicle.

Painting

Do not electrostatically paint your

truck or any component on your

truck without rst removing all of

the electronic components from the

truck. It is not possible to list all of

the electronics that could be affected,

but a few examples include the

alternator, engine Electronic Control

Unit (ECU), transmission ECU, ABS

ECU, navigation devices, diagnostic

devices, and monitoring devices.

Fifth Wheel Maintenance

Proper preventive maintenance is

essential to trouble-free service and

safe operation of the fth wheel.

Every 15,000 miles or monthly:

• Refer to specic manufacturer's

literature for any special

instructions.

• Steam clean the fth wheel.

• Check lock guard operation using

a commercial lock tester.

• Clean and oil all moving parts.

• Lubricate the lock mechanism with

a lithium-base grease.

• All grease ttings (especially those

which grease the top surface of

the fth wheel).

(04/13) Y53-1200-1B1 5-105

FRAME

Every 60,000 miles or 6 months:

• Refer to specic manufacturer's

literature for any special

instructions.

• Remove fth wheel from vehicle.

Refer to the Shop Manual, “Fifth

Wheel Removal.”

• Steam clean the fth wheel and

mounting brackets.

• Check all moving parts for

excessive wear or damage.

Replace all worn or broken parts.

• Complete two-month service

procedure.

• Install fth wheel. Refer to

the Shop Manual, “Fifth Wheel

Installation.”

Frame Fastener Torque

Requirements Standard Grade 8 UNF or UNC and Metric

Tighten all frame fasteners with a

torque wrench. Torque specications

apply to the following fasteners with

lightly lubricated threads.

NOTE

Whenever possible, torque all frame

fasteners on the nut end, not the bolt

head.

FASTENER

SIZE

TORQUE *

Nm Lb-Ft

5/16 22-30 16-22

3/8 41-54 30-40

7/16 75-88 55-65

1/2 109-122 80-90

9/16 156-190 115-140

5/8 224-265 165-195

3/4 394-462 290-340

7/8 517-626 380-460

1 952-1,129 700-830

1-1/8 1,346-1,591 990-1,170

1-1/4 1,877-2,217 1,380-1,630

METRIC WITH NYLON INSERT NUTS

M5 8-12 6-9

M6 9-15 7-11

M8 23-31 17-23

M10 33-43 24-32

M12 75-101 55-75

M16 163-217 120-160

M20 352-460 260-340

* ESNA Style Lock Nut, with nylon insert.

Lubricate nylon insert nut lightly with SAE

20/30 oil.

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

FRAME

Sliding Fifth Wheels

Lubricate bearing surface of support

bracket through the grease ttings on

the side of the fth wheel plate. Use a

water resistant lithium-base grease.

NOTE

The plate must be lifted up slightly to

relieve the weight of the bracket while

applying grease.

(04/13) Y53-1200-1B1 5-107

FRONT AXLE AND SUSPENSION

FRONT AXLE AND

SUSPENSION

Axle Lubrication

Change bearing lubrication when seals

are replaced, or brakes are relined.

See Preventive Maintenance Schedule

on page 5-12.

Thoroughly clean hubs and bearings

with solvent and a stiff bristle brush,

then dry and inspect components for

wear or damage. Re-lubricate with

approved axle lubricant.

Kingpin Lubrication

Lubricate with approved lubricant.

Lubricate knuckle thrust bearings,

knuckle pins, and tie rod ends. See

Preventive Maintenance Schedule

on page 5-12. Lack of lubrication

causes premature wear and hard

steering. Lubrication schedule may be

shortened if necessary.

Suspension Lubrication

Each standard spring anchor pin

has a grease tting. Pressure

lubricate spring pins as specied. See

Preventive Maintenance Schedule on

page 5-12.

At regular intervals, the spring leaves

may be lubricated with a rust-inhibiting

oil applied with a spray gun or brush.

Depending on your suspension,

lubricate all spring pins until grease

ows out of both ends of the bushing.

Look for signs of rust or water in the

ushed grease. If a pin will not accept

grease, it should be removed, cleaned,

and inspected.

CAUTION

Do not spray the suspension with

chemical products or mineral oil; it can

cause damage to the bushings.

5-108 Y53-1200-1B1 (04/13)

FRONT AXLE AND SUSPENSION

Inspection

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. Defective parts must be

replaced. Because repaired springs

cannot be fully restored to their original

service life, replace the complete

assembly if cracks or other defects are

detected.

Visually inspect shock absorbers and

rubber bushings.

Wheel Alignment

For driving safety and comfort, and

to prolong the life of your vehicle, it

is important to have wheels correctly

aligned. Check tire wear frequently.

Uneven tire wear is a sign that the

wheels may be misaligned.

If you see uneven wear, take your

vehicle to an authorized dealer familiar

with aligning wheels on your vehicle.

(04/13) Y53-1200-1B1 5-109

FRONT AXLE AND SUSPENSION

U-Bolt Torque

It is important that U-bolts remain tight.

Severe use of your vehicle will cause

them to loosen faster. But all vehicles

need to have their U-bolts checked and

tightened regularly. Be sure someone

with the proper training and the right

tools checks and tightens the U-bolts

on your vehicle.

New springs can settle in after service,

relieving the tension on the U-bolts.

Loose U-bolts can cause leaf spring

breakage, axle misalignment, hard

steering and abnormal tire wear.

All vehicles should have suspension

U-bolts tightened after the rst 500

miles (800 km) of operation. Re-torque

the front spring pinch bolts and shackle

pinch bolts.

Do not operate the vehicle if the

U-bolts are not properly tightened.

Loose U-bolts will cause the axle to

not be properly secured to the sus-

pension, 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.

WARNING!

U-bolts are difcult 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.

Tighten U-bolt nuts to the specied

torque value with the vehicle loaded to

its normal gross weight. The following

torque values apply to U-bolts and

nuts with clean threads lubricated with

Chevron zinc lubricant (SAE 20 or 30

oils acceptable but not preferred).

WARNING!

Do not replace U-bolts and nuts with

common U-bolts or standard nuts.

These parts are critical to vehicle

safety. If the wrong U-bolts or nuts

are used, the axle could loosen or

separate from the vehicle and cause

a serious accident. Use only U-bolts

and nuts of SAE Grade 8 specication

or better. Failure to comply may result

in death, personal injury, equipment or

property damage.

5-110 Y53-1200-1B1 (04/13)

FRONT AXLE AND SUSPENSION

Front Spring Suspension U-Bolts, Grade 8

U-BOLT SIZE TORQUE

DIAMETER

(Inch

Dimensions)

Nm Lb-Ft

3/4 333-408 245-300

7/8 598-734 440-540

1 925-1,060 680-780

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

1-1/4 1,890-2,120 1,390-1,560

1-1/2 3,130-3,860 2,300-2,840

(04/13) Y53-1200-1B1 5-111

HEATER AND AIR CONDITIONER

HEATER AND AIR

CONDITIONER

Introduction

The combination heater-air conditioner

provides comfort for those in the cab

through accurate control of the cab

environment in all weather conditions.

Regular attention to the items below

will help you keep the heater-air

conditioner unit running well.

Keep the vehicle's ventilation system,

engine exhaust system and cab

joints properly maintained. It is

recommended that the vehicle's

exhaust system and cab be serviced

as follows:

• Inspected by a competent

technician every 15,000 miles

• Whenever a change is noticed in

the sound of the exhaust system

5-112

• Whenever the exhaust system,

underbody or cab is damaged

To allow for proper operation of the

vehicle ventilation system, proceed as

follows:

• Keep the inlet grille at the base of

the windshield clear of snow, ice,

leaves and other obstructions at

all times.

• Keep the exhaust pipe area clear

to help reduce the buildup of

exhaust gas under the vehicle.

• Check the drain tube of the fresh

air inlet for trapped water before

assuming that there is a leak in the

heating system.

Y53-1200-1B1

Special Precautions

WARNING!

Excessive heat may cause the pres-

surized components of the air con-

ditioning system to explode. Never

weld, solder, steam clean, or use a

blow torch near any part of the air con-

ditioning system. Failure to comply

may result in death, personal injury,

equipment or property damage.

Air conditioning refrigerant can be haz-

ardous to your health. Do not expose

yourself to leaking refrigerant for pro-

longed periods near excessive heat,

open ames, or without proper venti-

lation. Failure to do so may result in

death or personal injury.

WARNING!

If a refrigerant leak develops in the

presence of excessive heat or an

open ame, hazardous gases may be

generated. If you become aware of a

(04/13)

HEATER AND AIR CONDITIONER

refrigerant leak on your vehicle have

your system serviced immediately and

observe the following precautions:

Stay away from the hot engine until the

exhaust manifold has cooled.

Do not permit any open ame in the

area. Even a match or a cigarette

lighter may generate a hazardous

quantity of poisonous gas.

Do not smoke in the area. Inhaling

gaseous refrigerant through a cigarette

may cause violent illness.

Air Filters

Cab Recirculation Air Filter

Please contact an authorized dealer

when the service interval is required to

inspect the cabin recirculation air lter.

Cabin Fresh Air Filter

The fresh air lter for the cab HVAC is

located in the air intake housing that is

located in the passenger rear corner of

the engine compartment. The lter can

be replaced without using any tools.

Inspect and clean cab air lter

element every 3 - 6 months of

service. Depending on the operating

environment, if air ow from the air

conditioner and heater is less efcient

or windows fog easier, you may need

to replace the cab air lter.

1. Tilt the hood open.

2. Locate air intake housing at

passenger rear corner of vehicle

under the rain tray.

(04/13) Y53-1200-1B1 5-113

HEATER AND AIR CONDITIONER

the side of the lter element with Sleeper HVAC Air Filter

the airow direction that is clearly

marked on the air intake housing. The sleeper recirculation lter is

located under the sleeper bunk on the

passenger side of the vehicle. Lift the

bottom bunk to access the unit. The

lter can be replaced without using

any tools.

1. Lift the sleeper bunk to expose the

sleeper HVAC module.

2. Find the retention tab at the side

of the lter element and move it to

release the lter. Moving this tab

3. Locate lter cover labeled “OPEN”

with an arrow pointing rearward in

vehicle. Slide lter cover rearward

in vehicle until you are able to

remove the cover.

4. Remove and inspect lter referring

to maintenance interval schedule.

5. Replace lter in housing taking

care to align the airow direction

that is indicated on the side of

6. Replace the lter cover on the air

intake housing and slide the cover

forward in vehicle. An audible

snap sound can be heard when

the cover is correctly in place. If

the snap feature is damaged there

are two screw features that may

be utilized to retain the cover in

place.

7. Close and secure hood of vehicle.

5-114 Y53-1200-1B1 (04/13)

HEATER AND AIR CONDITIONER

will allow the lter to be removed element such that it points into the Heater

in an upward direction. HVAC housing. • Check all heater controls for

4. Insert the lter and make sure the full-range operation.

retention tab has re-engaged to

secure the lter. • Check hoses, connections, and

heater core for condition and

5. Close the bunk. leaks.

CAUTION

During extreme cold weather, do not

blow hot defroster air onto cold wind-

shields. This could crack the glass.

Turn the air direction lever to Defrost

and adjust the fan speed accordingly

while the engine warms. If the en-

gine is already warm, move the tem-

perature selector to Cool, then grad-

ually increase the temperature when

you see that the windshield is starting

to warm-up.

3. Align the airow direction that is

indicated on the side of the lter

(04/13) Y53-1200-1B1 5-115

HEATER AND AIR CONDITIONER

Air Conditioner

WARNING!

The air conditioning system is under

pressure. If not handled properly dur-

ing servicing, it could explode. Any

servicing that requires depressurizing

and recharging the air conditioning

system must be conducted by a qual-

ied technician with the right facilities

to do the job. Failure to comply may

result in death, personal injury, equip-

ment or property damage.

• Listen to the compressor and drive

clutch for noise and vibration.

If you nd problems, have the

system checked thoroughly. A

malfunctioning clutch usually

indicates trouble elsewhere in the

system.

• Check the evaporator core, lter,

and condenser core for debris

restricting air ow. Clean if

necessary. Small particles may

be removed with compressed

air blown through the core in the

opposite direction of normal air

ow.

WARNING!

Wear eye protection any time you blow

compressed air. Small particles blown

by compressed air could injure your

eyes.

• Check the engine belt for condition

and proper tension.

• Check all hoses for kinks,

deterioration, chang, and leaks.

Adjust kinked or chang hoses to

eliminate restrictions and prevent

further wear.

• Check all components and

connections for refrigerant leaks.

If you discover a leak, do not try to

tighten a connection. Tightening

a connection may cause a leak

to worsen. Have a qualied

technician correct the problem.

NOTE

A leaking evaporator or condenser

core cannot be repaired; it must be

replaced.

Have the air conditioning system fully

serviced annually by your authorized

dealer. Qualied service technicians

will have to evacuate and recharge the

system.

5-116 Y53-1200-1B1 (04/13)

NOISE AND EMISSION CONTROL

NOISE AND EMISSION

CONTROL

Noise Emission Warranty

There are specic components on

the vehicle that are designed to meet

certain Environmental Protection

Agency (EPA) emissions and noise

regulations. To maintain conformance

with the regulations, these components

need to be functional and properly

maintained.

Tampering with Noise Control

System

Federal law prohibits the following

acts or the causing thereof:

(1) The removal or rendering

inoperative by any person other than

for purposes of maintenance, repair, or

replacement, of any device or element

of design incorporated into any new

vehicle for the purpose of noise control

prior to its sale or delivery to the

ultimate purchaser or while it is in use,

or (2) the use of the vehicle after such

device or element of design has been

removed or rendered inoperative by

any person.

Among those acts presumed to

constitute tampering are the acts listed

below:

Air Intake System

• Removing or rendering inoperative

the air cleaner/silencers or intake

piping.

Engine Cooling System

• Removing or rendering inoperative

the fan clutch.

• Removing the fan shroud.

Engine

• Removing or rendering engine

speed governor inoperative so as

to allow engine speed to exceed

manufacturer's specications.

• Modifying ECU parameters.

Exhaust System

• Removing or rendering inoperative

exhaust system components.

(04/13) Y53-1200-1B1 5-117

NOISE AND EMISSION CONTROL

Fuel System • Cutting holes in, or cutting away

• Removing or rendering engine part of noise insulators.

speed governor inoperative, • Removing hood-mounted noise

allowing engine speed to exceed insulation.

manufacturer's specications.

• Removing of air signal attenuator

on engines equipped with this

device.

• Removing of diesel exhaust uid

tank and system.

Inner Fender Shields and Cab Skirts

• Removing shield or skirts.

• Cutting away parts of shields,

skirts or damaged or loose

portions of shields or skirts.

Noise Insulating Blankets

• Removing noise insulators from

engine block or from around the

oil pan.

Inspection and Maintenance

Instructions

The following instructions are based on

inspection of the noise control system

at regular intervals as indicated in the

Noise Control System Maintenance

Log on page 5-124.

If, during periodic inspection and

maintenance of other systems and

components, it is found that parts of the

noise control system require attention,

we recommend that those parts be

inspected at more frequent intervals

to assure adequate maintenance and

performance.

5-118 Y53-1200-1B1 (04/13)

NOISE AND EMISSION CONTROL

Air Intake System Engine Mounted Noise Insulators

• Do all checks and maintenance • Check condition. Is the insulator

procedures listed in this manual secure? How you do this will

under Engine Air Intake System depend on the method of attaching

and Air Cleaner. See Air Dryer on the noise insulators on the engine

page 5-52. and around the oil pan (bolts,

snap fasteners, or straps). Tighten

• Check the induction tubing, elbow loose fasteners and repair or

connections, clamps, brackets, replace any worn or damaged

and fasteners for deterioration, fasteners.

cracks, and security.

• Check insulators around fasteners

• If you nd an air leak anywhere and stress points, especially

between the air cleaner and where they may be affected by

the engine, repair that leak engine vibration. Repair any

immediately. cracked or damaged mounting

points. Use suitable reinforcing

plates to ensure that the insulators

Air leaks cause excessive noise and

CAUTION

will remain in position.

may result in serious damage to the

engine. If you do not repair them the

engine damage will not be covered by

your warranty. Repair all air leaks as

soon as you nd them.

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 anges.

Refer to the engine manufacturer's

service manual for proper

tightening sequence and torque

values.

(04/13) Y53-1200-1B1 5-119

NOISE AND EMISSION CONTROL

Joints and Clamps

• Check for leaks, and tighten as

necessary. Check for deterioration

or dents in pipes and clamps which

could allow exhaust to escape.

• Replace any serviceable joints,

exible pipes and gaskets at the

service intervals.

Selective Catalyst Reduction (SCR) Piping

• Check SCR canister lter, clamps • Check exhaust piping for rust,

and mounting brackets. Tighten if corrosion, or damage. Replace

necessary. Inspect SCR canister deteriorated piping before holes

for signs of rust or corrosion. appear. If piping is perforated at

any point, temporary patching or

lagging is acceptable until you can

have permanent repairs made.

On turbocharged engines, check

joints at anges and mounting

brackets for tightness.

5-120 Y53-1200-1B1 (04/13)

NOISE AND EMISSION CONTROL

Diesel Particulate Filters (DPF)

• Check diesel particulate lter

(DPF), clamps, and mounting

brackets. Tighten if necessary.

Inspect diesel particulate lter

(DPF) for signs of rust or corrosion.

• Check internal bafing. You can

do this by listening for rattling

sounds while tapping on the diesel

particulate lter (DPF) with a

rubber mallet or revving the engine

up and down through its normal

operating range.

(04/13)

Diesel Exhaust Fluid Tank

Vehicles that comply with 2013 EPA

emission requirements will have a

Diesel Exhaust Fluid (DEF) tank

mounted to the vehicle frame.

The Diesel Exhaust Fluid (DEF) sys-

tem purges to prevent damage from

freezing. If your vehicle is equipped

with battery disconnect switches, do

NOT disconnect battery power within

two minutes of switching the ignition

key off. Failure to comply may result

in vehicle or property damage.

CAUTION

DEF Filter

The DEF system has a supply

pump lter and this lter should be

serviced according to the preventive

maintenance schedule. Follow these

steps to replace the DEF supply pump

lter:

1. Turn off the vehicle and allow the

vehicle to cool down. Take special

precaution with hot exhaust piping.

Y53-1200-1B1 5-121

NOISE AND EMISSION CONTROL

The exhaust piping can become ex-

tremely hot during engine operation

and can cause personal injury includ-

ing serious burns to the skin. Allow

adequate cooling time before working

near any part of the exhaust system.

WARNING!

2. Remove the pump protective plate

mounted on the bottom of the DEF

tank.

Exhaust Tail Pipe

3. Using a 27 mm socket wrench

(DIN3124), remove the lter cap • Check the mounting. Tighten as

that is screwed to the DEF Supply necessary. The miter cut at the tip

pump. of the pipe must be facing the rear

of the vehicle. Do not modify the

end of the pipe in any way.

5-122 Y53-1200-1B1 (04/13)

NOISE AND EMISSION CONTROL

Engine Fan and Shroud Hood Insulation Blanket

WARNING! • Check all fasteners for condition

and security. Repair or replace

Do not work on the fan with the engine any broken or defective fasteners.

running. The engine fan can engage

at any time without warning. Anyone • Check for chang or tears. Patch

near the fan when it turns on could be it if necessary. Find the cause of

injured. Before turning on the ignition, the damage. If any component

be sure that no one is near the fan. or accessory is causing wear or

damage and cannot be relocated,

• Check all fasteners for tightness. put reinforcing pads on the blanket

Check for stress cracks in the at the site of wear.

shroud. Make sure the shroud is

adjusted so that it does not touch

the fan blades.

• Check to verify that the fan is

disengaged (not turning) with

the engine running at normal

operating temperatures (from cold

to the point that the fan engages).

• Check fan blade mounting bolts.

Inspect fan blades to be sure they

are not cracked or bent.

Inner Fender Shields and Cab Skirts

• Check all fasteners that hold the

fender shields in place.

• Check fender shields for tire

marks, worn spots, or damage

from objects thrown from tire

treads.

• Check cab skirts, sills, and

brackets for overall condition

and repair them as necessary.

Damaged rubber fender shields

or cab skirting cannot be repaired.

You will need to replace it.

(04/13) Y53-1200-1B1 5-123

NOISE AND EMISSION CONTROL

Noise Control System -

Maintenance Log

To ensure your vehicles noise control

requirements are maintained, record

Noise Control System - Maintenance Log

maintenance checks. Use the

following log sheet and retain copies

of documents regarding maintenance

services performed and parts replaced

on the vehicle.

Component Recommended

Interval (Miles) Date & R.O. No. Repair Facility

& Location Work

Performed Date & R.O. No. Repair Facility &

Location Work

Performed

Exhaust System

Routing Integrity 25,000

Shutters

Shrouds 25,000

Hood Insulation

Blanket 10,000

Engine Mounted

Hose Insulators

Fasteners

10,000

Inner Fender

Shields 50,000

Cab Skirts

Fasteners 50,000

Air Intake

System Integrity

Element

5,000

Clutch Type Fan

Drive 10,000

5-124 Y53-1200-1B1 (04/13)

REAR AXLE AND SUSPENSION

REAR AXLE AND

SUSPENSION

General Maintenance

WARNING!

Do not work on the vehicle without the

parking brake set and wheels blocked

securely. If the vehicle is not secured

to prevent uncontrolled vehicle move-

ment, it could roll and may result in

death, personal injury, equipment or

property damage.

Your vehicle's suspension, by

design, requires a minimal amount of

maintenance. However, suspensions

in over-the-road operations require

periodic inspection to ensure trouble-

free performance.

WARNING!

Do not operate the vehicle if the

U-bolts are not properly tightened.

Loose U-bolts will cause the axle to

not be properly secured to the sus-

pension, 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.

WARNING!

Failure to maintain the specied

torque values or to replace worn parts

can cause component system failure,

possibly resulting in an accident. Im-

properly tightened (loose) suspension

U-bolts can lead to unsafe vehicle

conditions, including: hard steering,

axle misalignment, spring breakage or

abnormal tire wear. See Front Spring

Suspension U-bolts on page 5-111 for

proper torque specications. Failure

to comply may result in death, per-

sonal injury, equipment or property

damage.

Do not spray the suspension with

chemical products or mineral oil; it can

cause damage to the bushings.

CAUTION

(04/13) Y53-1200-1B1 5-125

REAR AXLE AND SUSPENSION

NOTE

Failure to follow these recommenda-

tions could void warranty.

Visual Inspection

For all vehicles, mandatory

maintenance procedures include

retightening of U-bolts and complete

inspection. However, even with proper

maintenance, many factors affect the

service life of springs and suspension

components, such as: fatigue, vehicle

gross weight, type of load, road

conditions, and vehicle speed.

It is important that U-bolts remain tight.

Severe use of your vehicle can cause

them to loosen faster. But all vehicles

need to have their U-bolts checked and

tightened regularly. Be sure someone

with the proper training and the right

tools checks and tightens the U-bolts

on your vehicle.

• After the rst 500 miles (800 km) of

operation, inspect the suspension

periodically, as noted below:

• Visually check for loose or missing

fasteners, cracks in hanger, or

axle connection brackets.

• Check that springs are centered in

hangers and in good condition.

• Check for cracks, wear marks,

splits, or other defects on the

surface of the spring.

• Replace defective parts. Because

repaired springs cannot be

fully restored to their original

service life, replace the complete

assembly if cracks or other defects

are detected.

• After replacement of any part or

discovery of loose components,

check the torque of all fasteners.

• New springs settle-in after the

vehicle's initial service, causing

the U-bolts to become loose.

5-126 Y53-1200-1B1 (04/13)

REAR AXLE AND SUSPENSION

Rear Suspension Fasteners

To maintain the performance of the

air suspension, check fastener torque

values after the rst 2,000 miles (3,218

km) of service and every 60,000 miles

(96,000 km) thereafter.

Torque recommendations apply to

fasteners supplied and installed by

vehicle manufacture. The values listed

in the tables below, are for cadmium

plated or phosphate and oil fasteners

only.

U-bolts are difcult 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.

U-Bolt Torque

NOTE

To ensure an accurate torque read-

ing, use properly maintained and cal-

ibrated torque wrenches.

Clean the nut and bolt. No dirt, grit, or

rust should be present.

WARNING!

Do not operate the vehicle if the

U-bolts are not properly tightened.

Loose U-bolts will cause the axle to

not be properly secured to the sus-

pension, 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.

Rear Suspension Fasteners (Metric and

Standard)

SIZE/TYPE TORQUE *

Nm Lb-Ft

M16

nylon-insert

nuts

163-217 120-160

M20

nylon-insert

nuts

352-460 260-340

M20 all-metal

lock nuts 427-475 315-350

1/2 in. nut 109-122 80-90

3/4 in. nut 394-462 290-340

1-1/4 in. nut 1,877-2,217 1,380-1,630

* Torque requirements apply to manufacturer

proprietary suspensions. All other

suspensions must refer and adhere to

original manufacturers shop manual. 5

NOTE

Whenever possible, torque all fasten-

ers on the nut end, not the bolt head.

(04/13) Y53-1200-1B1 5-127

REAR AXLE AND SUSPENSION

Rear Suspension U-Bolts, Grade 8

(lubricated*)

U-BOLT SIZE

DIAMETER

THREAD

TORQUE**

Nm Lb-Ft

3/4 333-408 245-300

7/8 598-734 440-540

1 925-1,060 680-780

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

1-1/4 1,890-2,120 1,390-1,560

1-1/2 3,130-3,860 2,300-2,840

*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.

WARNING!

Do not replace U-bolts and nuts with

common U-bolts or standard nuts.

These parts are critical to vehicle

safety. If the wrong U-bolts or nuts

are used, the axle could loosen or

separate from the vehicle and cause

a serious accident. Use only U-bolts

and nuts of SAE Grade 8 specication

or better. Failure to comply may result

in death, personal injury, equipment or

property damage.

Rear Axle Lubrication

Check oil level with the vehicle parked

on level ground and the uid warm.

The level should be even with the

bottom of the ller hole.

5 • Load the vehicle to its normal

gross weight before tightening

U-bolts. Loading the vehicle

ensures proper adjustment of the

U-bolt and spring assembly.

5-128 Y53-1200-1B1 (04/13)

REAR AXLE AND SUSPENSION

CAUTION

Do not mix lubricants of different

grades; although, mixing different

brands of the same grade lubricant

(meeting MIL L2105C), is acceptable.

Lubricants of different grades are not

compatible and could damage the

axle.

NOTE

In all cases, lubricant supplier as-

sumes full responsibility for the per-

formance of their product, and for

product and patent liability.

For recommended types and brands of

lubricants, contact your dealer.

Dana Spicer and Fabco

No initial drain is required on Dana

Spicer axles that are factory lled with

an Dana Spicer-approved synthetic

lubricant.

• Petroleum-based lubricants must

be drained within the rst 5,000

miles (8,000 km) if converting to

an approved synthetic lubricant.

Initial Change: See Preventive

Maintenance Schedule on page 5-12

for standard rear axle service intervals.

Change mineral-based lubricant in

other Dana Spicer and Fabco axle

assemblies (new or rebuilt) within the

rst 3,000 to 5,000 miles (4,800 to

8,000 km).

• For petroleum-based axles, use

lubricants meeting MIL L2105C/D

grade specications or approved

synthetic lubrication. Do not use

oil additives.

All Vehicles with Dana Spicer

and Fabco Axles: See Preventive

Maintenance Schedule on page 5-12.

Contact your dealer for approved

synthetic lubricant brands.

• Dana Spicer Axles with synthetic

lubrication and Out Runner Seals:

drain, ush, and rell at 500,000

miles (804,000 km).

Axle Housing Breather Vent:

• Check and clean the axle housing

breather vent at each oil level

check.

Meritor:

• See Meritor Lubrication

Maintenance Manual (MM1).

(04/13) Y53-1200-1B1 5-129

REAR AXLE AND SUSPENSION

Rear Axle Alignment

Continual road shock and load

stresses may force the rear axles

out of alignment. If you detect rapid

tire wear on the rear axles, you may

have misaligned axles. If you suspect

rapid tire wear, have your rear axle

alignment checked and adjusted by an

authorized dealer.

In addition to pre-delivery inspections,

suspension alignment should be

checked when any one of the following

conditions exist:

• Discovery of loose suspension

fasteners. (Loose, dened as any

torque below the recommended

torque value.)

• Discovery of elongated holes in a

suspension component.

• Bushing replacement.

• Excessive or abnormal tire wear.

5-130 Y53-1200-1B1 (04/13)

STEERING SYSTEM

Power Steering

Oil (under low pressure) provides the

power to operate the steering gear. It

also serves to lubricate moving parts

and remove heat. A loss of steering

efciency will occur if too much heat

builds up in the system.

WARNING!

Do not operate the vehicle if the steer-

ing system is not working properly.

You could lose control of your vehicle

if the steering system is not in good

working condition, which could re-

sult in a serious accident. For driving

safety, visually check the steering gear

and components. Frequent checks

are important for driving safety, espe-

cially after traveling over rough roads.

Failure to comply may result in death,

personal injury, equipment or property

damage.

If the steering feels unbalanced from

side-to-side while turning, check for

the following possible causes:

• unequal tire pressures

• vehicle overloaded or unevenly

distributed load

• wheels out of alignment

• wheel bearings improperly

adjusted.

If you cannot correct the problem,

check with an authorized dealer.

Your vehicle is equipped with integral

power steering. The system includes

an engine-driven uid pump, a uid

reservoir, the steering gear, and

connecting hoses. Because of the

hydraulic power assist, little effort is

required to turn the steering wheel.

When no input is applied through the

steering wheel, the steering gear will

return to the neutral position. If, for

any reason, the power assist system

goes out, steering the vehicle is still

possible, yet it will require much

greater effort.

Visually check the following parts:

• Crosstube: Is it straight?

• Draglink tube clamp: Check for

looseness or interference.

• Ball joints and steering U-joints:

Check for looseness.

• Steering wheel for excessive

free-play. Check the simplest

probable causes rst:

a. unequal tire pressures

b. loose cap nuts

c. bent crosstube

d. lack of lubrication.

• If these checks do not reveal the

problem, or if you correct them

and still have a steering problem,

(04/13) Y53-1200-1B1 5-131

STEERING SYSTEM

take your truck to an authorized Fluid Level and Rell

dealer for evaluation.

Have the power steering uid and

lters changed at an authorized dealer.

CAUTION

When adding uid, be sure to use uid

of the same type. While many u-

ids have the same description and in-

tended purpose, they should not be

mixed due to incompatible additives.

Mixing incompatible uids may lead to

equipment damage.

• Check and completely change the

uid level according to Preventive

Maintenance Schedule on page

5-12. Use the following procedure:

NOTE

Before removing reservoir cover, wipe

outside of cover so that no dirt can fall

into the reservoir.

• Maximum/Minimum level is

indicated on the reservoir. These

same levels are also indicated by

two lines on the dipstick in the

reservoir.

• There are two ways to check

whether the power steering uid

is at its proper level. Both checks

are with the engine NOT running.

1. If you check the uid with the

engine and steering system

COLD, the uid level should be

at/or above the Minimum indicator

level and should generally not

exceed the middle point between

Maximum and Minimum level

indicators.

2. If you check the uid with the

engine and steering system

WARM, the uid should NOT

exceed the Maximum level

indicator and should generally

not drop below the middle point

5-132 Y53-1200-1B1 (04/13)

STEERING SYSTEM

between the Maximum and 2. Bleed the system if necessary. Steering Shaft

Minimum level indicators.

The following are common torque

Fluid Filter Replacement specications for most steering shafts.

• Torque on U–joint pinch bolt and

nut (7/16 in) 74–81 Nm (55 to 60

lb-ft), lubricated.

• Torque on Pitman arm clamp bolt

and nut (3/4 in): 406–433 Nm (300

to 320 lb-ft), lubricated.

• For off–highway vehicles, tighten

the U–bolts after the rst day or

two of operation. Then check

weekly.

CAUTION

Servicing the power steering system

without bleeding it of trapped air may

cause damage to the power steering

pump.

1. Replace both uid and lter.

(04/13) Y53-1200-1B1 5-133

STEERING SYSTEM

WARNING!

If this chassis is equipped with an elec-

tronic stability system (ESP) and any

part of the steering system (e.g. link-

age, steering driveline, column, front-

end alignment, etc) is repaired, re-

moved, or disassembled in any way,

or if the steering angle sensor is re-

placed, the steering angle sensor must

be recalibrated. Any repairs or adjust-

ments to any part of the steering sys-

tem must be performed by an autho-

rized dealer. Failure to comply may

result in death, personal injury, equip-

ment or property damage.

5-134 Y53-1200-1B1 (04/13)

DRIVELINE

Driveshaft Maintenance

The slip joints and universal joints of

the driveshaft should be lubricated

periodically.

Use a good quality lithium-soap-base

or equivalent extreme pressure (E.P.)

grease: NLGI Grade 2.

Dana SPL U-joints and driveshafts

should be inspected every time

a vehicle comes in for scheduled

maintenance (Refer to Spicer

Driveshaft service manual DSSM-0100

(3264-SPL) for detailed instructions).

Use only Spicer Driveshaft approved

lubricants when greasing Spicer SPL

U-joints.

U-Joints

The slip joints and universal joints of

the drive shaft should be lubricated

according to Preventive Maintenance

Schedule on page 5-12.

Use a good quality lithium-soap-base

or equivalent extreme pressure (E.P.)

grease: NLGI Grade 2.

Use only Spicer Driveshaft approved

lubricants when greasing Spicer SPL

U-joints.

For SPL170XL and SPL250XL, the

U-joint lube interval changes after the

initial lube at 350,000 miles. After

the rst lube interval, the U-joint

needs lubrication every 150,000 miles.

Inspection of the U-joints is the same

regardless of when the U-joint grease

interval occurs.

WARNING!

Improper lubrication of U-joints can

cause them to fail prematurely. The

driveshaft could separate from the ve-

hicle and result in an accident. Make

sure lubricant is purged at all four ends

of each U-joint and loosen caps if nec-

essary. Also, regularly inspect U-joints

for excessive wear or movement, and

repair or replace as necessary. Fail-

ure to comply may result in death,

personal injury, equipment or property

damage.

(04/13) Y53-1200-1B1 5-135

TIRES AND WHEEL

Tires

WARNING!

Do not repair damaged tires unless

you are fully qualied and equipped to

do so. Wheel and tire assemblies can-

not be worked on without proper tools

and equipment, such as: safety cages

or restraining devices. Have all tire re-

pairs performed by an expert. Stand

away from the tire assembly while the

expert is working. Failure to do this

may result in death or injury.

Your tires are a very important part of

your vehicle’s whole braking system.

How fast 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,

efcient operation of your vehicle.

Regular, frequent inspection and the

right care will give you the assurance

of safe and reliable tire operation.

Here are some tips on maintaining

your tires.

Checking Ination Pressure

Give your tires a visual test every day,

and check ination with a gauge every

week:

• When checking tire pressure,

inspect each tire for damage to

sidewalls, cuts, cracks, uneven

wear, rocks between duals, etc. If

a tire appears underinated, check

for damage to the wheel assembly.

Don’t forget to check between dual

wheels. If you nd wheel damage,

have an expert tire service repair

it.

• Maximum tire pressure will be

indicated on the sidewall of a tire.

• Check pressure only when the

tires are cool. Warm or hot tires

cause pressure buildup and will

give you an inaccurate reading.

So never deate a warm tire to the

specied pressure.

5-136 Y53-1200-1B1 (04/13)

TIRES AND WHEEL

Underinated Tires

Low pressure is a tire’s worst enemy.

Underination allows tires to ex

improperly, causing high temperatures

to build up. Heat causes early tire

damage such as ex break, radial

cracks, and ply separation. Low

pressure may affect control of your

vehicle, especially at the front wheels.

Most tire wear problems are caused

by underination as the result of slow

leaks, so you’ll want to check tire

pressure regularly. Lower tire pressure

does not provide better traction on ice

or snow.

WARNING! WARNING!

Do not operate a vehicle with underin-

ated tires. The extra heat caused by

underination can cause sudden tire

failure such as a tire re or blow out,

which can cause an accident result-

ing in death or personal injury. Low

pressure may affect control at the front

wheels, which could result in an acci-

dent involving death or personal injury.

Keep your tires inated to the manu-

facturer's recommended air pressure.

Do not attempt to raise the vehicle to

remove or install a damaged tire and

wheel assembly if you are not fully

qualied and not equipped with the

proper tools and equipment. Do not at-

tempt to re-inate a tire that has been

run at. Obtain expert help. A person

can be seriously injured or killed if us-

ing the wrong service methods. Truck

tires and wheels should be serviced

only by trained personnel using proper

equipment. Follow OSHA regulations

per section 1910.177.

NOTE

Follow all warnings and cautions con-

tained within the tire and wheel manu-

facturers literature.

(04/13) Y53-1200-1B1 5-137

TIRES AND WHEEL

1 3

Proper-Ination: the Over-Ination:

correct prole for full reduces the tread

contact with the road. contact area with

the road surface,

TREAD CONTACT concentrating all of

TREAD CONTACT WITH ROAD the vehicle weight

WITH ROAD on the center of the

tread. This causes

premature wear of the

2 tire.

Under-Ination:

causes abnormal tire

deection, which builds

up excessive heat,

running the risk of

TREAD CONTACT failure. It also causes

WITH ROAD irregular wear.

Overloaded Tires

Overloading your truck is as damaging

to your tires as underination. The

following chart shows how neglect or

deliberate abuse can affect the life of

your tires.

5 EFFECT OF LOAD PRESSURE ON TIRE LIFE

Vehicle Load Normal 20% Over 40% Over 60% Over 80% Over 100% Over

Tire Pressure Normal 20% Low 30% Low 35% Low 45% Low 55% Low

Expected Total Tire

Mileage Normal 70% 50% 40% 30% 25%

Overinated Tires

Too much air pressure reduces the tire

tread contact area and results in rapid

wear in the center of the tread.

5-138 Y53-1200-1B1 (04/13)

TIRES AND WHEEL

WARNING!

Overinated tires can cause acci-

dents. They wear more quickly than

properly inated tires and are more

subject to punctures, cracks, and

other damage. They could fail and

cause you to lose control of your ve-

hicle resulting in an accident causing

death or personal injury. Be sure all

tires are inated correctly according to

the manufacturer's recommendations.

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 dan-

gerous. Never mix tires of different de-

sign such as steel belted radials and

bias ply tires, etc. Mixing tire types and

sizes will adversely affect the road-

holding ability of both types of tires and

can lead to loss of vehicle control and

causing death or personal injury.

WARNING!

Do not install regrooved or reinforce-

ment-repaired tires on steering axles.

They could fail unexpectedly and

cause you to lose control of your ve-

hicle resulting in an accident causing

death or personal injury.

(04/13) Y53-1200-1B1 5-139

TIRES AND WHEEL

Replacing Tires

Front: Replace front tires when less

than 4/32 in. of tread remains. Check

at three places equally spaced around

the tire.

Drive Axles or Trailers: Replace tires

on drive axles or trailers when less than

2/32 in. of tread depth remains in any

major groove. Check at three places

equally spaced around the tire. See

the next illustration for recommended

measuring points for tread depth.

Steer Tire Points (left), Drive Tire

Points (right)

5-140

WARNING!

Do not replace original equipment

tires with load ratings less than the

original tires. Doing so could lead to

unintentional overloading of the tire,

which could cause a failure resulting

in loss of vehicle control and an acci-

dent. Failure to comply may result in

death, personal injury, equipment or

property damage.

NOTE

To prolong your tires’ life and make

them safer, have their radial and lateral

run-out checked at your dealer. And

of course, you should have your tires

balanced anytime you change a tire.

Y53-1200-1B1

Greenhouse Gas Certied Tires

Replacing a tire that is greenhouse

gas certied.

NOTE

The tires installed on this vehicle at the

factory as original equipment may be

certied for Greenhouse Gas and Fuel

Efciency regulations. Replacement

tires must be of equal or lower rolling

resistance level (TRRL or Crr). Consult

with your tire supplier(s) for appropri-

ate replacement tires.

Verify if your vehicle is equipped with

Greenhouse Gas certied tires by

checking the Vehicle Emission Control

label on the driver's side door frame. If

these tires were installed at the factory,

Lower Rolling Resistance codes (LRR)

identify which tires are certied.

(04/13)

TIRES AND WHEEL

Maintaining a greenhouse gas

certied tire.

In order to limit the rolling resistance of

the tires and optimize fuel economy,

the maintenance procedures specied

by the tire manufacture must be

followed.

For warranty information, See

Greenhouse Gas Tires on page 6-9.

Tire Chains

If you need tire chains, install them on

both sides of each driving axle.

CAUTION

Chains on the tires of only one tandem

axle can damage the driveline U-joints

and the interaxle differential. Your re-

pairs could be costly and time-con-

suming.

Speed Restricted Tires

WARNING!

This vehicle may be equipped with

speed restricted tires. Check each

tire’s sidewall for maximum rated

speed. The vehicle should not be op-

erated at sustained speed in excess

of maximum rated speed. Failure to

comply with these speed restrictions

could cause sudden tire failure which

can result in death, personal injury or

property damage.

(04/13) Y53-1200-1B1 5-141

TIRES AND WHEEL

Wheel Mounting and

Fastening

After the vehicle travels about 50 to 100

miles (80 to 160 km), wheel mountings

seat in and will lose some initial torque.

Check hub/wheel mountings after this

initial period and retighten.

Wheel Cap Nut Torque

WARNING!

Never use oil or grease on studs or

nuts; improper torque readings will

result, which could cause improper

wheel clamping and could lead to a

wheel failure resulting in an accident.

Failure to comply may result in death,

personal injury, equipment or property

damage.

Wheel Cap Nut Torque

At the rst scheduled lube interval,

have all wheel cap nuts torqued to

their specied value listed in Wheel

Cap Nut Torque on page 5-142. After

that, check wheel cap nuts at least

once a week. Contact an authorized

dealer for information on the proper

installation procedure for the wheels

on your truck. This is a job you may

not be able to do yourself. You need

the right torquing equipment to do it.

WHEEL and NUT STUD SIZE TORQUE FOR INNER and OUTER CAP NUTS and RIM CLAMP NUTS

CONFIGURATION Nm Lb-Ft

Steel or Aluminum Disc-Type

Wheel; Double Cap Nut Mounting;

Standard 7/8 Radius Ball Seat

3/4-16 610-680 450-500

1-1/8-16 610-680 450-500

Heavy-Duty Steel Disc-Type Wheel;

Double Cap Nut Mounting; 15/16-12 1,020-1,220 750-900

1-1/8-16 1,020-1,220 750-900

1-3/16 Radius Ball Seat: 1-15/16-12 1,020-1,220 750-900

Hub-Piloted Disc-Type Wheel

w/Two Piece Flanged Cap Nuts:

Steel or Aluminum Wheel

PHP-10; Budd Uni-Mount-10;

WDH-8

M22-1.5 610-680 450-500

5-142 Y53-1200-1B1 (04/13)

TIRES AND WHEEL

WHEEL and NUT

CONFIGURATION STUD SIZE TORQUE FOR INNER and OUTER CAP NUTS and RIM CLAMP NUTS

Nm Lb-Ft

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

1-14 240-410 175-300

Rim Clamp Nut Torque

Cast Spoke Wheel Assembly 1/2” Dia.

5/8” Dia.

3/4” Dia.

110-120 80-90

220-250 160-185

305-335 225-245

Threads should be clean and dry. Do

not lubricate wheel nuts or studs.

Proper Torque and Sequence

Proper wheel torque can best be

obtained on level ground. Install lug

nuts and nger-tighten in the numerical

sequence as shown below, see Nut

Tightening Sequence for Hub Piloted

Disc Wheels on page 5-143 or Nut

Tightening Sequence for Stud Piloted

Disc Wheels on page 5-144. This

procedure will ensure that the wheel is

drawn evenly against the hub. Torque

each nut to the torque value listed in

Wheel Cap Nut Torque on page 5-142.

Tighten wheel cap nuts properly. If

they are not tightened properly, wheel

nuts could eventually cause the wheel

to become loose, to fail, and/or to

come off while the vehicle is moving,

possibly causing loss of control and

may result in death, personal injury,

equipment or property damage.

WARNING!

Nut Tightening Sequence for Hub

Piloted Disc Wheels

(04/13) Y53-1200-1B1 5-143

TIRES AND WHEEL

Wheel Replacement with

Disc Brake Option

Use only the wheel brand, size and

Nut Tightening Sequence for Stud part number originally installed. Use

Piloted Disc Wheels of a different wheel brand or size could

cause valve stem to interfere with a

brake component which could lead to

loss of vehicle control. Failure to com-

ply may result in death, personal injury,

equipment or property damage.

WARNING!

Vehicles equipped with front disc

brakes are tted with wheels designed

specically for disc brake applications.

If it ever becomes necessary to

replace an original equipment wheel,

the replacement wheel must be the

same brand and size as the take-off

wheel. On vehicles equipped with 22.5

in. disc wheels, installing the wrong

replacement wheel could result in

the wheel valve stem making contact

with the disc brake assembly. When

installing any replacement wheel,

always inspect the tires/wheels to

ensure there is adequate clearance

between other vehicle components.

With the hood open, check for

clearance between the wheel and disc

brake assembly. Use a hydraulic jack

to raise the front of the vehicle off

the ground to allow the wheel to spin

freely. While rotating the wheel, check

to ensure there is adequate clearance

between the wheel and disc brake

assembly.

5-144 Y53-1200-1B1 (04/13)

TIRES AND WHEEL

WARNING!

If the hood falls, anyone under it could

be injured. Always make sure that the

hood hold open device engages when

the hood is in its open position any

time anyone gets under the hood for

any reason.

• The hood could hurt someone

that is in the way of its descent.

Before lowering the hood, be sure

no objects or people are in the

way.

Always support the vehicle with appro-

priate safety stands if it is necessary to

work underneath the vehicle. A jack is

not adequate for this purpose.

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 manu-

facturer's literature for the proper way

to mount and demount your tires and

rims. Follow their precautions exactly.

Disc Wheels

WARNING!

Use the correct components and tools

when working on wheels. Grooves in

the wheel disc or other damage to the

disc can weaken the wheel and cause

it to eventually come off. This could

cause you to lose control of your ve-

hicle, and may result in an accident.

Failure to comply may result in death,

personal injury, equipment or property

damage.

The end of the wheel wrench must

be smooth. Burrs on the end of the

wrench can tear grooves in the disc.

These grooves may lead to cracks in

the disc, and can cause it to fail.

(04/13) Y53-1200-1B1 5-145

WHEEL BEARING

Wheel Bearing Adjustment

For safe, reliable operation and

adequate service life, your wheel

bearings must be adjusted properly at

the recommended intervals. Contact

your authorized dealer to make sure

the wheel bearings are properly

adjusted.

5-146 Y53-1200-1B1 (04/13)

TRANSMISSION MAINTENANCE

TRANSMISSION

MAINTENANCE

Introduction

Proper maintenance of the

transmission will ensure that the

vehicle will operate efciently.

To check the transmission uid level,

park the vehicle on level ground. For

an automatic transmission the oil level

should be checked with the engine

idling and the transmission uid at

operating temperature. Checking the

uid of a manual transmission may be

done with the engine off.

The recommended uid replacement

intervals contain an initial change and

a separate interval for the changes

after the initial drain. When the oil

needs to be replaced, be sure to refer

to the manufacturer’s literature on

the correct grade and type of oil to

purchase.

For more details, please refer to

the maintenance section in the

transmission manufacturer’s manual

or service literature.

CAUTION

When adding oil, types and brands of

oil should not be intermixed because

of possible incompatibility, which could

decrease the effectiveness of the lubri-

cation or cause component failure.

Initial Change: drain and replace

according to Preventive Maintenance

Schedule on page 5-12; for some

transmissions this may not be required.

Oil Change

Change uid according to change

procedures specied in the

Transmission Service Manual.

Use the recommended types of oil

as specied in the Operation and

Service Manual (included with vehicle).

Select from the appropriate lubricant

for varying ambient (outside air)

temperatures.

(04/13) Y53-1200-1B1 5-147

TRANSMISSION MAINTENANCE

Transmission Lubricants

Manual Transmission

Manual transmissions are designed so

that the internal parts operate in a bath

of oil circulated by the motion of gears

and shafts.

Service Intervals

For recommended types and brands

of all lubricants, see the transmission

manufacturer's Service Manual and

Preventive Maintenance Schedule on

page 5-12.

Check all hoses for kinks, deterioration,

chang, and leaks. Adjust kinked or

chang hoses to eliminate restrictions

and prevent further wear. To ensure

proper inspection, it may be necessary

to inspect under and inside frame rails

and unclip harnesses, hoses and cable

bundles.

Standard Transmission Oil Level

NOTE

The vehicle must be parked on level

ground.

See the Transmission Operator's

Manual for information on checking the

transmission oil level.

5-148 Y53-1200-1B1 (04/13)

TRANSMISSION MAINTENANCE

Automatic Transmissions

Service Intervals

Check daily with engine idling. See

Preventive Maintenance Schedule on

page 5-12 for service intervals.

Automatic Transmission Oil Level

NOTE

The vehicle must be parked on level

ground.

See the Transmission Operator's

Manual for information on checking the

transmission oil level.

(04/13) Y53-1200-1B1 5-149

CLUTCH

Introduction

The clutch pedal transmits force from

the operator to the clutch via hydraulic

and air assist action. The clutch pedal

position is factory set and does not

require adjustment.

Clutch Hydraulic Fluid

Visually inspect the clutch uid from the

reservoir. There are molded lines with

the letters MIN to indicate minimum

uid level and MAX to indicate the

maximum uid level recommended for

proper operation. Be sure to maintain

the uid between the MIN and MAX

levels indicated on the plastic reservoir.

If the uid level repeatedly goes below

the MIN line, then it is time to have

your clutch adjusted or the hydraulic

system inspected for service.

To replace the uid, locate the drain

tting on the air solenoid mounted to

the transmission housing. Open this

tting and allow uid to drain out of the

system. Once all the uid is drained

out, close the tting and ll the system

through the master cylinder reservoir

in the engine compartment. Once the

system is full, then purge the system of

air by simultaneously pressing on the

pedal and opening the tting to allow

air to escape. Close the tting when

uid starts coming out. Then rell the

reservoir. Repeat this until all air has

been purged from the system.

Replace with the recommended uid

Component Lubrication Index on page

5-39.

5-150 Y53-1200-1B1 (04/13)

CLUTCH

Clutch Adjustment

Some clutches are self-adjusting,

however; there are manually adjusted

clutches that will require the operator

to know when to adjust the clutch. The

clutch will need adjustment when your

clutch pedal stroke seems to get longer

and its effectiveness at a seamless

shift becomes less.

Another sign of the clutch needing

adjustment is the level of the uid in

the reservoir. If the hydraulic uid is

not leaking, but the uid level is getting

lower, then the clutch may need to be

adjusted. Please take the vehicle to

an authorized dealership to have the

clutch adjusted.

Clutch Adjustment – Normal

Wear

See the clutch manufacturer's Service

Manual for the proper adjustment

procedures.

(04/13) Y53-1200-1B1 5-151

INFORMATION

CONSUMER INFORMATION AND VEHICLE IDENTIFICATION

Vehicle Identication .............. 6-3

General VIN Information . . . . . . . . . . . . . 6-4

Component Identication. . . . . . . . . . . . . 6-7

CONSUMER INFORMATION

Federal Safety Standard Certication Label . . . . 6-8

How to Order Parts ............... 6-8

NHTSA Consumer Information . . . . . . . . . . 6-8

Canadian Consumer Information . . . . . . . . . 6-9

Warranty.................... 6-9

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

CONSUMER INFORMATION AND VEHICLE IDENTIFICATION

CONSUMER Assembly Plant Code

INFORMATION Model Year Designations

CODE YEAR

9 2009

A 2010

B 2011

C 2012

D 2013

E 2014

F 2015

G 2016

H 2017

I 2018

F = KENMEX

AND VEHICLE

M = Ste. Therese

IDENTIFICATION

R = Renton

Vehicle Identication

J = Chillicothe

The 17-digit Vehicle Identication

Number (VIN) is used to register

your vehicle for warranty, license and

insurance.

1 Manufacturer Identier

2 Vehicle Attributes

3 Reserved Space

4 Model Year

5 Assembly Plant

6 Serial Number (Chassis

Number)

(04/13) Y53-1200-1B1 6-3

CONSUMER INFORMATION AND VEHICLE IDENTIFICATION

General VIN Information

VIN Locations

The full, 17-digit VIN is located on the

Weight Rating Data Label. The label is

located on the driver's side door edge

or on the driver's side door frame.

Chassis Number

The Chassis Number refers to the last

six characters of the VIN. This number

will allow your dealer to identify your

vehicle. You will be asked for this

number when you bring it in for service.

Chassis Number Locations

• Right frame rail, top ange, 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 Identication label

Certication Labels

Your vehicle information and

specications are documented on

labels. As noted below, each label

contains specic information pertaining

to vehicle capacities and specications

that you should be aware of.

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

CONSUMER INFORMATION AND VEHICLE IDENTIFICATION

Components and Weights Label

The Components and Chassis Weight

Label is located on either the driver’s

side door edge or on the driver’s

side door frame. It includes chassis

number, chassis weight and gross

weight, plus model information for the

vehicle, engine, transmission, and

axles.

Tire and Rim Data Label

The Tire, Rim and Weight Rating

Data Label is located on the driver’s

side door edge or on the driver’s side

door frame. It contains the following

information:

• GVWR - Gross Vehicle Weight

Rating

• GAWR FRONT, INTERMEDIATE

and REAR - Gross Axle Weight

Ratings for Front, Intermediate

and Rear Axle

• TIRE/RIM SIZES AND INFLATION

PRESSURES - Tire/Rim Sizes

and Cold Pressure Minimums

• VIN including CHASSIS NUMBER

Do not exceed the specied load rat-

ing. Overloading can result in loss of

vehicle control and personal injury, ei-

ther by causing component failures or

by affecting vehicle handling. Exceed-

ing load ratings can also shorten the

service life of the vehicle.

WARNING!

The components of your vehicle

are designed to provide satisfactory

service, if the vehicle is not loaded

in excess of either the gross vehicle

weight rating (GVWR), or the maximum

front and rear gross axle weight ratings

(GAWRs).

NOTE

GVW is the TOTAL SCALE WEIGHT

the vehicle is designed to carry. This

includes the weight of the empty vehi-

cle, loading platform, occupants, fuel,

and any load.

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

CONSUMER INFORMATION AND VEHICLE IDENTIFICATION

Noise Emission Label

The Noise Emission Label is located

in the driver's side door frame. It

contains information regarding U.S.

noise emission regulations, chassis

number, and date of manufacture.

Paint Identication Label

The Paint Identication Label contains

the paint colors used by the factory

to paint your vehicle. It lists frame,

wheels, cab interior and exterior

colors. This label is located inside the

glove box.

Federal Safety Standard

Certication Label

The NHTSA regulations require a label

certifying compliance with Federal

Safety Standards, for United States

and U.S. Territories, be afxed to

each motor vehicle and prescribe

where such label may be located.

This certication label, which indicates

the date of manufacture and other

pertinent information, is located on

the driver’s side door edge or on the

driver’s side door frame.

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

CONSUMER INFORMATION AND VEHICLE IDENTIFICATION

Component Identication

Each of the major components on

your vehicle has an identication label

or tag. For easy reference, record

component numbers such as, model,

serial, and assembly number.

Engine: For further information,

please refer to the Engine Operation

and Maintenance Manual.

Transmission: For both manual

and automatic transmissions, the

identication number is stamped on a

tag afxed 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.

Drive Axles: The drive axle numbering

system includes three labels or stamps:

1. Axle Specication Number, usually

stamped on the right rear side of

the axle housing. This number

identies the complete axle.

2. Axle Housing Number Tag, usually

located on the left forward side

of the housing arm. This tag

identies the axle housing.

3. Axle Differential Carrier

Identication, usually located

on the top side of the differential

carrier. The following information

is either stamped, or marked with a

metal tag: Model No., Production

Assembly No., Serial No., Gear

Ratio, and Part Number.

(04/13) Y53-1200-1B1 6-7

CONSUMER INFORMATION

CONSUMER

INFORMATION

Federal Safety Standard

Certication Label

The National Highway Trafc Safety

Administration regulations require

a label certifying compliance with

Federal Safety Standards, for United

States and U.S. Territories, be afxed

to each motor vehicle and prescribe

where such label may be located.

This certication label, which indicates

the date of manufacture and other

pertinent information, is located on the

left hand cab door post.

How to Order 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.

NHTSA Consumer

Information

If you believe that your vehicle has

a defect, which could cause a crash

or could cause death or personal

injury, you should immediately inform

the National Highway Trafc Safety

Administration (NHTSA) in addition to

notifying the vehicle manufacturer.

If NHTSA receives similar complaints,

it may open an investigation, and

if it nds that a safety defect exists

in a group of vehicles, it may order

a recall and remedy campaign.

However, NHTSA cannot get involved

in individual problems between you,

your dealer, and vehicle manufacturer.

Contacting NHTSA is possible through

telephone, written mail and email.

NHTSA also has a website where you

can input your comments directly to

them on the web. Please use any of

the four ways to contact NHTSA:

6-8 Y53-1200-1B1 (04/13)

CONSUMER INFORMATION

Toll Free 888-327-4236

(800-4249153 TTY)

8:00 am to 10:00 pm ET

Monday-Friday

Ofce of Defects

Investigations/CRD

NVS-216

1200 New Jersey Ave SE.

Washington, D.C. 20590

www www.safercar.gov

@ nhtsa.webmaster@dot.gov

Canadian Consumer

Information

Canadian customers who wish to report

a safety-related defect to Transport

Canada, Defect Investigations and

Recalls, may telephone the toll free

hotline 1-800-333-0510, or contact

Transport Canada by mail at:

Transport Canada, ASFAD

Place de Ville Tower C

330 Sparks Street

Ottawa ON K1A 0N5

For additional road safety information,

please visit the Road Safety website

at:

http://www.tc.gc.ca

Warranty

Greenhouse Gas Tires

The following warranty is for vehicles

equipped with Greenhouse Gas

certied tires:

VEHICLE EMISSIONS LIMITED

EXPRESS WARRANTY RELATED

TO ORIGINAL EQUIPMENT TIRES

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”).

This vehicle emissions limited express

warranty relating to original equipment

tires is valid for two (2) years or 24,000

miles, whichever occurs rst. 6

(04/13) Y53-1200-1B1 6-9

CONSUMER INFORMATION

YOUR SOLE AND EXCLUSIVE

REMEDY AGAINST PACCAR

Inc IS LIMITED TO THE

REPAIR OR REPLACEMENT

OF ORIGINAL EQUIPMENT TIRES

AT AUTHORIZED UNITED STATES

AND CANADIAN PACCAR DEALERS,

SUBJECT TO PACCAR’S TIME AND

MILEAGE LIMITATIONS LISTED

ABOVE. This Vehicle Emissions

Limited Express Warranty relating to

original equipment tires begins on

the date of delivery of the vehicle

to the rst purchaser or lessee and

accrued time and mileage is calculated

when the vehicle is brought into an

authorized dealer for correction of

the Warrantable Emissions Failures

relating to the original equipment tires.

PACCAR MAKES NO OTHER

VEHICLE EMISSIONS WARRANTIES

RELATING TO THE ORIGINAL

EQUIPMENT TIRES, EXPRESS

OR IMPLIED. WHERE PERMITTED

BY LAW, PACCAR EXPRESSLY

DISCLAIMS ANY WARRANTY OF

MERCHANTABILITY OR FITNESS

FOR A PARTICULAR PURPOSE

RELATING TO VEHICLE EMISSIONS.

IT IS AGREED THAT PACCAR

SHALL NOT BE LIABLE FOR

INCIDENTAL OR CONSEQUENTIAL

DAMAGES INCLUDING, BUT NOT

LIMITED TO: LOSS OF INCOME

OR LOST PROFITS; VEHICLE

DOWNTIME; COMMUNICATION

EXPENSES; LODGING AND/OR

MEAL EXPENSES; FINES;

APPLICABLE TAXES OR BUSINESS

COSTS OR LOSSES; ATTORNEY’S

FEES; AND ANY LIABILITY YOU MAY

HAVE IN RESPECT TO ANY OTHER

PERSON OR ENTITY RELATING

TO WARRANTABLE EMISSIONS

FAILURES.

This Vehicle Emissions Limited

Express Warranty relating to

original equipment tires is limited

to emissions compliance only.

The tires are separately warranted

by their manufacturer for defects in

materials and workmanship other than

those which cause non-compliance

with U.S. and Canadian GHG

regulations, subject to limitations and

conditions contained within the tire

manufacturer’s warranty agreement.

You are responsible for the safe

operation and maintenance of the

vehicle and its tires. PACCAR does

not warrant wear and tear of the tires.

6-10 Y53-1200-1B1 (04/13)

Index

5th wheel

maintenance ....................5-105

About the Manual ....................1-3

ABS off-road switch................ 3-60

Accessories

cigarette lighter .................. 3-94

radio .............................. 3-94

sleeper alarm clock ............. 3-91

Accessory drive belts .............. 5-97

Active warnings .................... 3-17

Adaptive cruise control ............ 4-37

Adding electrical options .......... 5-84

Additional sources of information. ..1-8

California proposition 65 warning 1-6

data recorder ......................1-6

installed equipment -operator's

manuals.......................1-8

other sources ......................1-9

Adjustable auxiliary axles ......... 4-43

liftable/non-steerable pusher

calibration................... 4-46

liftable/steerable calibration .... 4-46

tag axle calibration .............. 4-46

After-treatment system

introduction ...................... 4-51

Air cleaners........................5-100

Air compressor..................... 5-56

Air conditioner button .............. 3-86

Air dehumidication. . . .... . . .... . . . 3-88

Air disc brakes

maintenance..................... 5-59

Air distribution dial ................. 3-85

Air dryer............................. 5-52

Air dryer (Bendix® AD-IS series) . 5-53

Air dryer overhaul .................. 5-53

Air lter restriction gauge.......... 3-44

Air gauges

air pressure - air suspension air

bags #1 & #2 ............... 3-47

tag axle air pressure ............ 3-43

tractor air brake pressure. . .... . 3-47

tractor air brake pressure -

primary/secondary ......... 3-12

trailer air brake pressure.. . . .... 3-48

trailer air tank pressure ......... 3-48

Air intake system. .................. 5-99

Air suspension height/air pressure 4-49

Air system

air cleaners .....................5-100

air compressor................... 5-56

air dryer .......................... 5-52

air lter restriction gauge ....... 3-44

air gauges and air leaks ........ 5-55

air intake system ................ 5-99

draining air tanks ................ 5-54

primary air pressure gauge.. . . . 5-55

secondary air pressure gauge . 5-55

turbocharger ..................... 5-99

Air system maintenance. .......... 5-49

Air tanks ............................ 5-54

Alarms

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

Index

engine overspeed air shutdown

alarm ........................ 3-40

headlight on alarm .............. 3-41

low coolant level alarm.......... 3-40

stop engine alarm ............... 3-40

Alert screens

fault alert ......................... 4-39

impact alert ...................... 4-38

level 1 following distance alert . 4-38

level 2 following distance alert . 4-38

level 3 following distance alert . 4-38

stationary object alert ........... 4-38

Allison transmission lubrication ... 5-43

Anti-lock brake system warning

light ............................ 3-37

Anti-lock brakes

trailer ABS ....................... 4-24

trailer ABS (without PLC)....... 4-25

wheel spin control ............... 4-30

Anti-lock brakes (ABS)

electronic stability program

(ESP)........................ 4-26

roll stability program (RSP). . . . . 4-26

Appliances.......................... 3-95

Assembly plant code ................6-3

Audible alarm.........................3-8

Automated transmission and shift

indicator area ................. 3-18

Automatic and automated

transmissions ................. 4-19

Automatic Slack Adjusters ........ 5-61

Automatic transmissions

oil level ..........................5-149

service intervals ................5-149

Auxiliary axles...................... 4-43

Auxiliary lights switch .............. 3-63

Auxiliary transmission ............. 4-20

Auxiliary transmission oil temperature

gauge .......................... 3-49

Auxiliary transmission warning

light ............................ 3-42

Axle creep rating ................... 4-45

Axle lubrication....................5-108

Back up alarm mute switch ....... 3-60

Batteries

battery access ................... 5-85

battery care ...................... 5-89

battery charging ................. 5-89

jump starting vehicles.............2-8

removing and installing

batteries..................... 5-87

Battery access ..................... 5-85

Battery care ........................ 5-89

Battery chargning .................. 5-89

Beacon lights switch ............... 3-63

Belt damage and repair ........... 1-28

Bendix® AD-IS series air dryer ... 5-53

Brake adjustment .................. 5-58

Brake gauges

tractor air brake pressure. . .... . 3-47

tractor primary/secondary air brake

pressure..................... 3-12

trailer air brake pressure.. . . .... 3-48

trailer air tank pressure ......... 3-48

Brake Level Switch ................ 3-61

Brake system

adjustment ....................... 5-58

retarders ......................... 4-33

roll stability program (RSP). . . . . 4-26

spring brakes .................... 2-20

yaw control....................... 4-27

Bulb replacement

headlight ......................... 5-78

Bulb specications................. 5-79

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

Index

Cab air distribution................. 3-89

Cab and frame access ............ 1-10

Cab dimmer switch ................ 3-60

Cab recirculation air lter......... 5-113

Cab storage ........................ 3-95

glove box......................... 3-95

Cabin fresh air lter...............5-113

California Proposition 65 Warning. .1-6

Canadian consumer information.. . .6-9

Certication labels ...................6-4

components and weights label.. .6-5

federal safety standard certication

label ...........................6-6

noise emission label ..............6-6

paint identication label...........6-6

tire and rim data label.............6-5

Chassis number......................6-4

Chassis number locations...........6-4

Check engine warning light ....... 3-40

Check messages ....................3-9

Check transmission warning light 3-42

Checking tire ination pressure.. 5-136

Chrome and aluminum surfaces.. 5-63

Cigarette lighter .................... 3-94

Cleaning vinyl and upholstery .... 5-67

Cleaning, protecting and weather

stripping ....................... 5-64

Climbing onto the deck plate..... . 1-13

Clock................................ 3-17

to set alarm time................. 3-28

to set clock display .............. 3-28

to set home/local time........... 3-28

to turn alarm ON/OFF........... 3-28

Clutch

clutch brake...................... 4-16

clutch linkage adjustment.... . . 5-151

clutch travel...................... 4-16

double clutching ................. 4-18

identication .......................6-7

riding the clutch.................. 4-20

Clutch adjustment.. . . .... . . . .... . . 5-151

Clutch brake........................ 4-17

Clutch hydraulic uid .............5-150

Clutch maintenance ..............5-150

Clutch travel ........................ 4-17

Coasting ............................ 4-52

Component identication reference 6-7

Components and weights label . .. . .6-5

Consumer information

Federal safety standards .........6-8

how to order parts.................6-8

Controls............................. 3-94

Coolant Level....................... 5-74

Cooling system

adding coolant................... 5-73

fan ................................ 5-98

fan clutch......................... 5-98

maintenance..................... 5-72

Cooling system maintenance ..... 5-72

Cruise control indicator ............ 3-18

Cruise control on/off switch ....... 3-61

Cruise control set/resume switch. 3-61

Daily checks........................ 1-37

Dash switches...................... 3-50

Data recorder.........................1-6

Daytime running light (DRL) ...... 3-63

Deck plate access ................. 1-13

Deep snow and mud switch.... . . . 4-31

DEF lter...........................5-121

Defrost vents ....................... 3-85

Defrosting and defogging the

windshield ..................... 3-86

Descending a grade ............... 4-53

Diesel exhaust uid gauge........ 3-14

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

Index

Diesel Exhaust Fluid Tank . .... . . 5-121

Diesel particulate lter (DPF)

regeneration switch........... 3-62

Diesel particulate lter (DPF) warning

light ............................ 3-38

Differential lock..................... 4-40

Dim Control Operation............. 3-93

Disc wheels........................5-145

Displays/menu screens

clock display ..................... 3-28

driver performance center ...... 3-19

fuel economy .................... 3-24

ignition timer ..................... 3-24

settings........................... 3-27

tire pressure monitoring system

(TPMS)...................... 3-23

to set time ........................ 3-28

trip information................... 3-24

truck information................. 3-25

virtual gauges.................... 3-23

warning and faults............... 3-26

Dome lights switch................. 3-64

Door lock ........................... 1-11

key fob synchronization......... 1-13

remote keyless entry (RKE)

system ...................... 1-12

Door mounted controls ............ 3-75

Double clutching ................... 4-18

Drive axle temperature gauge .... 3-46

Drive axles

identication .......................6-7

Driver controlled main differential 2-16

Driver information display

tire pressure monitoring system

(TPMS)...................... 3-23

Driver performance center ..3-12, 3-14

fuel economy .................... 3-24

ignition timer ..................... 3-24

menu screens.................... 3-19

settings........................... 3-27

trip information................... 3-24

truck information................. 3-25

virtual gauges.................... 3-23

warning and faults............... 3-26

Driver's

daily checks...................... 1-37

weekly checks ................... 1-40

Driver's check list .................. 1-36

Driveshaft Maintenance ..........5-135

Driving tips

coasting .......................... 4-52

descending a grade ............. 4-53

engine RPM...................... 4-53

fuel economy .................... 4-55

optimal engine speed ........... 4-54

using the driver information

display....................... 4-55

using the driver performance

center ....................... 3-14

using the tachometer............ 4-54

Driving with deated air springs .. 4-50

Drum brakes

maintenance ..................... 5-61

Dual Axle Diff-Lock Switch .. . . .... 3-60

Dual range (two-speed) rear axle 4-41

Dump truck gate switch ........... 3-60

Dump truck, body up warning light 3-38

Dump truck, gate warning light ... 3-38

Dump truck, trailer body up warning

light ............................ 3-38

Eaton/Dana axle lubrication.... . . . 5-46

Electrical and alternator

precautions.................... 5-91

Electrical system

adding electrical options ........ 5-84

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

Index

batteries.......................... 5-85

battery care ...................... 5-89

battery charging ................. 5-89

electrical and alternator

precautions ................. 5-91

fuses, circuit breakers and

relays........................ 5-80

jump starting vehicles.............2-8

removing and installing

batteries..................... 5-87

Electrical system maintenance ... 5-77

Electronic stability program (ESP) 4-26

Emergency

battery connections ............. 2-10

emergency equipment kit....... 1-36

jump starting vehicles.............2-8

Emergency equipment ............ 1-36

Emergency welding...............5-104

Engine

air cleaners .....................5-100

air intake system ................ 5-99

drive belts ........................ 5-97

engine mounting................5-101

exhaust system.................5-101

identication .......................6-7

lubrication ........................ 5-94

pipe and hose clamp torque

values .................5-37, 5-95

Engine (block) heater.............. 5-75

Engine block heater .................4-6

Engine brake on/off switch .. . . .... 3-61

Engine control display ............. 4-14

Engine cool down .................. 4-60

Engine fan .......................... 5-98

Engine fan control ................. 4-12

Engine fan override switch .... . . . . 3-61

Engine fan warning light........... 3-40

Engine heater switch .............. 3-62

Engine heater warning light .... . .. 3-40

Engine is overheating ...............2-5

Engine lubrication.................. 5-94

Engine maintenance............... 5-93

Engine mounted noise insulators 5-119

Engine Mounting..................5-101

Engine oil pressure gauge ........ 3-45

Engine oil pressure lamp turns on. .2-4

Engine oil temperature gauge .... 3-45

Engine operation

engine block heater ...............4-6

engine control display........... 4-14

engine cool down................ 4-60

engine fan control ............... 4-12

winterfronts ...................... 4-13

Engine overspeed ................. 4-53

Engine overspeed air shutdown

(manual) ....................... 3-62

Engine overspeed air shutdown

(test) ........................... 3-62

Engine overspeed air shutdown

alarm........................... 3-40

Engine retarder warning light ..... 3-40

Engine warm-up......................4-7

Environmental Protection ...........1-7

Ether metering equipment ........ 4-10

Ether start switch .................. 3-61

Ether start warning light ........... 3-40

Exhaust system ...................5-101

Extended life coolant (ELC)

What to Check in an ELC-lled

Cooling System ............ 5-72

Exterior lights self test .... . . .3-64, 3-77

Exterior maintenance.............. 5-63

Exterior washing ................... 5-66

Fan control dial..................... 3-85

Fasten seat belt warning indicator 3-41

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

Index

Federal safety standard certication

label........................ 6-6, 6-8

Fifth wheel

maintenance ....................5-105

Fifth wheel slide switch............ 3-62

Final stopping procedures ........ 4-62

Flood lights switch ................. 3-64

Floor and defrost vents............ 3-85

Floor vents.......................... 3-85

Fog lights switch ................... 3-64

Forward PTO switch. .............. 3-66

Forward pusher axle switch. . .... . 3-66

Forward Rear Axle Diff-Lock

Switch.......................... 3-60

Forward trailer axle lift switch .... . 3-66

Frame fastener torque

requirements .................5-106

Front axle and suspension

maintenance .................5-108

Fuel economy ................3-24, 4-55

Fuel lter restriction pressure

gauge .......................... 3-44

Fuel lters .........................5-103

Fuel gauges

fuel lter restriction pressure ... 3-44

fuel tank(s) level ...................3-9

Fuel heater ......................... 3-63

Fuel pressure gauge............... 3-46

Fuel shut-off valve ................. 4-61

Fuel shut-off valves ...............5-103

Fuel specication .................. 4-60

Fuel system

fuel lters........................5-103

shut-off valves ..................5-103

Fuller transmission lubrication .... 5-41

Fuse inspection and replacement . 2-7,

5-84

Fuse or relay blows..................2-6

Fuses, circuit breakers and relays 5-80

Gauges

air pressure -primary ........... 3-12

air pressure -secondary..... . . . 3-12

auxiliary transmission oil

temperature................. 3-49

diesel exhaust uid (DEF) ...... 3-14

engine coolant (water)

temperature................. 3-11

engine oil pressure ........3-11, 3-45

engine oil temperature .......... 3-45

fuel lter restriction pressure ... 3-44

fuel tank(s) level ...................3-9

primary air pressure............. 5-55

pusher axle(s) air pressure ... .. 3-43

secondary air pressure ......... 5-55

speedometer.......................3-9

suspension load air pressure

#1............................ 3-47

suspension load air pressure

#2............................ 3-47

tachometer....................... 3-10

tag axle air pressure ............ 3-43

tractor brake application air

pressure..................... 3-47

trailer air tank air pressure..... . 3-48

trailer brake application air

pressure..................... 3-48

transfer case oil temperature... 3-48

transmission retarder oil

temperature................. 3-49

Gauges (optional)

air lter restriction ............... 3-44

drive axle temperature (forward and

rear) ......................... 3-46

fuel pressure..................... 3-46

manifold pressure ............... 3-45

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

Index

transmission temperature ...... 3-46

Gauges (standard)

tachometer ....................... 4-54

GAWR -Gross Axle Weight Rating 6-5,

1-35

GCW - Gross Combination

Weight ......................... 1-35

Generic air accessory switch ..... 3-63

Generic spare switch .............. 3-63

Glove box........................... 3-95

Greenhouse gas certied tires... 5-140

Greenhouse Gas Tires

warranty ............................6-9

Guide to the Warning Symbols ... 3-29

GVWR - Gross Vehicle Weight

Rating..................... 6-5, 1-35

Hazard lights switch ............... 3-64

Header.............................. 3-18

Headlight aiming ................... 5-79

Headlight on alarm................. 3-41

Headlight replacement ............ 5-78

Headlight switch.................... 3-64

Heater and air conditioner ....... 5-112

air conditioner................... 5-116

heater ........................... 5-115

Heater and air conditioner

maintenance ................. 5-112

Heating and air conditioning

air conditioner button............ 3-86

defrost vents..................... 3-85

fan control dial ................... 3-85

oor and defrost vents .......... 3-85

oor vents........................ 3-85

outside air/recirculation air

button ....................... 3-85

panel and oor vents............ 3-85

panel vents....................... 3-85

sleeper heater -A/C controls... 3-89

sleeper override ................. 3-85

temperature control set point... 3-86

Heating and Air Conditioning

automatic control mode......... 3-83

buttons and dials ................ 3-85

cab controls...................... 3-79

introduction ...................... 3-80

manual control mode............ 3-82

max defrost mode ............... 3-84

High exhaust system temperature

(HEST) warning light ......... 3-39

Hill hold ............................. 4-19

Hood hold downs .................. 1-15

Hood hold-open device............ 1-17

Hood latch .......................... 1-16

Hood tilting

hood hold downs ................ 1-15

hood hold-open device ......... 1-17

hood latch........................ 1-16

How to order parts ...................6-8

Idling the engine .....................4-9

Ignition key switch ................. 3-96

Ignition timer........................ 3-24

In-cab battery box.................. 5-86

Inspection of the engine oil level . 5-94

Installed Equipment -Operator's

Manuals .........................1-8

Instrument cluster....................3-7

Instrument panel .....................3-5

Instrument system self test .........3-8

Instrumentation

driver performance center ...... 3-12

instrument cluster .................3-7

instrument panel...................3-5

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

Index

instrument system self test .......3-8

menu control switch (MCS)..... 3-19

Inter axle diff lock warning light .. . 3-38

Inter-Axle Differential Lock Switch 3-60

Jump starting vehicles...............2-8

Key fob operation .................. 1-12

Key fob synchronization. .......... 1-13

Keys

remote keyless entry (RKE) .... 1-11

Kingpin lubrication ................5-108

Komfort-Latch® Feature .......... 1-26

Lane departure warning (LDW)

light ............................ 3-41

Lap/shoulder belt .................. 1-23

Left turn signal light indicator ..... 3-42

Load distribution ................... 1-35

Low air alarm turns on...............2-3

Low coolant level warning light ... 3-40

Low voltage disconnect (LVD) . . . .3-60,

5-77

Lubricant specications ........... 5-35

Lubrication.......................... 5-38

Main content area.................. 3-19

Maintenance

5th wheel. .......................5-105

air cleaners .....................5-100

air conditioner................... 5-116

air intake system ................ 5-99

air system ........................ 5-49

Allison transmission lubrication 5-43

brake adjustment................ 5-58

brake inspection................. 5-59

chrome and aluminum surfaces 5-63

cleaning vinyl and upholstery .. 5-67

clutch ............................5-150

cooling system................... 5-72

driver's check list ................ 1-36

Eaton/Dana axle lubrication .... 5-46

electrical system................. 5-77

emergency welding ............5-104

engine ............................ 5-93

exterior ........................... 5-63

frame fastener torque

requirements ..............5-106

frame fastener torque table. . . . 5-106

front axle and suspension

lubrication .. . .. . .. . .. . .. . .. . 5-108

fuel system......................5-103

Fuller transmission lubrication . 5-41

heater ........................... 5-115

inspection .......................5-109

lubricant specications. . .... . . .. 5-35

maintenance schedule.. . . . .... . 5-12

Meritor axle lubrication. ......... 5-45

noise and emission control

standards .................. 5-117

oil changes....................... 5-44

rear axle alignment.............5-130

rear axle and suspension. . .... 5-125

rear axle lubrication ............5-128

rear suspension fasteners torque

painted surfaces................. 5-63

preventive maintenance ..........5-9

table ........................5-127

rear suspension U-bolt torque

table ........................5-128

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

Index

safety restraint system -

inspection................... 5-68

safety restraint system - inspection

guidelines................... 5-69

sliding fth wheel ...............5-107

Spicer transmission lubrication. 5-43

stainless steel.................... 5-64

steering and driveline ..........5-131

steering gear lubrication ........ 5-48

tail pipe surface cleaning ....... 5-64

tires ..............................5-136

transmission ....................5-147

U-bolt torque.................... 5-110

U-bolt torque table ............. 5-111

universal joint lubrication ....... 5-47

vehicle cleaning ................. 5-65

washing chassis................. 5-67

washing exterior................. 5-66

wheel alignment ................5-109

wheel bearing lubrication ....... 5-47

windshield wiper/washer.. . . .... 5-71

Maintenance Procedures

inspection of the engine oil level 5-94

topping up the engine oil ....... 5-95

Maintenance schedule ..............5-9

Malfunction Indicator Lamp (MIL) 3-39

Manifold pressure gauge.......... 3-45

Manual transmission............... 4-15

clutch brake...................... 4-17

clutch travel...................... 4-17

double clutching ................. 4-18

release bearing wear............ 4-20

riding the clutch.................. 4-20

shifting gears .................... 4-17

Manual windshield

defrosting/defogging. ......... 3-87

Marker/clearance light switch ..... 3-65

Marker/Clearance/Cab light

switch .......................... 3-65

Marker/Clearance/Trailer light

switch .......................... 3-65

Master lubrication index ........... 5-38

Matching tires .....................5-139

MCS knob cue ..................... 3-19

Menu control switch (MCS) ....... 3-19

Meritor axle lubrication ............ 5-45

Mirror heat switch .................. 3-76

Mirrors .............................. 3-75

mirror heat switch ............... 3-76

power mirror switch ............. 3-76

NHTSA consumer information .. .. ..6-8

Noise and emission control

maintenance ................. 5-117

Noise control inspections ........ 5-118

air intake system ............... 5-119

diesel particulate lters ........5-121

engine fan and shroud .... . . . .. 5-123

engine mounted noise

insulators................... 5-119

exhaust system................. 5-119

exhaust tail pipe ................5-122

hood insulation blanket ........5-123

inner fender shields and cab

skirt .........................5-123

joints and clamps...............5-120

maintenance log................5-124

piping ............................5-120

Noise emission label.................6-6

Odometer/trip odometer........... 3-16

Off-road ABS function switch ..... 4-31

Oil changes......................... 5-44

Oil gauges

(04/13) Y53-1200-1B1 Index-9

Index

auxiliary transmission oil

temperature................. 3-49

engine oil pressure ........3-11, 3-45

engine oil temperature .......... 3-45

transfer case oil temperature... 3-48

transmission retarder oil

temperature................. 3-49

Oil pressure gauge ................ 3-11

Operating hydraulic clutch ........ 4-15

Operating procedure

automatic and automated

transmissions. . . ..... . . .... . 4-19

refueling.......................... 4-61

stopping procedures ............ 4-62

transmission retarder ........... 4-34

Optimal engine speed ............. 4-54

Outside air / recirculation air ...... 3-89

Outside air temperature ........... 3-16

Outside air/recirculation air button 3-85

Overinated tires..................5-138

Overloaded tires ..................5-138

Paint identication label .............6-6

Painted surfaces ................... 5-63

Index-10

Painting ............................5-105

Panel and oor vents .............. 3-85

Panel vents......................... 3-85

Park brake warning light........... 3-37

Parking brake ...................... 4-23

Parking brake valve................ 3-60

Passenger seat swivel............. 1-22

Passenger side 'down' mirror ..... 3-99

Pintle hook switch.................. 3-66

Pipe and hose clamp torque

values....................5-37, 5-95

Power door lock.................... 3-77

Power line communication (PLC). 4-24

Power mirror switch................ 3-76

Power Take-off (PTO) switch ..... 3-65

Power take-off (PTO) warning

light ............................ 3-41

Power window...................... 3-77

Pressure gauges

engine oil pressure ........3-11, 3-45

Pump mode warning light ......... 3-41

Pusher axle(s) air pressure gauge 3-43

Radio................................ 3-94

Y53-1200-1B1

Rear axle - dual range

(two-speed).................... 4-41

Rear axle alignment ..............5-130

Rear axle and suspension

maintenance .................5-125

rear suspension fasteners .... . 5-127

visual inspection. .... . . . .... . . .. 5-126

Rear axle lubrication..............5-128

Rear PTO switch ................... 3-66

Rear Rear Axle Diff-Lock Switch . 3-60

Rear suspension fasteners .... . . 5-127

Rear suspension fasteners torque

table...........................5-127

Rear suspension U-bolt torque

table...........................5-128

Rear trailer axle lift switch......... 3-67

Recovery hitch capacities ......... 2-18

Recovery hitch connection ........ 2-14

Recovery hitch installation ........ 2-15

Recovery procedure ............... 2-13

Recovery rigging................... 2-19

Relling your radiator .............. 5-74

Refrigerator warning light ......... 3-41

Refueling ........................... 4-60

fuel specication................. 4-61

Release bearing wear ............. 4-20

(04/13)

Index

Remote keyless entry (RKE)..... . 1-12

Remote Keyless Entry (RKE) ... .. 5-92

batteries.......................... 1-13

key fob operation ................ 1-12

key fob synchronization......... 1-13

Remote throttle control switch .... 3-62

removing and installing batteries . 5-87

Replacing tires ....................5-140

Returning vehicle to service ...... 2-20

Riding the clutch ................... 4-20

Right turn signal light indicator. . .. 3-42

Roll stability program (RSP) ...... 4-26

Roof mounted condenser fan

switch .......................... 3-66

Safe vehicle operation............. 1-33

Safety

about the manual..................1-3

air suspension height/air

pressure..................... 4-49

cab and frame access .......... 1-10

deck plate access ............... 1-13

deated air springs .............. 4-50

driver's check list ................ 1-36

emergency equipment kit....... 1-36

introduction ........................1-3

safe vehicle operation........... 1-33

safety alerts........................1-3

suspension air pressure gauge 4-49

vehicle loading................... 1-34

vehicle safety ......................1-5

Safety alerts ..........................1-3

Safety restraint belts............... 1-22

belt damage and repair ......... 1-28

during pregnancy................ 1-28

inspection ........................ 5-68

safety restraint tips .............. 1-31

Safety restraint system

inspection ........................ 5-68

Seat adjustment.................... 1-19

passenger seat swivel .......... 1-22

Seat belts........................... 1-19

adjustments...................... 1-19

belt damage and repair ......... 1-28

during pregnancy................ 1-28

Komfort-Latch feature........... 1-26

lap/shoulder belt................. 1-23

safety restraint tips .............. 1-31

Seats

adjustments...................... 1-19

Komfort-Latch feature........... 1-26

tether belts ....................... 1-25

To adjust an external tether belt 1-26

Seats and restraints ............... 1-19

Service brake warning light ....... 3-38

Service transmission warning light 3-42

ServiSignal Mini Indicator ........5-101

Setting System Alarm ............. 3-92

Setting System Time............... 3-92

Shut-down

fuel specication................. 4-61

location of fuel shut-off valves.. 4-61

refueling.......................... 4-60

sleeper bunk..................... 4-58

Single Rear Axle Diff Lock Switch 3-60

Sleeper Alarm Clock............... 3-91

dim control operation............ 3-93

setting system alarm ............ 3-92

setting system time.............. 3-92

snooze operation................ 3-93

turning the alarm on/off ......... 3-93

Sleeper bunk ....................... 4-58

sleeper restraint ................. 4-59

Sleeper bunks and restraints ..... 1-29

Sleeper heater -A/C controls ... .. 3-89

Sleeper HVAC air lter ........... 5-114

(04/13) Y53-1200-1B1 Index-11

Index

Sleeper occupant restraint ........ 4-59

Sliding 5th wheel

maintenance ....................5-107

Sliding Fifth wheel

maintenance ....................5-107

Snooze Operation ................. 3-93

Speed restricted tires .............5-141

Speedometer .........................3-9

Spicer transmission lubrication ... 5-43

Spot light. switch................... 3-65

Spring brakes—manual release .. 2-20

Stainless steel...................... 5-64

Starting procedure

cold temperature ..................4-6

engine warm-up ...................4-7

ether metering ................... 4-10

normal temperature ...............4-5

Stationary PTO operation ......... 4-12

Steer axle

identication .......................6-7

Steer Axle Diff Lock Switch ....... 3-60

Steering and driveline

maintenance .................5-131

uid level and rell .............5-132

Steering column.................... 3-67

tilt/telescoping ................... 3-68

Index-12

trailer brake hand valve......... 3-72

turn signal/high beam switch ... 3-69

Steering gear lubrication .......... 5-48

Steering system maintenance

steering shaft ...................5-133

Steering wheel controls ........... 3-73

Stop engine lamp turns on ..........2-4

Stop engine warning light ......... 3-40

Suspension air pressure gauge .. 4-49

Suspension dump switch. ......... 3-66

Suspension dump warning light .. 3-41

Suspension lift switch. ............. 3-66

Suspension load air pressure

gauges......................... 3-47

Suspension lubrication ...........5-108

Switches

2 speed transfer case. .......... 3-59

ABS off-road switch ............. 3-52

accessory air switch. ............ 3-54

air conditioner button............ 3-86

auxiliary light switch . ............ 3-54

axle switch, diff-lock - dual ..... 3-50

axle switch, diff-lock - forward

rear .......................... 3-50

axle switch, diff-lock - rear rear 3-51

Y53-1200-1B1

axle switch, diff-lock - single

rear .......................... 3-51

axle switch, diff-lock - steer..... 3-51

axle switch, inter axle differential

locked (tandem)............ 3-51

axle switch, pusher.............. 3-57

axle switch, tag .................. 3-57

axle switch, two speed.......... 3-51

back up alarm mute switch ..... 3-51

beacon light switch .............. 3-55

brake level switch ............... 3-52

brake on/off switch .............. 3-52

cab dimmer ...................... 3-52

cruise control .................... 4-35

cruise control on/off switch ..... 3-52

cruise control set/resume

switch ....................... 3-53

dash switches.................... 3-50

daytime running light switch .. .. 3-55

diesel particulate lter (DPF)

regeneration switch ........ 3-54

dome light switch ................ 3-55

dual range rear axle switch.. . . . 4-41

dump truck gate switch ......... 3-52

engine fan override switch..... . 3-53

engine fan switch. ............... 4-12

(04/13)

Index

engine heater switch............ 3-53

ether start switch ................ 3-53

exterior lights self test........... 3-77

exterior lights self test switch... 3-55

fth wheel slide switch .......... 3-54

ood light switch. ................ 3-55

fog light switch................... 3-55

forward power take-off (PTO)

switch ....................... 3-57

forward trailer axle lift switch ... 3-58

fuel heater switch................ 3-54

hazard light switch .............. 3-56

headlight switch ................. 3-64

headlight switch and parking

lights......................... 3-56

low voltage disconnect (LVD) ..3-51,

3-60

marker light switch .............. 3-56

marker/clearance/cab light

switch ....................... 3-56

marker/clearance/trailer light

switch ....................... 3-56

mud and snow traction control . 3-56

off-road ABS function switch

(option)...................... 4-31

optional deep snow and mud

switch ....................... 4-31

outside air/recirculation air

button ....................... 3-85

overspeed air shutdown

(manual) .................... 3-53

overspeed air shutdown (test).. 3-53

parking brake valve ............. 3-52

pintle hook switch ............... 3-58

power door lock ................. 3-77

power take-off (PTO) switch. . .. 3-57

power window ................... 3-77

rear power take-off (PTO)

switch ....................... 3-57

rear trailer axle lift switch ....... 3-58

remote throttle switch ........... 3-53

roofdenser switch ............... 3-57

sleeper override ................. 3-85

spare switch ..................... 3-54

spot light switch ................. 3-56

suspension dump switch ....... 3-57

suspension lift switch ........... 3-58

temperature control set point... 3-86

third axle lift switch .............. 3-58

trailer axle (3rd axle) lift switch . 3-58

trailer belly dump switch ........ 3-58

trailer dump gate switch ........ 3-59

trailer hotline switch ............. 3-59

trailer marker light interrupter

switch ....................... 3-69

trailer suspension air dump.. ... 3-59

transfer case..................... 3-59

turn signal/high beam switch ... 3-69

under hood air intake ........... 3-54

winch clutch switch.............. 3-59

windshield wipers/washer ...... 3-71

Tachometer......................... 3-10

Tag axle air pressure gauge ...... 3-43

Tag axle switch..................... 3-66

Tail pipe surface cleaning ......... 5-64

Telematic system

care and operation .............. 3-98

disclaimer ........................ 3-99

Temperature control dial........... 3-86

Temperature gauges

engine oil temperature .... . . . ... 3-45

transmission retarder oil

temperature................. 3-49

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

Index

water temperature (engine

coolant) ..................... 3-11

Tether belts ......................... 1-25

Third axle lift switch................ 3-66

Third trailer axle lift switch ........ 3-66

Tilt/telescoping steering column . . 3-68

Tire and rim data label...............6-5

GAWR ..............................6-5

Tire chains .........................5-141

Tire Chains ......................... 2-22

Tire ination warning light ......... 3-42

Tire Pressure Monitoring System

(TPMS) ........................ 3-23

Tires................................5-136

greenhouse gas certied tires.5-140

ination check ..................5-136

replacement.....................5-140

tire chains .......................5-141

Tires and wheels

wheel cap nut torque

sequence ..................5-143

wheel cap nut torque table .... 5-142

wheel mounting and fastening 5-142

To jump start your vehicle . .... . . ....2-9

Topping up the engine oil ......... 5-95

Towing the vehicle ................. 2-23

Traction control switch............. 3-65

Traction control warning light ..... 3-37

Tractor brake application air pressure

gauge .......................... 3-47

Trailer ABS ......................... 4-24

Trailer air suspension switch.. .... 3-67

Trailer air tank air pressure gauge 3-48

Trailer anti-lock brake system warning

light ............................ 3-38

Trailer belly dump switch.......... 3-67

Trailer brake application air pressure

gauge .......................... 3-48

Trailer brake hand valve........... 3-72

Trailer dump gate switch .......... 3-67

Trailer hotline switch............... 3-67

Transfer case oil temperature

gauge .......................... 3-48

Transfer case switch............... 3-67

Transmission

identication .......................6-7

lubricants........................5-148

maintenance ....................5-147

oil change .......................5-147

shifting gears in a new vehicle . 4-17

transmission tips ................ 4-20

Transmission maintenance ..... . 5-147

Transmission retarder ............. 4-34

Transmission retarder oil temperature

gauge .......................... 3-49

Transmission retarder warning

light ............................ 3-42

Transmission temperature gauge 3-46

Transmission temperature gauges

auxiliary transmission oil

temperature................. 3-49

Transmissions

automatic and automated ...... 4-19

auxiliary transmission .... . . . .... 4-20

transmission retarder ........... 4-34

Trip information .................... 3-24

Trip reset............................ 3-14

Truck information .................. 3-25

Turbocharger....................... 5-99

Turn signal/high beam switch . .. . . 3-69

Turning the Alarm On/Off ......... 3-93

Two speed axle switch ............ 3-60

Two speed transfer case switch .. 3-67

U-bolt torque ...................... 5-110

U-Joints ............................5-135

Index-14 Y53-1200-1B1 (04/13)

Index

Under hood air intake switch..... . 3-62

Underinated tires ................5-137

Universal joint lubrication.......... 5-47

Use of instrument cluster display . 4-55

Using the tachometer.............. 4-54

Vehicle cleaning.................... 5-65

Vehicle identication

assembly plant code ..............6-3

chassis number....................6-4

chassis number locations.........6-4

model year designations table ...6-3

VIN number........................6-3

VIN number locations .... . . . .... . .6-4

Vehicle loading . .................... 1-34

GAWR............................ 1-35

GCW.............................. 1-35

GVWR............................ 1-35

load distribution.................. 1-35

Vehicle recovery

driver controlled main

differential................... 2-16

recovery guidelines ............. 2-12

recovery hitch capacities ....... 2-18

recovery hitch connection ...... 2-14

recovery hitch installation....... 2-15

recovery procedure ............. 2-13

recovery rigging ................. 2-19

returning vehicle to service ... .. 2-20

sand, mud, snow and ice ....... 2-22

spring brakes .................... 2-20

towing the vehicle ............... 2-23

Vehicle safety ........................1-5

Vehicle telematic system.......... 3-97

VIN number location.................6-4

Vinyl and upholstery

cleaning .......................... 5-67

Virtual gauges ...................... 3-23

Wait to start warning light ......... 3-41

Warning and faults................. 3-26

Warning light/indicator symbols .. 3-30

anti-lock brake system (ABS) .. 3-37

anti-lock brake system (ABS),

trailer ........................ 3-38

axle, inter-axle differential locked

(tandem axles) ............. 3-38

axle, traction control. ............ 3-37

dump truck, body up ............ 3-38

dump truck, gate ................ 3-38

dump truck, trailer body up ..... 3-38

emissions, diesel particulate lter

(DPF)........................ 3-38

emissions, high exhaust system

temperature (HEST) ....... 3-39

engine brakesaver or transmission

retarder...................... 3-42

engine, check engine ........... 3-40

engine, engine fan .............. 3-40

engine, ether start ............... 3-40

engine, heater ................... 3-40

engine, low coolant level ....... 3-40

engine, overspeed air

shutdown.................... 3-40

engine, retarder (brake) ........ 3-40

engine, stop engine ............. 3-40

engine, wait to start ............. 3-41

lane departure warning (LDW) . 3-41

lights, high beam ................ 3-41

malfunction indicator lamp...... 3-39

park brake........................ 3-37

power take-off (PTO)............ 3-41

power take-off (PTO), pump

mode ........................ 3-41

(04/13) Y53-1200-1B1 Index-15

Index

rationality check ................. 3-38

refrigerator ....................... 3-41

seat belt, fasten ................. 3-41

service transmission ............ 3-42

suspension dump ............... 3-41

tire ination....................... 3-42

transmission, auxiliary .......... 3-42

transmission, check ............. 3-42

turn signal, left ................... 3-42

turn signal, right ................. 3-42

water in fuel (WIF)............... 3-41

wheel spin control ............... 4-30

Warning/informational screen. .... 3-99

Warranty ..............................6-9

greenhouse gas tires..............6-9

Washing chassis ................... 5-67

Water in fuel (WIF) warning light . 3-41

Water temperature gauge......... 3-11

Weekly checks ..................... 1-40

Welding (emergency).............5-104

What to do if...........................2-3

engine is overheating .............2-5

engine oil pressure lamp turns

on..............................2-4

fuse or relay blows ................2-6

low air alarm turns on.............2-3

stop engine lamp turns on........2-4

you need roadside assistance ...2-3

Wheel alignment ..................5-109

Wheel bearing adjustment .... . . . 5-146

Wheel bearing lubrication ......... 5-47

Wheel cap nut torque. . .. . .. . .. . .. 5-142

Wheel mounting and fastening .. 5-142

Wheel replacement with disc brake

option .........................5-144

Wheel spin control ................. 4-30

Wheel spin control warning lamp. 4-30

Winch clutch switch................ 3-67

Windshield wiper/washer. . .... . . .. 5-71

maintenance..................... 5-71

Windshield wipers/washer ........ 3-71

Winterfronts ........................ 4-13

Yaw control ......................... 4-27

Yaw stability ........................ 4-27

Index-16 Y53-1200-1B1 (04/13)

Your Servicing Dealer Is:

Need Help? Give Us A Call -

24 Hours a Day

1-800-KW-ASSIST

1-800-592-7747

KENWORTH TRUCK COMPANY

P.O. Box 1000

Kirkland, Washington 98083-1000

(425) 828-5000

CANADIAN KENWORTH COMPANY

6711 Mississauga Road N.

Mississauga, Ontario L5N 4J8

(905) 858-7000

Do not remove the manual from vehicle.

Before operating vehicle study the manual carefully.

Read and understand all Warnings, Cautions and Notes.

Stoneridge Electronics 32476 Remote Control Transmitter User Manual

Stoneridge Electronics Remote Control Transmitter

User manual

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